Knitted heel element, upper and article of footwear with knitted element

Abstract

Knitted elements, including knitted heel elements, configured with cushioning and stiffness features, as well as uppers and articles of footwear having the knitted elements. 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] A conventional heel element, which can be broadly defined as an element that provides structure, cushioning, and / or support to the heel area of ​​an upper of an article of footwear, is typically formed from a rigid or semi-rigid material such as leather, plastic, or the like. Furthermore, conventional heel elements are typically attached to an outward-facing surface of the upper during the manufacturing process. In instances where the heel element includes cushioning, such as adjacent to a collar area 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 can undesirably increase the overall carbon footprint associated with footwear manufacturing. Utility Model Content

[0005] Conventional heel elements, which can be broadly defined as elements that provide structure, cushioning, and / or support to the heel area of ​​a footwear upper, are typically formed from rigid or semi-rigid materials such as leather or plastic. Furthermore, conventional heel elements are typically attached to the outward-facing surface of the upper during the manufacturing process, or otherwise inserted into the upper. In some cases, such rigid or semi-rigid materials may include sharp edges, which can cause discomfort to the wearer, including heel irritation, a common reason for returning or discarding footwear. Additionally, where the heel element includes cushioning, such as adjacent to the collar area of ​​the upper, the cushioning element is typically secured to the heel element in an additional manufacturing step. In addition to increasing the time, expense, and complexity associated with manufacturing footwear, these additional manufacturing steps can increase the overall carbon footprint of footwear manufacturing. Furthermore, adding reinforcements and / or cushioning elements can increase the volume and weight of footwear, as well as other undesirable properties.

[0006] In aspects herein, an article of footwear having a knitted element, including a knitted heel element, methods of manufacturing the knitted element and footwear, and in some aspects, an array of articles of footwear including knitted heel elements that can have different amounts of cushioning and / or rigidity depending on the intended use of the article of footwear are provided. With respect to the knitted heel element, aspects herein contemplate the use of different knit structures, different material processing, different types of yarns, and / or different amounts of particular yarns to achieve different amounts of cushioning and / or rigidity in different knit zones of the knitted heel element. In aspects, the knitted heel element can be incorporated into an upper as a heel counter, for example, imparting a structure of stiffness and cushioning in the heel region without the need for a traditional heel counter component that is manufactured separately and incorporated into the upper in one or more additional manufacturing steps. The use of such a knitted heel element 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 automated knitting machines and post-processing techniques.

[0007] In example aspects, in the knitted heel element, the amount of cushioning and rigidity can be independently controlled such that a particular knit zone can have, for example, a large amount of cushioning and rigidity or stiffness, a large amount of cushioning and a small amount of rigidity or stiffness, a small amount of cushioning and a large amount of rigidity or stiffness, or a small amount of both cushioning and rigidity or stiffness. In some examples, the knitted heel element can include a transition region between different knit zones, where the transition region can include an intermediate amount of rigidity or stiffness and / or an intermediate amount of cushioning relative to the knit zones adjacent to the transition region.

[0008] In some aspects, the cushioning and rigidity can be controlled to form an elastic, reversibly collapsible knitted heel element that facilitates putting on and taking off the article of footwear. For example, a cushioning knit zone can be positioned adjacent to a collar region of the article of footwear, and a rigidity knit zone can be positioned adjacent to a sole structure of the article of footwear below the cushioning knit zone. The knit structure, the type of yarn used, and / or the amount of yarn used can be adjusted such that when a wearer places his or her foot into the article of footwear and the wearer’s heel presses down on the cushioning knit zone and / or collapses the cushioning knit zone downward toward the rigidity knit zone, the wearer can easily slide her foot into the article of footwear. Once positioned within the article of footwear, the cushioning knit zone can quickly spring back up and return to its extended shape. This feature is particularly useful for wearers with different hand and / or arm dexterity or coordination abilities, as it enables the wearer to put on the article of footwear substantially without the use of hands.

[0009] In a first example knit structure, the knit heel element can include a first knit layer forming an outward-facing surface of the knit heel element, a second knit layer forming an inward-facing surface of the knit heel element, and a third knit layer positioned between the first knit layer and the second knit layer, where the first knit layer, the second knit layer, and the third knit layer are integrally knit with one another in a single knit event (e.g., a manufacturing process performed by a knitting machine). In a first knit zone of the knit heel element, the thermoformed layer is at least partially positioned between the first knit layer and the third knit layer, which first knit zone can correspond to a lower portion of the knit heel element positioned adjacent to a sole structure when the knit heel element is incorporated into an upper of an article of footwear. The thermoformed layer can provide rigidity to the first knit zone, which can help support an Achilles area of a wearer’s foot. In example aspects, the first knit zone can also include yarn ends of a cushioning yarn positioned between the second knit layer and the third knit layer. Positioning the cushioning yarn between the second knit layer and the third knit layer can position the cushioning yarn closer to a skin surface of a wearer as compared to positioning the cushioning yarn between the first knit layer and the third knit layer. The cushioning yarn can provide some cushioning between the skin surface of the wearer and the more rigid thermoformed layer in the first knit zone.

[0010] The first knit structure can also include a second knit zone located in an upper portion of the knit heel element adjacent to a collar region of the upper. The second knit zone can include a number of yarn ends of a cushioning yarn positioned between the second knit layer and the third knit layer. The cushioning yarn can help provide cushioning for the collar region of the upper, which facilitates comfort for a wearer. In some example aspects, the second knit zone can also include yarn ends of a low-melt thermoplastic positioned between the first knit layer and the third knit layer. The low-melt thermoplastic can help provide some elasticity and structure to the knit heel element in the second knit zone so that the knit heel element does not fold in an undesirable manner.

[0011] To form the first knit structure, the first knit layer, the second knit layer, and the third knit layer are knitted on a double bed knitting machine during a single knitting event (e.g., a knitting operation performed by a knitting machine). In one example aspect, the first knit layer and the third knit layer can be knitted in a half-gauge structure on a first needle bed of the knitting machine. For example, the first knit layer can be knitted on first needles, third needles, fifth needles, etc. of the first needle bed, and the second knit layer can be knitted on second needles, fourth needles, sixth needles, etc. of the first needle bed. The second knit layer can be knitted on a second needle bed of the knitting machine. In this aspect, the first knit layer and the third knit layer have about half the number of knit stitches per inch or centimeter as the second knit layer. In some aspects herein, it is contemplated that the first knit layer, the second knit layer, and the third knit layer are knitted using high melt thermoplastic yarns (e.g., such as high melt polyester yarns and / or high melt recycled polyester yarns). Examples of polyesters that can be used in the yarns included in the knit structures described herein include polyethylene terephthalate (PET) and polybutylene terephthalate (PBT), among others. In example aspects, to increase structural stability, the high melt thermoplastic yarns can be plated with a fusible yarn as defined below.

[0012] During the single knitting event, the yarn end including the low melt thermoplastic material can be positioned between the first knit layer and the third knit layer. In some aspects, the yarn end including the low melt thermoplastic material can be interlaced with knit stitches forming the first knit layer and the third knit layer. In one example, the yarn end including the low melt thermoplastic material can be intermittently floated between the first knit layer and the third knit layer and then tacked with knit stitches forming the first knit layer and / or the third knit layer. During the single knitting event, the yarn end including the buffer yarn can be positioned between the second knit layer and the third knit layer. In some aspects, the yarn end including the buffer yarn can be embedded between the second knit layer and the third knit layer, for example, via a combination feeder, although aspects herein also contemplate interlacing the buffer yarn with one or more knit stitches forming the second knit layer and the third knit layer. Aspects herein contemplate varying the number of yarn ends of the low melt thermoplastic material and / or the buffer yarn to achieve different functional purposes for different knit zones (e.g., the first knit zone and the second knit zone) of the knit heel element. Aspects herein also contemplate varying 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 for different knit zones. Any and all of these aspects and any variations thereof are contemplated to be within the scope herein.

[0013] The method of manufacturing the knit heel element can further include applying one or more of heat and pressure to the first knit region of the knit heel element. The heat can be sufficient to melt the end of the yarn comprising the low-melt thermoplastic material, but not so high as to melt, scorch, burn, or otherwise destroy the structural integrity of the cushioning yarn and the high-melt thermoplastic yarn used to form the first knit layer, the second knit layer, and the third knit layer. Pressure can be applied to cause the melted thermoplastic material to flow in one or more planes or directions. For example, the melted thermoplastic material can flow in the x, y plane, such that the melted thermoplastic material spreads between the first knit layer and the third knit layer. The melted thermoplastic material can also flow in the z direction, such as, for example, into and / or through the first knit layer, such that, in some aspects, the melted thermoplastic material can be deposited onto the outward-facing surface of the knit heel element. The knit heel element is then cooled, which causes the melted thermoplastic material to re-solidify and form a thermoformed layer positioned at least partially between the first knit layer and the third knit layer. In some aspects, the thermoformed layer extends at least partially into and / or through the first knit layer.

[0014] In further example aspects, the amount of pressure applied to the first knit region can be calibrated such that the thermoformed layer does not extend completely through the second knit layer or does not substantially extend through the second knit layer, thereby maintaining the functional properties of the cushioning yarn positioned between the second knit layer and the third knit layer. As described above, the thermoformed layer can impart structural rigidity to the first knit region of the knit heel element. In example aspects, no heat and / or pressure is applied to the second knit region of the knit heel element, such that a thermoformed layer is not formed in the second knit region, and the functional properties of the second knit region can be cushioning rather than rigidity. In some example aspects, a second heat and pressure can be applied to soften the thermoplastic material, including the thermoformed layer, to shape the knit heel element into a desired three-dimensional shape. The knit heel element can then be incorporated into a heel region of an upper of an article of footwear.

[0015] In a second example knit structure, the knit heel element can include a first knit layer forming an outward-facing surface of the knit heel element and a second knit layer forming an inward-facing surface of the knit heel element, where the first knit layer and the second knit layer are integrally knit with one another in a single knitting event. In a first knit zone of the knit heel element, a thermoformed layer is positioned at least partially between the first knit layer and the second knit layer, which first knit zone can correspond to a lower portion of the knit heel element positioned adjacent to a sole structure when the knit heel element is incorporated into an upper of an article of footwear. In example aspects, the thermoformed layer can include one or more ends of a cushioning yarn. In additional example aspects, the thermoformed layer can also include one or more ends of a high-melt thermoplastic yarn, such as a high-melt PET yarn and / or a high-melt recycled PET yarn. The thermoformed layer can provide rigidity to the first knit zone, and when used, the additional yarn ends of the cushioning yarn and / or the high-melt thermoplastic yarn can provide additional structural stability to the first knit zone by acting as a scaffolding-type structure within the thermoformed layer.

[0016] The second knit structure can also include a second knit zone positioned at an upper portion of the knit heel element adjacent to a collar region of the upper. The second knit zone can include the first knit layer and the second knit layer. The second knit zone can also include yarn ends of a cushioning yarn positioned between the first knit layer and the second knit layer. The cushioning yarn can help provide cushioning to the collar region of the upper, which facilitates comfort for a wearer. In some example aspects, the second knit zone can also include yarn ends of a low-melt thermoplastic material positioned between the first knit layer and the second knit layer. The low-melt thermoplastic material can help provide some structure and elasticity to the knit heel element in the second knit zone such that the knit heel element does not inadvertently fold over.

[0017] To form the second knit structure, the first knit layer and the second knit layer can be knit on a double bed knitting machine during a single knitting event. In one example aspect, the first knit layer can be knit on a first bed of the knitting machine, and the second knit layer can be knit on a second bed of the knitting machine. Aspects herein contemplate that one or more yarns from the first knit layer can be intermittently transferred to the second knit layer, and one or more yarns for the second knit layer can be intermittently transferred to the first knit layer. After the transfer, aspects herein contemplate that the yarns can be knit one or more knit stitches on the opposite bed before being transferred back to the original bed. Aspects herein contemplate that the first knit layer and the second knit layer are knit using a high-melt thermoplastic yarn and / or a high-melt recycled thermoplastic yarn, such as a high-melt PET yarn and / or a high-melt recycled PET yarn. In example aspects, the high-melt thermoplastic yarn can be plated with a fusible yarn for additional structural stability.

[0018] During a single knitting event, the yarn end comprising the low melt thermoplastic material can be selectively positioned between the first knitted layer and the second knitted layer. Aspects herein contemplate that the low melt thermoplastic yarn can comprise a low melt PET yarn and / or a low melt polyamide yarn. In some aspects, the low melt thermoplastic yarn can be formed entirely of low melt PET and / or low melt polyamide (e.g., joined with a knitted zone incorporating a cushioning yarn or yarn end to help contain the expansion of the cushioning yarn or yarn end in a desired manner). In various examples, the yarn positioned between the first knitted layer and the second knitted layer in at least the first knitted zone of the knitted heel element is a multi-component yarn having a high melt thermoplastic material adjacent to a low melt thermoplastic material. For example, a yarn comprising a core / sheath configuration can be used in such a configuration where the core of the high melt thermoplastic yarn is surrounded by a sheath of low melt thermoplastic material. In other aspects, such a multi-component yarn having a high melt thermoplastic material and a low melt thermoplastic material can have other configurations, such as a side-by-side configuration where the low melt thermoplastic material is positioned in a side-by-side configuration with the high melt thermoplastic material, a trilobal configuration, etc. In some aspects, the yarn end comprising the low melt thermoplastic material (e.g., formed entirely of thermoplastic material or can include those comprising a core / sheath configuration including a thermoplastic material) can be interlaced with the knitted stitches forming the first knitted layer and the second knitted layer. For example, the yarn end comprising the low melt thermoplastic material can be intermittently floated between the first knitted layer and the second knitted layer and then tacked with the knitted stitches forming the first knitted layer and the second knitted layer. During a single knitting event, the yarn end comprising the cushioning yarn can be positioned between the first knitted layer and the second knitted layer. In some aspects, the yarn end comprising the cushioning yarn can be embedded between the first knitted layer and the second knitted layer, although aspects herein also contemplate interlacing the cushioning yarn with one or more knitted stitches forming the first knitted layer and / or the second knitted layer. In one example aspect, the tacking comprising the low melt thermoplastic material can be used to adjust the amount of cushioning provided by the cushioning yarn. For example, a greater number of tacks 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 lesser number of tacks per inch or centimeter can allow the cushioning yarn to fully expand, resulting in slightly more or less compact cushioning.

[0019] Aspects herein contemplate independently varying the number of yarn ends of the low melt thermoplastic material and / or the cushioning yarn to achieve different functional purposes for different knitted zones (e.g., the first knitted zone and the second knitted zone) of the knitted heel element. Aspects herein also contemplate varying the type of yarn positioned between the first knitted layer and the second knitted layer to achieve different functional purposes for different knitted zones. Any and all of these aspects and any variations thereof are contemplated to be within the scope herein.

[0020] The manufacturing method can further include applying one or more of heat and pressure at a first temperature to the first knit region of the knit heel element. In one aspect, this is done while the knit heel element is in a flat or planar configuration (so-called "flat pressing"). The heat can be sufficient to melt the yarn ends comprising the low-melt thermoplastic material, but not so high as to melt, scorch, burn, or otherwise compromise the structural integrity of the cushioning yarns, the high-melt thermoplastic yarns used to form the first knit layer and the second knit layer, and / or the high-melt thermoplastic core of the yarns having a core / sheath configuration. Pressure can be applied to cause the melted thermoplastic material to flow in one or more planes. In example aspects, flat pressing can be advantageous because it generally facilitates more uniform distribution and flow of the melted thermoplastic material compared to, for example, three-dimensional pressing. The melted thermoplastic material can flow in the x, y plane, such that it spreads between the first knit layer and the second knit layer. The melted thermoplastic material can also flow in the z direction, such as, for example, into, through, and / or substantially through the first knit layer. As the melted thermoplastic material flows through the first knit layer, it can form a deposit on the outward-facing surface of the knit heel element. The knit heel element is then cooled, which causes the melted thermoplastic material to re-solidify and form a thermoformed layer positioned at least partially between the first knit layer and the second knit layer. In some aspects, the thermoformed layer extends at least partially into and / or through the first knit layer. As described above, the thermoformed layer can impart structural rigidity or stiffness to the first knit region of the knit heel element. The amount of rigidity can be increased by using yarn ends comprising the cushioning yarns and yarn ends comprising the core / sheath configuration. The high-melt thermoplastic cores of the cushioning yarns and the core / sheath yarns can act as scaffolding positioned within the thermoformed layer. In example aspects, heat and pressure at the first temperature are not applied to the second knit region of the knit heel element, such that a thermoformed layer is not formed in the second knit region, and the functional properties of the second knit region can be cushioning rather than rigidity.

[0021] In example aspects, the method can further include subsequently positioning the knit heel element on a three-dimensional (3-D) form, such as, for example, a shoe last. When positioned on the 3-D form, heat and pressure at a second temperature are applied to the knit heel element, where the heat and pressure are applied to the entirety of the knit heel element, rather than a particular knit region. In this aspect, the heat can be sufficient to soften the thermoformed layer in the first knit region, and further soften the yarn ends comprising thermoplastic material in the second knit region. Softening the thermoplastic material allows the knit heel element to conform to the shape of the 3-D form. Upon cooling, the knit heel element retains the desired shape. The method can further include incorporating the 3-D knit heel element into a heel region of an upper of an article of footwear.

[0022] In various aspects, one or more thermoforming processes can 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 performed thermoforming processes, the knitted heel element can be thermoformed into a three-dimensional shape (e.g., a three-dimensional shape generally corresponding to the heel area of ​​a footwear upper and / or corresponding to the 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.

[0023] 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, footwear articles configured for basketball can generally cover the wearer's ankle (for example, such as high-top sneakers). In this respect, compared with footwear articles configured for running, for example, the knitted heel element may need a larger buffer zone (for example, a second knitted zone), wherein the shoe collar is generally placed under the wearer's ankle (for example, running). In another example, compared with footwear articles configured for running, articles configured for global football (also referred to as soccer) sports may need to increase rigidity around the lower portion 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 a buffer yarn in a specific zone to promote increased cushioning, increasing the size or surface area of ​​a specific buffer zone (e.g., the second knit zone) or stiffness zone (e.g., the first knit zone), adding more yarn ends of a yarn comprising a thermoplastic material in a specific zone to promote increased stiffness after processing, etc. The tuck frequency between different knit layers can also be used to adjust the amount of cushioning imparted by the use of the buffer yarn. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] Examples of various aspects of this disclosure are described in detail below with reference to the accompanying drawings, in which:

[0025] Figure 1 illustrates a medial view of an example article of footwear having a knitted heel element according to aspects herein;

[0026] Figure 2 The diagram shows the various aspects of the present invention. Figure 1 a lateral side view of an example article of footwear;

[0027] Figure 3 The diagram shows the various aspects of the present invention. Figure 1 a rear view of an example article of footwear;

[0028] Figure 4A FIG. 1 illustrates one configuration of a knitted heel element according to aspects herein;

[0029] Figure 4B FIG. 2 illustrates another configuration of a knitted heel element according to aspects herein similar to Figure 4A FIG. 1 ;

[0030] Figure 4C FIG. 3 illustrates another configuration of a knitted heel element according to aspects herein similar to Figure 4A FIG. 2;

[0031] Figure 5 FIG. 4 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 zone of a knitted heel element according to aspects herein;

[0032] Figure 6 FIG. 5 illustrates a cross-section taken at cut line 6-6 of FIG. 4 and schematically depicts a first example knit structure at a second knit zone of a knitted heel element according to aspects herein similar to Figure 5 FIG. 4;

[0033] Figure 7 FIG. 6 illustrates an example needle mark of a needle bed of a multi-bed knitting machine for partially knitting Figure 5 FIG. 1 and Figure 6 FIG. 2 according to aspects herein;

[0034] Figure 8 FIG. 7 illustrates a block diagram of an example method of manufacturing at least Figure 5 FIG. 1 and Figure 6 FIG. 2 according to aspects herein;

[0035] Figure 9 FIG. 8 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 zone of a knitted heel element according to aspects herein;

[0036] Figure 10 FIG. 9 illustrates a cross-section taken at cut line 10-10 in FIG. 4 and schematically depicts a second example knit structure of a second knit zone of a knitted heel element according to aspects herein similar to Figure 9 FIG. 5;

[0037] Figure 11 FIG. 10 illustrates a flow diagram of an example method of manufacturing at least Figure 9 FIG. 1 and Figure 10 FIG. 2 according to aspects herein; and

[0038] Figure 12One example of an array of articles of footwear configured for different athletic activities is illustrated, wherein the articles of footwear include knitted heel elements having different configurations, in accordance with aspects herein. DETAILED DESCRIPTION

[0039] As used herein, an article of footwear generally includes a sole structure secured to an upper. The articles of footwear described herein can include running shoes, baseball shoes, basketball shoes, skateboarding shoes, cycling shoes, American football shoes, tennis shoes, soccer shoes, training shoes, walking shoes, hiking shoes, and the like. The concepts described herein can also be applied to other footwear types that are considered to be non-athletic, such as dress shoes, loafers, sandals, casual shoes, and work boots. As used herein, an article of footwear can be divided into different general regions. A forefoot region generally includes portions of the article of footwear that correspond with the toes and the joints connecting the metatarsal bones with the phalanges of the foot. A midfoot region generally includes portions of the article of footwear that correspond with the arch area of the foot and the area of the foot behind the toes. A heel region generally corresponds with the back of the foot, including the heel bone. The articles of footwear described herein can include a lateral side and a medial side, the lateral side corresponding with the outer side of the foot (e.g., the surface of the foot facing away from the other foot), and the medial side corresponding with the inner side of the foot (e.g., the surface of the foot facing toward the other foot). The different regions and different sides described above are intended to represent general areas of the footwear to aid the following discussion, and are not intended to be precise areas of demarcation. The different regions and different sides can 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 that is applied to an upper, including the cushioning properties and / or stiffness properties described herein. For example, the knitted element can be applied to an insole region of the upper, a toe region of the upper, a heel region of the upper, and the like. The concepts described herein can involve a knitted heel element that is positioned in a heel region of the upper and that generally extends from the sole structure to a collar region of the upper.

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

[0042] The term "knit", as used herein, for example, to describe a knit 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 interlooping loops (also referred to as interlacing) that define courses and wales. As used herein, the term "course" refers to a major horizontal row of knitted loops produced by adjacent needles during the same knitting event (in a standing fabric knitted on a knitting machine). Courses can include one or more stitch types known in the knitting art, such as knit stitches, miss stitches, tuck stitches, transfer stitches, rib stitches, and the like, which terms are known in the knitting art. The term "course direction" refers to a direction parallel to the knitted courses of a fabric piece. The term "wale", as used herein, is a major vertical column of knitted loops that are interlooped or interlaced, typically produced by the same needle in successive (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 knit construction", as used herein, refers to a knit construction that is typically formed on at least two beds of needles of a knitting machine (e.g., a multi-bed construction). These multi-bed knit constructions can have two opposing knit loops and / or tuck layers, such as one loop layer (e.g., a first knit layer) formed on a first needle bed and a second loop layer (e.g., a second knit layer) formed on a second needle bed. In example aspects, the two layers can be joined by a yarn that interlooms with the yarns in the first knit layer and the second knit layer of the double knit construction. Common double knit constructions include double-bed knit structures such as double jersey, rib, interlock, and the like that are initially formed on at least two needle beds, as well as other knit structures having two opposing faces or layers of knit loops or tucks, including full-gauge and less than full-gauge (e.g., half-gauge) variations of these structures. For example, as described with respect to the first knit structure, aspects herein contemplate knitting two layers (e.g., a first knit layer and a third knit layer) on a single needle bed using half-gauge knit techniques.

[0044] The term "integral knit", as used herein, can refer to a knit fabric having yarn from one or more courses of knit loops in a first region or zone interlooming with one or more courses of knit loops in another region or zone (e.g., a first knit zone and a second knit zone). The interlooming can be by simple knit stitches, tuck stitches, held stitches, float stitches, or miss stitches, among others. In this way, the regions or zones that are knit together as one have a seamless transition such that they seamlessly extend into one another.

[0045] The term "yarn end" as used herein refers to the number of individual yarns. For example, five ends of yarn A would mean five individual strands of yarn A, where each strand can include a monofilament yarn or a multifilament yarn. When using a double bed knitting machine, the yarn ends are typically fed by one or more yarn feeders during a carriage pass. Thus, using the above example, five ends of yarn A would be fed by a feeder during a single pass of the carriage in a first direction. Alternatively, different ends of the same yarn (e.g., yarn A) can be fed by different feeders during a single pass of the carriage in a first direction.

[0046] Using a knit construction to form a knitted element can provide advantages including, but not limited to, a certain degree of elasticity (e.g., as expressed in terms of Young's modulus), air permeability, flexibility, strength, moisture absorption, weight, abrasion resistance, and / or any combination thereof. These properties can be achieved by selecting a particular knit structure, by varying the dimensions and tension of the knit structure, by using one or more yarns formed from a particular material (e.g., a polyester material, a relatively inelastic material, or a relatively elastic material such as an elastic yarn, a thermoplastic material, or a similar material), and / or by selecting a particular size (e.g., denier) or tenacity (e.g., in grams per denier, "g / D") of the yarns and / or by using a combination thereof. Using a knit construction can also provide desirable aesthetic properties by incorporating yarns having different colors, textures, or other visual properties arranged in a particular pattern. The yarns themselves and / or the knit structure formed from one or more of the yarns can vary at different locations such that the knitted element can have different properties as described herein.

[0047] Yarns according to aspects described herein can include monofilament yarns and / or multifilament yarns. In aspects, these can be formed from synthetic materials. In some aspects, yarns can generally be described or designated as high-melt point yarns or low-melt point yarns. High-melt point yarns can be used for knitting, for example, the first knit layer, the second knit layer, and the third knit layer in the first knit structure, and the first layer and the second layer in the second knit structure. In this context, the term “high-melt point” generally refers to yarns that are at least partially formed from materials that melt or soften at a particular high temperature, for example, at a temperature between about 175 to 200 degrees Celsius or higher. In one example, high-melt point thermoplastic yarns used in aspects herein can have a melting temperature of at least about 175 degrees Celsius. High-melt point thermoplastic yarns can include high-melt point PET yarns, high-melt point recycled PET yarns, buffer yarns, core / sheath yarns with a core comprising a high-melt point material (e.g., a high-melt point PET core) and a sheath comprising a low-melt point material, elastic yarns, and other high-melt point synthetic thermoplastic yarns. Low-melt point yarns can include low-melt point thermoplastic yarns. In this context, the term “low-melt point” generally refers to yarns that are at least partially formed from materials that melt or soften at a temperature that is lower than the temperature of a high-melt point yarn, for example, at a temperature between about 60 to 170 degrees Celsius or lower. In aspects, for example, low-melt point yarns can be partially or entirely formed from 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 aspects herein, low-melt point yarns can be selected such that their low-melt point materials melt or soften at a temperature that is at least about 10 to 150 degrees Celsius lower than the associated high-melt point yarns that are also incorporated into a knit element. In other words, low-melt point yarns and high-melt point yarns in a knit element can be selected such that there is a particular melting / softening temperature differential. Low-melt point thermoplastic yarns can include synthetic polymeric materials formed from polymers that melt at a relatively lower temperature, for example, less than 160 degrees Celsius in particular aspects. In example aspects, low-melt point yarns can be entirely formed from a low-melt point thermoplastic material such as low-melt point PET or low-melt point polyamide. The term “fusible yarn” can be used herein to describe these types of yarns.

[0048] In some example aspects, the yarns used in portions of the knit structures described herein can be formed of materials that melt at different temperatures to impart selective properties to those portions of the knit structure. For example, areas of the knit element, such as heel areas and / or areas forming a portion of a heel counter, can include yarns that partially or entirely include a material that melts at a temperature, such as a temperature between about 175 and 200 degrees Celsius. These yarns are considered high melt point yarns. Other areas of the knit element, such as heel areas and / or areas forming another portion of a heel counter, can include yarns that partially or entirely include a material that melts at a temperature, such as a temperature between about 50 and 160 degrees Celsius. As described herein, the particular yarns (e.g., single component or multi-component), materials (e.g., meltable or non-meltable and melting or softening temperature), and locations of the yarns in the knit element can be selected to allow the yarns to fuse at desired temperatures in desired areas and produce a desired thermoformed structure. These selectively positioned and thermoformed structures can impart stiffness, such as to define a heel counter area.

[0049] In aspects herein, the knit element (e.g., forming a portion of an upper of an article of footwear, such as, for example, a heel region or a heel counter, among others) can include a variety of types of meltable yarns in aspects. For example, in some aspects, a twisted yarn including a high melt point filament polyester twisted with a low melt point meltable polyester can be used in the knit element. The twisted yarn can be used in areas of the knit element where high stiffness and stiffness are desired (e.g., can be used to replace the stiffness of a traditional heel-counter insert or attachment formed of foam, plastic, polymer, leather, or other stiff material, injection molded polymer, etc.). The combination of the fused low melt point meltable polyester and the high melt point filament polyester can be used to impart additional reinforcement in the associated area. In additional aspects, a meltable yarn can be used in cushioning areas of the knit element, such as a heel region or a heel counter, to generally help maintain the cushioning yarns in place during the knitting process. In these aspects, the meltable yarn can be formed of a completely low melt point polymer, such as a low melt point meltable polyester. In this case, upon thermal processing, the low melt point meltable polymer melts, reflows, and then occupies the space between the cushioning yarns where it re-solidifies to help accommodate the expansion of the cushioning yarns without substantially limiting or constraining the packing or cushioning performance of the cushioning yarns.

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

[0052] As used herein, term " buffer yarn " can describe in various aspects yarn with, for example, about 1 / 16 inch (or about 1.58 millimeter) or larger full diameter (for example, when not restricted or compressed).However, other buffer yarns can have other diameters (for example, 1 / 8 inch or about 3.18 millimeter, 1 / 4 inch or about 6.35 millimeter, or even larger).Two non-limiting examples of buffer yarn are 5500 denier type and 3500 denier type multifilament polyester yarn, and this multifilament polyester yarn has been deformed into fluff.These types of yarn are normally compressible, and this contributes to their buffering characteristics.Especially, these yarns can have a first diameter under uncompressed state, and have a smaller second diameter under compressed state.Specific example is " LILY " yarn sold by a certain company, but other yarns from other manufacturers can also be buffer yarn.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 can 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] All measurements provided herein are made on the knitted element, upper, and / or article of footwear at standard ambient temperature and pressure (298.15 K and 100 kPa) and in a resting (unstretched) state, unless otherwise specified. As used herein, the term "about" means ±10% of the indicated value.

[0056] Figures 1 to 3 An inside view, an outside view, and a rear view of an example article of footwear 100 are schematically depicted, respectively, having an upper 110, a sole structure 112 secured to the upper 110, and a knitted heel element 114 at a heel region of the upper 110. With reference to the knitted heel element 114, the knitted heel element 114 includes an outward-facing surface 116 and an opposite inward-facing surface 118. The article of footwear 100 is shown in the form of an athletic shoe, although other types of shoes (e.g., sandals, loafers, boots, etc.) are contemplated herein. The article of footwear 100 includes a forefoot region 120 having a toe region 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 article of footwear 100 includes a collar 130, which in example aspects can include an upper edge of the knitted heel element 114. The collar 130 includes an opening 132 for receiving a wearer’s foot. The article of footwear 100 also includes a throat region 134 and an optional tongue 136. Although not shown, aspects herein contemplate that the article of footwear 100 can include additional elements layered on top of the upper 110, including, for example, a leather material, a synthetic leather material, a knitted or woven fabric, a polymeric skin, etc.

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

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

[0059] In example aspects, the knit heel element 114 can also include an optional collar (collar 130) that extends seamlessly or integrally from the second knit region 140. In example aspects, the collar 130 can have a rigidity or stiffness that is less than the second knit region 140 and the first knit region 138. In aspects, the collar 130 can include an elastic yarn (e.g., a stretch yarn) that facilitates the stretch needed when a wearer inserts their foot into the opening 132, as well as the subsequent recovery when the foot is fully inserted into the article of footwear 100. In example aspects, the collar 130 does not include the thermoplastic polymer material of the low-melt thermoplastic yarn of the first knit region 138 and the second knit region 140, and can also not include any thermoplastic polymer material. In some examples, the collar 130 includes only the elastic yarn. The demarcation between the second knit region 140 and the collar 130 can 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, such that there is a gradual decrease in the cushioning level transitioning to a gradual increase in the stretch and recovery level as the second knit region 140 transitions to the collar 130. In yet other example aspects, a separate collar element can be added to the knit heel element 114 in a subsequent manufacturing step (e.g., a post-knitting step). In this aspect, the second knit region 140 can terminate at an upper edge, and the separate collar element can be attached to the upper edge of the second knit region 140. The shape configuration depicted for the knit 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 a configuration of the knit heel element 114A in isolation, or more precisely, a configuration of the knit heel element 114A removed from the article of footwear 100 and positioned in a flat (planar) configuration, with the outward-facing surface 116 of the knit heel element 114A visible. The knit heel element 114A has a knit construction, as indicated by knit courses 402 extending in a course direction and knit wales 404 extending in a wale direction, as shown in the magnified view. While the course direction shown in the magnified view is generally a lateral direction, such that the knit courses 402 generally extend from the lateral side to the medial side, it should be understood that the knit heel element 114A can be knit in another manner, such that the knit courses 402 extend in a different direction. For example, the knit courses 402 can extend in a superior-inferior direction along the height of the knit heel element 114A, or can extend radially from the periphery to a common portion, such as the opening 132 (as shown) or the heel counter 134. Figures 1 to 2

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

[0062] The knit heel element 114A depicted in FIG. 4 is depicted as a separate heel element that can be joined to other components to form the upper 110. However, it is contemplated that aspects herein include knitting the knit heel element 114A integrally with structures forming other portions of the upper 110, such as a midfoot portion, a forefoot portion, and / or a subfoot portion, for example, in a common knitting operation performed by a knitting machine.

[0063] The knit heel element 114A in FIG. 4 is generally symmetrical with respect to an assumed vertical midline 418 (which generally extends from the collar 130 to the bite line 106), although aspects herein contemplate that the knit heel element 114A can not be symmetrical with respect to the vertical midline 418. As noted above, the function of the first knit zone 138 is generally to provide support for the Achilles region of the wearer’s foot, which is generally aligned with the vertical midline 418. As such, less rigidity or stiffness can be required as the knit heel element 114A extends toward the first side edge 414 and the second side edge 416. Conversely, as noted above, the function of the second knit zone 140 is generally to provide cushioning proximate the collar 130 and along the lateral side of the wearer’s heel. These functional differences are reflected in the arrangement and configuration of the first knit zone upper edge 146.

[0064] In one example, a first distance 148 between 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 (which are aligned with the boundary line 144) may be greater than a 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 the center area 153), as shown in FIG. Figure 4C , generally smaller). A larger distance (e.g., first distance 148) between 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 corresponds to an increased surface area of ​​the second knitted area 140 having cushioning properties. A smaller distance (e.g., second distance 150) between the first knitted area upper edge 146 and the second knitted area upper edge 147 at the vertical centerline 418 corresponds to an increased surface area of ​​the first knitted area 138 having hardness or rigidity. This 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, soccer, 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 FIG4 , 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 present at and / or adjacent to the central region 153 is increased. In some aspects, this may be achieved additionally or alternatively by including a fusible yarn having 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 of ​​the knitted heel element 114A shown in FIG is covered by, for example, the second knitted area 140 having a more cushioned structure. This can help increase the stiffness, rigidity, and support of the knitted heel element as described herein, particularly when 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 A somewhat similar configuration is provided, but the relative areas of the first knitted area 138 and the second knitted area 140 are adjusted so as to be Figure 4AIn contrast, the first knit zone 138 covers a greater surface area of the knit heel element 114B than the second knit zone 140. This results in a shift in the geometry of the first knit zone upper edge 146 and the second knit zone upper edge 147, and by association, a change in the relative positions of the first boundary line 142 and the second boundary line 144, as shown in Figure 4B In contrast, the first knit zone 138 covers a greater surface area of the knit heel element 114B than the second knit zone 140. This results in a shift in the geometry of the first knit zone upper edge 146 and the second knit zone upper edge 147, and by association, a change in the relative positions of the first boundary line 142 and the second boundary line 144, as shown in Figure 4A With the knit heel element 114B, as the first knit zone 138 and the second knit zone 140 transition outward in a direction perpendicular to the vertical midline 418, the knit zones 138, 140 transition upward a shorter distance to the collar 130 than the knit heel element 114A shown in Figure 4A This shorter distance at which the first knit zone 138 converges with the collar 130 on opposite sides of the central portion 153 reduces the lateral displacement of the more cushioned zone 140. From this point, the first knit zone 138 and the collar 130 extend without the second knit zone 140. This can increase the stiffness around the lateral heel regions of the knit heel element 114. This has been shown to enhance support in these regions, and reduce sagging, folding, and bunching around the lateral portions of the knit heel element 114B, which is undesirable in certain applications.

[0067] In some aspects of the knit heel element 114, such as the first knit zone 138 having a more rigid structure, can extend substantially through the area of the second knit zone 140 having a more cushioned structure, for example. For example, as shown in Figure 4C The knit heel element 114C is configured such that the first knit zone 138 extends substantially through the second knit zone 140 along the vertical midline 418, as shown. This configuration can impart additional reinforcement and support along and / or adjacent to the heel line 155 of the knit heel element 114C, and partitions the second knit zone 140 (e.g., having a more cushioned structure) onto opposite lateral sides of the vertical midline 418.

[0068] Looking again at 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 centerline 418, wherein the first knitted area 138 includes a protruding portion 159 on each side of the recess 157, each of the protruding portions 159 extending further upward relative to the recess 157. Thus, 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 centerline 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 centerline 418. When the upper 110 having the knitted heel element 114 is worn, the protruding portions 159 can be positioned behind the wearer's lateral and medial malleolus. Having this smaller distance (e.g., the third distance 151) between the first knitted area upper edge 146 and the second knitted area upper edge 147 at the protrusion 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 slope downward (or as shown) as the second knitted area upper edge 147 extends away from the vertical centerline 418. Figure 4B and Figure 4C As shown, it is tilted upward to achieve greater stiffness in these areas.) In this way, 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 knit structure 500 taken at cutting line 5-5 of FIG4 is schematically depicted, corresponding to the first knit region 138. As described above, the knitted heel element 114 may be knitted using at least the first knit structure 500 or the second example knit structure described above. Figures 9 to 11 Aspects associated with a second example knit structure are described.

[0070] refer to Figure 5, the first knit structure 500 at the first knit area 138 includes a first knit layer 510 forming the outer-facing surface 116 of the knitted heel element 114, a second knit layer 512 forming the inner-facing surface 118 of the knitted heel element 114, and a third knit layer 514 positioned between the first knit layer 510 and the second knit layer 512. In an exemplary aspect, each of the first knit layer 510, the second knit layer 512, and the third knit 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, although other high-melting point yarn types are also contemplated herein. In an exemplary aspect, the high-melting point yarn can be plated with a fusible yarn to impart stability and / or structure to the first knit layer 510, the second knit layer 512, and / or the third knit layer 514.

[0071] In an exemplary aspect, yarn transfer may occur between the first knit layer 510 and the second knit layer 512, as indicated by 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. Yarn transfer may also occur between the third knit layer 514 and the second knit layer 512, as indicated by 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 knit layer 510 and the third knit 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 knit layer 510 and the third knit layer 514. In this way, the yarn transfer 513 between the second knit layer 512 and the first knit layer 510 is performed at a different needle position than the yarn transfer 515 between the second knit layer 512 and the third knit layer 514.

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

[0074] In the first knit zone 138, the first knit structure 500 can also include a yarn end of the cushioning yarn 520 positioned between the second knit layer 512 and the third knit layer 514. While only one yarn end of the cushioning yarn 520 is depicted, aspects herein contemplate that there can be multiple yarn ends of the cushioning yarn 520 between the second knit layer 512 and the third knit layer 514 in the first knit zone 138, depending on the desired level of cushioning. In other aspects, there can be zero yarn ends of the cushioning yarn 520 between the second knit layer 512 and the third knit layer 514. In example aspects, and as shown, the cushioning yarn 520 can be embedded between the second knit layer 512 and the third knit layer 514. When the cushioning yarn 520 is embedded, it does not form interlooped stitches with other yarns. For smaller diameter cushioning yarns, the cushioning yarn 520 can be knitted into one or more of the second knit layer 512 and the third knit layer 514 using, for example, intermittent tuck and float stitches.

[0075] The cushioning yarns 520 are compressible yarns such that the diameter can be compressed or reduced when a compressive force is applied. In one example aspect, the yarn transfers 513 between the second knit layer 512 and the first knit layer 510 and the yarn transfers 515 between the second knit layer 512 and the third knit layer 514 can each apply tension to the cushioning yarns 520 between these knit layers 510, 512, and 514, which reduces the diameter and loft of the cushioning yarns 520. As such, a greater density of the transfers 513 and / or 515 results in less cushioning as compared to a lower density of the transfers 513 and 515. In another way, the compression from the greater density of the transfers 513 and 515 can compress the cushioning yarns 520 to create a more dense cushioning structure.

[0076] The location of the thermoformed layer 516 between the first knit layer 510 and the third knit layer 514 means that the thermoformed layer 516 is positioned closer to the outward-facing surface 116 of the knit heel element 114 as compared to the location of the cushioning yarns 520 between the second knit layer 512 and the third knit layer 514. This can have a functional advantage in that the hardness and / or rigidity associated with the thermoformed layer 516 can be uncomfortable for the wearer. Thus, positioning the cushioning yarns 520 closer to the skin surface of the wearer’s foot can cushion the effects of the thermoformed layer 516 on the wearer’s skin and make the knit heel element 114 more comfortable to wear. In other words, in the first knit structure 500, the cushioning yarns 520 create a separation between the thermoformed layer 516 and the wearer’s skin, which contributes to wear comfort. Additionally, positioning the thermoformed layer 516 closer to the outward-facing surface 116 can have the effect of providing waterproof or water-resistant properties and abrasion resistance to the knit heel element 114.

[0077] Figure 6 The first knit structure 500 at the second knit zone 140 of the knit heel element 114 is schematically depicted. The first knit structure 500 at the second knit zone 140 includes the first knit layer 510, the second knit layer 512, the third knit layer 514, the cushioning yarns 520, and the transfers 513 and 515 between the first knit layer 510, the second knit layer 512, and the third knit layer 514. The first knit structure 500 at the second knit zone 140 is similar to the first knit structure 500 at the first knit zone 130, except that the first knit structure 500 at the second knit zone 140 does not include the thermoformed layer 516. Figure 5 The discussion of these elements provided also applies to Figure 6. Instead of the thermoforming layer 516 being at least partially located between the first knit layer 510 and the third knit layer 514 in the first knit area 138, a number of 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 comprising, 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 comprises 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] Aspects of the present disclosure contemplate that the yarn ends of the low-melting thermoplastic material 610 may be interwoven with one or more yarns in the first knit layer 510 and the third knit layer 514, such as Figure 6 The zigzag configuration is shown in FIG. The interweaving nature of the yarn ends of the low-melting thermoplastic material 610 in the second knit region 140 is opposite to that of the thermoformed layer 516 comprising the low-melting thermoplastic material in the first knit region 138. In this aspect of the second knit region 140, the yarn ends of the low-melting thermoplastic material 610 can be intermittently floated and tucked into the first knit layer 510 and the third knit layer 514. In exemplary aspects, the amount of tucking per inch or centimeter can be increased to increase the compression of the cushioning yarn 520, thereby producing a denser cushion. Alternatively, the amount of tucking per inch or centimeter can be decreased to reduce the compression of the cushioning yarn 520, thereby producing a less dense or loftier cushion.

[0079] Figure 7A schematic diagram depicting possible knit mechanism types for forming the first knit layer 510, the second knit layer 512, and the third knit layer 514 is depicted. For example, the first knit layer 510 and the third knit layer 514 can be knitted on one bed of a knitting machine, each layer knitted using a half-gauge technique. For example, the yarns used to form the first knit layer 510 can be knitted on needles 1, 3, 5, etc., and the yarns used to form the third knit layer 514 can be knitted on needles 2, 4, 6, etc. Thus, the first knit layer 510 and the third knit layer 514 are knitted each time the knitting carriage passes. The yarns used to form the first knit layer 510 and the third knit layer 514 can not interlaced with one another, but can instead overlap one another such that the first knit layer 510 can generally be positioned on the outward-facing side of the third knit layer 514. The second knit layer 512 can be knitted on an opposing bed of the knitting machine using a full-gauge technique. For example, the yarns of the second knit layer 512 can be knitted on all needles (e.g., needles 1, 2, 3, 4, 5, etc.). The result of this technique (forming the first knit layer 510 and the third knit layer 514 with a half-gauge and the second knit layer 512 with a full-gauge) can be that the number of knit stitches per inch or centimeter of the first knit layer 510 and the third knit layer 514 can be about 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 knit heel element, such as, for example, the knit heel element 114 using the first knit structure 500, in accordance with aspects herein is depicted. In block 810, a first knit layer (such as the first knit layer 510), a second knit layer (such as the second knit layer 512), a third knit layer (such as the third knit layer 514) are knitted on a knitting machine during a single knitting event. In example aspects, the knit heel element can be knit to shape such that no additional trimming or cutting is required. In other example aspects, the knit heel element can be cut to shape during the manufacturing process. Further, in example aspects, the knit heel element is knit as a separate member, but it is also contemplated that the knit heel element can be integrally knit with the remainder of the upper or at least other portions of the upper outside of the heel region.

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

[0082] In block 812, the yarn ends comprising low-melt thermoplastic material, such as the yarn ends of material 610, can be positioned between the first knit layer and the third knit layer. In example aspects, the yarn ends comprising low-melt thermoplastic material can be interwoven with the yarns in the first knit layer and the third knit layer, for example, using tuck stitches and floats. Aspects herein contemplate that the yarn ends comprising low-melt thermoplastic material can be positioned by zone based on the desired end functionality. For example, in a knit zone of the knit element where greater stiffness or rigidity is desired, such as the first knit zone 138, a greater number of yarn ends of thermoplastic material can be positioned between the first knit layer and the third knit layer. In a knit zone of the knit element where a greater amount of cushioning is desired, such as the second knit zone 140, a lesser number of yarn ends comprising thermoplastic material can be positioned between the first knit layer and the third knit layer. In some example aspects, zero yarn ends of thermoplastic material can be positioned between the first and third knit layers.

[0083] In block 814, the yarn ends comprising cushioning yarn, such as the cushioning yarn 520, are positioned between the second knit layer and the third knit layer. The cushioning yarn can be embedded, particularly when it has a relatively high diameter. Otherwise, they can be interwoven with the yarns in the second knit layer and / or the third knit layer. Aspects herein contemplate that the yarn ends of the cushioning yarn can be positioned by zone based on the desired end functionality. For example, in a knit zone of the knit heel element where high cushioning is desired, such as the second knit zone 140, a greater number of yarn ends of the cushioning yarn can be positioned between the second knit layer and the third knit layer. In a knit zone of the knit heel element where a greater amount of stiffness or rigidity is desired, such as the first knit zone 138, a lesser number of yarn ends comprising the cushioning yarn can be positioned between the second knit layer and the third knit layer. In some example aspects, zero yarn ends of the cushioning yarn can be positioned between the second knit layer and the third knit layer.

[0084] Aspects herein also contemplate that the amount of cushioning imparted by the cushioning yarn can be adjusted by the transfers, such as transfers 513 and 515, between the first knit layer, the second knit layer, and the third knit layer and / or by the tuck stitches of the low-melt thermoplastic yarn. For example, a greater number of transfers or tuck stitches per inch or centimeter can compress the cushioning yarn, resulting in less cushioning and / or more dense cushioning. Conversely, a lesser number of transfers or tuck stitches per inch or centimeter can result in greater cushioning or less dense cushioning.

[0085] Blocks 810, 812, and 814 are described above separately to discuss the specific details of each aspect of the knit structure. However, it should be understood that these steps can occur simultaneously, such that the high-melt yarns for the first knit layer, the second knit layer, the third knit layer, the yarns with low-melt thermoplastic material, and the cushioning yarns can be knitted across the needle bed in a single pass using a carriage with multiple feeders.

[0086] In block 816, one or more of heat and pressure are applied to the first knit region, such as the first knit region 138 of the knit heel element. The heat can be at a temperature sufficient to melt the low-melt thermoplastic material of the yarn positioned between the first knit layer and the third knit layer, but not so high as to damage the high-melt yarns, including the yarns used to form the first knit layer, the second knit layer, and the third knit layer, the cushioning yarns, and / or the core of the yarns having a low-melt thermoplastic material in the core / sheath configuration. The applied pressure causes the molten thermoplastic material to flow between the first knit layer and the third knit layer. Upon cooling, a thermoformed layer, such as the thermoformed layer 516, is formed between the first knit layer and the third knit layer. In some aspects, the pressure can be sufficient to cause the thermoplastic material to penetrate or permeate the first knit layer and / or the third knit layer. Again, the pressure can be adjusted such that the molten thermoplastic material does not contact the second knit layer and / or the cushioning yarns positioned between the second knit layer and the third knit layer, thereby helping to maintain the loft and / or cushioning imparted by the cushioning yarns in the areas in which they are positioned. In example aspects, no heat and pressure are applied to the second knit region, such as the second knit region 140, such that no thermoformed layer is formed in the second knit region.

[0087] Aspects herein contemplate that after the knit heel element is cooled and the thermoformed layer is formed, additional heat and pressure can be applied to the entire knit heel element (e.g., to the first knit region and the second knit region). In this application, the heat can be sufficient to soften, but not melt, the thermoplastic material of the yarn ends in the second knit region and the thermoformed layer. This application can occur after the knit heel element is positioned on a 3-D form, such as a last. Additionally, pressure can be applied to the knit heel element to conform it to the 3-D form. In some aspects, the pressure can be achieved by applying sand on the 3-D form. For example, the knit heel element can be positioned on the 3-D form and placed in a vacuum chamber, and sand is passed through the chamber as 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 knit heel element, such that the knit heel element as a whole closely conforms to the three-dimensional shape of the 3-D form.

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

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

[0090] In some aspects, there can be a transfer of yarns between the first knit layer 910 and the second knit layer 912, as indicated by the dashed transfer line 913. For example, yarns from the first knit layer 910 can be intermittently transferred to the second knit layer 912, where it can be knit in one or more knit stitches of the second knit layer 912 before being transferred back to the first knit layer 910. In some aspects, yarns from the second knit layer 912 can be intermittently transferred to the first knit layer 910, where it can be knit in one or more knit stitches of the first knit layer 910 before being transferred back to the second knit layer 912. In some aspects, the transferred yarns can be non-fusible yarns plated with fusible yarns, e.g., yarns including thermoplastic polymers or other materials, which can be heated, melted, reflowed, and then cooled into a different solidified shape, distribution, or geometry. In this way, the transfer of yarns can facilitate the positioning of fusible yarns (e.g., which subsequently fuse) on the outward-facing surface to help reduce or limit stretch and / or elasticity on such surface.

[0091] The knit heel elements described herein can be configured to provide overall rigidity, stiffness, and support, which can replace traditional heel counters that otherwise require the incorporation of additional elements such as stiffening materials (e.g., pre-formed injection molded heel counter members, pre-formed die cut and formed heel counters, etc.), collar foams, collar linings, adhesives, and / or coupling elements that are typically added to the heel portion of an upper during a footwear manufacturing process. To provide the desired stiffness and support, a thermoplastic material can be incorporated in, for example, the first knit zone 138 via knitting. In one example, the thermoplastic material can be incorporated by including one or more of a TPU yarn and a fusible yarn between the first knit layer 910 and the second knit layer 912. In non-limiting examples, one or more of the TPU yarn and the fusible yarn can float between the first layer and the second layer and be tacked into one or more of the first knit layer and the second knit layer. In one example, the amount of fusible polymer is less than the amount of TPU polymer. For example, this can be achieved by incorporating a greater number of yarn ends having TPU and a lesser number of yarn ends having fusible polymer in the knit heel element. The knit heel element is then post-processed to form the thermoformed layer 914. The above-described configurations and their formation processes can significantly reduce the number of manufacturing steps and separate components required to produce footwear having these heel characteristics, reduce manufacturing time, and thus increase the sustainability of footwear manufacturing.

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

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

[0094] In example aspects, 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 tuck and float stitches. In example aspects, the yarn end of the buffer yarn 918 can help space the first knit layer 910 apart from the second knit layer 912 based on the large diameter of the buffer yarn 918 such that the thermoformed layer 914 has an increased thickness compared to if the buffer yarn were not incorporated into the first knit zone 138.

[0095] In example aspects, the second knit structure 900 can also include at least one end of a high-melt yarn 920 (such as a high-melt polyester yarn) positioned between the first knit layer 910 and the second knit layer 912 and within the thermoformed layer 914. As described below, the high-melt yarn 920 can be a core of a previously existing core / sheath yarn prior to thermoforming. In the first knit zone 138, the sheath of the core / sheath yarn can include a low-melt thermoplastic polymer material that melts to at least partially form the thermoformed layer 914, leaving the core of the high-melt yarn 920 after thermoforming. In example aspects, the high-melt yarn 920 can be interlaced and / or tuck knitted with one or more yarn loops of the first knit layer 910 and the second knit layer 912, as shown. In other aspects, the high-melt yarn 920 can be embedded similarly to the buffer yarn 918. In example aspects, the high-melt yarn 920 and the buffer yarn 918 can act as a scaffold around which the thermoformed layer 914 is formed. In this aspect, the high-melt yarn 920 and the buffer yarn 918 can increase the structural stability of the first knit zone 138 and can also contribute to the rigidity and / or stiffness of the first knit zone 138. Figure 5

[0096] Figure 10 ​A second knit structure 900 at the second knit zone 140 of the knit heel element 114 is schematically depicted. The second knit structure 900 at the second knit zone 140 includes a first knit layer 910, a second knit layer 912, a transfer 913 between the first knit layer 910 and the second knit layer 912, and a cushion yarn 918 embedded between the first knit layer 910 and the second knit layer 912. The transfer 913 can help to lock the cushion yarn in place and can expose some portions of the cushion yarn on the outer surface, which can enhance the softness of the outer surface. The transfer 913 can also help to accommodate and / or limit the expansion of the cushion yarn in the second knit structure 900. The second knit structure 900 can be formed by knitting the second knit zone 140 with the first knit layer 910, the second knit layer 912, and the transfer 913. The second knit structure 900 can be formed by knitting the second knit zone 140 with the first knit layer 910, the second knit layer 912, and the transfer 913. The second knit structure 900 can be formed by knitting the second knit zone 140 with the first knit layer 910, the second knit layer 912, and the transfer 913. Figure 9 The discussion of these elements provided also applies to Figure 10Instead of a thermoforming layer 914 being at least partially positioned between the first knit layer 910 and the second knit layer 912 in the first knit zone 138, a plurality of yarn ends of the low-melting thermoplastic yarn 1010 are positioned between the first knit layer 910 and the second knit 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 knit zone 138, there may be four ends of the buffer yarn, and in the buffer area of ​​the second knit zone 140, some zones may have four ends of the buffer yarn, while other zones (e.g., zones closer to the 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 shoe collar 130) may have zero to three ends of the buffer yarn. In example 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 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 example 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 an exemplary aspect, the second knitted area 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 area 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 restricting 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] Aspects of the present invention contemplate that the yarn ends of the low-melt thermoplastic yarn 1010 may be interwoven with one or more yarns in the first knit layer 910 and the second knit layer 912, such as Figure 10In this aspect, the yarn ends of low-melt thermoplastic yarn 1010 can be intermittently floating and tacked into the first knit layer 910 and the second knit layer 912. The combination of the buffer yarn 918 and the low-melt thermoplastic yarn 1010 can help to space the first knit layer 910 apart from the second knit layer 912, which can contribute to the cushioning performance of the knit heel element 114 in the second knit zone 140. In example aspects, the transfer 913 and / or tuck of the low-melt 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 lesser number of transfers and / or tucks per inch or centimeter will provide a less dense (e.g., more lofted) cushioning structure.

[0098] Figure 11 A block diagram depicting an example method 1100 of manufacturing a knit heel element, such as the knit heel element 114 using the second knit structure 900, is depicted in accordance with aspects herein. In block 1110, a first knit layer, such as the first knit layer 910, and a second knit layer, such as the second knit layer 912, are knit on a knitting machine during a single knitting event. The knit heel element can be knit into shape such that additional trimming or cutting is not required. In other aspects, additional cutting or trimming can be required to form the knit heel element. The first knit layer and the second knit layer can be knit on opposing beds of the knitting machine. The first knit layer and the second knit layer can be knit using, for example, high-melt thermoplastic yarn, such as high-melt PET yarn and / or high-melt recycled PET yarn. In example aspects, the high-melt yarn can be plated with a meltable yarn to impart additional structure and stability to the first knit layer and the second knit layer.

[0099] In block 1112, yarn ends comprising a low-melt thermoplastic material, such as the yarn ends 1010, can be positioned between the first knit layer and the second knit layer. In this aspect, the yarn ends comprising a low-melt thermoplastic material can comprise meltable yarn, and the number of yarn ends can be five yarn ends. In example aspects, the yarn ends comprising a low-melt thermoplastic material can be interwoven with the yarns in the first knit layer and the second knit layer, for example, using tucks and floats. Aspects herein contemplate that the yarn ends comprising a low-melt thermoplastic material can be positioned in zones based on the desired end functionality. For example, in knit zones of the knit element where greater stiffness or rigidity is desired, such as the first knit zone 138, a greater number of yarn ends of thermoplastic material can be positioned between the first knit layer and the second knit layer. In knit zones of the knit element where a greater amount of cushioning is desired, such as the second knit zone 140, a lesser number of yarn ends comprising thermoplastic material, including zero yarn ends, can be positioned between the first knit layer and the second knit layer.

[0100] In block 1112, one or more yarn ends of the core / sheath yarn having a high melting point core and a low melting point thermoplastic material sheath can be positioned between the first knit layer and the second knit layer. In example aspects, the core / sheath yarn can be positioned zonally based on desired end functionality. For example, to impart an additional level of structural stability and / or rigidity to a particular knit zone, the core / sheath yarn can be positioned in the area of the knit heel element corresponding to the first knit zone. Consistent with this, the core / sheath yarn can not be positioned zonally in the area of the knit heel element corresponding to the second knit zone.

[0101] In block 1114, yarn ends comprising a cushioning yarn, such as the cushioning yarn 918, are positioned between the first knit layer and the second knit layer. In one example aspect, the yarn ends can comprise one yarn end, although a greater number of yarn ends are contemplated herein. For cushioning yarns having a diameter above a particular threshold, the cushioning yarns can be embedded. Otherwise, they can interlace with the yarns in the first knit layer and the second knit layer. In one example aspect, the yarn ends of the cushioning yarns can be positioned uniformly across the knit heel element. Other aspects herein contemplate that the yarn ends of the cushioning yarns can be positioned zonally based on desired end functionality. For example, in knit zones of the knit element where a greater level of cushioning is desired, such as the second knit zone 140, a greater number of yarn ends of the cushioning yarns can be positioned between the first knit layer and the second knit layer.

[0102] Aspects herein further contemplate that the amount of cushioning imparted by the cushioning yarns can be adjusted by the number of transfers and / or tuck stitches, such as the transfer 913, and / or tuck stitches of the low melting point thermoplastic yarns between the first knit layer and the second knit layer. For example, a greater number of transfers and / or tuck stitches per inch or centimeter can compress the cushioning yarns, resulting in less cushioning and / or more dense cushioning. Conversely, a lesser number of transfers and / or tuck stitches per inch or centimeter can result in greater cushioning or less dense cushioning.

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

[0104] In block 1116, one or more of heat and pressure at a first temperature are applied to the first knit region, such as the first knit region 138 of the knit heel element. In example aspects, the heat and pressure at the first temperature can be applied while the knit 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 of the yarns positioned between the first knit layer and the second knit layer (e.g., the thermoplastic sheath of the fusible yarns and core / sheath yarns), but not so high as to damage the high-melt yarns, including the yarns used to form the first knit layer and the second knit layer, the core of the core / sheath yarns, and / or the cushioning yarns. An example temperature can include, for example, about 135 degrees Celsius. The applied pressure causes the melted thermoplastic material to flow between the first knit layer and the second knit layer.

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

[0106] In block 1120, the cooled knit heel element is positioned on a three-dimensional (3-D) form, such as the heel region of a shoe last. In example aspects, the 3-D form can be placed in a vacuum chamber. In block 1122, heat and pressure at a second temperature are applied to the entire knit heel element. In example aspects, the heat at the second temperature can be sufficient to soften the thermoformed layer and / or soften the ends of the yarns comprising the thermoplastic material, such as the ends of yarns 1010, but not melt the thermoplastic material. In example aspects, the heat at the second temperature can be from about 70 degrees Celsius to about 100 degrees Celsius. When the thermoplastic material is softened, pressure is applied to the knit heel element to cause the knit heel element to conform to the shape of the 3-D form. In one instance, the pressure can be imparted by sand poured over the 3-D form. The use of sand can ensure that the pressure is more evenly distributed to the knit heel element, such that the knit heel element as a whole closely conforms to the three-dimensional shape of the 3-D form.

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

[0108] Figure 12 An array of articles of footwear is depicted, including a first article of footwear 1210 and a second article of footwear 1212. In example aspects, 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 knit heel element 1218 having a first knit zone 1220, a second knit zone 1222, and a collar 1223 that can be knit using the first knit structure 500 or the second knit structure 900. In example aspects, the first article of footwear 1210 is configured for a first type of athletic activity. In Figure 12 In the illustrative examples shown, the first type of athletic activity can include basketball, although this is just one example. With reference to an article of footwear configured for basketball, generally, the collar of the article of footwear extends farther up on the wearer's foot than an article of footwear for running, soccer, etc. (e.g., so-called high-top shoes). Because the collar 1223 extends farther up and can be positioned around the wearer's ankle malleolus, it can be desirable to increase the amount and / or area of cushioning to protect the sensitive skin around the malleolus. A separate view of the first knit heel element 1218 is depicted below the first article of footwear 1210.

[0109] In example aspects, 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 knit heel element 1227 having a third knit zone 1228 corresponding to the first knit zone 138; a fourth knit zone 1230 corresponding to the second knit zone 140; and a collar 1231 that can be knit using the first knit structure 500 or the second knit structure 900. In example aspects, the second article of footwear 1212 is configured for a second type of athletic activity that is different from the first type of athletic activity. In Figure 12 In the illustrative examples shown, the second type of athletic activity can include soccer, although this is just one example. In an article of footwear configured for soccer, generally, the collar 1231 is positioned below the ankle malleolus, and the need for rigidity or support in the heel region increases to support the wearer's Achilles tendon and heel region as the wearer performs various maneuvers. A separate view of the second knit heel element 1227 is depicted below the second article of footwear 1212.

[0110] By using the first knit structure 500 or the second knit structure 900, different knit zones of the articles of footwear 1210 and 1212 can be tailored to meet different requirements of different sporting activities. For example, with reference to the first article of footwear 1210, due to the increased need for cushioning to protect the wearer’s ankle malleolus, the second knit zone 1222 can include a greater number of yarn ends of cushioning yarns or a lesser number of yarn ends of yarns that include thermoplastic material (including zero yarn ends of yarns that include thermoplastic material). Additionally or alternatively, the size or surface area of the second knit zone 1222 can be increased relative to the first knit zone 1220 to provide a greater amount of cushioning. In another example, the number of transfers between knit layers (e.g., the first knit layer, the second knit layer, and the third knit layer in the first knit structure or the first knit layer and the second knit layer in the second knit structure) can be reduced to increase the amount of cushioning or loft in the second knit zone 1222.

[0111] With reference to the second article of footwear 1212, which has an increased need for rigidity or stiffness in the third knit zone 1228, the third knit zone 1228 can include a greater number of yarn ends of yarns that include thermoplastic material, thereby forming a thicker or denser thermoformed layer. Additionally, if desired, the number of cushioning yarns in the third knit zone 1228 can be reduced. Additionally or alternatively, the size or surface area of the third knit zone 1228 can be increased relative to the fourth knit zone 1230 to provide a greater surface area of rigidity or stiffness.

[0112] In aspects, the upper and / or article of footwear includes a knit element. The knit element includes a knit heel element. The knit heel element is thermoformed and / or at least partially fused, thereby including a layer of thermoformed and / or fused polymer material that provides increased stiffness. The layer of increased stiffness forms an integrated knit heel counter. The integrated knit heel counter provides stiffness in the heel region without the need for inserting, attaching, or incorporating a separate component of a traditional heel counter, such as in an additional manufacturing step after the knitting operation that forms the knit element and the thermoforming operation that forms the layer of increased stiffness.

[0113] Aspect 1 A knit heel element includes a first knit composite zone including a low-melt thermoplastic material and a first knit structure, a second knit composite zone integrally extending from the first knit composite zone, the second knit composite zone including the low-melt thermoplastic material and a second knit structure, wherein the low-melt thermoplastic material has a lesser weight concentration in the second knit composite zone compared to the first knit composite zone, and a knit collar integrally extending from the second knit composite zone, the knit collar including one or more elastic yarns.

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

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

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

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

[0118] Aspect 6 . The 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 . The knitted heel element according to any one of aspects 1 to 6, wherein the thermoformable layer comprises at least one high-melting point thermoplastic yarn.

[0120] Aspect 8 . The knitted heel element according to any one of aspects 1 to 7, wherein the second knit structure includes at least a first knit layer and a second knit 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 formed entirely 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. The knit heel element according to any of aspects 1-10, wherein the low-melt thermoplastic material heat-formed between the first knit layer and the second knit layer is dispersed between the second number of yarn ends, each of the yarn ends comprising a cushioning yarn.

[0124] Aspect 12 . A knit heel element comprising: a first knit region comprising a first stiffness; a second knit region extending integrally from the first knit region, the second knit region comprising a second stiffness less than the first stiffness; and a knit collar extending integrally from the second knit region, the knit collar comprising one or more elastic yarns.

[0125] Aspect 13 . The knit heel element according to aspect 12, wherein the first knit region is positioned at a lower end of the knit heel element, and the second knit region extends upwardly from the first knit region to the knit collar.

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

[0127] Aspect 15 . The knit heel element according to any of aspects 12-14, wherein the first knit region and the second knit region comprise a thermoformed layer.

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

[0129] Aspect 17 . The knit heel element according to any of aspects 12-16, wherein the higher stiffness of the heel counter is provided without a separately formed component incorporated into or onto the knit heel element to increase the stiffness.

[0130] Aspect 18. An article of footwear comprising: a sole structure; and an upper secured to the sole structure, the upper comprising a knitted element, the knitted element comprising a first knitted zone and a second knitted zone, the first knitted zone comprising: a first knitted layer, a second knitted layer, and a thermoformed layer at least partially between the first knitted layer and the second knitted layer, the thermoformed layer comprising a low-melt thermoplastic material, and the second knitted zone comprising: the first knitted layer, the second knitted layer, a first number of yarn ends comprising the low-melt thermoplastic material.

[0131] Aspect 19 . The article of footwear according to aspect 18, wherein the upper comprises a unitary knitted heel counter formed of the low-melt thermoplastic material that is thermoformed.

[0132] Aspect 20 . The article of footwear according to aspect 18 or 19, wherein the unitary knitted heel counter has a higher stiffness than a remainder of the knitted element without a separate component incorporated into or onto the knitted element to increase stiffness.

[0133] Aspect 21 . The article of footwear according to any of aspects 18-20, wherein the thermoformed layer comprises at least one end of a cushioning yarn, and wherein the second knitted zone comprises a second number of yarn ends of the cushioning yarn.

[0134] Aspect 22 . The article of footwear according to any of aspects 18-21, wherein the first knitted layer and the second knitted layer each comprise a high-melt thermoplastic yarn.

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

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

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

[0138] Aspect 26. The article of footwear according to any one of aspects 18-25, wherein the first number of yarn ends comprising the low-melt thermoplastic material are 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.

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

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

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

[0142] Aspect 30 . The article of footwear according to any one of aspects 18-29, wherein the first number of yarn ends comprising the low-melt 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 of the first knit region.

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

[0144] Aspect 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 outward-facing surface of the knitted heel element, the second knitted layer comprising an inward-facing surface of the knitted heel element, the array of articles of footwear comprising at least: a first article of footwear configured for a first type of athletic activity, the first knitted heel element of the first article of footwear comprising: a first knitted zone located at a lower portion of the first knitted heel element and a second knitted zone located above the first knitted zone, the first knitted zone comprising a thermoformed layer, the thermoformed layer comprising a low-melt thermoplastic material and positioned at least between the first knitted layer and the second knitted layer, the second knitted zone comprising a first quantity of yarn ends and a second quantity of yarn ends, the first quantity of yarn ends comprising the low-melt thermoplastic material, the second quantity of yarn ends comprising a cushioning yarn; and a second article of footwear configured for a second type of athletic activity different from the first type of athletic activity, the second knitted heel element of the second article of footwear comprising: a third knitted zone located at a lower portion of the second knitted heel element and a fourth knitted zone located above the third knitted zone, the third knitted zone comprising a thermoformed layer, the thermoformed layer comprising the low-melt thermoplastic material and positioned at least partially between the first knitted layer and the second knitted layer, the fourth knitted zone comprising a third quantity of yarn ends and a fourth quantity of yarn ends, the third quantity of yarn ends comprising the low-melt thermoplastic material, the fourth quantity of yarn ends comprising a cushioning yarn, wherein the first knitted zone of the first article of footwear and the third knitted zone of the second article of footwear comprise different surface areas, and / or the second knitted zone of the first article of footwear and the fourth knitted zone of the second article of footwear comprise different surface areas.

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

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

[0147] Aspect 35. The array of articles of footwear of any of aspects 32-34, wherein the first heel counter and the second heel counter are integrally formed with the first knitted heel element and the second knitted heel element, respectively, without a separate component integrated into or on the first knitted heel element and the second knitted heel element to increase stiffness.

[0148] Aspect 36 . The array of articles of footwear of any of aspects 32-35, wherein the thermoformed layer in each of the first knitted zone of the first article of footwear and the third knitted zone of the second article of footwear comprises at least one end of a high-melt thermoplastic yarn.

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

[0150] Aspect 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 yarn ends comprising a low-melt thermoplastic material between the first knitted layer and the second knitted layer; positioning yarn ends comprising a cushioning yarn between the first knitted layer and the second knitted layer; and thermoforming at least a first knitted zone of the knitted element such that a thermoformed layer is at least partially formed between the first knitted layer and the second knitted layer, the thermoformed layer being in a heel region.

[0151] Aspect 39 . The method of aspect 38, further comprising: forming the knitted element into an upper, and incorporating the upper into an article of footwear such that the thermoformed layer forms an integral heel counter in the heel region of the article of footwear.

[0152] Aspect 40 . The method of aspect 38 or 39, wherein the integral heel counter is formed without a separate component integrated into or on the heel region to increase stiffness of the heel region.

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

[0154] Aspect 42 An article of footwear, comprising: a sole structure; and an upper secured 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 positioned between the first knitted layer and the second knitted layer, wherein: in at least a first knitted zone of the knitted element, a thermoformed layer is at least partially positioned between the first knitted layer and the third knitted layer, and in at least a second knitted zone of the knitted element, a first number of yarn ends comprising cushioning yarns are positioned between the second knitted layer and the third knitted layer.

[0155] Aspect 43 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 of the knitted heel elements 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 heel element, the second knitted layer comprising an inward-facing surface of the knitted heel element, the third knitted layer positioned between the first knitted layer and the second knitted layer, the array of articles of footwear comprising at least: a first article of footwear configured for a first type of athletic activity, the first knitted heel element of the first article of footwear comprising: a first knitted zone located at a lower portion of the first knitted heel element and a second knitted zone located at an upper portion of the first knitted heel element, the first knitted zone comprising a thermoformed layer at least partially positioned between the first knitted layer and the third knitted layer, the second knitted zone comprising a first number of yarn ends of cushioning yarns positioned between the second knitted layer and the third knitted layer; and a second article of footwear configured for 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 zone located at a lower portion of the second knitted heel element and a fourth knitted zone located at an upper portion of the second knitted heel element, the third knitted zone comprising a thermoformed layer at least partially positioned between the first knitted layer and the third knitted layer, the fourth knitted zone comprising a second number of yarn ends of cushioning yarns positioned between the second knitted layer and the third knitted layer, wherein the first knitted zone of the first article of footwear and the third knitted zone of the second article of footwear comprise different surface areas, and / or the second knitted zone of the first article of footwear and the fourth knitted zone of the second article of footwear comprise different surface areas.

[0156] Aspect 44A method of manufacturing a knitted element for an upper, the method comprising: knitting a first knit layer, a second knit layer, and a third knit layer on a knitting machine, the third knit layer positioned between the first knit layer and the second knit layer; positioning one or more yarn ends comprising a low-melt thermoplastic material between the first knit layer and the third knit layer; and positioning one or more yarn ends comprising a cushioning yarn between the second knit layer and the third knit layer.

[0157] Aspect 45 An article of footwear comprising: a sole structure; and an upper secured to the sole structure, the upper comprising a knitted element, the knitted element having a first knit region and a second knit region, the first knit region comprising: a first knit layer, a second knit layer, and a thermoformed layer at least partially between the first knit layer and the second knit layer, the thermoformed layer comprising at least one end of a low-melt thermoplastic material and a cushioning yarn, the second knit region comprising: the first knit layer, the second knit layer, a first quantity of yarn ends, and a second quantity of yarn ends, the first quantity of yarn ends comprising the low-melt thermoplastic material, the second quantity of yarn ends comprising the cushioning yarn.

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

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

[0160] Aspects of the disclosure have been described with the intention of being illustrative and not limiting. Alternative aspects will become apparent to those skilled in the art without departing from the scope of the disclosure. Alternative means of implementing the improvements described above can be developed by those skilled in the art without departing from the scope of the disclosure.

[0161] It should be understood that certain features and sub-combinations are of utility and can be employed without reference to other features and sub-combinations and are contemplated within the scope of the claims. Not all of the steps listed in each figure need be performed in the particular order described.

Claims

1. A knitted heel element, characterized in that The knitted heel element comprises: a first knitted composite region comprising a low-melting thermoplastic material and a first knitted structure; a second knit composite region extending integrally from the first knit composite region, the second knit composite region comprising the low-melt thermoplastic material and a second knit structure, wherein the low-melt thermoplastic material has a lesser concentration by weight in the second knit composite region than in the first knit composite region; and A knitted shoe collar integrally extends from the second knitted composite region, the knitted shoe collar comprising one or more elastic yarns.

2. The knitted heel element of claim 1 , wherein the low-melt 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, characterized in that The first knitted structure includes a first knitted layer and a second knitted layer.

4. The knitted heel element according to claim 1, characterized in that The low-melt thermoplastic material in the first knitted composite region comprises a thermoformable layer.

5. The knitted heel element according to claim 4, characterized in that 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, characterized in that The thermoforming layer includes at least one buffer yarn.

7. The knitted heel element according to claim 4, characterized in that The thermoforming layer includes at least one high melting point thermoplastic yarn.

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

9. The knitted heel element according to claim 8, characterized in that The second knit structure includes a first number of yarn ends positioned between the first knit layer and the second knit layer, each formed entirely of a low-melt thermoplastic material.

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

11. The knitted heel element according to claim 10, characterized in that 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 shoe upper, characterized in that: The upper includes the knitted heel element according to claim 1 .

13. A footwear product, characterized in that: The article of footwear includes a sole structure secured to an upper including the knitted heel element according to claim 1 .

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