Spacer knit component, uppers and footwear with the same, and methods of manufacturing the same

Abstract

Knitted components with spacer knit structures, uppers, articles, and footwear with the same, and methods of manufacturing the same. In aspects, a knitted component includes a spacer knit structure that includes a pair of opposite knit layers and a filament that extends between the pair of opposite knit layers, and that is interlooped with the pair of opposite knit layers, providing cushioning therein. The spacer knit structure is manipulated, e.g., using pressure and heat, such that it has at least one zone comprising a fused area that maintains the spacer knit structure in a compressed shape. In additional aspects, textiles, uppers, and articles of footwear including the knitted component are provided, along with methods of manufacturing the same.

Description

SPACER KNIT COMPONENT, UPPERS AND FOOTWEAR WITH THE SAME, AND METHODS OF MANUFACTURING THE SAMEFIELD OF THE INVENTION

[0001] The field relates to knitted components with spacer knit constructions.BACKGROUND OF THE INVENTION

[0002] Textiles with spacer knit constructions can be used for different purposes. For example, spacer knit constructions can be used to provide a degree of cushioning or padding. This can be useful in applications where such cushioning or padding is desired, e.g., seating, sporting equipment, articles, etc. In certain articles, such as footwear, zonal cushioning properties can be desirable for functional and performance purposes. However, zonal cushioning has traditionally required use of different materials or composite constructions, which can increase the complexity and cost of manufacturing, and limit the efficiency in producing activity-specific footwear, among other limitations.SUMMARY OF THE INVENTION

[0003] In brief, and at a high-level, this disclosure describes, among other things, knitted components with spacer knit structures, uppers and articles of footwear with the same, and methods of manufacturing the same, among other things.

[0004] In aspects, a knitted component is provided. The knitted component can include a spacer knit structure. In aspects, a spacer knit structure includes a pair of opposite knit layers and a filament, e.g., a mono-filament or multi-filament, that is integrally knitted with the pair of opposite knit layers, such that the filament extends between, and is interlooped with, the pair of opposite knit layers, in a repeating fashion. The filament has a higher stiffness, or lower pliability, knit layers, creating a cushioned structure. In aspects, in addition to filaments, other yams, strands, or cables that have higher stiffness than one or more yams of the opposite knit layers can also be used to form a spacer knit structure as described herein.

[0005] In aspects, a knitted component with a spacer knit structure can be manipulated to modify its cushioning properties, e.g., so that distinct areas of the spacer knit structure have different cushioning characteristics. For example, one or both knit layers of a spacer knit structure may include a fusible material. The fusible material can be thermoformed, e.g., using heat and pressure, to create a fused area that helps retain parts of the spacer knit structure in aparticular shape, e.g., a compressed shape. In some aspects, the spacer knit structure can include low-melting yarn(s) and high-melting yarn(s). Low-melting yams include material that melts at a lower temperature than a material included in the high-melting yams. Low-melting yam(s) can include a thermoplastic polymer material (hereinafter “TPM”) that melts at a particular temperature. In aspects, low-melting yam(s) can be formed entirely from TPM or partially from TPM, e.g., in the latter case by having a multi-component configuration, e.g., a core-sheath configuration, or the like. Multi-component yams that include a low-melting material, e.g., as a sheath, and a high-melting material, e.g., as a core, can be incorporated into a spacer knit structure so that a fused area can be formed between a network of interlooped (core) yarns. In aspects herein, to manipulate a spacer knit stmcture into a desired configuration, pressure is applied to the spacer knit structure so that the spacer knit structure adopts a desired shape, and heat is applied to the spacer knit structure so that the low-melting material in the spacer knit stmcture is thermoformed. The resulting fused area formed on and / or in the spacer knit stmcture helps hold or maintain the spacer knit structure in the desired shape, e.g., compressed shape. This allows cushioning properties to be modified in different areas of a spacer knit structure, e.g., so that desired functional and performance characteristics can be obtained.

[0006] In aspects herein, a knitted component with a spacer knit stmcture can be processed, e.g., compressed and thermoformed, using a press-mechanism. The press-mechanism can include plates, e.g., fixed and / or movable, that can shift into contact with the spacer knit stmcture. In aspects, the press-mechanism can be configured to impart heat and / or pressure and / or energy (e.g., ultrasonic energy or vibration) to the knitted component to change its cushioning profile. In one example, a press-mechanism is operated to compress a spacer knit structure into a desired shape, and heats the knitted component so that low-melting yam(s) or materials thereof melt, re-flow, cool, and then re-solidify to form a fused area that at least partially maintains the spacer knit structure in the desired shape, e.g., compressed shape. High- melting yarns of the knitted component, e.g., the filament or other high-melting yarns incorporated into the opposite knit layers of the spacer knit stmcture, generally retain their stmcture, e.g., are substantially not melted, deformed, burned, charred, singed, or otherwise degraded, such that, in some aspects, a network of interlooped yams is at least partially retained. The fused area helps retain parts of the spacer knit stmcture in a desired geometry. In aspects, a press-mechanism can include plates having non-flat geometries so that certainareas of the spacer knit structure have distinct geometries, e.g., distinct thicknesses, contours, and / or degrees of compression.

[0007] In aspects, a textile is provided. The textile includes a knitted component having a spacer knit structure that is thermoformed, e.g., using heat and pressure, to produce a fused area that maintains the spacer knit structure in a desired shape, e.g., a compressed or partially compressed shape, providing zonal cushioning properties to the textile.

[0008] In aspects, articles are provided. The articles can include a knitted component having a spacer knit structure that is thermoformed, e.g., using heat and pressure, to produce a fused area that helps maintain the spacer knit structure in a desired shape, e.g., a compressed or partially compressed shape, providing zonal cushioning properties to the article. In aspects, the articles can include uppers, articles of footwear, and / or articles of apparel, e.g., upper body articles of apparel, lower body articles of apparel, outerwear, hats, gloves, and the like; articles can also include sporting equipment, e.g., protective pads, e.g., shin guards, shoulder pads, knee pads, or other padding structures for different sports such as American Football or Equestrian sports; and / or articles can also include bags, backpacks, seating, upholstery, outdoor gear or equipment, and the like, among other things.

[0009] In aspects, articles of footwear are provided. The articles of footwear can include an upper formed with a knitted component having a spacer knit structure modified at strategic locations. For example, the upper can include one or more zones where the spacer knit structure is uncompressed or only partially compressed to thereby impart cushioning at such zones. In aspects, these zones can be on or adjacent to a medial side of the upper, a lateral side of the upper, a collar area of the upper, a liner of the upper, or any combination thereof, e.g., to impart cushioning in those areas. The upper can also include one or more zones where the spacer knit structure is compressed, partially or fully, to thereby provide a reduced level of cushioning or substantially no cushioning at such zones, e.g., to enhance other properties such as the ability to transfer force at those zones. In aspects, these zones can be located on or adjacent to a toe area, a heel area, a throat area, or any combination thereof, or at other locations. In some aspects, an upper formed with a spacer knit structure can have portions or sections that do not include or omit the spacer knit structure, e.g., being instead formed of another textile, e.g., a knit textile, if incorporating a spacer knit structure entirely across the upper is not desired, e.g., to limit material cost.

[0010] In aspects, a global football shoe or cleat (i.e., soccer shoe or cleat) is provided that includes an upper formed with a knitted component that includes a spacer knit structure thathas been processed, e.g., using heat and pressure, to form a fused area that helps maintain the spacer knit structure in a modified shape, e.g., a compressed or partially compressed shape, providing zonal cushioning in distinct areas of the upper. The distinct areas of modified cushioning can be located on the upper to enhance performance capabilities, e.g., in ballreceiving and ball-kicking, among other things. In aspects, a spacer knit structure can be incorporated into any area of an article of footwear, e.g., in and / or proximate and / or adjacent to an arch area to provide cushion and support in that area; and / or in and / or proximate and / or adjacent to a heel area to provide cushion and support in that area.

[0011] In aspects, a plurality of articles of footwear are provided. Each article of footwear includes an upper formed with a knitted component that includes a spacer knit structure that has been processed, e.g., using heat and pressure, to form a fused area that helps maintain the spacer knit structure in a modified shape, e.g., a compressed or partially compressed shape, providing zonal cushioning in distinct areas of the upper. Each article of footwear, e.g., being associated with a particular sporting use, may thus include distinct areas of zonal cushioning, to enable tuned and activity-specific properties. In addition, such properties can be provided with reduced need for post-knitting manufacturing operations or special materials.

[0012] In aspects, methods of manufacturing knitted components, uppers, and articles including articles of footwear having spacer knit structures are provided. In aspects, the knitted components and spacer knit structures thereof can be processed to form fused areas that impart zonal cushioning characteristics. In aspects, a method of manufacturing includes forming a knitted component with a spacer knit structure, processing the knitted component with heat and / or pressure, e.g., provided by a press-mechanism, and fusing, while the spacer knit structure is at least partially compressed, part of the spacer knit structure such that the spacer knit structure is substantially fixed in a desired geometry by a fused area that is formed on the spacer knit structure. The method can further include incorporating the knitted component with modified spacer knit structure into textiles, uppers, articles of footwear, and other items of wear and use.

[0013] This summary is intended to introduce a selection of concepts in a simplified form which are further described below in the detailed description section of this disclosure. This summary is not intended to identify key or essential features of the claimed subject matter, nor is it intended to be used as an aid in isolation to determine the scope of the claimed subject matter.BRIEF DESCRIPTION OF THE DRAWINGS

[0014] The aspects herein related to knitted components, uppers, and articles of footwear with spacer knit structures, and methods of manufacturing the same, are described in detail in connection with the attached figures, which depict non-limiting examples, wherein:

[0015] FIGS . 1 A- 1 C depict an article of footwear that includes an upper formed of a knitted component that includes a modified spacer knit structure, in accordance with aspects herein;

[0016] FIG. 2 depicts a cross-section of a spacer knit structure, e.g., that can be incorporated into uppers, footwear, or other articles, in accordance with aspects herein;

[0017] FIGS. 3 A and 3B depict cross-sections of a modified spacer knit structure, in accordance with aspects herein;

[0018] FIG. 3C depicts a cross-section, perspective view of the modified spacer knit structure of FIG. 3B, in accordance with aspects herein;

[0019] FIGS. 4A-4D depict different types of yams or filaments that can be used in the knitted components described herein, in accordance with aspects herein;

[0020] FIGS. 5 A and 5B depict a press-mechanism that can be used for processing knitted components with spacer knit structures, in accordance with aspects herein;

[0021] FIGS. 6A-6C depict an upper that includes a knitted component with a modified spacer knit structure, in accordance with aspects herein;

[0022] FIGS. 7 A and 7B depict a wearer demonstrating functional benefits of articles of footwear incorporating the aspects described herein; and

[0023] FIG. 8 depicts a block diagram of an example method of manufacturing different aspects described herein.DETAILED DESCRIPTION OF THE INVENTION

[0024] In general, this disclosure describes, among other things, knitted components with spacer knit structures that are modified to produced desired cushioning characteristics in distinct zonal areas, and textiles, uppers, and articles, e.g., articles of footwear, having the same, and methods of manufacturing the same.

[0025] Knitted components and the associated techniques described herein can provide a spacer knit structure with zonal cushioning characteristics that can impart different benefits in performance and functionality to associated articles. In addition, the techniques described herein can allow a knitted component with zonal cushioning properties to be produced in asimpler, more integrally-formed, and more adaptable fashion. This can reduce or limit the need to incorporate additional components, e.g., bulking materials, inserts, cushioning features, and like, in a post-knitting process. The techniques described herein can also increase the speed, efficiency, and adaptability of producing knitted components with distinct zonal cushioning properties, e.g., more readily allowing for the functional characteristics of different types of articles to be changed in manufacturing. This contributes to more streamlined, cost-efficient, and sustainable manufacturing, among other benefits. Examples of the aforementioned aspects and others are described below in connection with attached FIGS. 1-8.

[0026] In general, and in accordance with aspects herein, a spacer knit structure can include a pair of opposite knit layers and a spacing element, e.g., a filament, e.g., a mono-filament or multi-filament, that is integrally knitted with the pair of opposite knit layers, such that the filament extends between, and is interlooped with, the pair of opposite knit layers, in a repeating fashion. The spacing element, e.g., filament in one example, has a higher stiffness, or lower pliability, than one or more yarns forming the knit layers, and thus expands the pair of opposite knit layers, creating a cushioned structure. In aspects, the spacing element can be a filament, or another type of yarn, strand, or cable, or other type of linear elongated element that has a higher stiffness than one or more yarns of the knit layers such that cushioning is imparted. Filaments are referenced herein simply for example purposes.

[0027] Looking now at FIGS. 1A-1C, an article of footwear 10 with an upper 12 formed with a knitted component 14 is shown, in accordance with aspects herein. The knitted component 14 has been manipulated so that it provides distinct zonal cushioning properties, e.g., in at least zonal areas 16A and 16B. In particular, zonal areas 16A and 16B include different degrees of cushioning produced through modification of a spacer knit structure that forms at least part of the knitted component 14. FIG. 1A depicts a top-down perspective view of the article of footwear 10. FIG. IB depicts a lateral side 13 of the article of footwear 10. FIG. 1C depicts a medial side 15 of the article footwear 10. For example purposes, FIGS. 1A-1C depict the article of footwear 10 being a cleated shoe, e.g., suitable for global football (i.e., soccer). However, many other types of footwear can incorporate the aspects described herein.

[0028] Looking now at FIG. 2, a cross-section of a spacer knit structure 20 that can form part of a knitted component, e.g., the knitted component 14 in FIGS. 1A-1C, is shown, in accordance with aspects herein. In aspects, the spacer knit structure 20 can be formed using a knitting machine, e.g., an automated knitting machine, e.g., that includes a pair of oppositeneedle beds, a plurality of feeders, and a control system that directs the knitting machine to produce knitted components, e.g., during a knitting operation.

[0029] In FIG. 2, the spacer knit structure 20 includes a knit layer 22, a knit layer 24 that is opposite to the knit layer 22, and a filament 26 that extends between the knit layers 22, 24. In aspects, the filament 26 can be a mono-fdament or a multi-filament. The knit layers 22, 24 form a surface 21 and a surface 23. The knit layer 22 can be formed at least partially on a first needle bed of a knitting machine, and can include one or more yarns. The knit layer 24 can be formed at least partially on a second needle bed of the knitting machine, and can include one or more yarns, e.g., common or distinct from those in the knit layer 22. The filament 26 is incorporated such that it extends between the knit layers 22, 24. During a knitting process, the filament 26 is transferred between the needle beds, and through such transfer is interlooped with loops of the knit layer 22 and with loops of the knit layer 24. This causes the filament 26 to extend back-and-forth between the knit layers 22, 24 in a repeating sequence, e.g., as shown in FIG. 2. The filament 26 is selected so that it has a higher stiffness, or rather, a lower pliability, than the one or more yams forming the knit layers 22, 24. Due to the higher stiffness, or lower pliability, the filament 26 extending between the knit layers 22, 24 expands the knit layers 22, 24, creating cushioning. In aspects, this cushioning can be compressed, and once uncompressed, the spacer knit structure expands back to its original shape.

[0030] Looking now at FIG. 3A, the spacer knit structure 20 of FIG. 2 is again shown, but processed / manipulated into a different configuration, in accordance with aspects herein. In particular, in FIG. 3A, the spacer knit structure 20 has been processed to produce different cushioning characteristics in different zones, e.g., zone 27 and zone 28. Zone 27 has, generally speaking, a thickness 30, and zone 28 has, generally speaking, a thickness 32. In the depicted example, the zone 27 is not processed (e.g., using heat and pressure) into a compressed shape. Zone 27 is therefore shown in an uncompressed shape, e.g., with a cushioned space 34 produced by the filament 26 substantially fully expanded between the knit layers 22, 24. The zone 28 is processed (e.g., using heat and pressure) into a different shape. In particular, the zone 28 is in a compressed shape, e.g., with the cushioned space 34 provided by the filament 26 compressed and / or compacted. This compressed shape is substantially maintained by a fused area 38 that is formed during processing of the spacer knit structure 20, as described further below.

[0031] The knit layers 22 and / or 24 can include material(s) that can be thermoformed to produce the fused area 38. The fused area 38 once formed can extend into and / or through theknit layers 22 and / or 24 and / or the surfaces 21 and / or 23. For example, a low-melting material can be incorporated into the knit layers 22, 24, e.g., by incorporating one or more yarns formed at least partially of the low-melting material (these are referred to herein as “low-melting yams”). For example, in aspects, a low-melting TPM yarn can be incorporated into the knit layer 22 and / or into the knit layer 24. High-melting yams can also be incorporated into the knit layers 22, 24. High-melting yarns are those formed at least partially of a material that does not melt during a thermoforming process that otherwise melts the low-melting yams or materials thereof to create a fused area, e.g., such as fused area 38. High-melting yarns can be formed of non-fusible materials that generally do not melt, deform, burn, char, or singe at temperatures that otherwise melt low-melting yams or materials thereof to create a fused area. In other words, in a knitted component, low-melting materials melt at a temperature that does not produce a similar melting of high-melting materials incorporated into the knitted component.

[0032] Low-melting yarns and materials can be incorporated into a spacer knit structure in different configurations. The following are intended to represent non-limiting examples. In some aspects, TPM yarn(s) incorporated into knit layer 22 and / or knit layer 24 can be partially formed of TPM or fully formed of TPM. In some aspects, the knit layer 22 and / or the knit layer 24 can be formed entirely of low-melting yarns. In some aspects, the knit layer 22 and / or the knit layer 24 can be formed of both low-melting yarns and high-melting yarns. In some aspects, one of knit layer 22 or 24 can be formed of low-melting yarns and the other of knit layer 22 or 24 can be formed of high-melting yams. In some aspects, knit layer 22 and knit layer 24 can include different ratios of low-melting yams and high-melting yams (e.g., by number of yam ends, percent of low-melting yarns by weight, or the like). In some aspects, low-melting yams can be incorporated between knit layer 22 and knit layer 24, e.g., as crossover yams extending between the knit layers 22, 24, e.g., proximate or adjacent to the filament 26, allowing those yarns to be melted and flow through the cushioned space 34. In some aspects, a film or skin of low-melting material (e.g., low melting TPM) can be provided on knit layer 22 and / or knit layer 24. In some aspects, a low-melting yam can be inlaid into the cushioned space 34 between the knit layers 22, 24 such that it can then be melted and flow through the cushioned space 34.

[0033] To form a fused area, TPM that melts at a particular temperature can be incorporated into the spacer knit structure 20 to facilitate desired material characteristics and processing operations. In some aspects, a low-melting yarn that includes a TPM that melts at a temperatureof between about 60-160 degrees Celsius can be used. In some aspects, a low-melting yarn with TPM that melts at a temperature that is between about 20-100 degrees Celsius less than a temperature at which at least some of the materials of a high-melting yarn(s) or filament(s) incorporated into the spacer knit structure 20 melt, deform, burn, char, and / or singe, can be used. In some aspects, a high-melting yarn can be formed of material(s) that melt, deform, or otherwise begin to degrade at a temperature that is between about 170-200 degrees Celsius, or higher. Yams of many different materials, different melting or degradation temperatures, and / or different structural properties can be incorporated into the spacer knit structures described herein.

[0034] Looking still at FIG. 3A, the zone 28 includes a fused area 38. The fused area 38 helps maintain the cushioned space 34 between the knit layers 22, 24 in a compressed shape as shown by the inward arrows in FIG. 3A. During thermoforming, pressure is applied to the zone 28 that reduces the knit layers 22, 24, the filament 26, and the cushioned space 34 into a compressed shape, e.g., as shown in FIG. 3 A. In addition, heat is applied to melt a fusible material (e.g., a low-melting yarn or material thereof in knit layers 22, 24) to thus form the fused area 38 that helps maintain the compressed shape in zone 28.

[0035] The fused area 38 can have different configurations but generally provides a substantially rigid structure that helps retain the spacer knit structure 20 in the modified shape in zone 28. In some aspects, both knit layers 22, 24 may include the fused area 38. In some aspects, only one knit layer 22 or 24 may include the fused area 38. In some aspects, the knit layers 22, 24 may have different concentrations of the fused area by weight, by volume, or by unit of surface area (e.g., grams per centimeter squared). In some aspects, the fused area 38 can be thermoformed such that melted material (e.g., TPM) passes from one knit layer 22, 24 to the other knit layer 22, 24, e.g., through the cushionedd space 34 where the filament 26 is located. This configuration can increase the strength, connection, and durability of the thermoformed structure.

[0036] Looking now at FIG. 3B, the spacer knit structure 20 of FIG. 2 is again shown, but manipulated into a different shape compared to FIG. 3A, in accordance with aspects herein. FIG. 3B shows a similar configuration as that shown in FIG. 3A with fused area 38. However, in contrast to FIG. 3A, the spacer knit structure 20 has been compressed differently and fused to produce distinct zones 40, 42, 44, 46, 48. Each generally delineated zone 40, 42, 44, 46, 48 includes a different compressed shape that is substantially maintained by the fused area 38. In addition, based on the compressed shape adopted at the time of fusing, the zones 40, 42, 44,46, 48 further include surface contours on surface 21. FIG. 3C depicts a cross-section, perspective view of the spacer knit structure 20 shown in FIG. 3B, illustrating the compression of the spacer knit structure 20 in the z-direction, and the location of compressed / uncompressed areas across the spacer knit structure 20 in the x-direction and y-direction. FIG. 3C depicts an aspect with the surface 21 contoured and the surface 23 substantially flat. However, in aspects, areas of either surface 21, 23 can be substantially flat, can be substantially contoured, or can be a combination of the same, based on the compressed shape adopted at the time materials are fused.

[0037] Looking now at FIGS. 4A-4D, cross-sections of different types of yams are shown, in accordance with aspects herein. FIGS. 4A-4D look axially along each yam, i.e., at its internal structure.

[0038] FIG. 4A shows a unitary component yam 50. In aspects, the unitary component yarn 50 can be a high-melting yarn, e.g., formed of polyester. Examples of polyesters that can be used in yarns described herein include polyethylene terephthalate (PET) and polybutylene terephthalate (PBT), among others. High-melting yarns can include high-melting PET yarns, high-melting recycled PET yarns, cushioning yarns, core / sheath yams in which the core comprises a high-melting material (e.g., a high-melting PET core) and the sheath comprises a low-melting material (e.g., low-melting TPM), elastane yams, or other high-melting synthetic, thermoplastic yams. In aspects, yam 50 can be incorporated into the knit layers 22 and / or 24. In aspects, the yam 50 can also represent a low-melting yam, e.g., one used in the knit layers 22, 24. For example, the yarn 50 can be formed substantially entirely of a material that can be thermoformed to produce a fused area. Low-melting yams described herein can be formed of low-melting thermoplastic polyurethane (TPU), low-melting thermoplastic polyethylene (TPE), and / or low-melting polyamide, and / or other synthetic polymeric materials having a lower melting or degradation temperature than high-melting yarns that are used. The yarn 50 can also represent a filament used in a spacer knit structure, e.g., the filament 26 in FIG. 2.

[0039] FIG. 4B depicts one example of a multi-component yarn, e.g., a bi-component yarn 52. The bi-component yam 52 has a core 54 and a sheath 56. In aspects, the fused areas, e.g., 38, described herein for compressing a spacer knit structure, can be formed by melting a fusible material that is part of a bi-component yam, e.g., the sheath 56. In aspects, the core 54 of the yarn 52 can be a high-melting material, e.g., a high-melting PET, and the sheath 56 can be a low-melting material that is fusible, e.g., a low-melting TPM (e.g., TPU or TPE), PET, or polyamide that melts at a selected temperature that is lower than a temperature at which high-melting material of the core 54 melts, deforms, burns, chars, singes, or otherwise begin to degrade. In aspects herein, by thermoforming and melting the low-melting material of the sheath 56, the core 54 can remain substantially non-melted and intact, thereby allowing the core 54 to remain as part of a network of interlooped yams, e.g., in knit layers 22 and / or 24.

[0040] FIG. 4C depicts another bi-component yarn 58. The bi-component yarn 58 can have similar characteristics as those described in connection with the yarn 52, e.g., being formed of high-melting and low-melting materials. However, the materials that are incorporated into the bi-component yam 58 are integrated side-by-side. In aspects, this can facilitate a different melting and distribution of fused material in, on, and / or around a spacer knit structure.

[0041] FIG. 4D depicts a multi-component yarn 60. Multi-component yams may include two, three, or more distinct components combined into a single, common yarn that can be incorporated into a knitted component. For example, such yams can have a core and one or multiple sheaths, e.g., as shown with dotted line 55 in FIG. 4B. Or, such yams can have materials combined by winding, braiding, or twisting the materials together. One example of the latter is generally shown in FIG. 4D.

[0042] Looking now at FIGS. 5A and 5B, a molding tool and / or pressing apparatus is shown in accordance with aspects herein. In this particular example, the tool and / or apparatus is a press-mechanism 70 adapted for manipulating textiles to produce the modified spacer knit structures described herein. The press-mechanism 70 can be one directed by a control system. The press-mechanism 70 is adjustable between an open configuration, e.g., as shown generally in FIG. 5A, and a closed configuration, e.g., as shown generally in FIG. 5B. In the open configuration, a spacer knit structure 71 can be positioned on a bottom press plate 72. The press -mechanism 70 can then be operated to lower a top press plate 74 onto the spacer knit structure 71 that is positioned on the bottom press plate 72. In some aspects, both press plates 72, 74 can be shifted. The press-mechanism 70 can be used to apply pressure to the spacer knit structure 71 in addition to heat, e.g., generated via electrical resistance heating. Flatness or contours on the press plates 72 and / or 74 can impart a desire shape (flat or curved / contoured) at desired locations on the spacer knit structure 71. The application of heat thermoforms the fusible materials in spacer knit structure 71 creating a fused area, e.g., a fused layer, fused region, fused body, or other fused structure depending on the disbursement and penetration of the fused material. The fused area produced by thermoforming then at least partially holds, retains, maintains, fixes, and / or secures the spacer knit structure 71 in its compressed shape that was maintained initially by the press-mechanism 70. FIG. 5B depicts how the surfaceprofile of the press-plates 72 and / or 74 can be used to produce different shapes of the spacer knit structure 71.

[0043] In aspects, a molding tool and / or pressing apparatus, e.g., such as the pressmechanism 70, can have different configurations. For example, in some aspects, a molding tool and / or pressing apparatus can be shaped such that it can impart a desired shape, thickness, and / or dimensionality to a spacer knit structure that is manipulated and pressed. For example, either or both plates 72, 74 of the press-mechanism 70 can be shaped to impart such dimensionality to a spacer knit structure. Looking at FIG. 3B as an example, the shape and position of the press plates can allow the knit layer 22 to be countered against the knit layer 24 such that a desired thickness of cushioning can be provided between the knit layers 22, 24. This can provide the benefit of helping to reduce protrusion of the spacer knit structure out of a surface of an upper forming part of an article of footwear among other benefits.

[0044] Looking now at FIGS. 6A and 6B, an upper 80 for an article of footwear, e.g., the article of footwear 10 of FIGS. 1A-1C, is shown, in accordance with aspects herein. The upper 80 includes a top surface or outer-facing surface 82, as best shown in FIG. 6A, and a bottom or inner-facing surface 84, as best shown in FIG. 6B. The upper 80 includes a spacer knit structure. In aspects, the upper 80 can be knitted such that part or substantially all of the upper 80 includes the spacer knit structure. In aspects, one or more areas of the upper 80 are modified with heat and pressure to create a modified spacer knit structure having areas of different cushioning, e.g., as described herein. FIGS. 6A and 6B depict how some areas 86 of the upper 80 have been pressed and thermoformed using a higher degree of compression (e.g., with press plates close together) and some areas 90 of the upper 80 have pressed and thermoformed with a lesser degree of compression, e.g., due to cavities, contours, or indentations in the press plates that allow the spacer knit structure of the upper 80 to remain partially or fully expanded during the thermoforming process. Parts of the upper 80 that are compressed and heat-processed can include a fused area, e.g., similar to the fused area 38, that helps maintain the compressed shape of the compressed areas 86 as shown in FIGS. 6A and 6B.

[0045] FIG. 6A shows how the outer-facing surface 82 of the upper 80 has areas 90 of higher cushioning, e.g., where the spacer knit structure is not compressed or not fully compressed, and areas of lower or substantially no cushioning, e.g., where the spacer knit structure is substantially compressed and fused. Depending on the intended use of the upper 80 and associated footwear, the zonal application of higher cushion, intermediate cushsion, and lower cushion can support the intended athletic activity or functionality. For example, theupper 80 can be configured for global football (soccer). In such aspects, the higher cushioning can be positioned in areas expected to receive an inbound ball, such that the cushioning dampens the impact, reduces the velocity of the ball, and helps limit the ball from spinning, to enhance receiving and transitioning the ball. These higher cushioning areas can be positioned in areas that are determined to frequently receive a ball, e.g., the medial side or lateral side of the upper 80. The areas with less or substantially no cushioning can be suitable for ball kicking due to the ability to increase the transfer of force to the ball due to the limited cushioning. For example, such areas can be positioned in the toe region 96 or in a throat region. Other articles of footwear can similarly be adapted based on their intended use. For example, strategic positioning of zonal cushioning from spacer knit structures on shoes for tetherball, football, kickball, or other sports can be provided. FIG. 6B shows the bottom or inner-facing surface 84 of the upper 80. In aspects, the spacer knit structure of the upper 80 may be processed as shown in FIGS. 3A and 3B such that one side is substantially flat, or can be processed such that both sides substantially have a curve or contour, e.g., as shown in FIG. 6C. FIG. 6C depicts a cross-section of the upper 80 along cut-line 7-7 as identified in FIG. 6A.

[0046] Looking now at FIGS. 7A and 7B, a wearer 88 using an article of footwear 91 that includes a knitted component with a modified spacer knit structure is shown, in accordance with aspects herein. In FIGS. 7 A and 7B, the article of footwear 91 is presented as a global football shoe (soccer shoe). The article of footwear 91 includes an upper 92. The upper 92 can be formed at least partially from a knitted component 94. The knitted component 94 can include a spacer knit structure that has been processed, e.g., thermoformed using heat and pressure, as described herein. Thus, as a result, certain surface portions or regions of the upper 92 have a higher loft / cushioning due to the more expanded nature of the spacer knit structure in those areas. This includes areas 96 of the article of footwear 91 as shown in FIGS. 7A and 7B. These more cushioned areas 96 can be positioned to enhance performance in certain activities. For example, the more cushioned areas 96 can be suitable for receiving, dampening impact from, and stopping a game ball 95, as shown in FIG. 7A. Thus, these more cushioned areas 96 may be located on certain areas of lateral and / or medial sides of the article of footwear91 to provide such benefits during gameplay. Due to the adaptable nature of modifying a spacer knit structure of a knitted component forming an upper as described herein, the cushioned areas can easily be located in other areas to provide similar benefits for other intended uses. In addition, FIGS. 7A and 7B depict how some areas 97 of the knitted component 94 of the upper92 have been processed, e.g., thermoformed using heat and pressure, to a greater degree suchthat those areas 97 have a reduced loft or cushioning or substantially no loft or cushioning. Those areas 97 can be more suitable for kicking a ball due to a greater transfer of force from the wearer 88 to the ball 95, e.g., as shown in FIG. 7B. For example, such areas 97 may be located in a toe region 93.

[0047] Looking now at FIG. 8, a block diagram of an example method 800 of manufacturing, e.g., a knitted component with a modified spacer knit structure, is shown, in accordance with aspects herein. In block 802, the method 800 includes forming a spacer knit structure comprising a first knit layer, e.g., the knit layer 22 in FIG. 2, a second knit layer, e.g., the knit layer 24 in FIG. 2, and a filament, e.g., the filament 26 in FIG. 2, that extends between the first knit layer and the second knit layer, and that is interlooped with the first knit layer and the second knit layer. In block 804, the method 800 includes pressing, using a pressmechanism, e.g., such as the press-mechanism 70 in FIGS. 5A and 5B, the spacer knit structure into a compressed shape, e.g., as shown in the non-limiting examples of FIGS. 3A and 3B. In block 804, the method 800 includes heating, using the press-mechanism, the spacer knit structure such that a fused area, e.g., such as the fused area 38 shown in FIGS. 3A and 3B and / or otherwise described herein, is formed, such that once cooled the fused area maintains the spacer knit structure in a compressed shape. The fused area may be formed of a polymer that is incorporated into the spacer knit structure that is melted by the heat of the pressmechanism and then cooled as described herein.

[0048] Y ams used in different aspects herein include high-melting yams and low-melting yams. The examples provided herein in connection with such yarns and materials thereof are intended to be non-limiting in nature. In aspects herein, high-melting yarns and low-melting yams can be combined in different fashions, e.g., through being integrated into different knit layers, or through being plated for greater structural stability, or through being inlaid, e.g., with one type of yarn (e.g., low-melting yam) being inlaid into a knit structure formed by the other type of yarn (e.g., high-melting yarn).

[0049] The spacer knit structures described herein can further incorporate additional knit structural elements to impart unique characteristics. For example, high-tenacity yarns (e.g., having a tenacity of at least 5 grams per denier) can be incorporated for greater strength. Elasticated yarns have a degree of stretch can also be incorporated. In addition to traditional knitting that produces uppers with medial-lateral courses formed by a knitting machine, wedging may also be used to produce radially knitted courses that impart additional containment properties to certain parts of a knitted component formed into an upper or othercomponent for an article. In addition, TPM that once melted increases frictional characteristics on an outer-facing surface of a knitted component formed into an upper can also be used with aspects described herein.

[0050] The term “article of footwear” as used herein refers to one that generally includes a sole structure secured to an upper. The articles of footwear described herein may comprise a running shoe, a baseball shoe, a basketball shoe, a skateboarding shoe, a cycling shoe, an American football shoe, a tennis shoe, a global football shoe, a training shoe, a walking shoe, a hiking shoe, and the like. The concepts described herein may also be applied to other footwear types that are considered non-athletic such as dress shoes, loafers, sandals, casual shoes, and work boots. As used herein, the article of footwear may be divided into different general regions. A forefoot region generally includes portions of the article of footwear that correspond to the toes and joints connecting the metatarsals with the phalanges. A midfoot region generally includes portions of the article of footwear corresponding with an arch area and an instep area of the foot. A heel region generally corresponds with rear portions of the foot including the calcaneus bone. The article of footwear described herein may include a lateral side which corresponds with an outside area of the foot (e.g., the surface that faces away from the other foot) and a medial side which corresponds with an inside area of the foot (e.g., the surface that faces toward the other foot). The different regions and sides described above are intended to represent general areas of footwear to aid in the following discussion and are not intended to demarcate precise areas. The different regions and sides may be applied to the article of footwear as a whole, to the upper, and to the sole structure.

[0051] The term “knit element” or “knitted component” as used herein, refers to a textile piece that is formed from at least one yam that is manipulated (e.g., with a knitting machine) to form a plurality of intermeshed loops (also known as interlooping) that define courses and wales. The term “course,” as used herein, refers to a predominantly horizontal row of knit loops (in an upright textile as it is knit on the knitting machine) that is produced by adjacent needles during the same knitting event. The course may comprise one or more stitch types, such as a knit stitch, a missed stitch, a tuck stitch, a transfer stitch, a rib stitch, and the like, as these terms are known in the art of knitting. The term “course-wise direction” refers to a direction that is parallel to the knit courses of the textile piece. The term “wale,” as used herein, is a predominantly vertical column of intermeshed or interlooped knit loops, generally produced by the same needle at successive (but not necessarily all) courses or knitting cycles. The term “wale- wise direction” refers to a direction that is parallel to the knit wales of the textile piece.

[0052] The term “double knit construction,” as used herein, refers to a knit construction that is generally formed on at least two needle beds of a knitting machine (e.g., a multi-bed construction). These multi-bed knit constructions may have two opposing layers of knit loops and / or tucks, e.g., one layer of loops formed on a first needle bed (e.g., a first knit layer), and a second layer of loops formed on a second needle bed (e.g., a second knit layer). In example aspects, the two layers may be joined by yarns that interloop with yams in both the first knit layer and the second knit layer of the double knit construction. Common double knit constructions include double jersey, rib, interlock, cardigan, and other “double bed” knit structures initially formed on at least two needle beds, and 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 those structures. For instance, as described with respect to the first knit structure, aspects herein contemplate knitting two layers on a single needle bed (e.g., the first and third knit layers) using a half-gauge knitting technique.

[0053] The term “integrally knit,” as used herein, may refer to a knit textile having a yarn from one or more knit courses in a first area or zone being interlooped with one or more knit courses of another area or zone (e.g., the first knit zone and the second knit zone). The interlooping may be through a simple knit stitch, a tuck stitch, a held stitch, a float or miss stitch, or the like. In this way, areas or zones that are integrally knit together have a seamless transition such that they seamlessly extend from one another.

[0054] The term “thermoformed,” as used herein, refers to a process of applying heat and / or energy to a fusible material such that it melts, flows, and then is re-solidified and hardened upon cooling into a new shape or geometry. Thus, in aspects, a thermoformed area may include the same polymeric material as the TPM that forms part of low-melting yams incorporated into knitted components described herein.

[0055] The term “cushioning yam,” as used herein, can in aspects describe yarns with a full diameter (e.g., when not restricted or compressed) of about 1 / 16 inch (or about 1.58 millimeters) or larger, for example. However, other cushioning yarns may have other diameters (e.g., 1 / 8 inch or about 3.18 millimeters, *4 inch or about 6.35 millimeters, or even larger). Two non-limiting examples of cushioning yams are a 5500 denier version and a 3500 denier version of multi-fdament polyester yam that has been texturized to loft. These types of yarns are generally compressible, which contributes to their cushioning features. Particularly, these yams may have a first diameter in an uncompressed state and a second, smaller diameter, in a compressed state. Particular examples are marketed as “LILY” yams and are sold by SawadaHong Kong Co. Ltd., though other yams from other manufacturers may also be cushioning yams. Another example of a cushioning yam may be a foamable or expandable yam and / or a scrap leather yarn (SLY yarn).

[0056] The term “outer-facing surface” as used herein refers to a surface of the knit element, an upper, or an article of footwear that faces the external environment. In some aspects, the outer-facing surface can mean the outermost-facing surface of the knit element, the upper, or the article of footwear.

[0057] The term “inner-facing surface” as used herein refers to a surface of the knit element, the upper, or the article of footwear that faces a void for receiving the wearer’s foot. In some aspects, the inner-facing surface may refer to the innermost-facing surface of the knit element, the upper, or the article of footwear.

[0058] In some aspects herein, there may be reference to stiffness or pliability, e.g., of a filament or yarn. The stiffness or pliability can be determined using testing methods such as ASTM D1388-18 or ASTM D1388-23 for fabrics of such materials, or through another standardized flexural rigidity test such as ASTM D790.

[0059] In some aspects herein, there may be reference to hardness or rigidity of a knit component with a spacer knit structure. The hardness can be measured using ASTM D2240 type A and type D scales.

[0060] Unless indicated otherwise, all measurements provided herein are taken when the knit element, the upper, and / or the article of footwear is at standard ambient temperature and pressure (298.15 K and 100 kPa) and is in a resting (non-tensioned) state. In addition, as used herein, the term “about” means within ± 10% of an indicated value.

[0061] Aspect 1. A knitted component, comprising: a spacer knit structure, comprising: a first knit layer; a second knit layer; a filament that extends between the first knit layer and the second knit layer, and that is interlooped with the first knit layer and the second knit layer; and a first zone comprising a fused area that maintains the spacer knit structure in a compressed shape.

[0062] Aspect 2. The knitted component of aspect 1, wherein the fused area comprises a thermoplastic polymer material that is thermoformed.

[0063] Aspect 3. The knitted component of aspect 1 or 2, wherein the spacer knit structure comprises one or more yams in the first knit layer and / or the second knit layer that comprise the thermoplastic polymer material.

[0064] Aspect 4. The knitted component of any of aspects 1-3, wherein each yarn of the one or more yams is formed entirely of the thermoplastic polymer material.

[0065] Aspect 5. The knitted component of any of aspects 1-4, wherein each yarn of the one or more yams comprises a multi-component yarn comprising the thermoplastic polymer material.

[0066] Aspect 6. The knitted component of any of aspects 1-5, wherein the multicomponent yarn comprises a core and a sheath, and wherein the sheath comprises the thermoplastic polymer material.

[0067] Aspect 7. The knitted component of any of aspects 1-6, wherein the spacer knit structure further comprises a second zone that comprises the fused area, wherein, in the first zone, the spacer knit structure in the compressed shape has a first thickness, and wherein, in the second zone, the spacer knit structure is maintained by the fused area in a compressed shape that has a second thickness that is different from the first thickness.

[0068] Aspect 8. The knitted component of any of aspects 1-7, wherein the spacer knit structure further comprises a second zone, wherein, in the first zone, the spacer knit structure in the compressed shape has a first thickness, and wherein, in the second zone, the spacer knit structure is uncompressed and has a second thickness that is greater than the first thickness.

[0069] Aspect 9. The knitted component of any of aspects 1-8, wherein the spacer knit structure comprises a plurality of zones comprising the first zone, wherein each zone of the plurality of zones comprises the fused area and is compressed to a corresponding thickness that is less than a thickness of the spacer knit structure in an uncompressed shape.

[0070] Aspect 10. The knitted component of any of aspects 1-9, wherein the knitted component comprises part of an article of footwear.

[0071] Aspect 11. An upper for an article of footwear, the upper comprising: a knitted component, comprising: a spacer knit structure, comprising: a first knit layer; a second knit layer; a filament that extends between the first knit layer and the second knit layer, and that is interlooped with the first knit layer and the second knit layer; and a first zone comprising a fused area that maintains the spacer knit structure in a compressed shape.

[0072] Aspect 12. The upper of aspect 1 1 , wherein the spacer knit structure further comprises a second zone comprising the fused area, wherein, in the first zone, the spacer knit structure in the compressed shape has a first thickness, and wherein, in the second zone, the spacer knit structure has a second thickness that is greater than the first thickness.

[0073] Aspect 13. The upper of aspect 11 or 12, wherein the article of footwear is a soccer shoe, and wherein the second zone is located on at least one of a medial side and a lateral side of the article of footwear, and wherein the first zone is located in at least a toe region of the article of footwear.

[0074] Aspect 14. An article of footwear, comprising: an upper, comprising: a knitted component, comprising: a spacer knit structure, comprising: a first knit layer; a second knit layer; a filament that extends between the first knit layer and the second knit layer, and that is interlooped with the first knit layer and the second knit layer; and a first zone comprising a fused area that maintains the spacer knit structure in a compressed shape.

[0075] Aspect 15. The article of footwear of aspect 14, wherein the fused area comprises a thermoplastic polymer material that is thermoformed.

[0076] Aspect 16. The article of footwear of aspect 14 or 15, wherein the spacer knit structure further comprises one or more yarns incorporated into the first knit layer and / or the second knit layer that comprise the thermoplastic polymer material.

[0077] Aspect 17. The article of footwear of any of aspects 14-16, wherein the spacer knit structure further comprises a second zone comprising the fused area, wherein, in the first zone, the spacer knit structure in the compressed shape has a first height, and wherein, in the second zone, the spacer knit structure has a second height that is greater than the first height.

[0078] Aspect 18. The article of footwear of any of aspects 14-17, wherein the article of footwear is a soccer shoe, and wherein the second zone is located on at least one of a medial side and a lateral side of the article of footwear, and wherein the first zone is located in at least a toe region of the article of footwear.

[0079] Aspect 19. A method of manufacturing, the method comprising: forming a spacer knit structure comprising a first knit layer, a second knit layer, and a filament that extends between the first knit layer and the second knit layer, and that is interlooped with the first knit layer and the second knit layer; pressing, using a press-mechanism, the spacer knit structure into a compressed shape; and heating, using the press-mechanism, the spacer knit structure so that a fused area is formed, wherein once cooled the fused area maintains the spacer knit structure at least partially in a compressed shape.

[0080] Aspect 20. The method of aspect 19, wherein the spacer knit structure is formed to comprise at least part of an upper.

[0081] Aspect 21. The method of aspect 19 or 20, further comprising incorporating the upper into an article of footwear.

[0082] Aspect 22. The method of any of aspects 19-21, wherein the article of footwear is a soccer shoe that comprises an outer-facing surface having at least a first zone and a second zone, and wherein, in the first zone, the spacer knit structure is maintained in a substantially fully compressed shape by the fused area, the first zone located in a toe region of the article of footwear, and wherein, in the second zone, the spacer knit structure is uncompressed, the second zone located on a medial side and / or a lateral side of the article of footwear.

[0083] Aspect 23. A plurality of articles of footwear, each comprising: an upper, comprising: a knitted component, comprising: a spacer knit structure, comprising: a first knit layer; a second knit layer; a filament that extends between the first knit layer and the second knit layer, and that is interlooped with the first knit layer and the second knit layer; and a plurality of zones including a first zone that comprises a fused area that maintains the spacer knit structure in a compressed shape in at least the first zone, wherein each article of footwear of the plurality of articles of footwear is configured for a different sporting use and has the first zone positioned in a different surface location thereon.

[0084] Aspect 24. The plurality of articles of footwear of aspect 23, wherein the plurality of articles of footwear comprises: a first article of footwear adapted for a first ball game, wherein the first zone is positioned at a first surface location on the first article of footwear; and a second article of footwear configured for a second ball game, wherein the first zone is positioned at a second surface location on the second article of footwear, that is at least partially distinct from the first surface location.

[0085] Aspect 25. The preceding aspects 1-25 in any combination, s

[0086] In some aspects, this disclosure may include the language, for example, “at least one of [element A] and [element B].” This language may refer to one or more of the elements. For example, “at least one of A and B” may refer to “A,” “B,” or “A and B.” In other words, “at least one of A and B” may refer to “at least one of A and at least one of B,” or “at least either of A or B.” In some aspects, this disclosure may include the language, for example, “[element A], [element B], and / or [element C].” This language may refer to either of the elements or any combination thereof. In other words, “A, B, and / or C” may refer to “A,” “B,” “C,” “A and B,” “A and C,” “B and C,” or “A, B, and C.” In addition, this disclosure may use the term “and / or” which may refer to any one or combination of the associated elements. In addition, this disclosure may use the term “a” (element) or “the” (element). This language may refer to the referenced element in the singular or in the plural and is not intended to be limiting in this respect.

[0087] The subject matter of this disclosure has been described in relation to particular aspects, which are intended in all respects to be illustrative rather than restrictive. In this sense, alternative aspects will become apparent to those of ordinary skill in the art to which the present subject matter pertains without departing from the scope hereof. In addition, different combinations and sub-combinations of elements disclosed, as well as use and inclusion of elements not shown, are possible and contemplated as well.

Claims

CLAIMSWhat is claimed is:

1. A knitted component, comprising: a spacer knit structure, comprising: a first knit layer; a second knit layer; a filament that extends between the first knit layer and the second knit layer, and that is interlooped with the first knit layer and the second knit layer; and a first zone comprising a fused area that maintains the spacer knit structure in a compressed shape.

2. The knitted component of claim 1 , wherein the fused area comprises a thermoplastic polymer material that is thermoformed.

3. The knitted component of claim 1 or 2, wherein the spacer knit structure comprises one or more yams in the first knit layer and / or the second knit layer that comprise the thermoplastic polymer material.

4. The knitted component of any of claims 1-3, wherein each yarn of the one or more yams is formed entirely of the thermoplastic polymer material.

5. The knitted component of any of claims 1-4, wherein each yarn of the one or more yams comprises a multi-component yarn comprising the thermoplastic polymer material.

6. The knitted component of any of claims 1-5, wherein the multicomponent yarn comprises a core and a sheath, and wherein the sheath comprises the thermoplastic polymer material.

7. The knitted component of any of claims 1-6, wherein the spacer knit structure further comprises a second zone that comprises the fused area, wherein, in the first zone, the spacer knit structure in the compressed shape has a first thickness, and wherein, in the second zone, the spacer knit structure is maintained by the fused area in a compressed shape that has a second thickness that is different from the first thickness.

8. The knitted component of any of claims 1 -7, wherein the spacer knit structure further comprises a second zone, wherein, in the first zone, the spacer knit structure in the compressed shape has a first thickness, and wherein, in the second zone, the spacer knit structure is uncompressed and has a second thickness that is greater than the first thickness.

9. The knitted component of any of claims 1-8, wherein the spacer knit structure comprises a plurality of zones comprising the first zone, wherein each zone of the plurality of zones comprises the fused area and is compressed to a corresponding thickness that is less than a thickness of the spacer knit structure in an uncompressed shape.

10. The knitted component of any of claims 1-9, wherein the knitted component comprises part of an article of footwear.

11. An upper for an article of footwear, the upper comprising: a knitted component, comprising: a spacer knit structure, comprising: a first knit layer; a second knit layer; a filament that extends between the first knit layer and the second knit layer, and that is interlooped with the first knit layer and the second knit layer; and a first zone comprising a fused area that maintains the spacer knit structure in a compressed shape.

12. The upper of claim 1 1 , wherein the spacer knit structure further comprises a second zone comprising the fused area, wherein, in the first zone, the spacer knit structure in the compressed shape has a first thickness, and wherein, in the second zone, the spacer knit structure has a second thickness that is greater than the first thickness.

13. The upper of claim 11 or 12, wherein the article of footwear is a soccer shoe, and wherein the second zone is located on at least one of a medial side and a lateral side of the article of footwear, and wherein the first zone is located in at least a toe region of the article of footwear.

14. An article of footwear, comprising: an upper, comprising: a knitted component, comprising: a spacer knit structure, comprising: a first knit layer; a second knit layer; a filament that extends between the first knit layer and the second knit layer, and that is interlooped with the first knit layer and the second knit layer; and a first zone comprising a fused area that maintains the spacer knit structure in a compressed shape.

15. The article of footwear of claim 14, wherein the fused area comprises a thermoplastic polymer material that is thermoformed.

16. The article of footwear of claim 14 or 15, wherein the spacer knit structure further comprises one or more yarns incorporated into the first knit layer and / or the second knit layer that comprise the thermoplastic polymer material.

17. The article of footwear of any of claims 14-16, wherein the spacer knit structure further comprises a second zone comprising the fused area, wherein, in the first zone, the spacer knit structure in the compressed shape has a first thickness, and wherein, in the second zone, the spacer knit structure has a second thickness that is greater than the first thickness.

18. The article of footwear of any of claims 14-17, wherein the article of footwear is a soccer shoe, and wherein the second zone is located on at least one of a medial side and a lateral side of the article of footwear, and wherein the first zone is located in at least a toe region of the article of footwear.

19. A method of manufacturing, the method comprising: forming a spacer knit structure comprising a first knit layer, a second knit layer, and a filament that extends between the first knit layer and the second knit layer, and that is interlooped with the first knit layer and the second knit layer; pressing, using a press-mechanism, the spacer knit structure into a compressed shape; and heating, using the press-mechanism, the spacer knit structure so that a fused area is formed, wherein once cooled the fused area maintains the spacer knit structure at least partially in a compressed shape.

20. The method of claim 19, wherein the spacer knit structure is formed to comprise at least part of an upper.

21. The method of claim 19 or 20, further comprising incorporating the upper into an article of footwear.

22. The method of any of claims 19-21, wherein the article of footwear is a soccer shoe that comprises an outer-facing surface having at least a first zone and a second zone, and wherein, in the first zone, the spacer knit structure is maintained in a substantially fully compressed shape by the fused area, the first zone located in a toe region of the article of footwear, and wherein, in the second zone, the spacer knit structure is uncompressed, the second zone located on a medial side and / or a lateral side of the article of footwear.

23. A plurality of articles of footwear, each comprising: an upper, comprising: a knitted component, comprising: a spacer knit structure, comprising: a first knit layer; a second knit layer; a filament that extends between the first knit layer and the second knit layer, and that is interlooped with the first knit layer and the second knit layer; and a plurality of zones including a first zone that comprises a fused area that maintains the spacer knit structure in a compressed shape in at least the first zone, wherein each article of footwear of the plurality of articles of footwear is configured for a different sporting use and has the first zone positioned in a different surface location thereon.

24. The plurality of articles of footwear of claim 23, wherein the plurality of articles of footwear comprises: a first article of footwear adapted for a first ball game, wherein the first zone is positioned at a first surface location on the first article of footwear; and a second article of footwear configured for a second ball game, wherein the first zone is positioned at a second surface location on the second article of footwear, that is at least partially distinct from the first surface location.

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