Knitted elements with buffer and stiffness regions, uppes and footwear with knitted

Abstract

Knitted elements, including knitted heel elements, configured with cushioning and stiffness features, as well as uppers and footwear having the knitted elements, and methods of making and integrating the knitted elements in footwear. Buffering and stiffness features may be provided in the knit element by positioning cushioning yarns and yarns comprising thermoplastic material in selected zones and / or in the knit layer. Heat and pressure may be selectively applied to the knit zone to melt the thermoplastic material and form a thermoformed layer having a desired degree of hardness and / or stiffness. The thermoformed layer may form at least a portion of an unitary knit heel stabilizer of an upper of the article of footwear, e.g., without the introduction of separate components that are traditionally attached or integrated to form the heel stabilizer.

Description

[0001] Cross-reference to related applications and priority claim

[0002] This non-provisional patent application claims priority to co-pending U.S. Provisional Patent Application No. 63 / 530,195, filed on August 1, 2023, entitled “Knit element with cushioning and rigidity zones,” the entire contents of which are incorporated herein by reference. Technical Field

[0003] The field relates to knitted elements for footwear, including knitted heel elements. Background Art

[0004] Conventional heel elements, which may be broadly defined as elements that provide structure, cushioning, and / or support to the heel region of an upper of an article of footwear, are typically formed of a rigid or semi-rigid material such as leather, plastic, or the like. Furthermore, conventional heel elements are typically attached to an outwardly facing surface of the upper during the manufacturing process. In instances where the heel element includes cushioning, such as adjacent to a collar region of the upper, the cushioning element is typically secured to the heel element in an additional manufacturing step. In addition to increasing the time and expense associated with manufacturing an article of footwear, these additional manufacturing steps may increase the overall carbon footprint associated with footwear manufacturing, which is undesirable. BRIEF DESCRIPTION OF THE DRAWINGS

[0005] Examples of various aspects of the present invention are described in detail below with reference to the accompanying drawings, in which:

[0006] Figure 1 illustrates a medial view of an example article of footwear having a knitted heel element according to aspects herein;

[0007] Figure 2 The diagram shows the various aspects of the present invention. Figure 1 a lateral view of an example article of footwear;

[0008] Figure 3 The diagram shows the various aspects of the present invention. Figure 1 a rear view of an example article of footwear;

[0009] Figure 4A One configuration of a knitted heel element according to aspects herein is illustrated;

[0010] Figure 4B Illustrated is similar to Figure 4A Another configuration of a knitted heel element;

[0011] Figure 4C Illustrated is similar to Figure 4A Another configuration of a knitted heel element;

[0012] Figure 5 illustrates a cross-section taken at cut line 5 - 5 in FIG. 4 , and schematically depicts a first example knit structure of a first knit region of a knitted heel element according to aspects herein;

[0013] Figure 6 A cross section taken at cutting line 6-6 of FIG. 4 is illustrated and schematically depicts a second knitted area of ​​a knitted heel element according to various aspects of the present disclosure. Figure 5 A first example knitted structure;

[0014] Figure 7 Illustrated is a method for partially knitting a Figure 5 and Figure 6 Example stitch markings of needle beds of a multi-bed knitting machine of an example knitting structure;

[0015] Figure 8 Illustrated is a method of manufacturing at least Figure 5 and Figure 6 A block diagram of an example method of an example knitted structure;

[0016] Fig. 9 illustrates a cross-section taken at cut line 9-9 in FIG. 4 and schematically depicts a second example knit structure of a first knit region of a knitted heel element according to aspects herein;

[0017] Fig.10 A cross section taken at cutting line 10-10 in FIG. 4 is illustrated and schematically depicts a second knitted region of a knitted heel element according to aspects of the present disclosure. Fig. 9 A second example knitted structure;

[0018] Fig.11 Illustrated is a method of manufacturing at least Fig. 9 and Fig.10 A flowchart of an example method of an example knitted structure; and

[0019] Fig.12 One example of an array of articles of footwear configured for different athletic activities according to aspects herein, wherein the articles of footwear include knitted heel elements having different configurations. DETAILED DESCRIPTION

[0020] Traditional heel element, which can be broadly defined as an element that provides structure, cushioning and / or support to the heel area of ​​the upper of a footwear article, is usually formed by a rigid or semi-rigid material such as leather, plastic, etc. In addition, traditional heel elements are usually attached to the outward-facing surface of the upper during the manufacturing process, or are otherwise inserted into the upper. In some cases, such rigid or semi-rigid materials may include sharp edges, which may cause discomfort to the wearer, including heel stimulation, which is a common reason for returning or discarding footwear. In addition, in the case where the heel element includes cushioning, such as the collar area adjacent to the upper, the cushioning element is usually fixed to the heel element in an additional manufacturing step. In addition to increasing the time, expense and complexity associated with manufacturing footwear articles, these additional manufacturing steps may increase the overall carbon footprint of footwear manufacturing. In addition, adding reinforcements and / or cushioning elements may increase the volume and weight of footwear articles, as well as other undesirable attributes.

[0021] In various aspects of the present invention, a footwear article having a knitted element (including a knitted heel element), a method of manufacturing a knitted element and footwear, and in some aspects, an array of footwear articles including a knitted heel element is provided, the knitted heel element can have different amounts of cushioning and / or rigidity depending on the intended use of the footwear article. With respect to the knitted heel element, various aspects of the present invention contemplate the use of different knitting structures, different material processing, different types of yarns and / or different amounts of specific yarns to achieve different amounts of cushioning and / or rigidity in different knitted areas of the knitted heel element. In various aspects, the knitted heel element can be incorporated into the upper as a heel stabilizer, such as a structure that imparts stiffness and cushioning in the heel area without the need for a traditional heel stabilizer component, which is manufactured separately and incorporated into the upper in one or more additional manufacturing steps. The use of such knitted heel elements has been shown to increase comfort, reduce manufacturing complexity, cost and number of steps, and provide a more seamless integration of components into knitted footwear manufactured using automatic knitting machines and post-processing techniques.

[0022] In example aspects, in a knitted heel element, the amount of cushioning and stiffness can be independently controlled such that a particular knitted area can have, for example, a large amount of cushioning and stiffness or hardness, a large amount of cushioning and a small amount of stiffness or hardness, a small amount of cushioning and a large amount of stiffness or hardness, or a small amount of cushioning and stiffness or hardness. In some examples, the knitted heel element can include transition regions between different knitted areas, wherein the transition regions can include an intermediate stiffness or hardness and / or an intermediate amount of cushioning relative to knitted areas adjacent to the transition regions.

[0023] In some respects, buffering and rigidity can be controlled to form an elastic, reversibly collapsible knitted heel element, which is convenient for putting on and taking off the footwear. For example, the buffer knitted area can be located adjacent to the collar area of ​​the footwear, and the rigid knitted area can be located below the buffer knitted area adjacent to the sole structure of the footwear. The knitted structure, the type of yarn used and / or the number of yarns used can be adjusted so that when the wearer puts his or her foot into the footwear, and the wearer's heel presses the buffer knitted area downwards towards the rigid knitted area and / or collapses the buffer knitted area downwards, the wearer can easily slide her foot into the footwear. Once positioned in the footwear, the buffer knitted area can rebound quickly upwards and return to its stretched shape. This feature is particularly useful for wearers with different hand and / or arm mobility or coordination abilities, because this feature enables the wearer to put on footwear without using his or her hands.

[0024] In a first example knitting structure, a knitted heel element may include a first knitting layer forming an outward-facing surface of the knitted heel element, a second knitting layer forming an inward-facing surface of the knitted heel element, and a third knitting layer positioned between the first knitting layer and the second knitting layer, wherein the first knitting layer, the second knitting layer, and the third knitting layer are knitted integrally with each other in a single knitting event (e.g., a manufacturing process performed by a knitting machine). In a first knitting area of ​​the knitted heel element, a thermoforming layer is at least partially positioned between the first knitting layer and the third knitting layer, and when the knitted heel element is incorporated into the upper of the footwear article, the first knitting area may correspond to the lower portion of the knitted heel element positioned adjacent to the sole structure. The thermoforming layer may provide rigidity for the first knitting area, which may help support the Achilles tendon area of ​​the wearer's foot. In example aspects, the first knitting area may also include yarn ends of a buffer yarn positioned between the second knitting layer and the third knitting layer. Positioning the buffer yarn between the second knitting layer and the third knitting layer may position the buffer yarn closer to the skin surface of the wearer than placing the buffer yarn between the first knitting layer and the third knitting layer. The cushioning yarns may provide some cushioning between the wearer's skin surface and the more rigid thermoforming layer in the first knitted zone.

[0025] The first knitted structure may also include a second knitted area, which is located at the upper portion of the knitted heel element, adjacent to the collar area of ​​the upper. The second knitted area may include several yarn ends of a buffer yarn positioned between the second knitted layer and the third knitted layer. The buffer yarn can help provide cushioning for the collar area of ​​the upper, which is convenient for the comfort of the wearer. In some example aspects, the second knitted area may also include yarn ends of a low-melting point thermoplastic material positioned between the first knitted layer and the third knitted layer. The low-melting point thermoplastic material can help provide some elasticity and structure to the knitted heel element in the second knitted area so that the knitted heel element does not fold in an undesirable manner.

[0026] In order to form the first knitted structure, during a single knitting event (e.g., a knitting operation performed by a knitting machine), a first knitted layer, a second knitted layer, and a third knitted layer are knitted on a double-bed knitting machine. In one exemplary aspect, the first knitted layer and the third knitted layer can be knitted in a half-gauge structure on the first needle bed of the knitting machine. For example, the first knitted layer can be knitted on the first needle, the third needle, the fifth needle, etc. of the first needle bed, and the second knitted layer can be knitted on the second needle, the fourth needle, the sixth needle, etc. of the first needle bed. The second knitted layer can be knitted on the second needle bed of the knitting machine. In this aspect, the number of knitted stitches per inch or centimeter of the first knitted layer and the third knitted layer is approximately half of the second knitted layer. In some aspects of this article, it is envisioned to use a high-melting point thermoplastic yarn (e.g., such as a high-melting point polyester yarn and / or a high-melting point recycled polyester yarn) to knit the first knitted layer, the second knitted layer, and the third knitted layer. Examples of polyesters that can be used in the yarn included in the knitted structure described herein include polyethylene terephthalate (PET) and polybutylene terephthalate (PBT), etc. In an exemplary aspect, to increase structural stability, the high melting point thermoplastic yarn may be plated with a fusible yarn as defined below.

[0027] During a single knitting event, the yarn end including the low-melting thermoplastic material can be positioned between the first knitting layer and the third knitting layer. In some aspects, the yarn end including the low-melting thermoplastic material can be interlaced with the knitting coils forming the first knitting layer and the third knitting layer. In one example, the yarn end including the low-melting thermoplastic material can be intermittently floated between the first knitting layer and the third knitting layer, and then tucked with the knitting coils forming the first knitting layer and / or the third knitting layer. During a single knitting event, the yarn end including the buffer yarn can be positioned between the second knitting layer and the third knitting layer. In some aspects, the yarn end including the buffer yarn can be embedded between the second knitting layer and the third knitting layer, for example, via a combined yarn feeder, although various aspects of this article also contemplate interlacing the buffer yarn with one or more knitting coils forming the second knitting layer and the third knitting layer. Various aspects of this article contemplate changing the number of yarn ends of the low-melting thermoplastic material and / or the buffer yarn regionally to achieve different functional purposes of different knitting areas (e.g., the first knitting area and the second knitting area) of the knitted heel element. Various aspects of the present invention also contemplate changing the type of yarn positioned between the first knit layer and the third knit layer and / or between the second knit layer and the third knit layer to achieve different functional purposes of different knit zones. Any and all of these aspects and any variations thereof are contemplated to be within the scope of the present invention.

[0028] The method for manufacturing a knitted heel element may also include applying one or more of heat and pressure to the first knitted area of ​​the knitted heel element. The heat may be sufficient to melt the yarn ends including the low-melting thermoplastic material, but may not be high enough to melt, scorch, burn or otherwise destroy the structural integrity of the buffer yarn and the high-melting thermoplastic yarn used to form the first knitted layer, the second knitted layer and the third knitted layer. Pressure may be applied to allow the molten thermoplastic material to flow in one or more planes or directions. For example, the molten thermoplastic material may flow in the x, y plane so that the molten thermoplastic material diffuses between the first knitted layer and the third knitted layer. The molten thermoplastic material may also flow in the z direction, such as, for example, into and / or through the first knitted layer, so that in some aspects, the molten thermoplastic material may be deposited on the outward-facing surface of the knitted heel element. The knitted heel element is then cooled, which causes the molten thermoplastic material to resolidify and form a thermoforming layer at least partially positioned between the first knitted layer and the third knitted layer. In some aspects, the thermoforming layer at least partially extends into and / or through the first knitted layer.

[0029] In further example aspects, the amount of pressure applied to the first knitted area can be calibrated so that the thermoforming layer does not extend completely through the second knitted layer or does not substantially extend through the second knitted layer, thereby maintaining the functional properties of the cushioning yarn positioned between the second knitted layer and the third knitted layer. As described above, the thermoforming layer can impart structural rigidity to the first knitted area of ​​the knitted heel element. In example aspects, heat and / or pressure are not applied to the second knitted area of ​​the knitted heel element so that the thermoforming layer is not formed in the second knitted area, and the functional properties of the second knitted area can be cushioning rather than rigidity. In some example aspects, a second heat and pressure may be applied to soften the thermoplastic material (including the thermoforming layer) to shape the knitted heel element into a desired three-dimensional shape. The knitted heel element can then be incorporated into the heel area of ​​the upper of the footwear article.

[0030] In a second example knitted structure, a knitted heel element may include a first knitted layer forming an outwardly facing surface of the knitted heel element and a second knitted layer forming an inwardly facing surface of the knitted heel element, wherein the first knitted layer and the second knitted layer are knitted integrally with each other in a single knitting event. In a first knitted area of ​​the knitted heel element, a thermoforming layer is at least partially positioned between the first knitted layer and the second knitted layer, and when the knitted heel element is incorporated into the upper of the footwear article, the first knitted area may correspond to the lower portion of the knitted heel element positioned adjacent to the sole structure. In example aspects, the thermoforming layer may include one or more ends of a buffer yarn. In additional example aspects, the thermoforming layer may also include one or more ends of a high-melting-point thermoplastic yarn, such as a high-melting-point PET yarn and / or a high-melting-point recycled PET yarn. The thermoforming layer may provide rigidity for the first knitted area, and when used, additional yarn ends of the buffer yarn and / or the high-melting-point thermoplastic yarn may provide additional structural stability for the first knitted area by acting as a bracket-type structure within the thermoforming layer.

[0031] The second knitted structure may also include a second knitted area, which is located at the upper portion of the knitted heel element, adjacent to the collar area of ​​the upper. The second knitted area may include a first knitted layer and a second knitted layer. The second knitted area may also include a yarn end of a buffer yarn positioned between the first knitted layer and the second knitted layer. The buffer yarn may help provide cushioning for the collar area of ​​the upper, which is convenient for the comfort of the wearer. In some example aspects, the second knitted area may also include a yarn end of a low-melting point thermoplastic material positioned between the first knitted layer and the second knitted layer. The low-melting point thermoplastic material may help provide some structure and elasticity to the knitted heel element in the second knitted area so that the knitted heel element will not be accidentally folded.

[0032] To form a second knitted structure, a first knitted layer and a second knitted layer can be knitted on a double-bed knitting machine during a single knitting event. In an exemplary aspect, the first knitted layer can be knitted on a first bed of the knitting machine, and the second knitted layer can be knitted on a second bed of the knitting machine. Various aspects of the present invention contemplate that one or more yarns from the first knitted layer can be intermittently transferred to the second knitted layer, and one or more yarns for the second knitted layer can be intermittently transferred to the first knitted layer. After the transfer, various aspects of the present invention contemplate that the yarn can be knitted one or more knitted loops on the relative bed before being transferred back to the original bed. Various aspects of the present invention contemplate knitting the first knitted layer and the second knitted layer using high-melting-point thermoplastic yarns and / or high-melting-point recycled thermoplastic yarns (such as high-melting-point PET yarns and / or high-melting-point recycled PET yarns). In exemplary aspects, for additional structural stability, the high-melting-point thermoplastic yarns can be plated with fusible yarns.

[0033] During a single knitting event, the yarn end including the low-melting thermoplastic material can be selectively positioned between the first knitting layer and the second knitting layer. It is contemplated in various aspects herein that the low-melting thermoplastic yarn may include a low-melting PET yarn and / or a low-melting polyamide yarn. In some aspects, the low-melting thermoplastic yarn may be formed entirely of low-melting PET and / or low-melting polyamide (e.g., connected to a knitting zone incorporating a buffer yarn or a yarn end to help contain the expansion of the buffer yarn or the yarn end in a desired manner). In various examples, the yarn positioned between the first knitting layer and the second knitting layer in at least the first knitting zone of the knitted heel element is a multi-component yarn having a high-melting thermoplastic material adjacent to the low-melting thermoplastic material. For example, a yarn including a core / sheath configuration may be used for this configuration, wherein the core of the high-melting thermoplastic yarn is surrounded by a sheath of the low-melting thermoplastic material. In other aspects, such multi-component yarns having high melting point thermoplastics and low melting point thermoplastics can have other configurations, such as side-by-side configurations, trilobal configurations, etc., in which the low melting point thermoplastic is positioned in a configuration side by side with the high melting point thermoplastic. In some aspects, yarn ends including low melting point thermoplastics (e.g., those formed entirely of thermoplastics or that may include a core / sheath configuration containing thermoplastics) can be interlaced with knitting coils forming the first knitting layer and the second knitting layer. For example, yarn ends including low melting point thermoplastics can be intermittently floated between the first knitting layer and the second knitting layer, and then tucked with knitting coils forming the first knitting layer and the second knitting layer. During a single knitting event, yarn ends including buffer yarns can be positioned between the first knitting layer and the second knitting layer. In some aspects, yarn ends including buffer yarns can be embedded between the first knitting layer and the second knitting layer, although aspects of this document also contemplate interlacing buffer yarns with one or more knitting coils forming the first knitting layer and / or the second knitting layer. In one example aspect, tucking comprising a low melting point thermoplastic material can be used to adjust the amount of cushioning provided by the cushioning yarn. For example, a greater number of tucking per inch or centimeter can help to slightly compress the volume of the cushioning yarn, resulting in slightly less and / or more compact cushioning. Conversely, a smaller number of tucking per inch or centimeter can fully expand the cushioning yarn, resulting in slightly more or less compact cushioning.

[0034] Various aspects of the present invention contemplate independently and regionally varying the number of yarn ends of the low-melting thermoplastic material and / or the buffer yarn to achieve different functional purposes of different knitted areas (e.g., the first knitted area and the second knitted area) of the knitted heel element. Various aspects of the present invention also contemplate varying the type of yarn positioned between the first knitted layer and the second knitted layer to achieve different functional purposes of the different knitted areas. Any and all of these aspects and any variations thereof are contemplated to be within the scope of the present invention.

[0035] The manufacturing method may also include applying one or more of heat and pressure at a first temperature to the first knitted zone of the knitted heel element. In one aspect, this is completed when the knitted heel element is in a flat or planar configuration (so-called "flat pressing"). The heat may be enough to melt the yarn ends including low-melting thermoplastic materials, but it cannot be high enough to melt, burn, burn or otherwise destroy the structural integrity of the high-melting thermoplastic core of the buffer yarn, the high-melting thermoplastic yarn for forming the first knitted layer and the second knitted layer, and / or the yarn with a core / sheath configuration. Pressure can be applied to make the molten thermoplastic material flow in one or more planes. In terms of examples, flat pressing can be advantageous because, compared with, for example, three-dimensional pressing, flat pressing is generally convenient for molten thermoplastic materials to be more evenly distributed and flowed. The molten thermoplastic material can flow in the x, y plane so that the molten thermoplastic material diffuses between the first knitted layer and the second knitted layer. The molten thermoplastic material can also flow in the z direction, such as, for example, into, through and / or substantially through the first knitted layer. When the molten thermoplastic material flows through the first knitted layer, it can form a deposit on the outward-facing surface of the knitted heel element. The knitted heel element is then cooled, which causes the molten thermoplastic material to resolidify and form a thermoforming layer that is at least partially positioned between the first knitted layer and the second knitted layer. In some aspects, the thermoforming layer extends at least partially into and / or through the first knitted layer. As described above, the thermoforming layer can impart structural rigidity or hardness to the first knitted area of ​​the knitted heel element. The amount of rigidity can be increased by using yarn ends including buffer yarns and yarn ends including a core / sheath configuration. The high melting point thermoplastic core of the buffer yarn and the core / sheath yarn can be used as a support positioned within the thermoforming layer. In exemplary aspects, heat and pressure at the first temperature are not applied to the second knitted area of ​​the knitted heel element, so that the thermoforming layer is not formed in the second knitted area, and the functional properties of the second knitted area can be buffering rather than rigidity.

[0036] In an example aspect, the method may also include subsequently positioning the knitted heel element on a three-dimensional (3-D) form (e.g., such as a shoe last). When positioned on the 3-D form, heat and pressure at a second temperature are applied to the knitted heel element, wherein the heat and pressure are applied to the entirety of the knitted heel element, rather than to a specific knitted area. In this aspect, the heat may be sufficient to soften the thermoforming layer in the first knitted area and further soften the yarn ends comprising thermoplastic material in the second knitted area. Softening the thermoplastic material allows the knitted heel element to conform to the shape of the 3-D form. Once cooled, the knitted heel element retains the desired shape. The method may also include incorporating the 3-D knitted heel element into the heel area of ​​the upper of a footwear article.

[0037] In various aspects, one or more thermoforming processes may be performed on a knitted heel element that includes a fusible material to thermoform and / or fuse the material to form a structure having a higher rigidity. In various aspects, during one or more of the thermoforming processes performed, the knitted heel element may be thermoformed into a three-dimensional shape (e.g., a three-dimensional shape that generally corresponds to a heel area of ​​a footwear upper and / or to a shape of a heel counter that forms part of an upper or footwear article) for providing stiffness, rigidity, and support, e.g., without incorporating a separately manufactured heel counter element.

[0038] Aspects of this paper also contemplate an array of footwear articles with knitted heel elements, which have different amounts of rigidity and cushioning according to the intended use of footwear articles. The knitted heel element can be formed using the above-mentioned first knitted structure or the above-mentioned second knitted structure. As an illustrative example, the footwear articles configured for basketball can generally cover the ankle bone of the wearer (for example, such as high-top sports shoes). In this respect, compared with the footwear articles configured for running, for example, the knitted heel element may need a larger buffer zone (for example, the second knitted zone), wherein the shoe collar is usually placed under the ankle bone of the wearer (for example, running). In another example, compared with the footwear articles configured for running, the articles configured for global football (also referred to as soccer) sports may need to increase rigidity around the lower part of the heel area to support the wearer's Achilles tendon during various football actions, and running may need greater flexibility in the heel area. The knit structures described herein can be easily customized, for example by adding more yarn ends of buffer yarns in specific zones to promote increased cushioning, increasing the size or surface area of ​​specific buffer zones (e.g., the second knit zone) or rigid zones (e.g., the first knit zone), adding more yarn ends of yarns comprising thermoplastic materials in specific zones to promote increased rigidity after processing, etc. The tucking frequency between different knit layers can also be used to adjust the amount of cushioning imparted by the use of buffer yarns.

[0039] As used herein, footwear generally includes a sole structure fixed to a shoe upper. Footwear described herein may include running shoes, baseball shoes, basketball shoes, skateboard shoes, cycling shoes, American football shoes, tennis shoes, global football shoes, training shoes, walking shoes, mountaineering shoes, etc. The concept described herein may also be applied to other footwear types that are considered to be non-sporty, such as dress shoes, loafers, sandals, casual shoes, and work boots. As used herein, footwear may be divided into different general areas. The forefoot area generally includes the part of the footwear corresponding to the toe and the joint connecting the metatarsal bones and the phalanges. The midfoot area generally includes the part of the footwear corresponding to the arch area and the instep area of ​​the foot. The heel area generally corresponds to the rear part of the foot including the calcaneus. Footwear described herein may include an outside and an inside, the outside corresponding to the outside area of ​​the foot (e.g., the surface facing away from another foot), and the inside corresponding to the inside area of ​​the foot (e.g., the surface facing another foot). The different regions and different sides described above are intended to represent general areas of footwear to aid in the following discussion and are not intended to delimit precise areas. The different regions and different sides may apply to the article of footwear as a whole, to the upper, and to the sole structure.

[0040] The term "knitted element" as used herein can be broadly applied to any knitted element applied to a shoe upper that includes the cushioning properties and / or stiffness properties described herein. For example, a knitted element can be applied to an insole area of ​​an upper, a toe area of ​​an upper, a heel area of ​​an upper, etc. The concepts described herein can relate to a knitted heel element that is positioned in the heel area of ​​an upper and generally extends from the sole structure to the collar area of ​​the upper.

[0041] As used herein, the term "outward-facing surface" refers to the surface of a knitted element, an upper, or a footwear article that faces the external environment. In some aspects, the outward-facing surface may refer to the outermost surface of a knitted element, an upper, or a footwear article. As used herein, the term "inward-facing surface" refers to the surface of a knitted element, an upper, or a footwear article that faces the cavity for accommodating the wearer's foot. In some aspects, the inward-facing surface may refer to the innermost surface of a knitted element, an upper, or a footwear article.

[0042] As used herein, the term "knitted", for example, to describe a knitted upper, refers to a fabric piece formed from at least one yarn that is manipulated (e.g., with a knitting machine) to form a plurality of interlocking loops (also referred to as interweaving) that define courses and wales. As used herein, the term "course" refers to a predominantly horizontal row of knitted loops (in an upright fabric knitted on a knitting machine) produced by adjacent needles during the same knitting event. A course may include one or more stitch types known in the knitting art, such as a knit stitch, a drop stitch, a tuck stitch, a transfer stitch, a rib stitch, etc., as such terms are known in the knitting art. The term "course direction" refers to a direction parallel to the knitted courses of a fabric piece. As used herein, the term "wale" is a predominantly vertical row of knitted loops that are interlocked or interwoven, typically produced by the same needle in consecutive (but not necessarily all) courses or knitting cycles. The term "wale direction" refers to a direction parallel to the knitted wales of a fabric piece.

[0043] The term "double-sided knitted structure" as used herein refers to a knitted structure (e.g., a multi-bed structure) that is typically formed on at least two needle beds of a knitting machine. These multi-bed knitted structures may have two opposing layers of knitted coils and / or tucks, such as one coil layer (e.g., a first knitted layer) formed on a first needle bed and a second coil layer (e.g., a second knitted layer) formed on a second needle bed. In exemplary aspects, the two layers may be linked by a yarn that is interwoven with yarns in the first knitted layer and the second knitted layer of the double-sided knitted structure. Ordinary double-sided knitted structures include "double-bed" knitted structures such as double-sided plain, rib, double rib, and placket that are initially formed on at least two needle beds, as well as other knitted structures having knitted coils or tucks on two opposing sides or layers, including full gauge and variants of these structures that are less than full gauge (e.g., half gauge). For example, as described with respect to the first knitted structure, various aspects of this document contemplate knitting two layers (e.g., a first knitted layer and a third knitted layer) on a single needle bed using half-gauge knitting technology.

[0044] The term "integrally knitted" as used herein may refer to a knitted fabric having yarns from one or more knitted courses in a first region or zone interlaced with one or more knitted courses in another region or zone (e.g., a first knitted zone and a second knitted zone). Interlacing may be performed by simple knit stitches, tuck stitches, hold stitches, float stitches, or drop stitches, etc. In this way, the regions or zones knitted integrally together have seamless transitions so that they extend seamlessly to each other.

[0045] As used herein, the term "yarn end" refers to the number of individual yarns. For example, the five ends of yarn A will mean five individual strands of yarn A, each of which may include a monofilament yarn or a multifilament yarn. When a twin-bed knitting machine is used, the yarn ends are typically supplied by one or more yarn feeders during the carriage passes through. Therefore, using the above example, the five ends of yarn A will be supplied by the yarn feeders during a single pass of the carriage in the first direction. Alternatively, different ends of the same yarn (e.g., yarn A) can be supplied by different yarn feeders during a single pass of the carriage in the first direction.

[0046] Using knitting construction to form knitting elements can provide advantages including but not limited to a certain degree of elasticity (for example, represented by Young's modulus), breathability, bendability, strength, hygroscopicity, weight, wear resistance and / or any combination thereof. These characteristics can be achieved by selecting a specific knitting structure, by changing the size and tension of the knitting structure, by using one or more yarns formed by specific materials (for example polyester materials, relatively inelastic materials or relatively elastic materials such as elastic yarns, thermoplastic materials or similar materials), and / or by selecting a specific size (for example, denier) or a yarn of toughness (for example, in grams per denier, "g / D") and / or by using their combination. Using knitting construction can also provide desired aesthetic properties by combining yarns with other visual properties with different colors, textures or arranged in a specific pattern. Yarn itself and / or the knitting structure formed by one or more of the yarns can change at different positions so that the knitting element can have different performances as described herein.

[0047] According to the yarn of various aspects described herein, monofilament yarn and / or multifilament yarn may be included. In various aspects, these may be formed by synthetic materials. In some aspects, yarn may be generally described or specified as high-melting-point yarn or low-melting-point yarn. High-melting-point yarn may be used for knitting, for example, the first knitting layer, the second knitting layer and the third knitting layer in the first knitting structure and the first and second layers in the second knitting structure. In this article, the term "high melting point" generally refers to a yarn formed at least in part by a material that melts or softens at a specific high temperature (e.g., between about 175 and 200 degrees Celsius or at a higher temperature). In an example, the high-melting-point thermoplastic yarn used in various aspects herein may have a melting temperature of at least about 175 degrees Celsius. High-melting-point thermoplastic yarn may include high-melting-point PET yarn, high-melting-point recycled PET yarn, buffer yarn, core / sheath yarn, wherein the core includes a high-melting-point material (e.g., a high-melting-point PET core) and the sheath includes a low-melting-point material, elastic yarn and other high-melting-point synthetic thermoplastic yarns. Low-melting yarns may include low-melting thermoplastic yarns. In this article, the term "low-melting point" generally refers to yarns formed at least in part by materials that melt or soften at a temperature lower than that of high-melting yarns (e.g., between about 60 and 170 degrees Celsius or lower). In various aspects, for example, low-melting yarns may be partially or completely formed by materials that melt or soften at about 50 degrees Celsius to about 70 degrees Celsius; from about 55 degrees Celsius to about 65 degrees Celsius; or at about 60 degrees Celsius. In various aspects of this article, low-melting yarns may be selected so that their low-melting materials melt or soften at a temperature lower than at least about 10 to 150 degrees Celsius of the associated high-melting yarns that are also incorporated into the knitting element. In other words, low-melting yarns and high-melting yarns in knitting elements may be selected so that there is a specific melting / softening temperature difference. Low-melting thermoplastic yarns may include synthetic polymer materials formed by polymers that melt at relatively low temperatures (e.g., less than 160 degrees Celsius in specific aspects). In an exemplary aspect, the low-melt yarn may be formed entirely of a low-melt thermoplastic material such as low-melt PET or low-melt polyamide. The term "fusible yarn" may be used herein to describe these types of yarns.

[0048] In some example aspects, the yarn used in the part of the knitted structure described herein can be formed by materials that melt at different temperatures to give those parts of the knitted structure selective properties. For example, the area of ​​the knitted element, such as the heel area and / or the area forming a part of the heel stabilizer, can include yarns that are partially or entirely included in a material that melts at a certain temperature (e.g., a temperature between about 175 and 200 degrees Celsius). These yarns are considered to be high melting point yarns. Other areas of the knitted element, such as the heel area and / or the area forming another part of the heel stabilizer, can include yarns that are partially or entirely included in a material that melts at a certain temperature (e.g., a temperature between about 50 and 160 degrees Celsius). As described herein, specific yarns (e.g., single component or multi-component), materials (e.g., fusible or infusible and melting or softening temperature) and yarn positions in the knitted element can be selected to allow the yarns to fuse in the desired area at the desired temperature and produce the desired thermoforming structure. These selectively positioned and thermoformed structures can impart stiffness, such as limiting the heel stabilizer area.

[0049] In various aspects of this article, knitting elements (e.g., forming a part of the upper of a footwear article, e.g., especially a heel area or a heel stabilizer) can include various types of fusible yarns in various aspects. For example, in some aspects, a twisted yarn comprising a high-melting filament polyester twisted with a low-melting fusible polyester can be used for knitting elements. Twisted yarns can be used for knitting element areas (e.g., can be used to replace the stiffness of traditional heel-stabilizer inserts or accessories formed by foam, plastic, polymer, leather or other rigid materials, injection molded polymers, etc.) where high rigidity and stiffness are desired. The combination of fused low-melting fusible polyester and high-melting filament polyester can be used to impart additional reinforcement in associated areas. In additional aspects, fusible yarns can be used for the buffer zone of knitting elements, such as a heel area or a heel stabilizer, to generally help keep the buffer yarn in place during the knitting process. In these aspects, fusible yarns can be formed by completely low-melting polymers (e.g., low-melting fusible polyesters). In this case, upon thermal processing, the low melting point fusible polymer melts, reflows, and then occupies the spaces between the buffer yarns where it resolidifies to help accommodate the expansion of the buffer yarns without substantially limiting or restricting the fill or cushioning properties of the buffer yarns.

[0050] Low-melting yarn can include yarn with high-melting thermoplastic core, and this core is formed by high-melting PET, for example, and is surrounded by low-melting thermoplastic material such as thermoplastic polyurethane (TPU), thermoplastic polyethylene (TPE) and / or sheath with other synthetic polymer materials with lower melting point relative to high-melting material.In one aspect, low-melting sheath can melt when applying temperature of 170 degrees Celsius or below 170 degrees Celsius (such as about 120 degrees Celsius), and high-melting core remains intact.In example aspect, the melting temperature of thermoplastic material can be fully different from the melting temperature of high-melting yarn, so that the thermoplastic material of low-melting yarn can be substantially completely melted without melting high-melting yarn or adversely affecting (such as burning, carbonizing or scorching) the characteristics of high-melting yarn.

[0051] As used herein, the term "thermoformed" refers to a structure formed by applying heat and / or pressure to a thermoplastic material to cause it to melt and then resolidify and harden upon cooling. Thus, in various aspects, the thermoformed layer may include the same polymer material as the thermoplastic material that forms part of the low-melting yarn described herein and is incorporated into the knitted element.

[0052] As used herein, the term "buffer yarn" can be described in various aspects with a full diameter (e.g., when unrestricted or compressed) of, for example, about 1 / 16 inch (or about 1.58 mm) or more. However, other buffer yarns can have other diameters (e.g., 1 / 8 inch or about 3.18 mm, 1 / 4 inch or about 6.35 mm, or even larger). Two non-limiting examples of buffer yarns are 5500 denier type and 3500 denier type multifilament polyester yarns, which have been deformed into fluff. These types of yarns are usually compressible, which contributes to their buffering characteristics. In particular, these yarns can have a first diameter in an uncompressed state, and have a smaller second diameter in a compressed state. A specific example is the "LILY" yarn sold by Sawada Hong Kong Co. Ltd., but other yarns from other manufacturers can also be buffer yarns. Another example of buffer yarn can be foamable or expandable yarn and / or waste leather yarn (SLY yarn).

[0053] Many aspects herein may relate to the hardness or stiffness of a knitted area associated with a knitted element. In various aspects, such hardness may be measured using the ASTM D2240 Type A and Type D scales.

[0054] Many aspects herein may relate to the elasticity or stiffness of a knitted area associated with a knitted element. In various aspects, such elasticity or stiffness may be measured using the SATRA TM83 test method.

[0055] Unless otherwise indicated, all measurements provided herein are made when the knitted element, upper and / or footwear article is at standard ambient temperature and pressure (298.15K and 100 kPa) and in a resting (untensioned) state. As used herein, the term "about" means within ±10% of the indicated value.

[0056] Figures 1 to 3 Schematically depicting a medial view, a lateral view, and a rear view of an example footwear article 100, respectively, the footwear article 100 having an upper 110, a sole structure 112 fixed to the upper 110, and a knitted heel element 114 located at the heel area of ​​the upper 110. Referring to the knitted heel element 114, the knitted heel element 114 includes an outwardly facing surface 116 and an opposite inwardly facing surface 118. The footwear article 100 is shown in the form of an athletic shoe, but other types of shoes (e.g., sandals, casual shoes, boots, etc.) are also contemplated herein. The footwear article 100 includes a forefoot region 120 having a toe area 121, a midfoot region 122, and a heel region 124 having a heel region 125, a medial side 126, and a lateral side 128. The footwear article 100 includes a collar 130, which, in an example aspect, can include an upper edge of the knitted heel element 114. Collar 130 includes an opening 132 for receiving a wearer's foot. Article of footwear 100 also includes a throat area 134 and an optional tongue 136. Although not shown, aspects herein contemplate that article of footwear 100 may include additional elements layered on top of upper 110, including, for example, leather materials, synthetic leather materials, knitted or woven fabrics, polymer leather, and the like.

[0057] Referring to the knitted heel element 114, in exemplary aspects, the knitted heel element 114 extends around the heel region 125 of the article of footwear and further extends forward (e.g., toward the toe region 121) on the medial side 126 and the lateral side 128 in the heel region 124 of the article of footwear 100. In exemplary aspects, the knitted heel element 114 includes a first knitted region 138, which may also be referred to as a first knitted composite region, extending a predetermined distance upward (e.g., toward the collar 130) from the intersection of the knitted heel element 114 with the sole structure 112 (e.g., the bite line 106). As will be further described, the first knitted region 138 may include a first hardness or rigidity or stiffness level that enables the first knitted region 138 to function as a heel counter that generally supports the wearer's heel and the lower portion of the wearer's Achilles tendon. The knitted heel element 114 also includes a second knitted area 140, which may also be referred to as a second knitted composite area, which extends seamlessly or integrally from the first knitted area 138 toward the collar 130. The second knitted area 140 has a second hardness or rigidity or stiffness level that is less than the first knitted area 138. To describe this differently, the concentration per unit volume, per unit surface area, and / or weight of the thermoplastic material in the second knitted area 140 or the second knitted composite area can be less than the concentration per unit volume, per unit surface area, and / or weight of the thermoplastic material in the first knitted area 138 or the first knitted composite area. In exemplary aspects, the second knitted area 140 exhibits a cushioning feature that facilitates comfort for the wearer, particularly around or near the sensitive lateral and medial malleolus of the wearer's foot.

[0058] In one non-limiting aspect, the demarcation between the first knitted area 138 and the second knitted area 140 can include an abrupt transition, as indicated by a first boundary line 142. In this aspect, the area immediately below the first boundary line 142 can exhibit stiffness characteristics, and the area immediately above the first boundary line 142 can exhibit cushioning characteristics, or higher cushioning characteristics than below the first boundary line 142. In other example aspects, the transition can be more gradual, such that as the first knitted area 138 transitions to the second knitted area 140, there is a gradual transition from a gradual decrease in stiffness level to a gradual increase in cushioning level.

[0059] In example aspects, the knitted heel element 114 may also include an optional collar (collar 130) extending seamlessly or integrally from the second knitted area 140. In example aspects, the collar 130 may have a stiffness or hardness less than the second knitted area 140 and the first knitted area 138. In various aspects, the collar 130 may include an elastic yarn (e.g., a stretch yarn) that facilitates the stretching required when the wearer inserts their foot into the opening 132, and the subsequent recovery when the foot is fully inserted into the footwear article 100. In example aspects, the collar 130 does not include the thermoplastic polymer material of the low-melting thermoplastic yarn of the first knitted area 138 and the second knitted area 140, and may also not include any thermoplastic polymer material. In some examples, the collar 130 includes only elastic yarn. The boundary between the second knitted area 140 and the collar 130 may include an abrupt transition, as indicated by the second boundary line 144. In this aspect, the area immediately below the second boundary line 144 can exhibit cushioning properties, and the area immediately above the second boundary line 144 can exhibit stretch and recovery properties. In other example aspects, the transition can be more gradual, so that when the second knitted area 140 transitions to the collar 130, the transition from a gradual decrease in cushioning level to a gradual increase in stretch and recovery level. In yet other example aspects, a separate collar element can be added to the knitted heel element 114 in a subsequent manufacturing step (e.g., a post-knitting step). In this aspect, the second knitted area 140 can terminate at an upper edge, and a separate collar element can be attached to the upper edge of the second knitted area 140. The shape configuration depicted for the knitted heel element 114 including the first boundary line 142 and the second boundary line 144 is an illustrative example, and other configurations can be contemplated herein.

[0060] FIG. 4 depicts the configuration of the knitted heel element 114A in isolation, or more specifically, the configuration of the knitted heel element 114A removed from the article of footwear 100 and positioned in a flat (planar) configuration, wherein an outwardly facing surface 116 of the knitted heel element 114A is visible. The knitted heel element 114A has a knitted construction, as indicated by the knitted coil rows 402 extending in the coil row direction and the knitted coil rows 404 extending in the coil wale direction, as shown in the enlarged view. Although the coil row direction shown in the enlarged view is generally a lateral direction, such that the knitted coil rows 402 generally extend from the outside to the inside, it should be understood that the knitted heel element 114A can be knitted in another manner such that the knitted coil rows 402 extend in a different direction. For example, the knitted coil rows 402 can extend in a top-to-bottom direction along the height of the knitted heel element 114A, or can extend radially from the periphery to a common portion, such as the opening 132 (e.g., Figure 1 to Figure 2 shown).

[0061] As depicted, knitted heel element 114A includes a lower edge 410, an upper edge 412, a first side edge 414 coupling a first end of lower edge 410 to a first end of upper edge 412, and a second side edge 416 coupling an opposite second end of lower edge 410 to an opposite second end of upper edge 412. In exemplary aspects, lower edge 410 will be coupled to sole structure 112 of article of footwear 100, first side edge 414 will be coupled to upper 110 on medial side 126 of article of footwear 100, and second side edge 416 will be coupled to upper 110 on lateral side 128 of article of footwear 100. In exemplary aspects, upper edge 412 of knitted heel element 114A may include a free edge (e.g., an edge that is not coupled to another element or structure) or may be attached to a separate element (e.g., a collar element). First knitted region 138 extends from lower edge 410 to first boundary line 142. Thus, the first boundary line 142 corresponds to the first knitted area upper edge 146. The second knitted area 140 extends from the first boundary line 142 (or the first knitted area upper edge 146) to the collar 130 and / or to the upper edge 412 if the collar 130 is not present.

[0062] 4 is depicted as a separate heel element that may be coupled to other components to form upper 110. However, it is contemplated that aspects herein include knitting knitted heel element 114A integrally with structures forming other portions of upper 110, such as a midfoot portion, a forefoot portion, and / or an underfoot portion, for example, in a conventional knitting operation performed by a knitting machine.

[0063] The knitted heel element 114A in FIG. 4 is generally symmetrical with respect to an assumed vertical midline 418 (which generally extends from the shoe collar 130 to the bite line 106), although aspects of the present invention contemplate that the knitted heel element 114A may not be symmetrical with respect to the vertical midline 418. As described above, the function of the first knitted area 138 is generally to provide support for the Achilles tendon area of ​​the wearer's foot, which is generally aligned with the vertical midline 418. Thus, when the knitted heel element 114A extends to the first side edge 414 and the second side edge 416, it may not require such a large hardness or rigidity. On the contrary, as described above, the function of the second knitted area 140 is generally to provide cushioning adjacent to the shoe collar 130 and along the side of the wearer's heel. These functional differences require to be reflected in the arrangement and configuration of the first knitted area upper edge 146.

[0064] In one example, the first distance 148 between the first knitted area upper edge 146 and the second knitted area upper edge 147 (which is aligned with the boundary line 144) at the first side edge 414 and the second side edge 416 may be greater than the second distance 150 between the first knitted area upper edge 146 and the second knitted area upper edge 147 at the vertical centerline 418 (e.g., at and / or adjacent to the center area 153), as shown in FIG. 4 (or as shown in FIG. 5 ). Figure 4C The first knitted area upper edge 146 and the second knitted area upper edge 147 at the first side edge 414 and the second side edge 416 have a larger distance (e.g., a first distance 148) corresponding to an increased surface area of ​​the second knitted area 140 having cushioning properties. The first knitted area upper edge 146 and the second knitted area upper edge 147 at the vertical midline 418 have a smaller distance (e.g., a second distance 150) corresponding to an increased surface area of ​​the first knitted area 138 having hardness or rigidity properties. Such positioning and relative areas of these areas can be based on the desired support in the heel area and / or different desired cushioning in the heel area, or can be different based on the intended use of the associated footwear (e.g., basketball, global football or other activities, etc.).

[0065] In some aspects, it may be desirable to have greater stiffness and / or rigidity at and / or near the central region 153 of the knitted heel element 114A shown in FIG. 4, for example, to allow for greater overall support and structural rigidity. To achieve this, the second distance 150 may be reduced so that the area of ​​the first knitted area 138 having the stiffness and / or rigidity properties is increased, and the stiffness and / or rigidity properties are present at and / or near the central region 153. In some aspects, this may be additionally or alternatively achieved by including a fusible yarn containing cushioning properties in the second knitted area 140.

[0066] In some aspects, for example, the area of ​​the first knitted area 138 having a more rigid structure can be larger than, for example, Figure 4A The area covered by the second knitted area 140, for example, having a more cushioned structure, in the knitted heel element 114A shown in FIG. This can help increase the rigidity, stiffness, and support of the knitted heel element as described herein, particularly when it is used as a heel counter, for example, in place of a conventional heel counter insert or attachment. To provide an example, Figure 4B A knitted heel element 114B is shown having a Figure 4A Somewhat similar configuration, but the relative areas of the first knitted area 138 and the second knitted area 140 are adjusted so as to be Figure 4AIn comparison, the first knitted area 138 covers a larger surface area of ​​the knitted heel element 114B than the second knitted area 140. This results in the geometrical offset of the upper edge 146 of the first knitted area and the upper edge 147 of the second knitted area, and by association changes the relative positions of the first boundary line 142 and the second boundary line 144, as shown in FIG. Figure 4B and Figure 4A With the knitted heel element 114B, when the first knitted area 138 and the second knitted area 140 transition outward in a direction perpendicular to the vertical centerline 418, the knitted areas 138 and 140 are in a direction perpendicular to the vertical centerline 418. Figure 4A The knitted heel element 114A shown transitions upward to the collar 130 a shorter distance than the one shown. This shorter distance that the first knitted area 138 converges with the collar 130 on opposite sides of the center portion 153 reduces the lateral displacement of the buffer zone 140. From this point on, the first knitted area 138 and the collar 130 extend without the second knitted area 140. This can increase the stiffness around the lateral heel area of ​​the knitted heel element 114. This has been shown to enhance support in these areas and reduce sagging, folding, and bunching around the lateral portion of the knitted heel element 114B, which is undesirable in certain applications.

[0067] In some aspects of the knitted heel element 114, for example, a first knitted region 138 having a more rigid structure can extend substantially through the area of ​​a second knitted region 140 having a more cushioning structure, for example. Figure 4C As shown, the knitted heel element 114C is configured such that the first knitted area 138 extends generally through the second knitted area 140 generally along the vertical midline 418. This configuration can impart additional reinforcement and support along and / or adjacent to the heel line 155 of the knitted heel element 114C and divide the second knitted area 140 (e.g., having a more cushioning structure) to the relatively outer side of the vertical midline 418.

[0068] Look again Figure 4AIn some aspects, the first knitted area upper edge 146 can be shaped such that the first knitted area upper edge 146 forms a recess 157 at the vertical midline 418, wherein the first knitted area 138 includes a protruding portion 159 on each side of the recess 157, and the protruding portions 159 each extend further upward relative to the recess 157. In this way, a third distance 151 between the first knitted area upper edge 146 and the second knitted area upper edge 147 at the lateral and medial sides of the vertical midline 418 can be less than a second distance 150 between the first knitted area upper edge 146 and the second knitted area upper edge 147 at the vertical midline 418. When the upper 110 with the knitted heel element 114 is worn, the protruding portions 159 can be used to be positioned behind the lateral and medial malleolus of the wearer. Having this smaller distance (e.g., third distance 151) between the first knitted area upper edge 146 and the second knitted area upper edge 147 at the protruding portion 159 corresponds to an increase in the surface area of ​​the first knitted area 138 having a hardness or rigidity property to provide posterior support to the wearer's lateral and medial malleolus. Additionally, in some aspects, the second knitted area upper edge 147 (aligned with the boundary line 144) can be inclined downward (or as shown) as the second knitted area upper edge 147 extends away from the vertical midline 418. Figure 4B and Figure 4C As shown, the second knitted area upper edge 147 can extend downward where the first knitted area upper edge 146 extends upward, and the third distance 151 between the first knitted area upper edge 146 and the second knitted area upper edge 147 is further reduced than the second distance 150 between the first knitted area upper edge 146 and the second knitted area upper edge 147.

[0069] Figure 5 A cross-section of a first example knitted structure 500 taken at the cut line 5-5 of FIG. 4 is schematically depicted, corresponding to the first knitted area 138. As described above, the knitted heel element 114 may be knitted using at least the first knitted structure 500 or the second example knitted structure described above. Figures 9 to 11 Aspects associated with a second example knit structure are described.

[0070] refer to Figure 5, the first knitted structure 500 at the first knitted area 138 includes a first knitted layer 510 forming an outward-facing surface 116 of the knitted heel element 114, a second knitted layer 512 forming an inward-facing surface 118 of the knitted heel element 114, and a third knitted layer 514 positioned between the first knitted layer 510 and the second knitted layer 512. In exemplary aspects, each of the first knitted layer 510, the second knitted layer 512, and the third knitted layer 514 can be knitted using a high-melting point yarn (such as a high-melting point PET yarn) and / or a high-melting point recycled PET yarn, but other high-melting point yarn types are also contemplated herein. In exemplary aspects, the high-melting point yarn can be plated with a fusible yarn to impart stability and / or structure to the first knitted layer 510, the second knitted layer 512, and / or the third knitted layer 514.

[0071] In exemplary aspects, there may be a yarn transfer between the first knit layer 510 and the second knit layer 512, as indicated by the dashed transfer line 513. For example, yarn from the first knit layer 510 may be intermittently transferred to the second knit layer 512, where it may be knitted in one or more knitted loops of the second knit layer 512 before being transferred back to the first knit layer 510. Additionally, yarn from the second knit layer 512 may be intermittently transferred to the first knit layer 510, where it may be knitted in one or more knitted loops of the first knit layer 510 before being transferred back to the second knit layer 512. There may also be a yarn transfer between the third knit layer 514 and the second knit layer 512, as indicated by the dashed transfer line 515. For example, yarn from the third knit layer 514 may be intermittently transferred to the second knit layer 512, where it may be knitted in one or more knitted loops of the second knit layer 512 before being transferred back to the third knit layer 514. Additionally, yarn from the second knit layer 512 may be intermittently transferred to the third knit layer 514 , where it may be knitted in one or more knit loops of the third knit layer 514 before being transferred back to the second knit layer 512 .

[0072] As referenced below Figure 7 To further explain, the first knitted layer 510 and the third knitted layer 514 can be knitted on one bed of a knitting machine, each bed using a half-gauge technique, wherein the needles on the needle bed are alternately used for the first knitted layer 510 and the third knitted layer 514. In this way, the yarn transfer 513 between the second knitted layer 512 and the first knitted layer 510 is performed at a different needle position than the yarn transfer 515 between the second knitted layer 512 and the third knitted layer 514.

[0073] In the first knitted area 138, the thermoforming layer 516 is at least partially positioned between the first knitted layer 510 and the third knitted layer 514. The thermoforming layer 516 is formed of a thermoplastic material, such as, for example, TPU, TPE, PET and / or polyamide. In example aspects, the thermoforming layer 516 can at least partially penetrate the first knitted layer 510 and / or the third knitted layer 514. In example aspects, the thermoforming layer 516 can completely penetrate the first knitted layer 510 so that the thermoplastic material of the thermoforming layer 516 is deposited on the outward-facing surface 116 of the knitted heel element 114, as indicated by reference numeral 518. The deposit can be continuous so that a film is formed on the outward-facing surface 116, or can be discontinuous in example aspects. Although in some aspects, the thermoforming layer 516 can completely penetrate the third knitted layer 514, in other aspects it may not completely penetrate the third knitted layer 514. In example aspects, the thermoforming layer 516 may not contact or substantially not contact the second knitted layer 512. As described below, the buffer yarn 520 can be positioned between the second knit layer 512 and the third knit layer 514. By having the thermoforming layer 516 not extend through the second knit layer and / or otherwise contact the buffer yarn 520 (in aspects that include the buffer yarn 520), the buffer yarn 520 can not be trapped by the thermoforming layer 516, which can promote its buffering properties.

[0074] In the first knitting area 138, the first knitting structure 500 may also include a yarn end of a buffer yarn 520 positioned between the second knitting layer 512 and the third knitting layer 514. Although only one yarn end of the buffer yarn 520 is depicted, it is contemplated in various aspects herein that multiple yarn ends of the buffer yarn 520 may exist between the second knitting layer 512 and the third knitting layer 514 in the first knitting area 138, depending on the desired buffering level. In other aspects, zero yarn ends of the buffer yarn 520 may exist between the second knitting layer 512 and the third knitting layer 514. In exemplary aspects, and as shown, the buffer yarn 520 may be embedded between the second knitting layer 512 and the third knitting layer 514. When the buffer yarn 520 is embedded, it does not form a mutually interlaced loop with other yarns. For buffer yarns of smaller diameters, the buffer yarn 520 may be knitted into one or more of the second knitting layer 512 and the third knitting layer 514 using, for example, intermittent tucking and floating yarns.

[0075] The buffer yarn 520 is a compressible yarn so that the diameter can be compressed or reduced when a compressive force is applied. In one exemplary aspect, the yarn transfer 513 between the second knitted layer 512 and the first knitted layer 510 and the yarn transfer 515 between the second knitted layer 512 and the third knitted layer 514 can each apply tension to the buffer yarn 520 between these knitted layers 510, 512 and 514, which reduces the diameter and bulkiness of the buffer yarn 520. In this way, compared with the transfer 513 and 515 of lower density, the transfer 513 and / or 515 of greater density causes a reduction in buffering. In another way, the compression from the transfer 513 and 515 of greater density can compress the buffer yarn 520 to generate a denser buffer structure.

[0076] The position of the thermoforming layer 516 between the first knitted layer 510 and the third knitted layer 514 means that the thermoforming layer 516 is positioned closer to the outward-facing surface 116 of the knitted heel element 114 than the position of the buffer yarn 520 between the second knitted layer 512 and the third knitted layer 514. This can have functional advantages because the hardness and / or rigidity associated with the thermoforming layer 516 may be uncomfortable for the wearer. Therefore, positioning the buffer yarn 520 closer to the skin surface of the wearer's foot can buffer the effect of the thermoforming layer 516 on the wearer's skin and make the knitted heel element 114 more comfortable to wear. In other words, in the first knitted structure 500, the buffer yarn 520 creates a separation between the thermoforming layer 516 and the wearer's skin, which contributes to comfortable wearing. Additionally, positioning the thermoforming layer 516 closer to the outward-facing surface 116 can have the effect of providing the knitted heel element 114 with waterproof or water-resistant properties and wear resistance.

[0077] Figure 6 The first knitted structure 500 at the second knitted area 140 of the knitted heel element 114 is schematically depicted. The first knitted structure 500 at the second knitted area 140 includes a first knitted layer 510, a second knitted layer 512, a third knitted layer 514, a buffer yarn 520, and transfers 513 and 515 between the first knitted layer 510, the second knitted layer 512, and the third knitted layer 514. Figure 5 The discussion provided for these components also applies to Figure 6. Instead of a thermoforming layer 516 that is at least partially located between the first knit layer 510 and the third knit layer 514 in the first knit zone 138, many yarn ends of the low-melting thermoplastic material 610 are located between the first knit layer 510 and the third knit layer 514. In one example aspect, the yarn ends of the low-melting thermoplastic material 610 may include fusible yarns that include, for example, low-melting PET and / or low-melting polyamide. In another example aspect, the yarn ends of the low-melting thermoplastic material 610 may include core / sheath yarns, wherein the sheath is formed of a low-melting thermoplastic material such as, for example, TPU or TPE, and the core includes a high-melting yarn such as high-melting PET. In yet another example aspect, the yarn ends of the low-melting thermoplastic material 610 may include a combination of fusible yarns and core / sheath yarns.

[0078] Various aspects of the present invention contemplate that the yarn ends of the low-melting thermoplastic material 610 can be interwoven with one or more yarns in the first knit layer 510 and the third knit layer 514, such as Figure 6 . The interlaced nature of the yarn ends of the low-melting thermoplastic material 610 in the second knitted area 140 is opposite to that of the thermoformed layer 516 including the low-melting thermoplastic material in the first knitted area 138. In this aspect of the second knitted area 140, the yarn ends of the low-melting thermoplastic material 610 can be intermittently floated and stuffed into the first knitted layer 510 and the third knitted layer 514. In exemplary aspects, the amount of tucking per inch or centimeter can be increased to increase the compression of the buffer yarn 520, thereby producing a denser buffer. Alternatively, the amount of tucking per inch or centimeter can be reduced to reduce the compression of the buffer yarn 520, thereby producing a less dense or fluffier buffer.

[0079] Figure 7A schematic diagram of a possible knitting machine configuration for forming a first knitting layer 510, a second knitting layer 512, and a third knitting layer 514 is depicted. For example, the first knitting layer 510 and the third knitting layer 514 can be knitted on a bed of a knitting machine, and each layer is knitted using a half-gauge technique. For example, the yarn used to form the first knitting layer 510 can be knitted on needles such as 1, 3, 5, and the yarn used to form the third knitting layer 514 can be knitted on needles such as 2, 4, 6. Therefore, each time the knitting carriage passes through, the first knitting layer 510 and the third knitting layer 514 will be knitted. The yarn used to form the first knitting layer 510 and the third knitting layer 514 may not be interwoven with each other, but may overlap each other, so that the first knitting layer 510 can generally be positioned on the outward-facing side of the third knitting layer 514. The second knitting layer 512 can be knitted on the relative bed of the knitting machine using a full-gauge technique. For example, the yarn of the second knitting layer 512 can be knitted on all needles (e.g., needles 1, 2, 3, 4, 5, etc.). The result of this technology (forming a first knit layer 510 and a third knit layer 514 with half gauge and a second knit layer 512 with full gauge) can be: the number of knit stitches per inch or centimeter of the first knit layer 510 and the third knit layer 514 can be approximately half the number of knit stitches per inch or centimeter of the second knit layer 512.

[0080] Figure 8 A block diagram of an example method 800 of manufacturing a knitted heel element (such as, for example, a knitted heel element 114 using a first knitting structure 500) according to various aspects of this invention is depicted. In frame 810, during a single knitting event, a first knitted layer (such as the first knitted layer 510), a second knitted layer (such as the second knitted layer 512), and a third knitted layer (such as the third knitted layer 514) are knitted on a knitting machine. In example aspects, the knitted heel element can be knitted to shape so that no additional trimming or cutting is required. In other example aspects, the knitted heel element can be cut to shape during the manufacturing process. In addition, in example aspects, the knitted heel element is knitted as a separate component, but it is also conceivable that the knitted heel element can be knitted integrally with the rest of the upper or at least other parts of the upper outside the heel area.

[0081] As described above, the third knitted layer is positioned between the first knitted layer and the second knitted layer. The first knitted layer and the third knitted layer can be knitted on one needle bed using a half-gauge technique, while the second knitted layer can be knitted on an opposite bed using a full-gauge technique. The first, second and third knitted layers can be knitted using, for example, high melting point thermoplastic yarns (such as high melting point PET yarns) and / or high melting point recycled PET yarns, both of which can optionally be plated with fusible yarns.

[0082] In frame 812, yarn ends including low-melting thermoplastic materials, such as yarn ends of material 610, can be positioned between the first knitting layer and the third knitting layer. In example aspects, yarn ends including low-melting thermoplastic materials can be interlaced with yarns in the first knitting layer and the third knitting layer, for example, using tucking and floating yarns. It is contemplated in various aspects herein that yarn ends including low-melting thermoplastic materials can be positioned in zones based on desired end functions. For example, in a knitting zone (such as the first knitting zone 138) of a knitting element that desires greater hardness or rigidity, a greater number of yarn ends of thermoplastic materials can be positioned between the first knitting layer and the third knitting layer. In a knitting zone (such as the second knitting zone 140) of a knitting element that desires a greater amount of buffering, a smaller number of yarn ends including thermoplastic materials can be positioned between the first knitting layer and the third knitting layer. In some example aspects, zero yarn ends of thermoplastic materials can be positioned between the first and third knitting layers.

[0083] In frame 814, the yarn ends including buffer yarns (such as buffer yarns 520) are positioned between the second knitting layer and the third knitting layer. The buffer yarns can be embedded, particularly when it has a relatively high diameter. Otherwise, they can be interwoven with the yarns in the second knitting layer and / or the third knitting layer. It is contemplated in various aspects herein that the yarn ends of the buffer yarns can be positioned based on the desired end functions in the partitions. For example, in the knitting area (such as the second knitting area 140) of the knitted heel element of the desired high buffering, the yarn ends of the buffer yarns can be positioned between the second knitting layer and the third knitting layer. In the knitting area (such as the first knitting area 138) of the knitted heel element of the desired greater hardness or rigidity, the yarn ends including the buffer yarns can be positioned between the second knitting layer and the third knitting layer. In some example aspects, the zero yarn ends of the buffer yarns can be positioned between the second knitting layer and the third knitting layer.

[0084] Aspects of the present invention also contemplate that the amount of cushioning imparted by the cushioning yarn can be adjusted by transfers (such as transfers 513 and 515) between the first knitted layer, the second knitted layer, and the third knitted layer and / or by tucking of the low-melting thermoplastic yarn. For example, a greater number of transfers or tucking per inch or centimeter can compress the cushioning yarn, resulting in less cushioning and / or a denser cushioning. Conversely, a smaller number of transfers or tucking per inch or centimeter can result in greater cushioning or a less dense cushioning.

[0085] Frame 810, 812 and 814 are described separately above to discuss the specific details of each aspect of the knitting structure. However, it should be understood that these steps can occur simultaneously, so that the high melting point yarn, the yarn with the low melting point thermoplastic material and the buffer yarn for the first knitting layer, the second knitting layer, the third knitting layer can be knitted across the needle bed in a single pass of the carriage using multiple yarn feeders.

[0086] In frame 816, one or more of heat and pressure is applied to the first knitted area, such as the first knitted area 138 of the knitted heel element. The heat can be at a temperature sufficient to melt the low-melting thermoplastic material of the yarn positioned between the first knitted layer and the third knitted layer, but not high enough to damage the high-melting yarn, which includes a yarn for forming the first knitted layer, the second knitted layer and the third knitted layer, a buffer yarn and / or a core with a low-melting thermoplastic material in terms of a core / sheath structure. The applied pressure causes the molten thermoplastic material to flow between the first knitted layer and the third knitted layer. When cooled, a thermoforming layer, such as a thermoforming layer 516, is formed between the first knitted layer and the third knitted layer. In some aspects, the pressure can be sufficient to make the thermoplastic material penetrate or permeate the first knitted layer and / or the third knitted layer. Similarly, the pressure can be adjusted so that the molten thermoplastic material does not contact the second knitted layer and / or the buffer yarn positioned between the second knitted layer and the third knitted layer, thereby helping to maintain the bulkiness and / or buffering imparted by the buffer yarn in the area where they are positioned. In an example aspect, heat and pressure are not applied to a second knit region, such as second knit region 140, such that a thermoformed layer is not formed in the second knit region.

[0087] Various aspects of the present invention contemplate that after the knitted heel element cools and the thermoforming layer is formed, additional heat and pressure can be applied to the entire knitted heel element (e.g., to the first knitted area and the second knitted area). In this application, the heat can be sufficient to soften but not melt the thermoplastic material and the thermoforming layer at the yarn ends in the second knitted area. The application can occur after the knitted heel element is positioned on a 3-D form such as a shoe last. In addition, pressure can be applied to the knitted heel element to conform it to the 3-D form. In some aspects, the pressure can be achieved by applying sand to the 3-D form. For example, the knitted heel element can be positioned on the 3-D form and placed in a vacuum chamber, and sand is passed through the chamber when the chamber and / or the 3-D form is heated. The use of sand can ensure that the pressure is more evenly distributed to the knitted heel element, so that the entirety of the knitted heel element closely conforms to the three-dimensional shape of the 3-D form.

[0088] In block 818, a knitted heel element is incorporated into a heel region and / or heel area (such as heel area 124 and heel area 125) of a footwear article, such as footwear article 100. The knitted heel element is positioned such that a first knitted area is located adjacent to the sole structure and a second knitted area is located adjacent to a collar of the footwear article. In this manner, in some aspects, the knitted heel element can form a footwear heel counter and replace a conventional footwear heel counter that is separately formed / incorporated into or onto the heel area in an additional manufacturing step.

[0089] Fig. 9 A cross section of a second example knitted structure 900 taken at the cutting line 9-9 of FIG. 4 is schematically depicted, corresponding to the first knitted area 138. The second knitted structure 900 at the first knitted area 138 includes a first knitted layer 910 that forms the outward-facing surface 116 of the knitted heel element 114, and a second knitted layer 912 that forms the inward-facing surface 118 of the knitted heel element 114. In exemplary aspects, each of the first knitted layer 910 and the second knitted layer 912 can be knitted using a high-melting point yarn (such as a high-melting point PET yarn) and / or a high-melting point recycled PET yarn, but other high-melting point yarn types are also contemplated herein. In exemplary aspects, the high-melting point yarn can be plated with a fusible yarn to give the first knitted layer 910 and the second knitted layer 912 additional structure and stability. In some aspects, the high-melting point yarn is plated with a fusible yarn in the first knitted layer 910, while the second knitted layer 912 that forms the side facing the inner skin includes a textured yarn. Examples of textured yarns include, but are not limited to, chenille yarn, peached yarn, and the like. Thus, as a result, when the knitted heel counter is processed (e.g., using heat and / or pressure) after knitting, the side facing the inner skin has a softer feel, thereby providing greater comfort to the user, and the first knit layer 910 (which forms the side facing outward) includes melted and reflowed polymers in the fusible yarn, which provides rigidity, protection, and weather resistance to the outer surface of the knitted heel counter. In other examples, additionally or alternatively, the first knit layer can include TPU yarn, and thus, when processed, the first knit layer can include melted and reflowed polymers from the fusible and / or TPU yarns.

[0090] In some aspects, there may be a yarn transfer between the first knitted layer 910 and the second knitted layer 912, as indicated by the dotted transfer line 913. For example, the yarn from the first knitted layer 910 may be intermittently transferred to the second knitted layer 912, where it may be knitted in one or more knitted loops of the second knitted layer 912 before being transferred back to the first knitted layer 910. In some aspects, the yarn from the second knitted layer 912 may be intermittently transferred to the first knitted layer 910, where it may be knitted in one or more knitted loops of the first knitted layer 910 before being transferred back to the second knitted layer 912. In some aspects, the transferred yarn may be a non-fusible yarn plated with a fusible yarn, for example, a yarn comprising a thermoplastic polymer or other material, which may be heated, melted, reflowed, and then cooled into a different solidified shape, distribution, or geometry. In this way, the transfer of the yarn may facilitate the positioning of the fusible yarn (e.g., which is subsequently fused) on the surface facing the outside to help reduce or limit the stretch and / or elasticity on such a surface.

[0091] The knitted heel element described herein can be configured to provide overall rigidity, stiffness and support, which can replace traditional heel stabilizers, which additionally need to be combined with additional elements, such as stiff materials (e.g., preformed injection molded heel stabilizer components, preformed punched and formed heel stabilizers, etc.), collar foam, collar lining, adhesives and / or coupling elements that are usually added to the heel portion of the upper during the footwear manufacturing process. In order to provide the desired stiffness and support, the thermoplastic material can be knitted and combined in, for example, the first knitted area 138. In one example, the thermoplastic material can be combined by including one or more of TPU yarn and fusible yarn between the first knitted layer 910 and the second knitted layer 912. In a non-limiting example, one or more of the TPU yarn and the fusible yarn can float between the first layer and the second layer and be stuffed into one or more of the first knitted layer and the second knitted layer. In one example, the amount of the fusible polymer is less than the amount of the TPU polymer. This can be accomplished, for example, by combining a greater number of yarn ends with TPU and a lesser number of yarn ends with a fusible polymer in a knitted heel element. The knitted heel element is then post-processed to form the thermoformed layer 914. The above configuration and its formation process can significantly reduce the number of manufacturing steps and separate parts required to produce footwear with these heel properties, reduce manufacturing time, and therefore increase the sustainability of footwear manufacturing.

[0092] In the first knitted area 138, a thermoforming layer 914 is at least partially positioned between the first knitted layer 910 and the second knitted layer 912. The thermoforming layer 914 is formed of a thermoplastic material, such as, for example, TPU, TPE, PET and / or polyamide. In example aspects, the thermoforming layer 914 can at least partially penetrate the first knitted layer 910 and / or the second knitted layer 912. In example aspects, the thermoforming layer 914 can completely penetrate the first knitted layer 910 so that the thermoplastic material of the thermoforming layer 914 is deposited on the outwardly facing surface 116 of the knitted heel element 114, as indicated by reference numeral 916. In example aspects, the deposit can be continuous or discontinuous. In example aspects, the thermoforming layer 914 can completely penetrate the second knitted layer 912, but in other aspects, it may not completely penetrate the second knitted layer 912. Thermoform layer 914 imparts rigidity or stiffness to second knit structure 900 in first knit area 138, which can help provide support to, for example, a wearer's Achilles tendon when knit heel element 114 is incorporated into an article of footwear.

[0093] In some aspects, the first knitted area 138 in the second knitted structure 900 may also include one or more yarn ends of a buffer yarn 918 positioned between the first knitted layer 910 and the second knitted layer 912 and further positioned within the thermoforming layer 914. In one example aspect, the buffer yarn 918 may have only one yarn end, although aspects of the present invention contemplate that the buffer yarn 918 may have more than one yarn end. In another example aspect, the buffer yarn 918 may have zero yarn ends. That is, the first knitted area 138 may not include a buffer yarn between the first knitted layer 910 and the second knitted layer 912; however, the second knitted layer 912 may include a textured yarn (e.g., chenille, peach skin polyester yarn, etc.) to provide a softer feel to the skin-facing side.

[0094] In an exemplary aspect, and as shown, the buffer yarn 918 can be embedded between the first knit layer 910 and the second knit layer 912. For smaller diameter buffer yarns, the buffer yarn 918 can be knitted into one or more of the first knit layer 910 and the second knit layer 912 using, for example, intermittent tucking and floating yarns. In an exemplary aspect, the yarn ends of the buffer yarn 918 can help to space the first knit layer 910 from the second knit layer 912 based on the large diameter of the buffer yarn 918, so that the thermoforming layer 914 has an increased thickness compared to if the buffer yarn was not incorporated into the first knit region 138.

[0095] In an exemplary aspect, the second knit structure 900 may also include at least one end of a high-melt point yarn 920 (such as a high-melt point polyester yarn) positioned between the first knit layer 910 and the second knit layer 912 and within the thermoforming layer 914. As described below, the high-melt point yarn 920 may be the core of a core / sheath yarn that previously existed prior to thermoforming. In the first knit region 138, the sheath of the core / sheath yarn may include a low-melt point thermoplastic polymer material that melts to at least partially form the thermoforming layer 914, leaving a core of the high-melt point yarn 920 after thermoforming. In an exemplary aspect, the high-melt point yarn 920 may be interwoven and / or tucked with one or more yarn loops of the first knit layer 910 and the second knit layer 912, such as Figure 5 As shown. In other aspects, the high-melting yarn 920 can be embedded similar to the buffer yarn 918. In an exemplary aspect, the high-melting yarn 920 and the buffer yarn 918 can be used as a support around which the thermoforming layer 914 is formed. In this aspect, the high-melting yarn 920 and the buffer yarn 918 can increase the structural stability of the first knitted area 138 and can also contribute to the rigidity and / or hardness of the first knitted area 138.

[0096] Fig.10A second knitted structure 900 at a second knitted area 140 of a knitted heel element 114 is schematically depicted. The second knitted structure 900 at the second knitted area 140 includes a first knitted layer 910, a second knitted layer 912, a transfer 913 between the first knitted layer 910 and the second knitted layer 912, and a buffer yarn 918 embedded between the first knitted layer 910 and the second knitted layer 912. The transfer 913 can help lock the buffer yarn in place and can expose portions of the buffer yarn on the outer surface, which can enhance the softness of the outer surface. The transfer 913 can also help accommodate and / or limit expansion of the buffer yarn in the second knitted structure 900. Fig. 9 The discussion provided for these components also applies to Fig.10. Instead of the thermoforming layer 914 being at least partially positioned between the first knitting layer 910 and the second knitting layer 912 in the first knitting zone 138, the yarn ends of many low-melting thermoplastic yarns 1010 are positioned between the first knitting layer 910 and the second knitting layer 912. In one exemplary aspect, the number of yarn ends of the low-melting thermoplastic yarn 1010 includes five yarn ends, although fewer yarn ends (including zero yarn ends) or more yarn ends are contemplated herein. For example, in various aspects, in the first knitting zone 138, there may be four ends of the buffer yarn, and in the buffer region of the second knitting zone 140, some zones may have four ends of the buffer yarn, and other zones (e.g., zones closer to the shoe collar 130) may have one to three ends of the buffer yarn. In some exemplary aspects, the number of yarn ends of the low-melting thermoplastic yarn 1010 includes five yarn ends, although fewer yarn ends (including zero yarn ends) or more yarn ends are contemplated herein. For example, in various aspects, in the first knitted area 138, there may be zero ends of the buffer yarn, and in the buffer area of ​​the second knitted area 140, some areas may have one to five ends of the buffer yarn, and other areas (e.g., areas closer to the collar 130) may have zero to three ends of the buffer yarn. In exemplary aspects, the low-melting thermoplastic yarn 1010 may include a fusible yarn formed entirely of a low-melting material such as low-melting PET and / or a low-melting polyamide. In exemplary aspects, the second knitted area 140 may not include yarns having a high-melting material (e.g., high-melting PET) and a low-melting thermoplastic material (e.g., TPU and / or TPE). In exemplary aspects, the low-melting thermoplastic yarn 1010 may include a fusible yarn formed entirely of a low-melting material such as low-melting PET and / or a low-melting polyamide. In example aspects, the second knitted zone 140 may not include yarns having a core of a high melting point material (e.g., high melting point PET) and a low melting point thermoplastic material (e.g., TPU and / or TPE). For example, the second knitted zone 140 may instead include yarns formed entirely of a low melting point thermoplastic material (e.g., TPU and / or TPE). When these yarns are fused so as to melt, reflow, and then resolidify, these yarns can occupy the space between the buffer yarns without substantially limiting or constraining the filling or cushioning properties of the buffer yarns. During the knitting process, the molten yarns can help keep the buffer yarns in place.

[0097] Various aspects of the present invention contemplate that the yarn ends of the low-melting thermoplastic yarn 1010 can be interwoven with one or more yarns in the first knit layer 910 and the second knit layer 912, such as Fig.10. In this aspect, the yarn ends of the low-melting thermoplastic yarn 1010 can be intermittently floated and stuffed into the first knitted layer 910 and the second knitted layer 912. The combination of the buffer yarn 918 and the low-melting thermoplastic yarn 1010 can help to space the first knitted layer 910 from the second knitted layer 912, which can help the cushioning performance of the knitted heel element 114 in the second knitted area 140. In exemplary aspects, the transfer 913 and / or tuck of the low-melting thermoplastic yarn 1010 can be used to adjust the amount of cushioning provided by the buffer yarn 918. For example, a greater number of transfers and / or tucks per inch or centimeter will provide a denser cushioning structure, and a smaller number of transfers and / or tucks per inch or centimeter will provide a less dense (e.g., more bulky) cushioning structure.

[0098] Fig.11 A block diagram of an example method 1100 of manufacturing a knitted heel element (such as a knitted heel element 114 using a second knitted structure 900) according to various aspects of the present invention is depicted. In frame 1110, during a single knitting event, a first knitted layer (such as the first knitted layer 910) and a second knitted layer (such as the second knitted layer 912) are knitted on a knitting machine. The knitted heel element can be knitted to shape so that no additional trimming or cutting is required. In other aspects, additional cutting or trimming may be required to form the knitted heel element. The first knitted layer and the second knitted layer can be knitted on the relative beds of the knitting machine. The first knitted layer and the second knitted layer can be knitted using, for example, high melting point thermoplastic yarns (such as high melting point PET yarns) and / or high melting point recycled PET yarns. In exemplary aspects, the high melting point yarns can be plated with fusible yarns to give the first knitted layer and the second knitted layer additional structure and stability.

[0099] In frame 1112, yarn ends including low-melting thermoplastic materials, such as yarn ends 1010, can be positioned between the first knitting layer and the second knitting layer. In this respect, the yarn ends including low-melting thermoplastic materials can include fusible yarns, and the number of yarn ends can be five yarn ends. In example aspects, the yarn ends including low-melting thermoplastic materials can be interwoven with the yarns in the first knitting layer and the second knitting layer, for example, using tucking and floating yarns. It is contemplated in various aspects herein that the yarn ends including low-melting thermoplastic materials can be positioned in zones based on the desired end functions. For example, in a knitting zone (such as the first knitting zone 138) of a knitting element that is expected to have greater hardness or rigidity, a greater number of yarn ends of thermoplastic materials can be positioned between the first knitting layer and the second knitting layer. In a knitting zone (such as the second knitting zone 140) of a knitting element that is expected to have a greater amount of buffering, a smaller number of yarn ends (including zero yarn ends) including thermoplastic materials can be positioned between the first knitting layer and the second knitting layer.

[0100] In frame 1112, one or more yarn ends of a core / sheath yarn having a high melting point core and a low melting point thermoplastic material sheath can be positioned between a first knitting layer and a second knitting layer. In exemplary aspects, the core / sheath yarn can be positioned in zones based on desired end functions. For example, in order to give a specific knitting zone an additional level of structural stability and / or rigidity, the core / sheath yarn can be positioned in a zone of a knitted heel element corresponding to a first knitting zone. In line with this, the core / sheath yarn can be positioned in a zone corresponding to a knitted heel element of a second knitting zone without being zoned.

[0101] In frame 1114, the yarn ends including buffer yarns such as buffer yarn 918 are positioned between the first knitting layer and the second knitting layer. In one example aspect, the yarn end can include one yarn end, although more yarn ends are contemplated herein. For buffer yarns with a diameter above a specific threshold, the buffer yarn can be embedded. Otherwise, they can be intertwined with the yarns in the first knitting layer and the second knitting layer. In one example aspect, the yarn ends of the buffer yarn can be uniformly positioned on the entire knitted heel element. Other aspects of this paper contemplate that the yarn ends of the buffer yarn can be positioned based on the desired end function and partition. For example, in a knitting area (such as the second knitting area 140) of a knitting element where a higher degree of buffering is desired, more yarn ends of the buffer yarn can be positioned between the first knitting layer and the second knitting layer.

[0102] Aspects of the present invention also contemplate that the amount of cushioning imparted by the cushioning yarn can be adjusted by transfers and / or tucking (such as transfer 913) between the first knit layer and the second knit layer and / or tucking of the low-melting thermoplastic yarn. For example, a greater number of transfers and / or tucking per inch or centimeter can compress the cushioning yarn, resulting in less cushioning and / or a more compact cushioning. Conversely, a smaller number of transfers and / or tucking per inch or centimeter can result in greater cushioning or a less compact cushioning.

[0103] Similar to blocks 810, 812, and 814 of method 800, blocks 1110, 1112, and 1114 of method 1100 are described above separately to discuss the specific details of each aspect of the knitted structure. However, it should be understood that these steps can occur simultaneously so that the high-melting yarn, yarn, low-melting thermoplastic yarn, core / sheath yarn, and buffer yarn for the first knit layer and the second knit layer can be knitted across the needle bed in a single pass of the carriage using multiple yarn feeders.

[0104] In frame 1116, one or more of heat and pressure at a first temperature is applied to a first knitted area, such as the first knitted area 138 of a knitted heel element. In exemplary aspects, heat and pressure at a first temperature can be applied when the knitted heel element is in a flat planar state (also referred to as flat pressing). The heat can be at a temperature sufficient to melt the thermoplastic material (e.g., a thermoplastic sheath of a fusible yarn and a core / sheath yarn) of the yarn positioned between the first knitted layer and the second knitted layer, but not high enough to damage the high melting point yarn, which includes the yarn used to form the first knitted layer and the second knitted layer, the core of the core / sheath yarn and / or the buffer yarn. The exemplary temperature can include, for example, about 135 degrees Celsius. The applied pressure causes the molten thermoplastic material to flow between the first knitted layer and the second knitted layer.

[0105] In block 1118, the knitted heel element is cooled. While cooling, a thermoformed layer, such as thermoformed layer 914, is formed between the first knitted layer and the second knitted layer in the first knitted region of the knitted heel element. In some aspects, the pressure can be sufficient to cause the thermoplastic material to penetrate or permeate the first knitted layer and / or the second knitted layer. In example aspects, the heat and pressure at the first temperature are not applied to the second knitted region, such as the second knitted region 140, so that the thermoformed layer is not formed in the second knitted region.

[0106] In frame 1120, the knitted heel element of cooling is positioned on a three-dimensional (3-D) form, such as the heel area of ​​a shoe last. In example, the 3-D form can be placed in a vacuum chamber. In frame 1122, heat and pressure at a second temperature are applied to the entire knitted heel element. In example, the heat at the second temperature can be sufficient to soften the thermoforming layer and / or soften the yarn ends including the thermoplastic material, such as the yarn ends 1010, but the thermoplastic material is not melted. In example, the heat at the second temperature can be from about 70 degrees Celsius to about 100 degrees Celsius. When the thermoplastic material softens, pressure is applied to the knitted heel element to make the knitted heel element conform to the shape of the 3-D form. In an example, pressure can be imparted by sand poured on the 3-D form. The use of sand can ensure that pressure is more evenly distributed to the knitted heel element, so that the integral body of the knitted heel element closely conforms to the three-dimensional shape of the 3-D form.

[0107] After the knitted heel element is removed from the 3-D form and the knitted heel element is allowed to cool, the knitted heel element is incorporated into an article of footwear at block 1124. For example, the knitted heel element is incorporated into a heel region and heel area (such as heel area 124 and heel area 125) of an article of footwear, such as article of footwear 100. The knitted heel element is positioned such that a first knitted area is located proximate to the sole structure and a second knitted area is located proximate to a collar of the article of footwear.

[0108] Fig.12 An array of articles of footwear is depicted, including a first article of footwear 1210 and a second article of footwear 1212. In an exemplary aspect, the first article of footwear 1210 includes an upper 1214 secured to a sole structure 1216. The first article of footwear 1210 also includes a first knitted heel element 1218 having a first knitted region 1220, a second knitted region 1222, and a collar 1223, which collar 1223 can be knitted using the first knitted structure 500 or the second knitted structure 900. In an exemplary aspect, the first article of footwear 1210 is configured for use in a first type of athletic activity. Fig.12 In the illustrative example shown, the first type of sporting activity may include basketball, although this is only an example. With reference to a footwear article configured for basketball, typically, the collar of the footwear article extends further over the wearer's foot than footwear articles used for running, global soccer, etc. (e.g., so-called high-top shoes). Because the collar 1223 extends further upward and can be positioned around the wearer's ankle, it may be desirable to increase the amount of cushioning and / or increase the area of ​​cushioning to protect the sensitive skin around the ankle. A separate view of the first knitted heel element 1218 is depicted below the first footwear article 1210.

[0109] In an exemplary aspect, the second article of footwear 1212 includes an upper 1224 secured to a sole structure 1226. The second article of footwear 1212 also includes a second knitted heel element 1227 having a third knitted area 1228 corresponding to the first knitted area 138; a fourth knitted area 1230 corresponding to the second knitted area 140; and a collar 1231 that can be knitted using the first knitted structure 500 or the second knitted structure 900. In an exemplary aspect, the second article of footwear 1212 is configured for use in a second type of athletic activity that is different from the first type of athletic activity. Fig.12 In the illustrated example, the second type of sporting activity may include soccer, although this is only one example. In a footwear article configured for soccer, collar 1231 is typically positioned below the ankle, and as the wearer performs various actions, the need for stiffness or support in the heel area increases to support the wearer's Achilles tendon and heel area. A separate view of second knitted heel element 1227 is depicted below second footwear article 1212.

[0110] By using the first knitting structure 500 or the second knitting structure 900, different knitting areas of the footwear articles 1210 and 1212 can be customized to meet the different requirements of different sports activities. For example, referring to the first footwear article 1210, due to its increased need for cushioning to protect the ankle of the wearer, the second knitting area 1222 can include a greater number of yarn ends of the cushioning yarn or a smaller number of yarn ends of the yarn including the thermoplastic material (including zero yarn ends of the yarn including the thermoplastic material). Additionally or alternatively, the size or surface area of ​​the second knitting area 1222 can be increased relative to the first knitting area 1220 to provide a greater amount of cushioning. In another example, the number of transfers between the knitting layers (e.g., the first knitting layer, the second knitting layer, and the third knitting layer in the first knitting structure or the first knitting layer and the second knitting layer in the second knitting structure) can be reduced to increase the amount of cushioning or bulk in the second knitting area 1222.

[0111] Referring to the second footwear article 1212, where the need for stiffness or hardness is increased in the third knitted area 1228, the third knitted area 1228 may include a greater number of yarn ends of the yarn containing the thermoplastic material, thereby forming a thicker or denser thermoforming layer. In addition, if desired, the number of buffer yarns in the third knitted area 1228 may be reduced. Additionally or alternatively, the size or surface area of ​​the third knitted area 1228 may be increased relative to the fourth knitted area 1230 to provide a greater stiffness or hardness surface area.

[0112] In various aspects, an upper and / or a footwear article includes a knitted element. The knitted element includes a knitted heel element. The knitted heel element is thermoformed and / or at least partially fused to include a thermoformed and / or fused polymer material layer that provides increased stiffness. The layer with increased stiffness forms an integrally woven heel stabilizer. The woven heel stabilizer provides stiffness in the heel area without the need to insert, attach, or combine a separate component of a traditional heel stabilizer, such as in an additional manufacturing step after a knitting operation to form the knitted element and a thermoforming operation to form the layer with increased stiffness.

[0113] Aspect 1 .A knitted heel element, comprising: a first knitted composite area, the first knitted composite area comprising a low-melting thermoplastic material and a first knitted structure; a second knitted composite area, the second knitted composite area extending as a whole from the first knitted composite area, the second knitted composite area comprising the low-melting thermoplastic material and the second knitted structure, wherein the weight concentration of the low-melting thermoplastic material in the second knitted composite area is smaller than that in the first knitted composite area; and a knitted collar, the knitted collar extending as a whole from the second knitted composite area, the knitted collar comprising one or more elastic yarns.

[0114] Aspect 2 .A knitted heel element according to aspect 1, wherein the low-melting point thermoplastic material is thermoformed to define a heel counter having a higher stiffness than the remainder of the knitted heel element.

[0115] Aspect 3 .A knitted heel element according to aspect 1 or 2, wherein the first knitted structure comprises a first knitted layer and a second knitted layer.

[0116] Aspect 4 . A knitted heel element according to any one of aspects 1 to 3, wherein the low-melting point thermoplastic material in the first knitted composite area comprises a thermoformed layer.

[0117] Aspect 5 .A knitted heel element according to any one of aspects 1 to 4, wherein the thermoforming layer is at least partially positioned between the first knitted layer and the second knitted layer of the first knitted structure.

[0118] Aspect 6 . A knitted heel element according to any one of aspects 1 to 5, wherein the thermoforming layer comprises at least one buffer yarn.

[0119] Aspect 7 . A knitted heel element according to any one of aspects 1 to 6, wherein the thermoforming layer comprises at least one high melting point thermoplastic yarn.

[0120] Aspect 8 .A knitted heel element according to any one of aspects 1 to 7, wherein the second knitted structure comprises at least a first knitted layer and a second knitted layer.

[0121] Aspect 9 .A knitted heel element according to any one of aspects 1 to 8, wherein the second knitted structure includes a first number of yarn ends positioned between the first knitted layer and the second knitted layer, each of the yarn ends being formed entirely of a low-melting point thermoplastic material.

[0122] Aspect 10 .A knitted heel element according to any one of Aspects 1 to 9, wherein the second knitted structure includes a second number of yarn ends, each of the yarn ends including a buffer yarn positioned between the first knitted layer and the second knitted layer, wherein the first number of yarn ends, each of which is completely formed of the low-melting point thermoplastic material, are thermoformed in the area between the first knitted layer and the second knitted layer.

[0123] Aspect 11.A knitted heel element according to any one of aspects 1 to 10, wherein the low-melting point thermoplastic material thermoformed between the first knitted layer and the second knitted layer is dispersed between the second number of yarn ends, each of the yarn ends comprising a buffer yarn.

[0124] Aspect 12 .A knitted heel element, comprising: a first knitted area, the first knitted area comprising a first hardness; a second knitted area, the second knitted area extending as a whole from the first knitted area, the second knitted area comprising a second hardness less than the first hardness; and a knitted collar, the knitted collar extending as a whole from the second knitted area, the knitted collar comprising one or more elastic yarns.

[0125] Aspect 13 .A knitted heel element according to aspect 12, wherein the first knitted area is positioned at a lower end of the knitted heel element and the second knitted area extends upward from the first knitted area to the knitted collar.

[0126] Aspect 14 .A knitted heel element according to aspect 12 or 13, wherein the first knitted region comprises a first concentration of thermoplastic polymer material per unit surface area, and wherein the second knitted region comprises a second concentration of thermoplastic polymer material per unit surface area, and wherein the first concentration is higher than the second concentration.

[0127] Aspect 15 . A knitted heel element according to any one of aspects 12 to 14, wherein the first knitted area and the second knitted area include a thermoformed layer.

[0128] Aspect 16 . A knitted heel element according to any one of aspects 12 to 15, wherein the thermoformed layer defines a heel counter having a higher stiffness than the remainder of the knitted heel element.

[0129] Aspect 17 .A knitted heel element according to any one of Aspects 12 to 16, wherein the increased stiffness of the heel counter is provided without a separately formed component being incorporated into or onto the knitted heel element to increase stiffness.

[0130] Aspect 18.A footwear article, comprising: a sole structure; and an upper fixed to the sole structure, the upper comprising a knitted element, the knitted element comprising a first knitted area and a second knitted area, the first knitted area comprising: a first knitted layer, a second knitted layer and a thermoforming layer at least partially located between the first knitted layer and the second knitted layer, the thermoforming layer comprising a low-melting-point thermoplastic material, and the second knitted area comprising: the first knitted layer, the second knitted layer, a first number of yarn ends, the first number of yarn ends comprising the low-melting-point thermoplastic material.

[0131] Aspect 19 . The article of footwear according to aspect 18, wherein the upper includes an integrally knitted heel counter formed from the low-melt thermoplastic material being thermoformed.

[0132] Aspect 20 .An article of footwear according to aspects 18 or 19, wherein the integrally knitted heel counter has a higher stiffness than the remainder of the knitted element without separate components being incorporated into or onto the knitted element to increase stiffness.

[0133] Aspect 21 .An article of footwear according to any one of aspects 18 to 20, wherein the thermoforming layer includes at least one end of a buffer yarn, and wherein the second knitted area includes a second number of yarn ends of the buffer yarn.

[0134] Aspect 22 . The article of footwear according to any one of aspects 18 to 21, wherein the first knit layer and the second knit layer each include a high melting point thermoplastic yarn.

[0135] Aspect 23 . The article of footwear according to any one of aspects 18 to 22, wherein the thermoforming layer further comprises at least one end portion of a high melting point thermoplastic yarn.

[0136] Aspect 24 .An article of footwear according to any one of aspects 18 to 23, wherein in the second knitted area, the first number of yarn ends comprising the low-melting thermoplastic material are each formed entirely of the low-melting thermoplastic material.

[0137] Aspect 25 . The article of footwear according to any one of aspects 18 to 24, wherein the first number of yarn ends comprising the low-melting thermoplastic material comprises one or more of low-melting polyethylene terephthalate yarns and low-melting polyamide yarns.

[0138] Aspect 26.A footwear article according to any one of aspects 18 to 25, wherein the first number of yarn ends comprising the low-melting thermoplastic material are the low-melting polyethylene terephthalate, and wherein the melting point of the low-melting polyethylene terephthalate yarn is less than or equal to about 135 degrees Celsius.

[0139] Aspect 27 .The footwear article according to any one of aspects 18 to 26, wherein the first number of yarn ends comprising the low-melting thermoplastic material are the low-melting polyamide yarns, and wherein the melting point of the low-melting polyamide yarns is less than or equal to about 135 degrees Celsius.

[0140] Aspect 28 . The article of footwear according to any one of aspects 18 to 27, wherein the first number of yarn ends comprising the low-melting thermoplastic material in the second knitted area is five yarn ends.

[0141] Aspect 29 . The article of footwear according to any one of aspects 18 to 28, wherein a buffer yarn is embedded between the first knitted layer and the second knitted layer in the first knitted area.

[0142] Aspect 30 .A footwear article according to any one of aspects 18 to 29, wherein the first number of yarn ends comprising the low-melting thermoplastic material in the second knitted zone are intermittently interwoven with yarns of one or more of the first knitted layer and the second knitted layer forming the first knitted zone.

[0143] Aspect 31 . The article of footwear according to any one of aspects 18 to 30, wherein the first knitted area comprises a higher concentration per unit surface area of ​​the low-melting thermoplastic material than the second knitted area.

[0144] Aspect 32.An array of footwear articles, each of which includes a sole structure, an upper fixed to the sole structure, and a knitted heel element, each knitted heel element including a first knitted layer and a second knitted layer, the first knitted layer including an outward-facing surface of the knitted heel element, the second knitted layer including an inward-facing surface of the knitted heel element, the array of footwear articles including at least: a first footwear article, the first footwear article being configured for a first type of sports activity, a first knitted heel element of the first footwear article including: a first knitted area located at a lower portion of the first knitted heel element and a second knitted area located above the first knitted area, the first knitted area including a thermoforming layer, the thermoforming layer including a low-melting thermoplastic material and being positioned at least between the first knitted layer and the second knitted layer, the second knitted area including a first number of yarn ends and a second number of yarn ends, the first number of yarn ends including the low-melting thermoplastic material, the second number The yarn ends include buffer yarns; and a second footwear article, the second footwear article being configured for a second type of sports activity different from the first type of sports activity, the second knitted heel element of the second footwear article including: a third knitted area located at a lower portion of the second knitted heel element and a fourth knitted area located above the third knitted area, the third knitted area including a thermoforming layer, the thermoforming layer including the low-melting point thermoplastic material and at least partially positioned between the first knitted layer and the second knitted layer, the fourth knitted area including a third number of yarn ends and a fourth number of yarn ends, the third number of yarn ends including the low-melting point thermoplastic material, and the fourth number of yarn ends including buffer yarns, wherein the first knitted area of ​​the first footwear article and the third knitted area of ​​the second footwear article include different surface areas, and / or the second knitted area of ​​the first footwear article and the fourth knitted area of ​​the second footwear article include different surface areas.

[0145] Aspect 33 .An array of footwear articles according to aspect 32, wherein the thermoformed layer of the first knitted heel element defines a first heel counter, the first heel counter comprises a first stiffness that is higher than the stiffness of the remainder of the first knitted region and the second knitted region, and wherein the thermoformed layer of the second knitted heel element defines a second heel counter, the second heel counter comprises a second stiffness that is higher than the stiffness of the remainder of the third knitted region and the fourth knitted region.

[0146] Aspect 34 . An array of articles of footwear according to aspects 32 or 33, wherein the first stiffness and the second stiffness are different.

[0147] Aspect 35.An array of footwear articles according to any one of Aspects 32 to 34, wherein the first heel counter and the second heel counter are formed integrally with the first knitted heel element and the second knitted heel element, respectively, without separate components being integrated in or on the first knitted heel element and the second knitted heel element to increase stiffness.

[0148] Aspect 36 .An array of footwear articles according to any one of aspects 32 to 35, wherein the thermoforming layer in each of the first knitted area of ​​the first footwear article and the third knitted area of ​​the second footwear article includes at least one end of a high melting point thermoplastic yarn.

[0149] Aspect 37 .An array of footwear articles according to any one of aspects 32 to 36, wherein each of the second number of yarn ends comprising the low-melting thermoplastic material in the second knitted region of the first footwear article and the third number of yarn ends comprising the low-melting thermoplastic material in the fourth knitted region of the second footwear article comprises one or more of low-melting polyethylene terephthalate yarn and low-melting polyamide yarn.

[0150] Aspect 38 .A method for manufacturing a knitted element for an upper of an article of footwear, the method comprising: knitting a first knitted layer and a second knitted layer; positioning an end of a yarn comprising a low-melting point thermoplastic material between the first knitted layer and the second knitted layer; positioning an end of a yarn comprising a buffer yarn between the first knitted layer and the second knitted layer; and thermoforming at least a first knitted area of ​​the knitted element so that a thermoforming layer is at least partially formed between the first knitted layer and the second knitted layer, the thermoforming layer being located in the heel area.

[0151] Aspect 39 .The method according to aspect 38 also includes: forming the knitted element into an upper and incorporating the upper into an article of footwear so that the thermoformed layer forms an integral heel counter in the heel area of ​​the article of footwear.

[0152] Aspect 40 .A method according to aspect 38 or 39, wherein the integral heel counter is formed without a separate component being integrated into or onto the heel area to increase the stiffness of the heel area.

[0153] Aspect 41 .A method according to any one of aspects 38 to 40, wherein during thermoforming, the heel region of the knitted element is thermoformed into a three-dimensional shape.

[0154] Aspect 42 .A footwear article, comprising: a sole structure; and an upper fixed to the sole structure, the upper comprising a knitted element, the knitted element comprising: a first knitted layer, a second knitted layer and a third knitted layer, the first knitted layer comprising an outward-facing surface of the knitted element, the second knitted layer comprising an inward-facing surface of the knitted element, the third knitted layer being positioned between the first knitted layer and the second knitted layer, wherein: in at least a first knitted area of ​​the knitted element, a thermoforming layer is at least partially positioned between the first knitted layer and the third knitted layer, and in at least a second knitted area of ​​the knitted element, a first number of yarn ends comprising a buffer yarn are positioned between the second knitted layer and the third knitted layer.

[0155] Aspect 43 .An array of footwear articles, each of which includes a sole structure, an upper fixed to the sole structure, and a knitted heel element, each of the knitted heel elements includes a first knitted layer, a second knitted layer and a third knitted layer, the first knitted layer includes an outward-facing surface of the knitted heel element, the second knitted layer includes an inward-facing surface of the knitted heel element, and the third knitted layer is positioned between the first knitted layer and the second knitted layer, the array of footwear articles includes at least: a first footwear article, the first footwear article is configured to be used for a first type of sports activity, the first knitted heel element of the first footwear article includes: a first knitted area located at a lower portion of the first knitted heel element and a second knitted area located at an upper portion of the first knitted heel element, the first knitted area includes a thermoforming layer at least partially positioned between the first knitted layer and the third knitted layer, the second knitted area includes a thermoforming layer A first number of yarn ends of a buffer yarn positioned between the second knitted layer and the third knitted layer; and a second footwear article, the second footwear article being configured for a second type of sports activity different from the first type of sports activity, the second knitted heel element of the second footwear article comprising: a third knitted area positioned at a lower portion of the second knitted heel element and a fourth knitted area positioned at an upper portion of the second knitted heel element, the third knitted area comprising a thermoforming layer at least partially positioned between the first knitted layer and the third knitted layer, the fourth knitted area comprising a second number of yarn ends of the buffer yarn positioned between the second knitted layer and the third knitted layer, wherein the first knitted area of ​​the first footwear article and the third knitted area of ​​the second footwear article comprise different surface areas, and / or the second knitted area of ​​the first footwear article and the fourth knitted area of ​​the second footwear article comprise different surface areas.

[0156] Aspect 44.A method for manufacturing a knitted element for a shoe upper, the method comprising: knitting a first knitted layer, a second knitted layer and a third knitted layer on a knitting machine, the third knitted layer being positioned between the first knitted layer and the second knitted layer; positioning one or more yarn ends comprising a low-melting point thermoplastic material between the first knitted layer and the third knitted layer; and positioning one or more yarn ends comprising a buffer yarn between the second knitted layer and the third knitted layer.

[0157] Aspect 45 .A footwear article, comprising: a sole structure; and an upper fixed to the sole structure, the upper comprising a knitted element, the knitted element having a first knitted area and a second knitted area, the first knitted area comprising: a first knitted layer, a second knitted layer and a thermoforming layer at least partially between the first knitted layer and the second knitted layer, the thermoforming layer comprising a low-melting-point thermoplastic material and at least one end of a buffer yarn, the second knitted area comprising: the first knitted layer, the second knitted layer, a first number of yarn ends and a second number of yarn ends, the first number of yarn ends comprising the low-melting-point thermoplastic material, and the second number of yarn ends comprising the buffer yarn.

[0158] Aspect 46 .A knitted heel element, comprising: a lower edge; an upper edge; a first side edge, the first side edge connecting the first end of the lower edge to the first end of the upper edge; a second side edge, the second side edge connecting the second end of the lower edge to the second end of the upper edge; a first knitted area, the first knitted area extending upward from the lower edge and terminating at the first knitted area upper edge; a second knitted area, the second knitted area extending upward from the first knitted area upper edge and terminating at the second knitted area upper edge, wherein: the first distance between the first knitted area upper edge and the second knitted area upper edge at the first side edge and the second side edge of the knitted heel element is greater than the second distance between the first knitted area upper edge and the second knitted area upper edge at the vertical center line of the knitted heel element.

[0159] Aspect 47 .A method of manufacturing, forming and / or assembling any of aspects 1 to 46 or other aspects described herein of the present disclosure.

[0160] The various aspects of the present disclosure have been described with illustrative, non-restrictive intent. For those skilled in the art, alternative aspects will become apparent without departing from the scope thereof. Those skilled in the art may develop alternative means for implementing the above improvements without departing from the scope of the present disclosure.

[0161] It should be understood that certain features and subcombinations are useful and may be employed without reference to other features and subcombinations and are contemplated to be within the scope of the claims.Not all steps listed in the various figures need to be performed in the particular order described.

Claims

1. A knitted heel element, comprising: a first knitted composite region, the first knitted composite region comprising a low-melting thermoplastic material and a first knitted structure; a second knitted composite region, the second knitted composite region integrally extending from the first knitted composite region, the second knitted composite region comprising the low-melting thermoplastic material and a second knitted structure, wherein the low-melting thermoplastic material is present in a lesser concentration by weight in the second knitted composite region than in the first knitted composite region; as well as A knitted collar integrally extends from the second knitted composite region, the knitted collar comprising one or more elastic yarns.

2. The knitted heel element of claim 1, wherein the low-melting thermoplastic material is thermoformed to define a heel counter having a higher stiffness than the remainder of the knitted heel element.

3. The knitted heel element according to claim 1, wherein the first knitted structure includes a first knitted layer and a second knitted layer.

4. The knitted heel element of claim 1, wherein the low-melt thermoplastic material in the first knitted composite area comprises a thermoformable layer. 5 . The knitted heel element according to claim 4 , wherein the thermoforming layer is at least partially positioned between the first knit layer and the second knit layer of the first knit structure.

6. The knitted heel element according to claim 4, wherein the thermoforming layer includes at least one cushioning yarn.

7. The knitted heel element of claim 4, wherein the thermoforming layer comprises at least one high melting point thermoplastic yarn.

8. The knitted heel element according to claim 1, wherein the second knitted structure includes at least a first knitted layer and a second knitted layer.

9. The knitted heel element of claim 8, wherein the second knit structure includes a first number of yarn ends positioned between the first knit layer and the second knit layer, each of which is completely formed of a low-melting point thermoplastic material.

10. A knitted heel element according to claim 9, wherein the second knitted structure includes a second number of yarn ends each comprising a buffer yarn positioned between the first knitted layer and the second knitted layer, wherein the first number of yarn ends each formed entirely of the low-melting point thermoplastic material are thermoformed in the area between the first knitted layer and the second knitted layer.

11. The knitted heel element according to claim 10, wherein the low-melting thermoplastic material thermoformed between the first knit layer and the second knit layer is dispersed between the second number of yarn ends each comprising a buffer yarn.

12. A knitted heel element, comprising: a first knitted region, the first knitted region comprising a first stiffness; a second knitted region, the second knitted region integrally extending from the first knitted region, the second knitted region comprising a second hardness less than the first hardness; as well as A knitted collar integrally extends from the second knitted region, the knitted collar comprising one or more elastic yarns.

13. The knitted heel element according to claim 12, wherein the first knitted area is positioned at a lower end of the knitted heel element and the second knitted area extends upward from the first knitted area to the knitted collar.

14. A knitted heel element according to claim 13, wherein the first knitted area includes a first concentration of thermoplastic polymer material per unit surface area, and wherein the second knitted area includes a second concentration of thermoplastic polymer material per unit surface area, and wherein the first concentration is higher than the second concentration.

15. The knitted heel element according to claim 14, wherein the first knitted area and the second knitted area include a thermoform layer.

16. The knitted heel element of claim 15, wherein the thermoformed layer defines a heel counter having a higher stiffness than a remainder of the knitted heel element.

17. The knitted heel element of claim 16, wherein the increased stiffness of the heel counter is provided without a separately formed component incorporated into or onto the knitted heel element to increase stiffness.

18. A footwear article comprising: Sole structure; as well as an upper secured to the sole structure, the upper comprising a knitted element, the knitted element comprising a first knitted region and a second knitted region, The first knitted area comprises: The first knitted layer, A second knitted layer, and a thermoforming layer at least partially located between the first knit layer and the second knit layer, the thermoforming layer comprising a low melting point thermoplastic material, and The second knitted area comprises: the first knitted layer, The second knitted layer, A first number of yarn ends include said low-melting thermoplastic material.

19. The article of footwear of claim 18, wherein the upper includes an integrally knitted heel counter formed from the low-melt thermoplastic material being thermoformed.

20. The article of footwear of claim 19, wherein the integrally knitted heel counter has a higher stiffness than the remainder of the knitted element without separate components being incorporated into or onto the knitted element to increase stiffness.

21. The article of footwear according to claim 18, wherein the thermoforming layer includes at least one end of a buffer yarn, and wherein the second knitted area includes a second number of yarn ends of the buffer yarn.

22. The article of footwear according to claim 18, wherein the first knit layer and the second knit layer each include a high melting point thermoplastic yarn.

23. The article of footwear of claim 18, wherein the thermoformable layer further comprises at least one end portion of a high melting point thermoplastic yarn.

24. The article of footwear according to claim 18, wherein in the second knit area, the first number of yarn ends comprising the low-melt thermoplastic material are each formed entirely of the low-melt thermoplastic material.

25. The article of footwear of claim 23, wherein the first number of yarn ends comprising the low-melt thermoplastic material include one or more of low-melt polyethylene terephthalate yarns and low-melt polyamide yarns.

26. The article of footwear of claim 25, wherein the first number of yarn ends comprising the low-melt thermoplastic material is the low-melt polyethylene terephthalate, and wherein the low-melt polyethylene terephthalate yarn has a melting point less than or equal to about 135 degrees Celsius.

27. The article of footwear of claim 25, wherein the first number of yarn ends comprising the low-melt thermoplastic material are the low-melt polyamide yarns, and wherein the low-melt polyamide yarns have a melting point less than or equal to about 135 degrees Celsius.

28. The article of footwear according to claim 18, wherein the first number of yarn ends comprising the low-melt thermoplastic material in the second knit area is five yarn ends.

29. The article of footwear recited in claim 18, wherein a cushioning yarn is embedded between the first knit layer and the second knit layer in the first knit area.

30. The footwear article of claim 18, wherein the first number of yarn ends comprising the low-melting thermoplastic material in the second knit region are intermittently interwoven with yarns forming one or more of the first knit layer and the second knit layer forming the first knit region.

31. The article of footwear according to claim 18, wherein the first knitted area includes a higher concentration per unit surface area of ​​the low-melting thermoplastic material than the second knitted area.

32. An array of articles of footwear, each of the articles of footwear comprising a sole structure, an upper secured to the sole structure, and a knitted heel element, each knitted heel element comprising a first knitted layer and a second knitted layer, the first knitted layer comprising an outwardly facing surface of the knitted heel element and the second knitted layer comprising an inwardly facing surface of the knitted heel element, the array of articles of footwear comprising at least: A first article of footwear, the first article of footwear being configured for use in a first type of athletic activity, the first knitted heel element of the first article of footwear comprising: a first knitted region located at a lower portion of the first knitted heel element, the first knitted region comprising a thermoformed layer, the thermoformed layer comprising a low melting point thermoplastic material and positioned at least between the first knitted layer and the second knitted layer, and a second knitted area located above the first knitted area, the second knitted area including a first number of yarn ends and a second number of yarn ends, the first number of yarn ends including the low-melting thermoplastic material and the second number of yarn ends including buffer yarns; and a second article of footwear configured for use in a second type of athletic activity different from the first type of athletic activity, a second knitted heel element of the second article of footwear comprising: a third knitted region located at a lower portion of the second knitted heel element, the third knitted region comprising a thermoformed layer, the thermoformed layer comprising the low-melting thermoplastic material and being at least partially positioned between the first knitted layer and the second knitted layer, and A fourth knitted zone located above the third knitted zone, the fourth knitted zone comprising a third number of yarn ends and a fourth number of yarn ends, the third number of yarn ends comprising the low-melting point thermoplastic material, the fourth number of yarn ends comprising buffer yarns, wherein the first knitted zone of the first footwear article and the third knitted zone of the second footwear article comprise different surface areas, and / or the second knitted zone of the first footwear article and the fourth knitted zone of the second footwear article comprise different surface areas.

33. An array of footwear articles according to claim 32, wherein the thermoformed layer of the first knitted heel element defines a first heel stabilizer, the first heel stabilizer includes a first stiffness that is higher than the stiffness of the remainder of the first knitted region and the second knitted region, and wherein the thermoformed layer of the second knitted heel element defines a second heel stabilizer, the second heel stabilizer includes a second stiffness that is higher than the stiffness of the remainder of the third knitted region and the fourth knitted region.

34. The array of articles of footwear recited in claim 33, wherein the first stiffness and the second stiffness are different.

35. An array of footwear articles according to claim 33, wherein the first heel counter and the second heel counter are formed integrally with the first knitted heel element and the second knitted heel element, respectively, without separate components being integrated in or on the first knitted heel element and the second knitted heel element to increase stiffness.

36. An array of footwear articles according to claim 32, wherein the thermoforming layer in each of the first knitted region of the first footwear article and the third knitted region of the second footwear article includes at least one end of a high-melting point thermoplastic yarn.

37. An array of footwear articles according to claim 32, wherein each of the second number of yarn ends comprising the low-melting thermoplastic material in the second knitted area of ​​the first footwear article and the third number of yarn ends comprising the low-melting thermoplastic material in the fourth knitted area of ​​the second footwear article comprises one or more of low-melting polyethylene terephthalate yarn and low-melting polyamide yarn.

38. A method of manufacturing a knitted element for an upper of an article of footwear, the method comprising: knitting a first knitted layer and a second knitted layer; positioning an end of a yarn comprising a low melting point thermoplastic material between the first knit layer and the second knit layer; positioning a yarn end including a buffer yarn between the first knit layer and the second knit layer; as well as At least a first knitted area of ​​the knitted element is thermoformed such that a thermoformed layer is at least partially formed between the first knitted layer and the second knitted layer, the thermoformed layer being located in the heel area.

39. The method of claim 38, further comprising: forming the knitted element into an upper, and The upper is incorporated into an article of footwear such that the thermoformed layer forms an integral heel counter in the heel region of the article of footwear.

40. The method of claim 39, wherein the integral heel counter is formed without a separate component integrated into or onto the heel area to increase stiffness of the heel area.

41. The method of claim 38, wherein during thermoforming, the heel region of the knitted element is thermoformed into a three-dimensional shape.

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