JP2023510999A - Article of footwear including circular knit construction - Google Patents

Abstract

One aspect of the disclosure is an article of footwear. The article of footwear includes a double layer knit upper having an insole, an upper portion contiguous with the insole, an ankle opening, and an inner void for receiving a wearer's foot. A double layer knit upper has an outer knit layer defining an outer surface of the double layer knit upper. A dual layer knit upper also has an inner knit layer monolithically knitted to an outer knit layer. The inner knit layer has a plurality of inner knit regions that spatially correspond to the plurality of outer knit regions of the outer knit layer. The outer knit layer and the inner knit layer substantially define the midsole and the upper portion of the double layer knit upper. [Selection drawing] Fig. 1

Description

The present disclosure relates to articles of footwear including circular knit constructions and methods of making such articles of footwear.
Background technology

A conventional article of footwear has a sole and an upper attached to the sole. Footwear manufacturing has historically been a labor-intensive cutting, sewing and assembly operation. Panels of upper material are cut to size and sewn together to create the upper. A sole is attached to the upper using a number of different techniques to create the finished article of footwear. A recent development in footwear design uses knitting techniques to form portions of the footwear, particularly the upper. In some cases, weft knitting is used to form plain knit fabric blanks. A blank of plain knitted fabric is formed into a specific shape so that it can be folded and wrapped into a substantially completed shoe upper. Once the upper is formed, a sole component or other durable structure is attached to the knitted shoe upper consistent with conventional footwear manufacturing techniques. Although some stitching is required to create a shoe upper using weft knitting, fewer stitching steps are required than traditional shoe manufacturing. Although flat knitting can increase material utilization, there are design limitations and production inefficiencies inherent in flat knitting because fabric cutting is minimized.

One embodiment of the present disclosure is an article of footwear, a knit blank, and a method for manufacturing an article of footwear and a knit blank. The article of footwear includes a double-layer knit upper having an insole, an upper portion contiguous with the insole, an ankle opening, and an inner void for receiving a wearer's foot. A double layer knit upper has an outer knit layer defining an outer surface of the double layer knit upper. A dual layer knit upper also has an inner knit layer monolithically knitted to an outer knit layer. The inner knit layer has a plurality of inner knit regions that spatially correspond to the plurality of outer knit regions of the outer knit layer. The outer knit layer and the inner knit layer substantially define the midsole and the upper portion of the double layer knit upper.

1 is a side view of an article of footwear according to one embodiment of the present disclosure; FIG. 2 is an exploded view of the article of footwear shown in FIG. 1; FIG. 3 is a cross-sectional view of the article of footwear taken along line 3-3 of FIG. 1; FIG. 4 is a side view of a knit blank used to form a component of the article of footwear shown in FIGS. 1-3; FIG. 3 is a side view of the interior of the knit blank used to form the component of the article of footwear shown in FIGS. 1 and 2, showing a portion of the knit blank removed to create the ankle portion of the article of footwear; FIG. 5 is a side view of a double layer knit footwear component formed from the knit blank shown in FIG. 4; FIG. 1 illustrates an article of footwear according to one embodiment of the present disclosure; 1 illustrates an article of footwear including a vane system according to one embodiment of the present disclosure; 1 illustrates an article of footwear including a collar according to one embodiment of the present disclosure; 1 illustrates an article of footwear including multiple features according to one embodiment of the present disclosure; 1 illustrates an article of footwear including multiple features according to one embodiment of the present disclosure; 1 illustrates an article of footwear including a vane system according to one embodiment of the present disclosure; 1 illustrates an article of footwear including a vane system according to one embodiment of the present disclosure; 1 illustrates an exemplary article of footwear including functional layers according to one embodiment of the present disclosure;

Embodiments of the present disclosure include articles of footwear that include a circular knit fabric formed into a double layer knit upper of article of footwear 10 . Article of footwear 10 is disclosed as having a configuration suitable for walking or running. Concepts associated with footwear also apply to many other types of athletic shoes, for example, baseball shoes, basketball shoes, cross-training shoes, cycling shoes, football shoes, tennis shoes, soccer shoes, sprint shoes, hiking boots, etc. obtain. This concept can also be applied to types of footwear generally considered non-athletic, such as dress shoes, loafers, sandals, work boots, and the like. The concepts disclosed in this application apply to a wide variety of footwear.

1-3, article of footwear 10 includes a sole component 20 and an upper knit component 30. As shown in FIG. For reference, article of footwear 10 can be divided into three general regions: forefoot region 11 , midfoot region 12 behind the forefoot region, and heel region 13 . Forefoot region 11 generally includes portions of article of footwear 10 corresponding to the toes and the joints that connect the metatarsals to the phalanges. Midfoot region 12 generally includes the portion of article of footwear 10 corresponding to the arch region of the foot. Heel region 13 generally corresponds to the rear portion of the foot. Article of footwear 10 also includes medial side 14 and lateral side 15 that extend through each of regions 11 - 13 and correspond to opposite sides of article of footwear 10 . The lateral side 15 corresponds to the lateral area of the foot, ie the surface facing away from the other foot, and the medial side 14 corresponds to the medial area of the foot, ie the surface facing the other foot. Regions 11 - 13 and sides 14 - 15 are intended to represent the overall region of article of footwear 10 . In addition to article of footwear 10 , regions 11 - 13 and sides 14 - 15 may also apply to sole component 20 and/or upper knit component 30 .

With continued reference to FIGS. 1-3, sole component 20 is secured to upper knit component 30 and extends between the foot and the ground when article of footwear 10 is worn. Sole component 20 may include a midsole, an outsole, and a liner (not shown). A midsole is secured to the upper knit component 30, as described further below. The midsole can be formed from a compressible polymer foam element, such as polyurethane or ethyl vinyl acetate foam, which, when compressed between the foot and the ground during walking, running, or other walking activities, causes the ground to move. Attenuates reaction force and provides cushioning. The outsole is secured to the underside of the midsole and may be formed from an abrasion resistant rubber material that is textured to provide traction. The construction and features of any sole component utilized with sole component 20 or upper knit component 30 may vary considerably.

Article of footwear 10 includes a plurality of tabs 22 a - 22 d that extend upwardly from sole component 20 along medial side 14 and lateral side 15 of article of footwear 10 . A plurality of tabs 22a-22d include securing members 24a-24d in the form of openings, slots, and/or hooks for receiving cord 18. As shown in FIG.

With continued reference to FIGS. 1-3, upper knit component 30 forms internal voids 31 within article of footwear 10 to receive and secure the foot to sole component 20 . A void 31 is shaped to accommodate the foot and extends along the lateral side of the foot, along the medial side of the foot, over the foot, around the heel and under the foot. Access to the void is provided by an ankle opening 32 located at least in heel region 13 . Cords 18 extend through portions of upper knitted component 30, as described above, to allow the wearer to alter the dimensions of upper knitted component 30 to fit the proportions of the foot. . Cords 18 allow the wearer to tighten upper knitted component 30 around the foot, and cords 18 allow the wearer to loosen upper knitted component 30 and pull the leg out of void 31 through ankle opening 32 . to make it easier to get in and out of.

With continued reference to FIGS. 1-3, upper knit component 30 is a double layer knit upper having a substantially monolithic circular knit fabric construction. The double layer knit upper includes an insole 41, a toe portion 42, a midfoot portion 44 (sometimes referred to as upper portion 44) contiguous with toe portion 42, a heel portion 46 contiguous and contiguous with midfoot portion 44, and It has an ankle portion 48 that defines an ankle opening 32 . Insole 41 extends from toe portion 42 along midfoot portion 44 to heel portion 46 . Sole component 20 is attached to insole 41 . In an alternative embodiment, a liner (not shown) is placed within the double layer knit upper along midsole 41 . Toe portion 42 , midfoot portion 44 , heel portion 46 , ankle portion 48 , and insole 41 generally refer to regions of upper knit component 30 .

2 and 3, the double layer knit upper has an outer knit layer 60 and an inner knit layer 80. As shown in FIG. Outer knit layer 60 and inner knit layer 80 together form toe portion 42, midfoot portion 44, heel portion 46, and ankle portion 48 of the double layer knit upper. However, the outer knit layer 60 defines the outer surface 50 of the double layer knit upper and the inner knit layer defines the inner surface 52 of the double layer knit upper. Outer knit layer 60 can thus be said to form the outward facing surfaces (not numbered) of toe portion 42 , midfoot portion 44 , heel portion 46 and ankle portion 48 . Conversely, inner knit layer 80 defines the inward facing surfaces (not numbered) of toe portion 42 , midfoot portion 44 , heel portion 46 and ankle portion 48 . Further, both the outer knit layer 60 and the inner knit layer 80 substantially define the midsole 41 of the double layer knit upper. Outer knit layer 60 and inner knit layer 80 may define edge 51 along ankle opening 32 . An optional binding 54 may be placed along edge 51 of ankle opening 32 .

The double layer knit upper includes at least one attachment member that integrates the outer knit layer 60 with the inner knit layer 80, thereby forming a double layer knit upper. The attachment member can be any material that fuses the outer knit layer 60 and the inner knit layer 80 together. Since the outer and inner knit layers are circular knit constructions, each layer has floats on the sides due to the different knit constructions formed in the knit regions described below. The float from the outer knit layer 60 faces the float from the inner knit layer 80 when the dual layer knit upper is formed. If the float is pulled or the layers are otherwise deformed, the float can create snags and deform the knit structure. The attachment member addresses this issue by integrating the outer knit layer and the inner knit layer. In particular, the attachment members adhere yarns from the outer knit layer 60 to yarns from the inner knit layer 80 . This adhesion minimizes distortion of the knit structure created during use. An attachment member joins the outer and inner knit layers to prevent the two layers from sliding relative to each other. The attachment members provide stability to the double layer knit upper. In one example, the attachment member may include binding threads. Binding yarns can form part of the knit stitches and can be interleaved or incorporated into the braid. When the binder yarns are exposed to a desired temperature (above the glass transition temperature), the binder yarns melt, thereby uniting the outer and inner knit layers 60,80. The binding thread can be a thermoplastic polyurethane thread. In another example, the binder yarns are low melting point thermoplastic yarns having a lower melting temperature than the yarns used to form the outer and inner knit layers 60,80. In alternate embodiments, the attachment member may be a low melt adhesive film, a low melt adhesive nonwoven web, or an adhesive coating. In yet another alternative embodiment, the attachment member may be a binding thread that adheres the outer and inner layers together.

Outer knit layer 60 has a plurality of outer knit regions 62a-62f, and inner knit layer 80 has a plurality of inner knit regions 82a-82g. The outer and inner knit regions contain selected textile structural elements. Selected textile structural elements may include the presence of specific knit stitches and/or specific yarns. Additionally, the selected textile structural elements may include specific knit stitches and/or lack of yarn. One or more of the plurality of outer knit regions 62a-62f of the outer knit layer 60 may spatially correspond to one or more of the plurality of inner knit regions 82a-82g. In embodiments in which the inner knit region spatially corresponds to the outer knit region, the inner knit region completely or partially underlies the outer knit region. For example, each of the inner knit regions 82a-82e underlies a respective outer knit region 62a-62d. However, outer knit layer 60 and inner knit layer 80 may include different knit regions in different locations than others.

FIG. 2 shows a plurality of outer knit regions 62a-62f. As shown, the plurality of outer knit regions includes the toe portion 42 and a first outer knit region 62 a along a portion of the midsole 41 . The first outer knit region 62a may be referred to as the front toe knit region. A second outer knit region 62 b extends across the top of toe portion 42 . The second outer knit region 62b may be referred to as the upper toe knit region. A third outer knit region 62 c extends across the top of midfoot portion 44 and rearwardly of toe portion 42 . The third outer knit region 62c may be referred to as the upper midsole knit region. A fourth outer knit region 62 d extends across heel portion 46 . The fourth region 62d is called the lateral heel region. A fifth outer knit region 62e forms the remaining region of the outer knit layer. A sixth outer knit region 62f is positioned along the ankle portion 48 above the outer heel portion 46. As shown in FIG. Each outer knit region 62a-62f may have different textile structural elements in terms of knit structure and/or yarn. Alternatively, each outer knit region 62a-62f may have a similar knit structure in terms of knit structure and/or yarn. In one example, upper midsole knit region 62c may include binding yarns. The binding thread can be, for example, a thermoplastic polyurethane thread. The binding yarns may facilitate holding the outer and inner knit layers 60,80 together.

As best shown in FIGS. 2 and 4, inner knit layer 80 includes a plurality of inner knit regions 82a-82g containing selected textile structural elements. Regions 82a-82g are not shown in FIG. 2, but are shown in FIG. 4 as part of knit blank 130. FIG. As shown, the plurality of inner knit regions includes a first inner knit region 82a along the toe portion and a portion of the midsole. The first inner knit region 82a may be referred to as the front toe knit region. A second inner knit region 82b extends across the top of the toe portion. The second inner knit region 82b may be referred to as the upper toe knit region. A third medial knit region 82c extends across the top of the midsole portion and rearwardly of the toe portion. The third medial knit region 82c may be referred to as the upper midsole knit region. A fourth inner knit region 82d extends across the heel portion. A fourth region 82d is referred to as the medial heel region. A fifth inner knit region 82 e forms the remaining region of the inner knit layer 80 . A sixth medial knit region 82g extends across the bottom of the midsole portion and rearwardly of the toe portion. The sixth medial knit region 82g may be referred to as the lower midsole knit region 82g. A seventh inner knit region 82f is positioned along the ankle portion. Each inner knit region 82a-82g may have different textile structural elements in terms of knit structure and/or yarn. Alternatively, each inner knit region 82a-82g may have a similar knit structure in terms of knit structure and/or yarn. In one example, upper midsole knit region 82c and/or lower midsole knit region 82g may include binding yarns. The binding yarns can be thermoplastic polyurethane yarns, as described above. The binding yarns may facilitate holding the outer and inner knit layers 60,80 together.

Double layer knit uppers can have a variety of circular knit constructions. For example, a double layer knit upper may include a single jersey knit construction, a double knit construction, a rib knit construction, a terry knit construction, or other types of weft knit constructions. Additionally, different regions of the double layer knit upper may include different stitches such as floats, presser stitches, skip stitches, and other stitches known to those skilled in the art. In one example, the outer knitted toe regions 62a, 82a of the outer layer and/or the inner layer may comprise a cushioned knit structure. Similarly, the outer and/or inner layer heel regions 62d, 82d can have a cushioned knit construction. The cushioned knit structure includes knitted terry loops.

The double layer knit upper can be formed from any number of types of yarns, such as spun yarns or continuous filament yarns. Yarns may include natural fibers, synthetic fibers, or blends of natural and synthetic fibers. Natural fibers include cotton, wool, bamboo, flax, hemp, and the like. Synthetic fibers may include polyethylene terephthalate (PET), polyolefin, polyamide 6, polyamide 6,6, polylactic acid (PLA) fibers, viscose rayon, acrylic, or other fiber types. Suitable thermoplastic synthetic staple fibers can be single component or bicomponent type fibers. Various spinning types are available, such as ring spinning, open-end, air-jet and compact spinning. Continuous filament yarns may include either or both single component or bicomponent filament types. Continuous filament yarns can be polyethylene terephthalate, polyolefin, and/or polyamide 6, polyamide 6,6, polylactic acid filaments. Yarns used in knitted fabrics can have various counts. For example, in one example, the knit yarn can have a count ranging between about 50 denier and about 250 denier (or more). Yarns are not limited to the denier ranges stated. Tie yarns are used in selected areas of the outer knit layer 60 and the inner knit layer 80 to help unite the outer and inner layers. The binding yarns can be yarns such as low melting point thermoplastic yarns or thermoplastic polyurethane yarns.

Another embodiment of the present disclosure is a method for forming article of footwear 10 . The method may include a knitting stage configuration to form circular knitted blank 130 . Following the knitting step, the method may include an assembly step in which a circular knitted blank 130 is formed into the upper knitted component 30 and the sole component 20 is attached to the midsole 41 of the upper knitted component 30 . 4-6, circular knit blank 130 has a first knit section 160 defining outer knit layer 60 and a second knit section 180 defining inner knit layer 80 . Circular knit blank 130 is folded upon itself to define a double layer knit upper such that inner knit layer 80 forms inner void 31 of article of footwear 10 .

The knitting stage utilizes a circular knitting machine (not shown) well known to those skilled in the art. A circular knitting machine can be a double needle machine containing two cylinders. Alternatively, a circular knitting machine with a cylinder and dial may be used. For illustration and clarity, the knitting process using a knitting machine with two cylinders is described below. It should be understood that other types of knitting machines can be used. Each cylinder has a plurality of needles arranged around the circumference of the cylinder, each needle being housed in a movable track. A cam assembly engages a needle along each cylinder. Rotational motion of the cam assembly (or relative motion of the cylinder) causes the needles to move up and down tracks through what is known in the art as a knitting cycle, creating a course of knit loops of interconnected yarn. . A course of knit loops defines a circular knit fabric blank 130 . Specific stitches and/or patterns can be formed in the circular knit blank 130 by varying the knitting cycle and/or holding specific needles in place during knitting. Circular knitting machines and basic circular knitting processes are well known to those skilled in the art. Various circular knitting processes may be used, such as tube circular knitting, narrow tube circular knitting jacquard, single knit circular knitting jacquard, double knit circular knitting jacquard knitting.

Referring to FIG. 4, circular knit blank 130 has a first end 132 and a second end 134 . Circular knit blank 130 is formed having a first knit section 160 defining first end 132 and a second knit section 180 defining second end 134 . The circular knit blank 130 is composed of interconnected rows of knit loops called courses, as described above. A first “course” of knitted blank 130 is located at first end 132 . Circular knitted blank 130 is formed course by course in direction K shown in FIG. 4 until circular knitted blank 130 is completed, as shown in FIG. Thus, during the knitting stage, the first knitted section 160 is knitted first and then the second knitted section 180 is formed into a single monolithic fabric with the first knitted section 160 .

Circular knitting of knit blank 130 begins with cylinder needles knitting first toe portion 142 of first knit section 160 . A circular knitting machine then knits a midsole portion including a first upper portion 144a and a first lower portion 144b. Next, the first heel portion 146 of the first knit section 160 is knitted adjacent to the first lower portion 144b. While knitting the first heel portion 146 , the knitting machine can selectively drop the needles and change the knitting direction to form the desired curve of the first heel portion 146 . After the first heel portion 148 is formed, the circular knitting machine knits the first ankle portion 148 of the first knit section 160 adjacent the first heel portion 148 and the first upper portion 144a. At this point, first knit section 160 is substantially complete. The first knit section 160 includes the outer knit layer 60 of the double layer knit upper, as described below. Thus, as the knitting machine forms the first knit section 160, different knit regions 62a-62f are created within the circular knit blank 130, as shown.

The knitting process continues to form second knit section 180 . During this stage of knitting, second ankle portion 248 of second knit section 180 is formed adjacent first heel portion 148 . A circular knitting machine knits a continuous second heel portion 246 adjacent to the second ankle portion 248 . A circular knitting machine knits a second upper portion 244 a and a second lower portion 244 b of the second knit section 180 . The knitting process continues to form second toe portion 242 of second knit section 180 adjacent second upper portion 244a and second lower portion 244b. A second toe portion 242 is formed at the end 134 to complete the circular knit blank 130 . As the knitting machine forms the second knit section 180, different knit regions 82a-82g are created in respective regions of the circular knit blank 130. As shown in FIG. As shown, the formed circular knit blank 130 is substantially a tubular structure having the shape of two crew cut socks connected as an ankle portion.

Additional yarn courses may be added to facilitate the transition to the next knitted blank formed by the circular knitting machine. The finished circular knit blank 130 is cut from the knitting machine using optional cutting equipment. The circular knitted blank 130 exits the knitting machine for further processing.

Completed circular knit blank 130 may have toe openings 152 and 252 in toe portion 142 and toe portion 242, respectively. Toe openings 152 and 252 may be closed with seams 154 and 254, as shown in FIG. In an alternative embodiment, the circular knit blank 103 can be formed to automatically close the toe openings 152 and 252 using bridge stitches or inlay yarns or the like.

Circular knit blank 130 may be cut to form ankle opening 32 by removing panel 156 from circular knit blank 130 . In an alternative embodiment, a circular knit blank 103 can be formed to define the ankle opening 32 during knitting. In such embodiments, the circular knit blank 130 may form a welt edge along the border of the ankle opening 32 to prevent fraying and provide a location for attachment of the binding 54 (FIGS. 1 and 6).

When circular knit blank 130 is completed, second knit section 180 is folded into first knit section 160 to form the double layer knit upper of the article of footwear. At this stage, the dual layer knit upper includes an outer knit layer 60 defined by a first knit section 160 and an inner knit layer 80 defined by a second knit section 180 . In this state, at least two of the plurality of outer knit regions 62a-62d of the outer knit layer 60 spatially correspond to at least two of the plurality of inner knit regions. According to the illustrated embodiment, inner knit regions 82a-82e underlie outer knit regions 62a-62e.

The method may include placing a liner component along the bottom of the first knit section prior to folding. Thus, the liner component is positioned between the outer knit layer and the inner knit layer.

The method may include attaching the sole directly to the outer knit layer of the double layer knit upper. Attaching the sole to the outer knit layer includes placing the dual layer knit upper over a positioning member of an injection molding machine (not shown). The sole component is then injection molded onto the outer knit layer of the double layer knit upper. Additionally, the method may include injection molding a plurality of tabs 22a-22d along the inner and outer sides of the double layer knit upper. The injection molding process may melt the TPU yarns in specific knit regions, thereby bonding the outer knit layer to the inner knit layer to form a monolithic double layer knit upper.

A double layer knit upper that is circular knit as described herein has several advantages. A wide range of knit constructions are possible across different areas of the upper while using a single fabric construction. Specific knit structures can be designed into various areas of the article of footwear as needed. Additionally, complex three-dimensional shapes that better conform to the anatomy of the wearer's foot can be formed during the knitting process. Because the circular knit upper is made to fit the wearer's foot, fewer assembly steps are required prior to attaching the upper to the sole to create the finished article of footwear. Fewer total component counts in the finished article of footwear reduce supply chain complexity and increase production efficiency and yield. Additionally, the circular knit double layer upper can be manufactured at relatively high production speeds, further enhancing production efficiency.

Article of footwear 300 may include multiple layers or may be continuous to form a single body. Article of footwear 300 may include first layer 301 and second layer 302 . First layer 301 and second layer 302 may comprise a soft material such as cloth. First layer 301 and second layer 302 may be generally tubular or may include other shapes. Second layer 302 may comprise a rigid material such as leather or plastic. First layer 301 and second layer 302 may be formed by circular knitting, flat knitting, or other manufacturing methods, or from other materials. Second layer 302 may be folded or inverted to be positioned adjacent to at least a portion of first layer 301 . Second layer 302 may comprise at least a portion of the interior or exterior of article of footwear 300 . Article of footwear 300 may include additional layers that may provide additional functionality.

As shown in FIG. 7, article of footwear 300 may include first layer 301 and second layer 302 . First layer 301 and second layer 302 may include generally tubular shapes. First layer 301 may comprise a waterproof breathable material suitable for forming at least a portion of the exterior of article of footwear 300 . The first layer 301 can be spray coated to provide waterproofness and can be breathable. The second layer 302 may comprise a soft material suitable for conforming to the wearer's foot and providing comfort. The second layer 302 may be or include a comfort liner. When second layer 302 is folded into first layer 301 , second layer 302 defines the interior of article of footwear 300 and first layer 301 defines the exterior of article of footwear 300 . Although first layer 301 and second layer 302 are mentioned, other arrangements may be used. For example, features of each layer may be switched between layers or combined.

One problem with conventional circular knit applications is that it is difficult to sew or adhere other materials to the circular knit upper due to the finished 3D shape.

As an example, most heat presses and sewing machines are optimized for processing rolls on a flat surface. If the circular knit upper has a 3D shape, normal planar work may not be suitable.

As a further example, 3D direct injection can be used to add additional structure, cushioning, lace detailing, etc. to circular knit uppers. This process can be implemented into long-lasting uppers and can be finished in 3D shapes.

As shown in FIG. 8, article of footwear 400 may include multiple layers or may be continuous to form a single body. Article of footwear 400 may include first layer 401 and second layer 402 . First layer 401 and second layer 402 may comprise a soft material such as cloth. First layer 401 and second layer 402 may be generally tubular or may include other shapes. Second layer 402 may comprise a rigid material such as leather or plastic. First layer 401 and second layer 402 may be formed by circular knitting, flat knitting, or other manufacturing methods, or from other materials. Second layer 402 may be folded or inverted so as to be positioned adjacent to at least a portion of first layer 401 . Second layer 402 may comprise at least a portion of the interior or exterior of article of footwear 400 . Article of footwear 400 may include additional layers that may provide additional functionality.

As shown in FIG. 8, article of footwear 400 may include first layer 401 , second layer 402 , and vane system 403 . The vane system 403 may include laces, eyelets, straps, hook-and-loop fasteners, or other types of fasteners. The vane system 403 may be positioned adjacent to part of the first layer 401, part of the second layer 402, or part of both layers 401,402. First layer 401 and second layer 402 may comprise a generally tubular shape, which may be circular knit. A second layer 402 may be folded into the first layer 401 . Second layer 402 may define a medial portion of article of footwear 400 and first layer may define a lateral portion of article of footwear 400 . As shown, vane system 403 may be circumferentially disposed around second layer 402 . When second layer 402 is folded into first layer 401 , wing system 403 may be positioned between first circular knit layer 401 and second circular knit layer 402 of article of footwear 400 .

As shown in FIG. 9, article of footwear 500 may include multiple layers or may be continuous to form a single body. Article of footwear 500 may include first layer 501 and second layer 502 . First layer 501 and second layer 502 may comprise a soft material such as cloth. First layer 501 and second layer 502 may be generally tubular or may include other shapes. Second layer 502 may comprise a rigid material such as leather or plastic. First layer 501 and second layer 502 may be formed by circular knitting, flat knitting, or other manufacturing methods, or from other materials. Second layer 502 may be folded or inverted so as to be positioned adjacent to at least a portion of first layer 501 . Second layer 502 may comprise at least a portion of the interior or exterior of article of footwear 500 . Article of footwear 500 may include additional layers that may provide additional functionality.

As shown in FIG. 9, article of footwear 500 may include first layer 501 , second layer 502 , and collar portion 504 . As shown, first layer 501 may include a generally tubular shape. The first layer 501 can be circular knit. The second layer 502 may include a planar rectangular shape. The second layer 502 can be plain knit. Second layer 502 may include one or more weld reinforcements 505 to secure second layer 502 to first layer 501 . The second layer 502 may be configured for plain stitching operations 506 such as plain stitching, molding, or screen printing. Second layer 502 may be configured to be folded into or around first layer 501 to define collar portion 504 . The second layer 502 may be configured to be partially circumferentially disposed around the outer portion of the first layer 501 to define a collar portion 504 . The second layer 502 may also be placed adjacent the metatarsal, ankle, or other portion of the first layer 501 to define other features.

FIG. 10 illustrates that the article of footwear 600 can include multiple layers or can be continuous to form a single body. Article of footwear 600 may include first layer 601 and second layer 602 . First layer 601 and second layer 602 may comprise a soft material such as cloth. First layer 601 and second layer 602 may be generally tubular or may include other shapes. Second layer 602 may comprise a rigid material such as leather or plastic. First layer 601 and second layer 602 may be formed by circular knitting, flat knitting, or other manufacturing methods, or from other materials. Second layer 602 may be folded or inverted so as to be positioned adjacent to at least a portion of first layer 601 . Second layer 602 may comprise at least a portion of the interior or exterior of article of footwear 600 . Article of footwear 600 may include additional layers or features that may provide additional functionality.

As shown in FIG. 10, article of footwear 600 may include first layer 601 and second layer 602 . First layer 601 may be generally tubular. The first layer 601 can be circular knit. Second layer 602 may comprise a hard or rigid material, such as leather, rubber, or plastic, suitable for defining at least a portion of the exterior of article of footwear 600 . The second layer 602 can be flat knit. Second layer 602 may be configured to be positioned adjacent to at least an outer portion of first layer 601 . The second layer 602 may include reinforcement regions 610 . For example, as shown, reinforced region 610 may define heel cup 610a and toe cup 610b. A second layer 602 may include apertures 608 that define vane systems 603 or other features. Apertures 608 may include lacing holes or eyelets configured to receive laces or straps.

Article of footwear 600 may further include one or more ventilation regions 607 that provide ventilation. Vent area 607 may be generally triangular or planar, or may have other shapes. As shown, the first layer 601 and the second layer 602 may comprise multiple vent regions 607 . Vent areas 607 of first layer 601 correspond to vent areas 607 of second layer 607 and can be configured to be adjacently positioned when inverted to form article of footwear 600 .

Article of footwear 700 may include multiple layers or may be continuous to form a single body. Article of footwear 700 may include first layer 701 and second layer 702 . First layer 701 and second layer 702 may comprise a soft material such as cloth. First layer 701 and second layer 702 may be generally tubular or may include other shapes. Second layer 702 may comprise a rigid material such as leather or plastic. First layer 701 and second layer 702 may be formed by circular knitting, flat knitting, or other manufacturing methods, or from other materials. Second layer 702 may be folded or inverted so as to be positioned adjacent to at least a portion of first layer 701 . Second layer 702 may comprise at least a portion of the interior or exterior of article of footwear 700 . Article of footwear 700 may include additional layers that may provide additional functionality.

As shown in FIG. 11, article of footwear 700 may include first layer 701 and second layer 702 . First layer 701 and second layer 702 may be continuous to define a single body. The second layer 702 may be configured to invert adjacent to the outer surface of the first layer 701 . First layer 701 and second layer 702 may include one or more features. As shown, the second layer 702 can include multiple strips 709a, 709b, 709c. Strips 709a, 709b, 709c may comprise knitted material, rigid material, or a combination of knitted and rigid material to define different features. As shown, the first strip 709a can include a reinforced region 710 that can define a heel cup 710a. A second strip 709b may include apertures 708 that may define vane system 703 .

Article of footwear 800 may include multiple layers or may be continuous to form a single body. Article of footwear 800 may include first layer 801 and second layer 802 . First layer 801 and second layer 802 may comprise a soft material such as cloth. First layer 801 and second layer 802 may be generally tubular or may include other shapes. Second layer 802 may comprise a rigid material such as leather or plastic. First layer 801 and second layer 802 may be formed by circular knitting, flat knitting, or other manufacturing methods, or from other materials. Second layer 802 may be folded or inverted so as to be positioned adjacent to at least a portion of first layer 801 . Second layer 802 may comprise at least a portion of the interior or exterior of article of footwear 800 . Article of footwear 800 may include additional layers that may provide additional functionality.

As shown in FIG. 12, article of footwear 800 may include first layer 801 and second layer 802 . First layer 801 may be generally tubular. The first layer 801 can be circular knit. Second layer 802 may include an irregular planar shape. The second layer 802 can be flat knit. Article of footwear 800 may further include vane system 803 . As shown, second layer 802 can include member 811 configured to extend through at least a portion of first layer 801 . Member 811 may be configured to be removably received in aperture 808 in first layer 801 . Member 811 may include loops and hooks to define article of footwear 800 with a pull-through feature.

Article of footwear 900 may include multiple layers or may be continuous to form a single body. Article of footwear 900 may include first layer 901 and second layer 902 . First layer 901 and second layer 902 may comprise a soft material such as cloth. First layer 901 and second layer 902 may be generally tubular or may include other shapes. Second layer 902 may comprise a rigid material such as leather or plastic. First layer 901 and second layer 902 may be formed by circular knitting, flat knitting, or other manufacturing methods, or from other materials. Second layer 902 may be folded or inverted so as to be positioned adjacent to at least a portion of first layer 901 . Second layer 902 may comprise at least a portion of the interior or exterior of article of footwear 900 . Article of footwear 900 may include additional layers that may provide additional functionality.

As shown in FIG. 13, article of footwear 900 may include first layer 901 and second layer 902 . First layer 901 may include a generally tubular shape. The first layer 901 can be circular knit. The second layer 902 may include planar irregular shapes. The second layer 902 can be plain knit. A second layer 902 may be inverted adjacent to the outer surface of the first layer 901 . A second layer 902 may include a vane system 903 . As shown, second layer 902 may include apertures 908 (eg, lacing holes) that define vane system 903 . Second layer 902 may include reinforced regions 910 that may define heel cups 910 a and toe cups 910 b that provide structure and integrity to the exterior of article of footwear 900 .

FIG. 14 shows exemplary articles of footwear 950-954 that may include functional layers 960-965. Functional layers 960-965 may include insoles, midsoles, insulation, socks, collars, and other functional features within articles of footwear 950-954. As described and shown, one or more functional layers may be interposed between two knit layers (eg, circular knit layers), such as by using turn-up or other techniques. The functional layer may comprise a waterproof material or membrane, or a breathable waterproof membrane. The functional layer can be a preformed laminate or composite. The functional layer can be spray applied. The functional layer can be 3D direct injection. Functional layers can be applied to other configurations or other surfaces. By way of non-limiting example, one problem addressed by the present disclosure is that although circular knitting is fast, it is difficult to sew or affix things to the circular knitted upper due to the finished 3D shape. There are times when it is difficult. Most state-of-the-art heat presses and sewing machines are optimized for processing rolls on a flat surface. As an illustrative example, 3D direct injection is one method of applying additional structures, cushioning, string details, etc. that are optimized to work with 3D molding. This process can be implemented in a long lasting upper as a fully finished 3D shape.

As shown, functional layer 960 may include an insole incorporated into the midsole of article of footwear 950 . Functional layer 961 may include a knit midsole (eg, padding knit) within article of footwear 951 . Functional layer 962 may include thermal insulation incorporated within article of footwear 952 . Functional layer 963 a may include a midsole confined within article of footwear 953 . The midsole may include features such as outsole projections that may extend through the first and/or second layers. The protrusion may be configured to engage the ground. As an example, one or more of the first layer or the second layer may include apertures to allow protrusions from the confined midsole to extend therethrough. Various configurations of projections may be used, such as heel placement and forefoot placement. Functional layer 963b may include a foam collar encased within article of footwear 953 . Functional layer 964 may comprise the overall upper and outsole within article of footwear 954 . Functional layer 965 may include a custom inner sock within article of footwear 954 .
mode

The disclosure includes at least the following aspects:

Aspect 1: An article of footwear comprising a double layer knit upper having an insole, an upper portion contiguous with the insole, an ankle opening, and an inner void for receiving a wearer's foot, the double layer knit upper. teeth,
a) an outer knit layer defining the outer surface of the double layer knit upper, the outer knit layer having a plurality of outer knit regions;
b) an inner knit layer monolithically knitted to the outer knit layer to form an inner void, the outer knit layer having a plurality of inner knit regions spatially corresponding to the plurality of outer knit regions of the outer knit layer; and an inner knit layer having an inner knit layer and a sole attached to at least the midsole of the double layer knit upper, the inner knit layer substantially defining the midsole and the upper portion of the double layer knit upper.

Aspect 2. The article of footwear according to aspect 1, further comprising a midsole positioned between the outer knit layer and the inner knit layer along the midsole.

Aspect 3. The article of footwear according to aspect 1, wherein the outer knit layer and the inner knit layer are monolithic circular knit fabrics.

Aspect 4. The article of footwear according to aspect 1, wherein the outer knit layer and the inner knit layer each define a tubular knit shape.

Aspect 5. The article of footwear according to aspect 1, wherein the inner knit layer is monolithically knitted to the outer knit layer around at least a portion of the ankle opening.

Aspect 6. The article of footwear according to aspect 5, wherein the outer knit layer and the inner knit layer define a welt edge along at least a portion of the ankle opening.

Aspect 7. The article of footwear according to aspect 1, wherein the outer knit layer and the inner knit layer comprise binding along at least a portion of the ankle opening.

Aspect 8. The article of footwear according to aspect 1, further comprising at least one attachment member that integrates the outer knit layer and the inner knit layer.

Aspect 9. The article of footwear according to aspect 8, wherein the at least one attachment member adheres yarns of the outer knit layer to yarns of the inner knit layer.

Aspect 10. 9. The article of footwear according to aspect 8, wherein the at least one attachment member is a binding yarn.

Aspect 11. 11. The article of footwear according to aspect 10, wherein the binding yarn is a thermoplastic polyurethane yarn.

Aspect 12. 11. The article of footwear according to aspect 10, wherein the binding yarn is a low melting point thermoplastic yarn.

Aspect 13. The article of footwear according to aspect 10, wherein the outer knit layer comprises a first yarn, the inner knit layer comprises a second yarn, and the binding yarn has a lower melting temperature than the first yarn and the second yarn.

Aspect 14. The article of footwear according to aspect 8, wherein the at least one attachment member is an adhesive film.

Aspect 15. 9. The article of footwear according to aspect 8, wherein the at least one attachment member is a low melt adhesive web.

Aspect 16. The article of footwear according to aspect 8, wherein at least one of the plurality of outer knit regions comprises at least one attachment member.

Aspect 17. A dual layer knit upper has a toe portion, a first outer knit region of a plurality of outer knit regions in the outer knit layer extending across a rear upper portion of the toe portion, the first outer knit region comprising: 17. The article of footwear according to aspect 16, comprising at least one attachment member.

Aspect 18. The article of footwear recited in aspect 8, wherein at least one of the plurality of inner knit regions comprises at least one attachment member.

Aspect 19. A second outer knit region of the plurality of outer knit regions extends across the toe portion, a second inner knit region of the plurality of inner knit regions underlies the second outer knit region, and a second outer knit region of the plurality of inner knit regions. 19. The article of footwear according to aspect 18, wherein at least one of the knit region and the second inner knit region comprises at least one attachment member.

Aspect 20. 19. The article of footwear according to aspect 18, wherein the plurality of inner knit regions includes an inner central region along the midsole that includes the at least one attachment member.

Aspect 21. The article of footwear according to aspect 1, wherein the double layer knit upper has a heel portion connecting the midsole to the ankle portion, the heel portion having a cushioning knit structure.

Aspect 22. The article of footwear according to aspect 1, wherein the double layer knit upper has a toe portion, the toe portion having a cushioning knit structure.

Aspect 23. The article of footwear of aspect 1, further comprising a plurality of tabs extending upwardly from the sole along the medial and lateral sides of the article of footwear.

Aspect 24. 24. The article of footwear according to aspect 23, wherein the plurality of tabs includes securing members configured to receive a cord.

Aspect 25. A circular knit blank having a first end and a second end used to form an article of footwear, the first toe portion defining the first end of the circular knit blank; A first circular knit section having an upper portion, a first lower portion coupled to the first upper portion, a first heel portion, and a first ankle portion coupled to the first heel portion. a first circular knit section having a first plurality of knit regions each having a different knit construction; a second ankle portion monolithically knitted to the first ankle portion; a second heel portion coupled to the second ankle portion; a second upper portion coupled to the second ankle portion; a second lower portion coupled to the second upper portion and the second heel portion; a second toe portion defining a second end of the circular knit blank opposite the one end, a second plurality of circular knit sections each having a different knit construction; and a second circular knitted section having knitted regions of 1000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000001000000000000000000000000000000000000000000000000000000000000000000000 to 000000000000000000000000000000000 with the first circular knitting section to be folded into the second circular knitting section. wherein the first plurality of knit regions correspond to the second plurality of knit regions such that the knit regions of the circular knit regions overlap.

Aspect 26. 26. The circular knit blank of aspect 25, further comprising an opening positioned where the first ankle portion and the second ankle portion are joined.

Aspect 27. 26. The circular knit blank of aspect 25, further comprising at least one attachment member configured to adhere the first circular knit section and the second circular knit section together.

Aspect 28. A method of forming an article of footwear comprising circular knitting a tubular knitted blank having a first knitted section and a second knitted section, wherein: a) the first knitted section is joined with a first toe portion; , a first lower portion, a first upper portion, a first heel portion adjacent to the first lower portion, and a first ankle portion adjacent to the first heel portion and the first upper portion; b) the second knit section comprises a second toe portion, a second lower portion, a second upper portion, a second heel portion adjacent to the second lower portion, the second heel portion and the second circular knitting a tubular knitted blank comprising: a second ankle portion adjacent an upper portion of the footwear article; forming a double layer knit upper comprising an outer knit layer defined by a second knit section and an inner knit layer defined by a first knit section, the inner knit layer comprising a double layer knit A method comprising: folding a first knit section into a second knit section defining an inner void of the upper; and attaching a sole directly to an outer knit layer of a double layer knit upper.

Aspect 29. circular knitting in order,
a. knitting a first toe portion of the first knit section;
b. knitting a first upper portion and a first lower portion of a first knit section;
c. knitting a first heel portion of a first knit section adjacent to the first lower portion;
d. knitting a first ankle portion of a first knit section adjacent to the first heel portion and the first upper;
e. knitting a second ankle portion of a second knit section adjacent to the first heel portion;
f. knitting a second heel portion adjacent the second ankle portion of the second knit section;
g. knitting a second upper portion and a second lower portion of a second knit section;
h. 29. The method of aspect 28, comprising knitting a second toe portion of the second knit section adjacent the second upper portion and the second lower portion.

Aspect 30. Attaching the sole to the outer knit layer includes positioning the double layer knit upper over a positioning member of an injection molding device; injection molding the sole to the outer knit layer of the double layer knit upper; and injection molding a plurality of tabs along the inner and outer sides of the upper, wherein the plurality of tabs are configured to receive a cord.

Aspect 31. A first circular knit layer defining at least a portion of an outer surface and a second circular knit layer coupled to the first circular knit layer and folded into or around the first circular knit layer and a second circular knit layer sometimes configured to be positioned adjacent to at least a portion of the first circular knit layer.

Aspect 32. 32. The article of footwear recited in aspect 31, wherein the second circular knit layer extends from the first circular knit layer as a single body.

Aspect 33. 32. The article of footwear according to aspect 31, wherein the first circular knit layer comprises a generally tubular shape.

Aspect 34. 32. The article of footwear according to aspect 31, wherein the second circular knit layer comprises a generally tubular shape.

Aspect 35. 32. The article of footwear according to aspect 31, wherein the second circular knit layer comprises a planar shape.

Aspect 36. 32. The article of footwear according to aspect 31, wherein the first circular knit layer comprises a waterproof breathable material and the second circular knit layer comprises a comfort liner.

Aspect 37. such that at least a portion of the vane system is interposed between the second circular knit layer and the first circular knit layer when the second circular knit layer is folded into the first circular knit layer 32. The article of footwear of aspect 31, further comprising a vane system positioned adjacent to at least a portion of the second circular knit layer.

Aspect 38. 38. The article of footwear according to aspect 37, wherein at least a portion of the vane system is circumferentially disposed about the second circular knit layer.

Aspect 39. A first circular knit layer includes a generally tubular shape, a second circular knit layer includes a planar shape, and a planar second circular knit layer is folded into or around the first circular knit layer. 32. The article of footwear of aspect 31, wherein the article of footwear is configured for surface work prior to application.

Aspect 40. 40. The article of footwear according to aspect 39, wherein the planar work comprises one or more of flat stitching, fusing, molding, or screen printing.

Aspect 41. 40. The article of footwear according to aspect 39, wherein the planar second circular knit layer includes one or more welded reinforcing regions.

Aspect 42. An aspect wherein the first circular knit layer comprises a collar and the planar second circular knit layer is configured to be circumferentially disposed at least partially around the outer surface of the first circular knit layer. 32. The article of footwear according to 31.

Aspect 43. A first circular knit layer includes a generally tubular shape, and a second circular knit layer is on or within the first circular knit layer adjacent to one or more ankle portions. 32. The article of footwear according to aspect 31, wherein the article of footwear is configured to fold to be positioned adjacent a foot portion.

Aspect 44. A first circular knit layer includes one or more vented regions, and a second circular knit layer is configured to be folded over the first circular knit layer adjacent at least a portion of the vented regions. 44. The article of footwear according to aspect 43, wherein:

Aspect 45. 45. The article of footwear recited in aspect 44, wherein the second circular knit layer comprises one or more features configured to be positioned adjacent a portion of the ventilation region.

Aspect 46. The article of footwear according to aspect 45, wherein the one or more features include apertures.

Aspect 47. 44. The article of footwear recited in aspect 43, wherein the second circular knit layer comprises one or more features configured to be positioned adjacent to the first circular knit layer.

Aspect 48. The article of footwear according to aspect 47, wherein the one or more features include apertures, lace holes, or heel cups, or combinations thereof.

Aspect 49. The article of footwear according to aspect 47, wherein the one or more features include pull-throughs configured to extend through a portion of the first circular knit layer.

Aspect 50. An aspect wherein the first circular knit layer comprises a generally tubular shape and the second circular knit layer is configured to be folded so as to be positioned adjacent to an outer surface or an inner surface of the first circular knit layer. 32. The article of footwear according to 31.

Aspect 51. further comprising a functional layer interposed between the first circular knit layer and the second circular knit layer when the second circular knit layer is folded into or onto the first circular knit layer; 51. The article of footwear according to aspect 50.

Aspect 52. 52. The article of footwear according to aspect 51, wherein the functional layer comprises an insole.

Aspect 53. 52. The article of footwear according to aspect 51, wherein the functional layer comprises a midsole.

Aspect 54. 52. The article of footwear according to aspect 51, wherein the functional layer comprises thermal insulation.

Aspect 55. 52. The article of footwear according to aspect 51, wherein the functional layer comprises a collar.

Aspect 56. 51. The article of footwear according to aspect 50, wherein the second circular knit layer comprises apertures such that it is configured to be rolled.

Aspect 57. An article of footwear,
a first circular knit layer defining at least a portion of the outer surface;
A second layer coupled to the first circular knit layer and positioned adjacent at least a portion of the first circular knit layer when folded into or around the first circular knit layer. an article of footwear comprising: a second layer configured to

Aspect 58. 58. The article of footwear according to aspect 57, wherein the second layer comprises a planar shape.

Aspect 59. 59. The article of footwear according to aspect 58, wherein the planar configuration is configured for planar operations prior to being folded into or around the first circular knit layer.

Aspect 60. 58. The article of footwear of aspect 57, wherein the second layer is flat knit.

Aspect 61. 58. The article of footwear according to aspect 57, wherein the second layer includes one or more welded reinforcement regions.

Aspect 62. 58. The article of footwear recited in aspect 57, wherein the first circular knit layer includes a generally tubular shape and the second layer is configured to be folded to be positioned adjacent an outer surface of the first circular knit layer. Goods.

Aspect 63. 58. Claimed in aspect 57, wherein the first circular knit layer comprises a collar and the second layer is configured to be circumferentially disposed at least partially around an outer surface of the collar of the first circular knit layer. footwear articles.

Aspect 64. Aspect 57, wherein the first circular knit layer includes one or more vented regions, and the second layer is configured to be folded over the first layer adjacent at least a portion of the vented regions. Article of footwear as described in

Aspect 65. 58. The article of footwear of aspect 57, wherein the second layer comprises one or more features configured to be positioned adjacent to the first circular knit layer.

Aspect 66. The article of footwear according to aspect 65, wherein the one or more features include apertures, vane systems, lace holes, or heel cups, toe cups, or combinations thereof.

Aspect 67. The article of footwear of aspect 65, wherein the one or more features comprise a pull-through configured to extend through at least a portion of the first circular knit layer.

Aspect 68. a functional layer interposed between the first circular knit layer and the second layer when the second layer is folded into or over the first circular knit layer; 58. The article of footwear of aspect 57, comprising:

Aspect 69. 69. The article of footwear according to aspect 68, wherein the functional layer comprises an insole.

Aspect 70. 69. The article of footwear recited in claim 68, wherein the functional layer comprises a midsole.

Aspect 71. 69. The article of footwear recited in claim 68, wherein the functional layer comprises thermal insulation.

Aspect 71. 69. The article of footwear recited in claim 68, wherein the functional layer comprises a collar.

This disclosure describes certain embodiments and their detailed structure and operation. The embodiments described herein are described for purposes of illustration only and not limitation. Persons of ordinary skill in the art will recognize, in light of the teachings herein, that there may be a range of equivalents to the exemplary embodiments described herein. Most notably, other embodiments are possible. Modifications may be made to the embodiments described herein, and there may be equivalents to the components, parts, or steps that make up the described embodiments. For the sake of clarity and brevity, certain aspects of components or steps of particular embodiments have been described where and/or where such details would be apparent to those skilled in the art in light of the teachings herein. In cases where the details obscure the understanding of more pertinent aspects of the embodiments, they are presented without undue detail.

Claims (15)

An article of footwear,
a first circular knit layer;
A second layer coupled to the first circular knit layer and adjacent at least a portion of the first circular knit layer when folded into or around the first circular knit layer. a second layer configured to be arranged in the
a functional layer interposed between the first circular knit layer and the second layer when the second layer is folded into or around the first circular knit layer. Articles of footwear. The article of footwear recited in claim 1, wherein the functional layer comprises one or more of a waterproof membrane, a breathable waterproof membrane, or a spray application. The article of footwear recited in any one of claims 1-2, wherein the first circular knit layer defines at least a portion of an outer surface and the second layer comprises a second circular knit layer. 4. The article of footwear recited in claim 3, wherein the second layer extends from the first circular knit layer as a single body. The article of footwear according to any one of the preceding claims, wherein the first circular knit layer comprises a generally tubular shape. The article of footwear according to any one of the preceding claims, wherein the second layer comprises a generally tubular shape. The article of footwear according to any one of the preceding claims, wherein the first circular knit layer comprises a waterproof breathable material and the second layer comprises a comfort liner. such that at least a portion of the vane system is interposed between the second layer and the first circular knit layer when the second layer is folded into the first circular knit layer; The article of footwear according to any one of the preceding claims, further comprising a vane system positioned adjacent to at least a portion of said second layer. said first circular knit layer comprising a generally tubular shape and said second layer comprising a planar shape, said second layer being planar prior to being folded into or around said first circular knit layer. An article of footwear according to any preceding claim, configured for work. 10. The article of footwear recited in claim 9, wherein the second layer includes one or more welded reinforcement regions. 10. The first circular knit layer comprises a collar, and the second layer is configured to be circumferentially disposed at least partially around an outer surface of the first circular knit layer. 11. The article of footwear according to any one of clauses 1-10. such that the first circular knit layer comprises one or more ventilating regions and the second layer is folded into or around the first circular knit layer adjacent at least a portion of the venting regions; The article of footwear of any one of claims 1-11, wherein the article of footwear comprises: The second layer is configured to be positioned adjacent to the first circular knit layer when the second layer is folded into or around the first circular knit layer. 13. The article of footwear of any one of claims 1-12, comprising one or more features, wherein the one or more features comprise apertures, lace holes, or heel cups, or combinations thereof. . The second layer is one configured to be positioned adjacent to the first circular knit layer when the second layer is folded into or around the first circular knit layer. or a plurality of features, the one or more features comprising a pull-through configured to extend through a portion of the first circular knit layer. or the footwear article according to item 1. a functional layer interposed between the first circular knit layer and the second layer when the second layer is folded into or around the first circular knit layer; The article of footwear according to any one of the preceding claims, wherein the functional layer comprises an insole, midsole, insulation, or collar.

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