Article of footwear with upper and integrated sole structure

Abstract

Aspects herein are directed to an article of footwear having an upper, an upper for an article of footwear, and methods of manufacturing an upper for an article of footwear. The upper includes yarns and knit structures that, after processing, form, at least in part, a translucent or transparent thermoplastic polymer layer that facilitates visibility of a first sole structure, such as a midsole, that is removably positioned within a foot-receiving void of the upper. The translucent or transparent thermoplastic polymer layer may also directly secure a second sole structure to an underfoot portion of the upper.

What is claimed is: 
     
         1 . An article of footwear, comprising:
 an upper, comprising:   a first knit layer comprising a knitted mesh structure comprising a first set of yarns;   a thermoplastic polymer layer that at least partially covers and/or encapsulates the first set of yarns, wherein the thermoplastic polymer layer is translucent or transparent; and   at least one internal component of the article of footwear that is at least partially visible through the thermoplastic polymer layer.   
     
     
         2 . The article of footwear of  claim 1 , wherein the knitted mesh structure is at least partially visible through the thermoplastic polymer layer. 
     
     
         3 . The article of footwear of  claim 1 , wherein the at least one internal component comprises a midsole and/or a sole structure that is at least partially visible through both the thermoplastic polymer layer and the knitted mesh structure. 
     
     
         4 . The article of footwear of  claim 1 , wherein the thermoplastic polymer layer forms, at least in part, an outermost-facing surface of the upper. 
     
     
         5 . The article of footwear of  claim 1 , wherein the upper comprises an underfoot portion, the underfoot portion comprising the first knit layer and the thermoplastic polymer layer. 
     
     
         6 . The article of footwear of  claim 1 , wherein the first set of yarns is partially embedded within the thermoplastic polymer layer. 
     
     
         7 . The article of footwear of  claim 6 , wherein the thermoplastic polymer layer does not fully extend to an inner-facing surface of the first knit layer. 
     
     
         8 . The article of footwear of  claim 1 , wherein the thermoplastic polymer layer comprises a first sub-layer having a first thermoplastic polymer composition and a second sub-layer having a second thermoplastic polymer composition, the second sub-layer being positioned between the first knit layer and the first sub-layer. 
     
     
         9 . The article of footwear of  claim 8 , wherein the second thermoplastic polymer composition has a lower melting temperature than the first thermoplastic polymer composition. 
     
     
         10 . The article of footwear of  claim 9 , wherein the second thermoplastic polymer composition has a lower melting temperature than the first set of yarns. 
     
     
         11 . The article of footwear of  claim 1 , wherein the upper comprises a second knit layer comprising a second set of yarns and positioned interior to the first knit layer. 
     
     
         12 . The article of footwear of  claim 11 , wherein the upper comprises an underfoot portion, the underfoot portion comprising the first knit layer, the second knit layer, and the thermoplastic polymer layer. 
     
     
         13 . An article of footwear, comprising:
 an upper, comprising:   a composite layer comprising one or more knit layers and a thermoplastic polymer material forming a skin and/or a film,   wherein the one or more knit layers are positioned to form at least part of an inner-facing surface of the upper, wherein the thermoplastic polymer material forms at least part of an outer-facing surface of the upper and is translucent or transparent, and wherein at least one internal component of the article of footwear is at least partially visible through the composite layer.   
     
     
         14 . The article of footwear of  claim 13 , wherein the composite layer comprises a first surface comprising the thermoplastic polymer material and a second surface comprising at least part of the one or more knit layers, wherein the first surface has a smoother texture than the second surface. 
     
     
         15 . The article of footwear of  claim 14 , wherein a sole structure directly abuts the second surface. 
     
     
         16 . The article of footwear of  claim 15 , wherein the one or more knit layers comprises a first knit layer and a second knit layer, the second knit layer being interior to the first knit layer. 
     
     
         17 . An article of footwear comprising a medial side, a lateral side, a toe end, and a heel end, the article of footwear comprising:
 an upper comprising a first knit zone integrally knit with a second knit zone, the first knit zone comprising:   a first knit layer comprising a knitted mesh structure comprising a first set of yarns;   a second knit layer comprising a second set of yarns, the second knit layer positioned interior to the first knit layer; and   a thermoplastic polymer layer that is translucent or transparent and that at least partially covers and/or encapsulates the first set of yarns and/or the second set of yarns, wherein the thermoplastic polymer layer is absent from the second knit zone.   
     
     
         18 . The article of footwear of  claim 17 , wherein the polymer layer forms an outermost-facing surface of the upper in the first knit zone. 
     
     
         19 . The article of footwear of  claim 17 , wherein the second knit zone comprises a single jersey knit structure. 
     
     
         20 . The article of footwear of  claim 19 , wherein the second knit zone comprises at least a tongue region of the upper, the tongue region comprising a plurality of rib structures.