Patent Description:
Conventional articles of footwear generally include two primary elements: an upper and a sole structure. The upper is secured to the sole structure and forms a void within the article of footwear for comfortably and securely receiving a foot. The sole structure is secured to a lower surface of the upper so as to be positioned between the upper and the ground. In some articles of athletic footwear, for example, the sole structure may include a midsole and an outsole. The midsole may be formed from a polymer foam material that attenuates ground reaction forces to lessen stresses upon the foot and leg during walking, running, and other ambulatory activities. The outsole may be secured to a lower surface of the midsole and forms a ground-engaging portion of the sole structure that is formed from a durable and wear-resistant material.

The upper of the article of footwear generally extends over the instep and toe areas of the foot, along the medial and lateral sides of the foot, and around the heel area of the foot. Access to the void on the interior of the upper is generally provided by an ankle opening in a heel area of the footwear. A lacing system is often incorporated into the upper to adjust the fit of the upper, thereby facilitating entry and removal of the foot from the void within the upper. The upper may include a tongue that extends under the lacing system to enhance adjustability of the footwear, and the upper may incorporate a heel counter to limit movement of the heel.

For certain activities, purposes and/or applications, it may be advantageous to provide an upper for an article of footwear that has certain desirable characteristics and properties. In order to impart the different properties to different areas, one or more yarns and/or material elements may be selected for forming the upper. In one example, it may be desirable to provide a knitted upper that is lightweight, while also breathable, durable, at least partially translucent and of high strength and containment. The upper may further include one or more additional optional elements or components that provide other desirable characteristics, including, but not limited to an inlaid component that may enhance comfort and fit, as well as provide enhanced gripping surfaces for certain activities including but not limited to skateboarding, soccer, climbing and the like where traction on at least a portion of the exterior surface of the footwear is desirable. It may also be advantageous to remove at least a portion of the mechanical stretch from a knitted component before forming the knitted component into an upper for an article of footwear. Thus, stretching the knitted component and subjecting it to a pre-determined post- processing method to retain the knitted component in a stretched condition for forming into an upper may also be desirable.

<CIT> discloses a method of knitting a knitted component for an upper of an article of footwear. The method may include performing multiple passes of at least one yarn feeder so as to form a first collar portion and a second portion of the knitted component.

<CIT> discloses a shoe upper in which a reinforcing section can be easily formed at the position of the heel or the toe, and a method for producing the same. The shoe upper comprises an instep cover section and a sole cover section which are integrally knitted in a seamless manner.

The objective technical problem to be solved may be considered in overcoming or at least reducing the disadvantages according to the prior art. The problem is solved by the subject matter of the independent claim.

The embodiments will be further described in connection with the attached drawings.

Certain aspects of the present disclosure relate to an article of footwear according to the subject matter of claim <NUM>. Illustrative, non-limiting examples of articles of footwear include a skateboarding shoe, a climbing shoe, a basketball shoe, a biking shoe, a cross-training shoe, a global football (soccer) shoe, an American football shoe, a bowling shoe, a golf shoe, a hiking shoe, a ski or snowboarding boot, a tennis shoe, a running shoe, and a walking shoe. The upper may also be incorporated into a non-athletic shoe, such as a dress shoe, a loafer, and a sandal.

Referring to <FIG>, an article of footwear <NUM> includes an upper <NUM> secured to a sole structure <NUM>. The upper <NUM> may include a lateral side <NUM> and a medial side <NUM>. The area of the shoe where the sole structure <NUM> joins the upper <NUM> may be referred to as the biteline <NUM>. The upper <NUM> may be joined to the sole structure <NUM> in a fixed manner using any suitable technique, such as through the use of an adhesive, by sewing, etc. It is contemplated that the upper <NUM> may extend partially or completely around the foot of a wearer and/or may be integral with the sole, and a sockliner may or may not be used. In some embodiments, the sole structure <NUM> may include a midsole (not shown) and an outsole.

The article of footwear <NUM> may additionally include a throat area <NUM> and an ankle opening <NUM>, which may lead to a void <NUM>. The void <NUM> of the article of footwear <NUM> may be configured to accommodate a foot of a person. The throat area <NUM> may be generally disposed in a midfoot area <NUM> of the upper <NUM>. The midfoot area <NUM> is generally an area of the upper <NUM> located between a heel area <NUM> and a toe area <NUM>. In some embodiments, a tongue may be disposed in the throat area <NUM>, but a tongue is an optional component. The tongue may be any type of tongue, such as a gusseted tongue or a burrito tongue. The article of footwear shown in <FIG> and <FIG> preferably includes a tongue that is integrally formed with the upper, such that the upper and the tongue are one piece and no separate attachment of a tongue component is necessary. However, in an embodiment where a tongue is not included, a tongue may be separately formed and later joined to the upper such as by adhesives, bonding and/or stitching, or, in yet another embodiment where no tongue is included, the lateral and medial sides of the throat area <NUM> may be joined together. As shown, in some embodiments, the article of footwear <NUM> may include an optional fastening element, such as a lace (which may be associated with a plurality of lace apertures <NUM>). The apertures may extend from a forefoot region, through a midfoot region and toward the throat area <NUM>. Any suitable type of fastening element may be used.

At least a portion of the upper <NUM>, and in some embodiments substantially the entirety of the upper <NUM>, and in still further embodiments the entire upper, may be formed of at least one knitted component <NUM>, such as made by a weft-knitting process on a flat knitting machine, for example. The knitted component <NUM> may additionally or alternatively form another element of the article of footwear, such as an underfoot portion, for example, and/or a heel element <NUM> as will be described in further detail below. Alternatively, a second or additional knitted component <NUM>, separately formed from knitted component <NUM>, may form another element of the article of footwear, such as an underfoot portion, for example, and/or a heel element <NUM>. In other words, additional elements such as an underfoot portion and/or a heel element <NUM> (or other elements or components) may be integrally formed with the upper <NUM> as a one-piece structure, or, alternatively, one or more such additional elements may be formed separately from the upper <NUM> and then later attached, secured or otherwise assembled as necessary.

The knitted component <NUM> has a first side <NUM> forming an inner surface of the upper <NUM> (e.g., facing the void <NUM> of the article of footwear) and a second side <NUM> forming an outer surface of the upper <NUM> (e.g. facing generally opposite the first side <NUM>). The first side <NUM> and the second side <NUM> of the knitted component <NUM> may exhibit different characteristics (e.g., breathability, gripping ability, abrasion resistance, strength, structure and comfort, among other advantageous characteristics mentioned herein). As previously mentioned, the knitted component <NUM> may be formed as an integral one-piece element during a knitting process, such as a weft knitting process (e.g., with a flat knitting machine or circular knitting machine), a warp knitting process, or any other suitable knitting process. That is, the knitting process on the knitting machine may substantially form the knit structure of the knitted component <NUM> without the need for significant post-knitting processes or steps. Alternatively, two or more portions of the knitted component <NUM> may be formed separately as distinct integral one-piece elements and then the respective elements attached. For example, the heel element <NUM> can be knitted separately from the upper <NUM> and then attached or secured to the upper <NUM> by adhesives, stitching, bonding or other mechanisms or a combination thereof. Additional portions or details may also be secured or attached to the upper for structural or aesthetic purposes, including heel reinforcements, lace aperture reinforcements, to reinforcements and the like. These additional portions may be formed of a separate knitted component that is later attached or by other textiles or materials including, but not limited to leather, suede, rubber, plastic and others.

Forming the upper <NUM> with the knitted component <NUM> may provide the upper <NUM> with advantageous characteristics including, but not limited to, a particular degree of elasticity (for example, as expressed in terms of Young's modulus), grip, breathability, bendability, strength, moisture absorption, weight, abrasion resistance, and/or a combination thereof. These characteristics may be accomplished by selecting a particular single layer or multi-layer knit structure (e.g., a ribbed knit structure, a single jersey knit structure, or a double jersey knit structure), by varying the size and tension of the knit structure, by using one or more yarns formed of a particular material (e.g., a polyester material, a relatively inelastic material, or a relatively elastic material such as spandex), by selecting yarns of a particular size (e.g., dtex), and/or a combination thereof. The knitted component <NUM> may also provide desirable aesthetic characteristics by incorporating yarns having different colors, reflectivity, textures, various degrees of transparency or translucency or other visual properties arranged in a particular pattern. In addition to incorporating different yarns, other materials may be incorporated into the knitted component including but not limited to leather, suede, rubber, plastic or other materials.

The yarns themselves and/or the knit structure formed by one or more of the yams or other materials of the knitted component <NUM> may be varied at different locations such that the knitted component <NUM> has two or more portions with different properties. In one non-limiting example, at least a portion of the knitted component <NUM> may be formed by one or more yarns and/or knitting techniques to provide an upper <NUM> that is lightweight, having relatively high strength and containment and also breathable. Other areas of the upper <NUM> formed by the knitted component <NUM> may be formed by one or more different yams and/or formed by different knitting techniques and/or other materials that result in a portion of the upper <NUM> that has different characteristics. For example, the yam(s) and/or the knitting techniques used to form the throat area <NUM> and/or the ankle opening <NUM> may be selected to provide relatively greater elasticity, soft hand, cushioning, enhanced comfort and moisture wicking properties to those regions. In some embodiments, the knitted component <NUM> may incorporate one or more materials with properties that change in response to a stimulus (e.g., temperature, moisture, electrical current, magnetic field, or light). In still other embodiments, the knitted component <NUM> may incorporate one or more materials that provide other desirable characteristics including but not limited to enhanced gripping surfaces.

For example, the knitted component <NUM> may include one or more yams formed of a thermoplastic polymer material (e.g., polyurethanes, polyamides, polyolefins, and nylons) that transitions from a solid state to a softened or liquid state when subjected to certain temperatures at or above its melting point and then transitions back to the solid state when cooled. The thermoplastic polymer material may provide the ability to heat and then cool a portion of the knitted component <NUM> to thereby form an area of fused or bonded or continuous material that exhibits certain advantageous properties including a relatively high degree of rigidity, strength, and water resistance, for example. Other advantages of providing one or more yams comprising a thermoplastic polymer material may include, for example, locking or securing the yarns of the knitted component into a particular position or configuration upon cooling, such that the knitted component <NUM> may be retained in that particular configuration. In one non-limiting example, this may include stretching the knitted component to a predetermined degree and then heating the knitted component <NUM> during a post processing method, such as steaming. Upon cooling, the fusible yams may lock the adjacent and/or surrounding yams in the stretched configuration to retain the knitted component <NUM> in this stretched condition. The knitted component <NUM> includes one or more yarns having a relatively high degree of tenacity relative to the other yams used to form the upper.

As used herein, "tenacity" is understood to refer to the amount of force (expressed in units of weight, for example: pounds, grams, centinewtons or other units) needed to rupture a yarn (i.e., the breaking force or breaking point of the yarn), divided by the linear mass density of the yam expressed, for example, in (unstrained) denier, decitex, or some other measure of weight per unit length. The amount of force needed to break a yam (the "breaking force" of the yarn) is determined by subjecting a sample of the yam to a known amount of force by stretching the sample until it breaks, for example, by inserting each end of a sample of the yarn into the grips on the measuring arms of an extensometer, subjecting the sample to a stretching force, and measuring the force required to break the sample using a strain gauge load cell. Suitable testing systems can be obtained from Instron (Norwood, MA, USA). Yarn tenacity and yarn breaking force are distinct from burst strength or bursting strength of a textile, which is a measure of the maximum force that can be applied to the surface of a textile before the surface bursts.

Generally, in order for a yam to withstand the forces applied in an industrial knitting machine, the minimum tenacity required is approximately <NUM>,<NUM> cN/dtex (<NUM> grams per denier (g/D)). Most synthetic polymer continuous filament yams formed from commodity polymeric materials generally have tenacities in the range of about <NUM>,<NUM> cN/dtex to about <NUM>,<NUM> cN/dtex (<NUM>/D to about <NUM>/D). For example, polyester filament yarns that may be used in the manufacture of knit uppers for article of footwear have tenacities in the range of about <NUM>,<NUM> cN/dtex to about <NUM>,<NUM> cN/dtex (<NUM>/D to about <NUM>/D). Filament yarns formed from commodity synthetic polymeric materials which are considered to have high tenacities generally have tenacities in the range of about <NUM>,<NUM> cN/dtex to about <NUM>,<NUM> cN/dtex (<NUM>/D to about <NUM>/D). For example, commercially available package dyed polyethylene terephthalate filament yam from National Spinning (Washington, NC, USA) has a tenacity of about <NUM>,<NUM> cN/dtex (<NUM>/D), and commercially available solution dyed polyethylene terephthalate filament yam from Far Eastern New Century (Taipei, Taiwan) has a tenacity of about <NUM>,<NUM> cN/dtex (<NUM>/D). Filament yarns formed from high performance synthetic polymer materials generally have tenacities of about <NUM>,<NUM> cN/dtex (<NUM>/D) or greater. For example, filament yarns formed of aramid typically have tenacities of about <NUM>,<NUM> cN/dtex (<NUM>/D), and filament yams formed of ultra-high molecular weight polyethylene (UHMWPE) having tenacities greater than <NUM>,<NUM> cN/dtex (<NUM>/D) are available from Dyneema (Stanley, NC, USA) and Spectra (Honeywell-Spectra, Colonial Heights, VA, USA).

It is also contemplated that the knitted component may also include one or more yams having relatively high elasticity. Suitable elasticated yarns may incorporate elastane fiber(s), such as those available from Invista Company under the LYCRA trademark. Such yams may have the configuration of covered LYCRA, for example yarns having a LYCRA core that is surrounded by a nylon sheath. Other fibers or filaments exhibiting elastic properties may also be utilized.

The knitted component <NUM> may also incorporate additional materials or components. In some non-limiting examples (such as the examples of <FIG>), the knitted component <NUM> may incorporate an inlaid component <NUM>. The inlaid component <NUM> may comprise one or more yarns, rubbers, plastics, leathers and/or other natural or synthetic components. As shown generally in <FIG>, the knitted component <NUM> (which may be incorporated into an article of footwear <NUM>) may include an inlaid component <NUM> that extends generally in a heel to toe direction when the knitted component <NUM> is incorporated into an article of footwear. In another example (also shown in <FIG> along with <FIG>), the inlaid component <NUM> may extend generally in a lateral to medial direction, and/or vertically when an associated article of footwear <NUM> is sitting on horizontal ground in a wearable state. In still another example, the inlaid component <NUM> may extend in multiple directions and/or may be located in certain portions of the upper <NUM> and be absent from other areas of the upper <NUM>. Such an arrangement may provide regional properties to certain portions of the upper, such that certain advantageous properties may deliberately be provided to certain parts of the upper while deliberately omitting certain properties from other parts of the upper <NUM>.

The knitted component <NUM> includes a seamless portion extending from the toe area <NUM>, through a midfoot area <NUM>, and to a heel area <NUM> on at least one of a lateral side <NUM> and a medial side <NUM> of the upper. In some embodiments, the knitted component <NUM> may include a first edge and a second edge, which may be terminal ends of the knitted component <NUM> after the knitting process when the knitted component <NUM> is removed from the knitting machine. After the knitting process, the knitted component <NUM> may be folded or otherwise manipulated such that a first edge and the second edge are secured together at a seam <NUM> during formation of the upper <NUM>. The seam <NUM> may be located on the lateral side <NUM> of the upper <NUM>, on the medial side <NUM> of the upper <NUM>, and/or in another location (e.g., at the back of the heel area <NUM> of the upper as shown in <FIG>). Forming the upper <NUM> such that it is in an appropriate shape for inclusion in an article of footwear <NUM> may further include lasting the upper <NUM>. An example of a lasting process is described in <CIT>, and issued as <CIT>.

When forming the knitted component <NUM>, the knitted component <NUM> may be oriented with respect to a needle bed of a knitting machine such that a feeder of the knitting machine is capable of moving in a single pass (i.e., without changing its feed direction) to knit a first course from the lateral side <NUM> to the medial side <NUM> of the knitted component. As such, as subsequent courses are formed that are parallel to the first course, the toe area <NUM> of the knitted component <NUM> will be formed first, followed by the midfoot area <NUM> of the knitted component <NUM>, and then the heel area <NUM> of the knitted component <NUM> (and/or vice versa, such that the knitted component is formed along a y-axis, in a heel-to-toe direction). Alternatively, the knitted component <NUM> may be oriented with respect to a needle bed of a knitting machine such that a first course is knit in a direction from heel to toe (or toe to heel). As such, when additional courses are formed parallel to the first course, one of the lateral or medial side is formed first, followed by a central portion such as the throat followed by the other of the lateral or medial side. As such, the knitted component is formed along an x-axis, in a side-to-side, or lateral-to-medial direction.

In one embodiment, the inlaid component <NUM> may be generally parallel to the course-wise direction of the knitted component <NUM>. In an alternative embodiment, the inlaid component <NUM> may be generally perpendicular to the course-wise direction of the knitted component <NUM>. It is also contemplated that the inlaid component <NUM> may be oriented in a particular direction in a forefoot and/or midfoot area of the upper <NUM> and be oriented in a different direction in a heel area of the upper <NUM>, for example.

As shown in <FIG>, at least a portion of the upper <NUM> may comprise a single layer <NUM>. As such, an outer surface (the second side <NUM>) of the single layer <NUM> forms an external surface of an upper <NUM> and the inner surface (the first side <NUM>) of the single layer <NUM> forms an inner surface of the upper <NUM>, facing the void <NUM> of the upper configured to receive the foot of a wearer.

In an alternative embodiment, one or more portions of the upper <NUM> may comprise more than a single layer <NUM>, such as a first layer and a second layer that are coextensive and/or overlapping, which may form a pocket therebetween. The pocket may be filled with another element (e.g., a filler material, such as foam, down, or another suitable material or object), but this is not required, and in exemplary embodiments, the pocket may be empty and/or filled with just air.

As mentioned above, the upper <NUM> comprises an ankle opening <NUM>, which leads to the void <NUM>, configured to accommodate a foot of a wearer. The ankle opening <NUM> is formed of at least two collars. The collar <NUM> of the upper <NUM> may be referred to herein as a "first collar" which forms a "first collar opening. " The one or more of the yarns and/or knitting techniques used to form the collar <NUM> may be the same as the yams and/or knitting techniques used to form other portions of the upper <NUM> or they may be different.

For example, as shown in <FIG>, the one or more yarn(s), as well as the one or more knitting technique(s) used to form the collar <NUM>, the throat area <NUM> and the remainder of the upper <NUM>, respectively, may differ in order to impart desired properties and characteristics to different regions of the upper <NUM> as described below.

One or more yarns may be used when knitting the knitted component <NUM> that is formed into an upper <NUM>. In one non-limiting example, a first yarn <NUM> may include a high tenacity polyester yarn. In one non-limiting example, the high-tenacity polyester yarn may be formed from polyethylene terephthalate (PET). The first yarn <NUM> may have a tenacity of at least <NUM> grams per denier, and more preferably higher than <NUM> grams per denier and even more preferably from <NUM> - <NUM> grams per denier. In one example, three ends of <NUM> denier high tenacity polyester yarn may be used. The high tenacity polyester may be translucent or at least partially transparent in some embodiments. This may allow one or more images, elements, symbols, logos or other objects that are behind portions of the knitted component <NUM> formed from the first yam <NUM>, (such as images or elements that are adjacent to the inner surface or first side <NUM> of the upper <NUM> and/or within the void <NUM> formed by the upper <NUM>, to be visible from the second side <NUM> or exterior of the upper <NUM>. This may enhance the visual properties and/or aesthetic appearance of the upper <NUM>, for example. It will be recognized that more or fewer ends of the first yarn <NUM>, having lower or higher tenacity and/or lower or higher denier, may be used as one of skill in the art would recognize to achieve the desired and necessary properties.

A second yarn <NUM> may be used to form at least a portion of the first knitted component <NUM>, alone or in combination with the first yarn <NUM>. The second yarn <NUM> may be the same as the first yarn <NUM> or it may be different. In one example, the second yarn <NUM> may have one or more thermoplastic polymers (collectively "the thermoplastic polymer material"), and in some embodiments, substantially the entirety of the second yam <NUM> may be formed of the thermoplastic polymer material. The thermoplastic polymer material of the second yam may have a melting temperature of between about <NUM>-<NUM> degrees C and more preferably <NUM>-<NUM> degrees C based on atmospheric pressure at sea level, though any other suitable melting temperatures is contemplated. In a non-limiting example, the second yam <NUM> may be referred to as a "fusible yam" sold under the trade name Grilon K-<NUM> by EMS-Griltech. The K-<NUM> yam is a multifilament yarn where the polymer basis is a copolyamide. It should also be noted that a yarn with a melting temperature below <NUM> degrees C that can be melted/post processed by steaming, heat and/or pressing to bind or fuse with the surrounding (non-low melt) yarns and hold them in place may be referred to as a 'fusible' or Tow melt' yam herein. In one example, two ends of <NUM> denier of the second yarn <NUM> may be used. Alternately, fewer ends of a higher denier second yam <NUM> may be used, such as one end of a <NUM> denier yarn. More or fewer ends of the second yarn <NUM> having lower or higher denier or lower or higher melting temperature may be used as one of skill in the art would recognize to achieve the desired and necessary properties.

A third yarn <NUM> may be used to form at least a portion of the knitted component <NUM>, alone or in combination with the first yarn <NUM> and/or the second yam <NUM>. In one example, the third yam <NUM> may also be a high tenacity polyester yarn formed from polyethylene terephthalate (PET). The third yarn <NUM> may sometimes be referred to herein as a high tenacity sewing thread or "M-<NUM>" and/or sold under the trade name "Gral" by Coats Group PLC. The term "thread" in reference to the third yarn <NUM> may infer to one of skill that this yam has an increased amount of twist to keep the filaments tighter/more compact, often useful for going smoothly and efficiently through sewing or knitting needles. In the present case, the third yarn <NUM> (e.g. high tenacity polyester sewing thread) may provide a different aesthetic as compared to the first yarn <NUM> (e.g. also a high tenacity polyester yam). The third yam <NUM> may have a tenacity of at least <NUM> grams per denier, and in some examples approximately <NUM>-<NUM> grams per denier and more preferably approximately <NUM> grams per denier. In one example, one end of the third yam <NUM> may be used, but it will be recognized that more or fewer ends of the third yarn <NUM>, having lower or higher tenacity and/or lower or higher denier, may be used as one of skill in the art would recognize to achieve the desired and necessary properties.

The high tenacity yarns, including the first yarn <NUM> (i.e. the high tenacity polyester yam) and/or the third yarn <NUM> (i.e. the high tenacity polyester sewing thread) may be knit alone or in combination with other yarns, such as the second yarn <NUM> (the fusible yarn). For example, the high tenacity polyester yarns <NUM>, <NUM> may be knit in combination with the fusible yam <NUM> mentioned above. The combination of yams as well as the knitting technique used to form the upper <NUM> is described in further detail below.

In addition to the first, second and third yams <NUM>, <NUM>, <NUM>, a fourth yam <NUM> may be used to form the knitted component <NUM>. The fourth yam <NUM> may be the same as the first, second and/or the third yarn <NUM>, <NUM>, <NUM>, or it may be different. In one example, the fourth yarn <NUM> used to form at least a portion of the knitted component <NUM> comprises a yarn that is different than the first, second and third yams <NUM>, <NUM>, <NUM> and comprises a relatively more elastic yam than the aforementioned first, second and third yams. In one example, the fourth yarn <NUM> may comprise a combination of a polyester yarn with an elastic core. In some embodiments, the fourth yam <NUM> may be referred to as"E08" which may be two strands of a textured polyester yam wrapped about an elastic (i.e. a 420D Spandex) core. Other suitable elastic yams may also include 'E06" which may be two strands of textured polyester wrapped around a 140D Spandex core or 'E04" which may be two strands of textured polyester wrapped around a 210D Spandex core, although other suitable elastane yarns may be used to achieve the necessary properties and characteristics. The combination of materials, such as the polyester yam and the elastic yarn that together form the fourth yarn <NUM> may be achieved by twisting, winding, braiding, and/or wrapping on about the other and the like, and/or the yarns may be a core/sheath configuration, and/or the yarns may be tacked along their length at a plurality of points.

During the knitting process, another yarn and/or material may be inlaid within the knitted component <NUM>. This inlaid component <NUM> (<FIG>) may be the same as one or more of the first, second, third or fourth yams. Alternatively, the inlaid component <NUM> may be another material including leathers, rubbers, plastics, nylon and/or other natural and/or synthetic materials or combinations thereof. The material of the inlaid component <NUM> may be selected depending on the structural or aesthetic or advantageous characteristic that is desired. In one non-limiting example, the inlaid component <NUM> may include a natural material such as leather, or a synthetic material such as synthetic leather. The inlaid component <NUM> may be in the form of a strip or cord or other type of elongated structure.

During or after the knitting process, a stimulus, such as heat, may be applied to at least a portion of, or to the entirety of the upper <NUM>. This heat may be in the form of steam, such as by a steam-providing device, for example. One or more effects may result from the exposure of the knitted component <NUM> to steam.

In one example, the steam may cause one or more of the yams used to form the knitted component <NUM> to melt into a softened or liquid state. For example, the steam may cause the second yarn <NUM> (the thermoplastic yarn, or "fusible yam," for example) having a melting temperature of <NUM> degrees C, to soften or become molten or enter into a relatively liquid state when the temperature reaches or exceeds the designated melting temperature of the yarn. When subjected to a stimulus, such as steam heat and/or pressure, the thermoplastic polymer material included with the second yarn <NUM> described above, may at least partially melt.

In one example, the steam may activate thermoplastic polymer materials in the second yarn <NUM>. Once this heat is removed and the article cools, the thermoplastic material present in the second yam <NUM> may at least partially fuse together with adjacent or surrounding yarns in its proximity within the knitted component <NUM>. In other words, the second yarn <NUM> may infiltrate and/or permeate any of the adjacent or surrounding knit loops and/or courses of the knitted component <NUM> formed from any of the other yams used to form the knitted component <NUM> and/or the inlaid component <NUM>. As a result, the at least a portion of one or more of the separate yams originally forming the knitted component <NUM> (and/or the inlaid component <NUM>) may become bonded and/or continuous with the second yam <NUM> to form a "fused" area. There may be fewer and relatively large fused areas in one or more portions of the upper, or there may be a plurality of relatively small fused areas throughout the upper. In some instances, the fused area may be small enough or they may be at least partially translucent or transparent such that they are not readily visible. When the thermoplastic material transitions back to a solid state upon cooling, this may cause the fused yams to remain fixed in (or at least have a tendency to remain fixed in) a desirable position and orientation. Heat-processing the fusible material of the fusible yarn may also enhance the rigidity, strength, and other mechanical properties of the knitted component at least in select locations and/or have the effect of securing or locking the relative positions of the yarns within the knitted component <NUM>.

As shown in <FIG>, at least a portion of the knitted component <NUM> forming the upper <NUM>, and more preferably, a majority of (i.e. greater than <NUM>%) or even more preferably a substantial majority (i.e. greater than <NUM>% or more) of the knitted component is formed from the first, second and third yarns <NUM>, <NUM>, <NUM>. The inlaid component <NUM> (<FIG>) may be incorporated into the portion of the knitted component <NUM> formed from the first, second and third yams <NUM>, <NUM>, <NUM>. Hereinafter, the portion of the upper <NUM> formed from the first, second and third yarns <NUM>, <NUM>, <NUM>, which, in one example, is the upper excluding the throat area <NUM> and/or the first collar <NUM>, will be referred to as the "body" <NUM> of the upper <NUM>. Stated differently, the body <NUM> of the upper <NUM>, with the exception of the throat area <NUM> and/or the collar <NUM>, is formed from the first, second and third yams, <NUM>, <NUM>, <NUM> and/or the inlaid component <NUM>, while the throat area <NUM> and/or the collar <NUM> are formed at least in part from the fourth yarn <NUM>. It is also contemplated, however, that one or more of the first, second and/or third yarns <NUM>, <NUM>, <NUM> may be present in lieu of, or in combination with, the fourth yarn <NUM> in the throat area <NUM> and/or the collar <NUM>. The inlaid component <NUM> may also be incorporated into the throat area <NUM> and/or the collar <NUM>.

As previously mentioned, different characteristics and advantageous properties may be imparted to different areas or regions of the upper. This may be accomplished by not only selecting a particular yarn or yarns to form different regions of the upper <NUM>. However, this may also be accomplished by selecting a particular knitting technique, selecting single layer or multi-layer knit structure (e.g., a ribbed knit structure, a single jersey knit structure, or a double jersey knit structure), by varying the size and tension of the knit structure, by using one or more yarns formed of a particular material (e.g., a polyester material, a thermoplastic material, a relatively inelastic material, or a relatively elastic material such as spandex, etc.), by selecting yams of a particular size (e.g., denier), and/or a combination thereof. In one example, the first, second and third yarns <NUM>, <NUM>, <NUM> forming the body <NUM> of the upper <NUM> may be knit using a particular knitting technique to achieve a particular knit density, for example, including but not limited to a half-gauge knit (knitting on every other needle of a knitting machine). This may include a half-gauge jersey knit as shown in <FIG> and <FIG>, for example. It is also contemplated that the body <NUM> of the upper <NUM> may be formed from a lesser gauge knit, including but not limited to a third gauge knit (knitting on every third needle) or quarter gauge knit (knitting on every fourth needle).

As such, in some embodiments, the body <NUM> of the upper <NUM> has a different stitch density than other portions, such as the throat area <NUM> and/or the collar <NUM>. For example, the body <NUM> has a half gauge stitch density or less-than half gauge stitch density. As used in this application, the terms "full gauge," "half gauge," and "less than full gauge," may generally refer to the stitch density of a knit component. Generally, a knit component may include an area having a "full gauge" stitch density if that area contains stitches (e.g., loops or tucks) formed on at least two consecutive needles of a needle bed (often more than two consecutive needles). Similarly, the same knit component may include an area having a "half gauge" stitch density, in which that area contains stitches formed on every other needle. Similarly, the same knit component may have "less than full gauge" areas that are neither full gauge nor half gauge, for example one-third gauge (stitches formed on every third needle) or one-quarter gauge (stitches formed on every fourth needle).

The relatively lower density knit structure provided by the half-gauge knitting technique therefore provides a lightweight, breathable upper. Additionally, any one or more of the first, second, third and/or fourth yarns <NUM>, <NUM>, <NUM>, <NUM> used to knit the upper <NUM> may be at least partially translucent and/or transparent either before and/or after any post-processing steps such as exposure to a stimulus (i.e. steam or other heat). Accordingly, the relatively low density of the knit combined with the translucency or transparency of one or more of the yarns used to form the knitted component <NUM> may result in the upper <NUM> also being at least partially translucent and/or transparent. This may reveal, display or otherwise show any auxiliary elements or components or other features (such as logos, decorative elements, colors, etc.) that may lie behind or underneath the first side <NUM> (the inner surface of the knitted component <NUM>) and/or within the void <NUM>. This may also allow the inlaid component <NUM> to be readily apparent, this providing an additional desirable aesthetic appearance to the upper <NUM> in addition to other advantages that may be provided by the inlaid component <NUM>.

This is shown, for example, in <FIG> and <FIG>. Placement of an additional or auxiliary element <NUM> within the void <NUM>, adjacent a first side <NUM>, is visible from the exterior of the footwear. <FIG> shows an auxiliary element <NUM> that extends at least partially around a lower perimeter of the article of footwear <NUM>, such as near the biteline <NUM> where the upper <NUM> meets and/or joins the sole structure <NUM>. While the auxiliary element <NUM> is shown generally as a band or a strip, the auxiliary element <NUM> may be of any shape, length, size and/or dimension. In another example shown in <FIG>, the auxiliary element <NUM> is a band that extends generally between the lateral and medial sides <NUM>, <NUM> of the upper <NUM>, over the top of the foot in the toe area <NUM>. The auxiliary element <NUM> may be formed from a knit structure or a non-knit structure, including but not limited to other textiles, rubbers, plastics, metals, cables, foams and/or padding. The auxiliary element <NUM> may be integrally formed with the upper <NUM> during the knitting process or it may be formed separately and later attached to the upper <NUM> such as by stitching, bonding, adhesives or other suitable attachment mechanisms. In one example, the auxiliary element <NUM> may provide enhanced structure, support, rigidity, water repellency, comfort, strength or other advantageous properties to the article of footwear <NUM>. Additionally or alternatively, the auxiliary element <NUM> may enhance the aesthetic visual and design properties of the upper, such as by providing additional colors, shine, reflectivity and allow the display of logos, placards, emblems and insignia as desired.

As described in further detail below with reference to the knit diagram shown in <FIG>, the body <NUM> of the upper <NUM> may be formed by a series of courses of the first, second and third yarns <NUM>, <NUM>, <NUM>. In one non-limiting example, a first course may be knit with a combination of the first yarn <NUM> (e.g., the high tenacity polyester yam) and the second yarn <NUM> (e.g., formed thermoplastic polymer material, the "fusible yam"). A second consecutive course may be formed from a combination of the third yarn <NUM> (e.g., the high tenacity polyester "sewing thread") and the second yarn <NUM> (e.g., formed thermoplastic polymer material, the "fusible yarn"). This pattern of yarn selection may be repeated, knitting on every other needle of a needle bed, to form a half-gauge knit body <NUM> for the upper <NUM>. It is noted that the use of one or more relatively high tenacity yarns, including the first yam <NUM> (e.g., the high tenacity polyester yarn) and/or the third yarn <NUM> (e.g., the high tenacity polyester "sewing thread") may provide the advantage of an upper <NUM> having relatively high strength and containment (e.g. "lock in" of a wearer's foot) even when knit as a relatively less dense, single layer, half-gauge structure using every other needle (as compared to a more densely knit structure formed as a "full gauge knit" using every needle of a knitting machine).

It is also contemplated that during the knitting process, the knitting machine may include an additional feeder that includes the component to be inlaid. For example, a feeder may be provided with (or connected to) a spool or other reservoir containing a leather strip or band. The leather strip may be inlaid within the knitted component <NUM>. Of course, materials other than leather may be inlaid within the knitted component depending on the advantageous characteristic to be achieved, including suede, faux leather, nylon, plastic, rubber and the like. One example of an inlay process that may be used to inlay the inlaid component <NUM> of <FIG> is described in <CIT>.

In one example, the inlaid component <NUM> provides an additional gripping characteristic that is advantageous to the wearer when participating in certain activities, including but not limited to skateboarding, soccer, climbing and the like. More specifically, the properties of the inlaid component <NUM> preferably provide at least a portion of the outer surface of the upper <NUM> with a greater or enhanced tackiness and ability to grip or temporarily adhere to another surface, such as a board, ball, wall or other surface. The result may be a greater friction between at least a portion of the upper <NUM> where the inlaid component <NUM> is present and the additional surface, such that the user experiences less slippage and feeling of enhanced tactile quality, feedback and control (e.g., "board feel" when referring to skateboarding, for example). Thus, in one example, one or more inlaid components <NUM> may provide an enhanced grip between the upper <NUM> and a surface of a skateboard, climbing wall and/or ball. In some embodiments, for example (such as that of <FIG>), each course of the knitted component <NUM> may include an inlaid component <NUM>, but this is not required.

As noted above, in addition to the body <NUM>, the upper <NUM> further includes throat area <NUM>. The knitting technique and/or yam(s) used to form the throat area <NUM> may be the same as the knitting technique and/or the yarn(s) used to form the body <NUM> or the yam(s) may be different. In one example, the throat area <NUM> is formed by a different knitting technique than the one used to form the body <NUM>. In one example, the throat area <NUM> may be a rib structure, a rib structure with mesh, a full gauge jersey, double jersey or other suitable knit structures that may be selected to achieve a desired characteristic. As shown in <FIG>, the throat area <NUM> may be a ribbed structure that is a relatively more dense knit structure than the body <NUM>. The throat area <NUM> may be formed at least in part from the fourth yam <NUM> (e.g., the relatively elastic yarn, such as E08 described above, or other relatively elastic yams). While the throat area <NUM> may be exclusively knit by the fourth yarn <NUM>, it is also contemplated that one or more of the first, second and/or third yams <NUM>, <NUM>, <NUM> may be present in the throat area <NUM>. The relatively high degree of stretch and/or elasticity provided by the fourth yarn <NUM> imparts stretch to the throat area <NUM> that may provide ease of entry of a wearer's foot into the void while also allowing the upper to conform to the foot when worn, and enhance comfort and fit.

As noted above, in addition to the body <NUM> and the throat area <NUM>, the upper <NUM> further includes collar <NUM>. The knitting technique and/or yarn(s) used to form the collar <NUM> are different from the knitting technique and/or the yarn(s) used to form the body <NUM> or the throat area <NUM>. The collar is formed by a different knitting technique than the one used to form the body <NUM> and the throat area <NUM>. For example, the collar may be a rib structure, a tubular structure, single full gauge jersey, double jersey or other suitable knit structures that may be selected to achieve a desired characteristic in the collar <NUM>. As shown in <FIG>, the collar <NUM> is a double jersey knit structure that is a relatively more dense knit structure than the body <NUM> and the throat area <NUM>. The collar <NUM> may be formed from the fourth yarn <NUM> (e.g., the relatively elastic yam, such as E08 described above). While the collar <NUM> may be exclusively knit by the fourth yarn <NUM>, it is also contemplated that one or more of the first, second and/or third yarns <NUM>, <NUM>, <NUM> may be present in the collar <NUM>. The relatively high degree of stretch and/or elasticity provided by the fourth yarn <NUM> imparts stretch to the collar <NUM> that may provide ease of entry of a wearer's foot into the void while also allowing the upper <NUM> to conform to the foot when worn, and enhance comfort and fit.

Referring now to <FIG> and <FIG>, the article of footwear <NUM> may include one or more additional components or elements. The additional components or elements may provide additional advantageous characteristics or propertiesThe additional knitted component <NUM> are knitted to form a heel element <NUM>. While the heel element <NUM> may be formed from the first knitted component <NUM> that forms the upper <NUM>, the heel element <NUM> may be formed separately from the upper <NUM>, such as from the second or additional knitted component <NUM>, for example, and then secured to the knitted component <NUM> that forms the upper <NUM>. The heel element <NUM> may be a single, unitary, one-piece structure formed by the additional knitted component <NUM> or it may be formed from multiple pieces that are attached together to form the heel element <NUM>. The heel element <NUM> may be secured to the upper <NUM> by stitching, bonding, adhesives or other suitable mechanisms of coupling or attachment.

It is also contemplated that the heel element <NUM> may be removable, such that attachment to the upper <NUM> may not necessarily be permanent or irreversible in some embodiments. In a non-limiting example, the heel element <NUM> may have one or more holes or apertures <NUM> formed therein which may generally align with one or more of the lace apertures <NUM> formed in the throat area of the upper <NUM>. When a shoelace or other similar securing mechanism is threaded through the one or more apertures <NUM> formed in the heel element <NUM> as well as the lace apertures <NUM> formed in the upper <NUM>, the lace may secure the heel element <NUM> in place, snugly against the first side <NUM> or inner surface of the upper <NUM> within the void <NUM> in the heel area <NUM> of the article of footwear. Heel element <NUM> may provide additional structure, support and form to the heel area <NUM> of the upper, as well as soft hand, breathability, cushioning, comfort and enhanced fit, for example.

One example of a heel element <NUM> is shown in <FIG> and <FIG>. As shown there, the heel element <NUM> generally comprises a central body portion <NUM> with a first arm <NUM> and a second arm <NUM> extending outwardly away from the central body portion <NUM>. The heel element <NUM> has an inner surface <NUM> and an outer surface <NUM>. When properly placed in its intended position within the void <NUM> of the article of footwear <NUM>, the outer surface <NUM> of the heel element <NUM> is adjacent to and/or abut the first side <NUM> of the upper <NUM>. The inner surface <NUM> of the heel element <NUM> would generally face the void <NUM>. The first arm <NUM> would extend towards at least one of the lateral and medial side <NUM>, <NUM> of the upper <NUM>, while the second arm <NUM> would extend towards the other of the lateral and medial side. The central body portion <NUM> of the heel element <NUM> may generally align with a center portion or "spine" of the heel area <NUM> of the upper <NUM>.

As shown in <FIG>, the heel element <NUM> may have an upper or top edge <NUM> extending along the top of the first arm <NUM>, across and along the top of the central body portion <NUM> and along the top of the second arm <NUM>. According to the claimed invention, when the heel element <NUM> is positioned within the void <NUM> of the article of footwear <NUM>, at least a portion of the top edge <NUM> may extend above the first collar <NUM> formed by the upper <NUM>. As such, the top edge <NUM> of the heel element <NUM> forms a second collar <NUM> for receiving the foot of wearer as shown in <FIG>. The central portion of the body portion <NUM> may extend upwards, such that the top edge <NUM> of the body portion <NUM> extends above the top edge <NUM> of the first arm <NUM> and second arm <NUM>. Thus, when the heel element <NUM> is properly placed in its intended position within the void <NUM> of the article of footwear <NUM>, the central portion of the body portion <NUM> of the heel element <NUM> may extend higher upon a wearer's ankle to cover at least a portion of the Achilles tendon, for example.

Furthermore, the heel element <NUM> may comprise a generally consistent knit density throughout, but in other versions, the heel element <NUM> may have different knit densities in different regions. For example, the portion of the heel element <NUM> that extends above the first collar <NUM> of the upper <NUM> may be less densely knit than other portions of the heel element <NUM>. As such, the portions of the heel element <NUM> that lie behind the upper <NUM> and which may be adjacent the first side <NUM> of the upper <NUM> may have a relatively more densely knit structure.

The first arm <NUM> and the second arm <NUM> each have a forward edge <NUM>. A bottom edge <NUM> of the heel element <NUM> extends along the bottom of the first arm <NUM>, across and along the bottom of the central body portion <NUM> and along the bottom of the second arm <NUM>. The heel element <NUM> may be knitted in a generally flat or two-dimensional configuration as it comes off the knitting machine. However, it may be shaped into a three-dimensional configuration before it is placed in its desired location within the void <NUM> of the article of footwear <NUM>. For example, the heel element <NUM> may be shaped on a last to form a gently curved or concaved structure that generally corresponds to the shape of the heel area of the upper <NUM>, such that it is configured to receive the foot of a wearer, for example.

When formed into a three dimensional configuration, such as that shown in one exemplary embodiment of <FIG>, the first arm <NUM> and second arm <NUM> extend generally forward in a direction towards the throat area <NUM> and/or the toe area <NUM> of the article of footwear <NUM>. Thus, it can be seen that the forward edges <NUM> also face in a generally forward direction within the void <NUM>. As previously mentioned, one or both of the first arm <NUM> and the second arm <NUM> may include one or more apertures, openings or holes <NUM> formed therein. In one example, the one or more holes <NUM> formed in either or both of the first arm <NUM> and/or the second arm <NUM> may generally align with one or more of the lace apertures <NUM> formed in the throat area <NUM> of the upper <NUM>. As shown in <FIG>, the first arm <NUM> and the second arm <NUM> each include at least one opening or aperture or hole <NUM> which generally aligns with the top-most lace aperture <NUM> formed in the upper <NUM>. When a lace element is threaded through the lace aperture <NUM> formed in the upper <NUM>, the lace may also extend through the holes <NUM> formed in the first arm <NUM> and the second arm <NUM> formed in the heel element <NUM>.

The heel element <NUM> may include an underfoot portion <NUM> that is configured to extend at least partially under the foot of a wearer. In one example, the underfoot portion <NUM> may be integrally formed with the knitted component <NUM> that forms the heel element <NUM>, such that the heel element <NUM> and the underfoot portion <NUM> are a unitary one-piece structure. In another embodiment, as shown in <FIG>, the underfoot portion <NUM> is a separately formed knitted structure that is attached to the heel element <NUM>. While the underfoot portion <NUM> of <FIG> is a knitted component, it is contemplated that the underfoot portion <NUM> can be formed from other non-knitted textiles or materials.

In one embodiment, the underfoot portion <NUM> may extend only a small distance under the foot of a wearer, such that the underfoot portion <NUM> extends to approximately the biteline <NUM> where the upper <NUM> meets the sole structure <NUM>. In other embodiments, the underfoot portion <NUM> may extend a farther distance underfoot, such as under the ball of the heel of the foot of a wearer. In still further embodiments, the underfoot portion <NUM> may extend still a further distance underfoot, such as far forward as the midfoot region <NUM> of the article of footwear <NUM>. The underfoot portion <NUM> may extend the entire distance between the lateral and medial side <NUM>, <NUM> of the upper <NUM> or the underfoot portion <NUM> may extend only a portion of the distance between the lateral and medial sides. A strobel, insert, liner or midsole structure (not shown) may extend over the top of the underfoot portion <NUM> (sandwiching the underfoot portion <NUM> between the strobel and the upper surface of a sole structure <NUM>, for example) or alternatively, the foot of a wearer may directly contact the underfoot portion <NUM> of the heel element <NUM>.

The heel element <NUM> may be formed by one or more yarns and knitting techniques to impart certain advantageous properties and characteristics. The heel element <NUM> may be formed from a full-gauge knit, half-gauge knit or lesser gauge, and may be a single layer or a double layer structure. In the case of a double-layer structure, a pocket may be formed between the layers which may be configured to receive one or more additional structures or elements, including but not limited to padding and the like. In one example, the heel element <NUM> is formed from a double jersey knit, although it shall be appreciated that other types of knit structures could be used including a single jersey, a ribbed structure, a mesh structure, a jacquard knit structure and combinations thereof.

The heel element <NUM> may be formed of one or more of the same yarns of the first knitted component <NUM> that forms the upper <NUM>, or the yams may be different. In one non-limiting example, the heel element <NUM> comprises the first yarn, second yarn, and third yam <NUM>, <NUM>, <NUM> used to form the body <NUM> of the upper <NUM> as well as the fourth yarn <NUM> used to form the throat area <NUM> and the first collar <NUM> of the upper <NUM>. In addition to the first, second, third and fourth yarns <NUM>, <NUM>, <NUM>, <NUM>, the heel element <NUM> may further include a fifth yarn <NUM>. The fifth yarn <NUM> may be the same as the other yarns or it may be different. In one embodiment, the fifth yam <NUM> may comprise thermoplastic polymer materials. More specifically, the fifth yarn <NUM> may comprise a thermoplastic polyurethane, or TPU. The TPU may be a coated yarn consisting of a multifilament polyester core yarn (150D) that is coated with a TPU resin sheath with a melting temperature of about <NUM>-<NUM> degrees C (having a 750D total yarn size). In one non limiting example, two ends of <NUM> denier TPU yam may be used, which may be sold under the trade name Dream-Sil®, a thermoplastic polyurethane coated yarn manufactured by Sambu Fine Chemical Co.

As such, when the heel element <NUM> is exposed to a stimulus, such as post processing methods including steaming, heat pressing and the like, the resin sheath of the fifth yam <NUM> may melt, whereas the polyester core, having a higher melting temperature, does not. As mentioned above, yams that have a melting temperature below about <NUM> degrees C (or, in this case a resin sheath having a melting temperature below about <NUM> degrees C) may be referred to or identified as a "fusible yam" like the second yam <NUM> formed of thermoplastic polymer materials described above (i.e. the K-<NUM>).

The first, second, third, fourth and fifth yams <NUM>, <NUM>, <NUM>, <NUM>, <NUM> may be knitted together to form the heel element <NUM>, or the yarns may be knitted in certain combinations or patterns. For example, one or more of the yams may be fed together on a particular feeder of a knitting machine or, in another example, a certain course of the knitted component <NUM> may include one or more of the first, second, third, fourth and fifth yams <NUM>, <NUM>, <NUM>, <NUM>, <NUM> or combinations thereof, while another course of the knitted component <NUM> may be formed from others of the aforementioned yarns or combinations thereof.

The fifth yarn <NUM>, or TPU, may preferably have a higher melting temperature than any one or more of the first, second, third and/or fourth yarns <NUM>, <NUM>, <NUM>, <NUM>. The fifth yam <NUM> may impart certain properties that are advantageous for including in a heel element <NUM>, such as, for example, stiffness, rigidity, shape, structure, durability and/or strength. When subjected to heat and/or pressure during a post-processing procedure (and, if desired, placing the heel element <NUM> on a last for molding and shaping) the fifth yarn <NUM> may allow the heel element <NUM> to retain its form and provide the desired rigidity shape and structure. While the fifth yam <NUM> may be present in the entire heel element <NUM> and/or the underfoot portion <NUM> of the heel element <NUM>, the fifth yarn <NUM> may be present in certain areas of the heel element <NUM> and present in only relatively small amounts or entirely absent from the underfoot portion <NUM>.

For example, the fifth yarn <NUM> may be more concentrated in certain areas of the heel element <NUM> and less concentrated in others. This may provide more rigidity and structure to the areas where the fifth yarn <NUM> is more highly concentrated. As shown in <FIG>, the fifth yam <NUM> may be more concentrated in the central zone <NUM> of the central body portion <NUM> from an area just below the second collar <NUM> of the heel element <NUM> to an area adjacent to the bottom edge <NUM>. The fifth yam <NUM> may also extend at least partially into the first arm <NUM> and the second arm <NUM> as necessary and desired to provide the appropriate stiffness, rigidity, shape and structure to the heel element <NUM>.

As shown in <FIG>, the top edge <NUM> of the heel element <NUM> which forms at least a portion of the second collar <NUM> may be formed from the fourth yarn <NUM> (the relatively elastic yam, such as E08 described above, or other relatively elastic yarns). It is also contemplated that the forward edges <NUM> of the first arm <NUM> and the second arm <NUM>, as well as the bottom edge <NUM> of the heel element <NUM> may also be formed from the fourth yarn <NUM>, or other suitable elastic yams. The underfoot portion <NUM> may also be formed from the fourth yam <NUM>, and preferably, the underfoot portion <NUM> may be formed substantially or entirely of the fourth yarn <NUM> or other suitable elastic yarns.

The fourth yarn <NUM> may be more concentrated in certain areas of the heel element <NUM> and less concentrated in others. This may provide more stretch, resilience and compliance to the areas where the fourth yarn <NUM> is more highly concentrated. As shown in <FIG> and <FIG>, the fourth yarn <NUM> may be more concentrated in the top edge <NUM> and/or adjacent the top edge <NUM> including, in one example, the area formed by the second collar <NUM> of the heel element <NUM> that extends above the first collar <NUM> of the upper <NUM>. The fourth yam <NUM> may also be more concentrated in the bottom edge <NUM> and/or in an area adjacent the bottom edge <NUM>, such as an area adjacent to the biteline <NUM>. The concentration of the fourth yarn <NUM> in an area that lies between the first area and the third area, including, for example, central zone <NUM>, may be less concentrated, thus providing a "high-low-high" elastic "gradient" in the heel element <NUM>. The fifth yam <NUM> may also extend at least partially into the underfoot portion <NUM> of the heel element <NUM>.

Once the heel element <NUM> has been knitted and then lasted to form a three-dimensional structure such as that shown in <FIG>, it is inserted through the first collar <NUM> of the upper <NUM> and into the void <NUM> of the article of footwear. The central body portion <NUM> of the heel element <NUM> generally aligns with the center of the heel area <NUM> of the upper <NUM>. The heel element <NUM> may be attached to the upper <NUM> as already described above, and, if apertures or holes <NUM> are present in the first arm and/or second arm <NUM>, <NUM>, a lace element can be fed there through. As such, when the laces are tightened by a wearer, the tension of the laces may pull the heel element <NUM> slightly forward to enhance fit, containment and comfort.

Turning now to <FIG>, a knit program <NUM> used to form at least a portion of the knitted component <NUM> will be described. In other words, the knit program <NUM> described hereinafter forms the portion of the upper <NUM> formed from the first, second and third yarns <NUM>, <NUM>, <NUM>, which, in exemplary <FIG>, is the majority of the upper (referred to herein as the "body" <NUM> of the upper) excluding the throat area <NUM> and/or the collar <NUM>. It is noted that the inlaid component <NUM> is not represented in the knit program <NUM>. Thus, the inlaid component <NUM> may be incorporated into the knitted component <NUM> during the knitting process or it may be inlaid as a separate or additional step following the knitting process.

First, looking to <FIG>, a program view of a knit program is illustrated. As shown, the knitted component <NUM> is formed on a knitting machine having a single bed, although it is contemplated that two beds may be used to form at least a portion of the knitted component <NUM>. It can be seen that the knitting is formed on every other needle of the needle bed, thus forming the previously described half-gauge structure, resulting in a lightweight and at least partially translucent or transparent upper, yet strong and having high containment (or "lock out") due to the use of one or more high tenacity yarns.

The knit diagram illustrates a first course <NUM> knit on a single needle bed. The first course includes a combination of the first yarn <NUM> (the high tenacity polyester) and the second yarn <NUM> (the fusible yarn). The combination of the first yarn <NUM> and the second yam <NUM> is knit on every other needle of the needle bed.

A second consecutive course <NUM> is then knit following the first course <NUM>. The second course <NUM> includes a combination of the second yarn <NUM> (the fusible yam) and the third yarn <NUM> (the high tenacity polyester "sewing thread"). The combination of the second and third yarn <NUM>, <NUM> are tucked on one needle (shown as an upside-down "U" in the diagram) which tucks on top of the first and second yarns <NUM>, <NUM> of the first course <NUM>. Following the tuck stitch of the second course <NUM>, the second and third yarns <NUM>, <NUM> float three needles then knit on the fourth needle. As shown in the knit program <NUM>, this sequence can then be repeated, starting again with a tuck stitch.

A third consecutive course <NUM> is then knit following the second course <NUM>. The third course <NUM> is a repeat of the first course <NUM>, which includes a combination of the first yam <NUM> (the high tenacity polyester) and the second yarn <NUM> (the fusible yam). The combination of the first yarn and the second yarn <NUM>, <NUM> is knit on every other needle of the needle bed.

A fourth consecutive course <NUM> is then knit following the third course <NUM>. The fourth course <NUM> includes a combination of the second yarn <NUM> (the fusible yarn) and the third yam <NUM> (the high tenacity polyester "sewing thread"). The combination of the second and third yams <NUM>, <NUM> are knitted on one needle, then float three needles. Following the three needle float, the combination of the second and third yarns <NUM>, <NUM> are then tucked (shown as an upside-down "U" in the diagram) which forms a tuck stitch on top of the first and second yarns <NUM>, <NUM> of the first course <NUM>. Following the tuck stitch, the second and third yarns <NUM>, <NUM> again float three needles then knit again on the fourth needle. As shown in the knit program <NUM>, this sequence can then be repeated, starting again with the knit loop on the fourth needle following the float sequence.

A fifth consecutive course <NUM> is then knit following the fourth course <NUM>. The fifth course <NUM> is a repeat of the first and third courses <NUM>, <NUM>, which includes a combination of the first yarn <NUM> (the high tenacity polyester) and the second yarn <NUM> (the fusible yarn). The combination of the first yarn and the second yarn <NUM>, <NUM> is knit on every other needle of the needle bed.

The knit sequence of <FIG> may be repeated, as necessary, to form a knitted component with a suitable size. Further, it is noted that the sequence(s) may be varied to incorporate different features by changing certain knit structures, by varying yam types, by increasing or decreasing the number of courses at each step, or by any other suitable adjustment to the knitting process or materials used. Further, other sequences may be used before, after, or between the sequences described above.

Referring now to <FIG> and <FIG>, processing of the knitted component <NUM> and formation of the upper <NUM> for an article of footwear are described. After the entirety of the upper <NUM> is formed, including the body <NUM> of the upper (using the knit sequences described above) and further including the throat area <NUM> and first collar <NUM>, the knitted component <NUM> may be subjected to one or more post-processing methods. In one example, it may be desirable to remove or otherwise eliminate a pre-determined amount of mechanical stretch of the knitted component <NUM> before it is assembled onto a sole structure <NUM> to form an article of footwear <NUM>. In one example, at least a portion of the mechanical stretch may be removed from the knitted component <NUM>, and in other examples, it is preferable to remove substantially all of the mechanical stretch from the knitted component <NUM>.

One non-limiting example of a test method used to illustrate the physical property measurements and stretch of a swatch or test sample of the knitted component <NUM> (comprising the first, second and third yarns <NUM>, <NUM>, <NUM>) is set forth below:.

In the chart above, fabric breaking strength and stiffness were determined using an Instron model <NUM> equipped with Bluehill <NUM> analysis software. Test specimens (<NUM>"x6") were cut in both the machine and cross machine directions and tested using <NUM>" flat faced grips. Samples were tested using a <NUM>" gauge length and a crosshead speed of <NUM> in/min. The breaking strength of the fabric was determined at the point of the first yarn break. Stiffness of the fabric was taken as the load (kgf) at <NUM>% elongation.

In the example above, the stiffness may refer to the force needed to stretch the sample a certain amount. This may provide information relating to how much lock out or containment is provided when this textile is formed into an upper <NUM> for an article of footwear <NUM>. The basis weight may refer to the grams per square meter for the specific sample size used. In other words, this measurement provides a normalized weight of a particular size sample swatch of the textile, which can then be used to calculate different sizes of the textile, such as the weight of an amount of the textile used to form an upper <NUM>.

To remove the desired amount of mechanical stretch, the knitted component <NUM> may first be stretched from its original first unstretched state (see <FIG>) to a second stretched state (see <FIG>). The knitted component <NUM> may be stretched in a cross-machine direction, which comprises stretching the knitted component in a course-wise direction, or width along the x-axis. The knitted component <NUM> may also be stretched in a machine direction, which comprises stretching the knitted component in a wale-wise direction, or length along the y-axis. The knitted component <NUM> may be stretched in only one of these directions, but preferably, the knitted component <NUM> is stretched along both the length and width. When an inlaid component is included (shown in <FIG>), the knitted component <NUM> may be stretched in a direction that is parallel to the inlaid component <NUM>, in a direction that is perpendicular to the inlaid component <NUM>, or both. In one non-limiting example, it was determined that the upper <NUM> had a relatively greater ability to stretch in a direction that is perpendicular to the direction of the inlaid component <NUM> (e.g., since the inlaid component <NUM> may itself be resistant to stretching). For example, where the inlaid component extends in a heel to toe direction, there may be greater stretch in the lateral to medial direction (at least in a pre-processed state). Whereas, where the inlaid component extends generally in a lateral to medial direction, there may be greater stretch in the heel to toe direction. However, it is also contemplated that the inlaid component <NUM> may have little to no effect on the general stretch characteristics of the knitted component <NUM> into which it is inlaid. Further, in embodiments where it is desirable to stretch the knitted component <NUM> in a direction parallel to the lengthwise direction of at least one inlaid component <NUM> (e.g., to remove elasticity in that direction after "processing" as described below), the inlaid component <NUM> may initially include slack, and such slack may be removed during the stretching step such that the inlaid component <NUM> is substantially taught (and/or stretched relative to its relaxed state) after post-knit processing.

It is estimated that above a <NUM>% stretch in both width and length could be a base level that may provide a desirable amount of the desired lockout benefit to a wearer when the knitted component <NUM> is formed into the upper <NUM>. However, stretching less or more than <NUM>% is also contemplated. One example of stretch percentages is illustrated in the chart below. As shown, a <NUM> x <NUM> test swatch of a knitted component <NUM> is stretched in both a length wise and width wise direction. "Unprocessed" refers to a sample of the knitted component <NUM> before stretching and steaming, while "processed" refers to the same sample after stretching and exposure to steam. The unprocessed state has a baseline of <NUM>%, such that after processing (the "processed state") it has been stretched <NUM>% in the width direction and <NUM>% in the length direction. It can be seen that the unprocessed sample weighed <NUM> grams, and, after stretching and steaming, it weighed <NUM> grams. The loss of mass may be attributable to various factors, including but not limited to stretching, where the density of the textile is reduced while the size increases. Also, reduction in mass may also be the result of any fusible material present in the yarns being lost due to the steaming process.

In order to satisfactorily stretch the upper <NUM> in preparation for post-processing methods such as steaming and/or heat pressing, the upper <NUM> may be secured to a stretching mechanism or device. This may include stretching the upper <NUM> in one or more directions with the inlaid component <NUM> present/incorporated into the upper <NUM>. In one example, the stretching device may be a jig <NUM>. As shown in <FIG>, a jig <NUM> may be used to hold and/or position the upper <NUM> during the steaming (heat) process. In other processing methods, the jig <NUM> may be used to hold and/or position the upper <NUM>, or other knitted components (such as the heel element <NUM>) during heating and exposure to pressure, such as by heat pressing. The jig <NUM> may be a separate element from the steaming device and/or, in the case of a heat press, the jig <NUM> may be disposed on a bottom plate of a heat press.

The jig <NUM> may have a top section (not shown) and a bottom section <NUM>, which may be formed using any material, such as rubber or metal or polymers or combinations thereof. If the material used to form the jig <NUM> has a melting temperature, the melting temperature should be above the typical temperature achieved during the steaming or heat-pressing process to ensure that the heat does not disfigure, alter, damage or otherwise negatively affect the jig <NUM>. The shape and configuration of the jig <NUM> is also not limited. In <FIG>, the shape of the jig <NUM> is generally rectangular. Also, the jig <NUM> may be a solid surface or plate, or, as shown in the cut-away portion of the knitted component <NUM> in <FIG>, the jig <NUM> have cut outs or openings formed therein to allow steam or heat or other forms of stimulus to pass through the jig <NUM> and make contact with the knitted component <NUM>.

The jig <NUM> may also include a positioning mechanism or device. As shown, the positioning mechanism includes a plurality of spring-loaded pins <NUM> that are configured to position the upper <NUM> on the jig <NUM>. Here, the shape formed by the plurality of spring-loaded pins <NUM> is substantially the same as the shape of the knitted component <NUM> being stretched and positioned on the jig <NUM>. It is also contemplated that the shape formed by the plurality of pins <NUM> generally corresponds to the shape of an upper <NUM> such that it corresponds with the outer perimeter of the upper <NUM>. The knitted component <NUM> or upper <NUM> may include a plurality of apertures configured to receive the spring-loaded pins <NUM>, and/or the spring-loaded pins may penetrate through the knitted component (or upper) as shown in <FIG> to hold it in position upon and within the jig <NUM>.

The jig <NUM> may further include a pad (not shown) configured to prevent the upper <NUM> from sticking to the jig <NUM> and/or a heat press. The pad may be insulative and/or provide cooling on one or both sides of the upper <NUM>. In one example, the pad may generally be in the shape of the entire upper, or it may be shaped and sized to a particular area of the upper <NUM>. The thickness of the pad may reduce the amount of heat applied and even reduce or substantially prevent the areas of the upper <NUM> not corresponding to a fused area (e.g., the throat area <NUM>) from being steamed and/or pressed, directly heated and/or burned. In one version, the pad is formed of Teflon and is approximately <NUM> thick, though any suitable thickness may be used. The spring-loaded pins <NUM> are configured to compress if necessary during the heat-pressing process such that they do not inhibit the pressure applied to the knitted component <NUM> (e.g., if the spring-loaded pins <NUM> are longer than the thickness of the knitted component <NUM>). In some versions, the jig <NUM> may be configured such that two or more knitted components <NUM> can be processed simultaneously.

When performing a heat pressing process (as opposed to only steaming process) a release paper (not shown) may be placed over certain areas of the knitted component <NUM>. The release paper is preferably constructed of a material that reduces or prevents the certain area of the upper <NUM> from sticking to it and therefore, the release paper may also prevent the certain areas of the knitted component from sticking to the jig <NUM>. The release paper may be configured to allow heat to be conducted to the knitted component <NUM> directly through the release paper and without interfering in the heating process.

For a steaming process, the jig <NUM>, with a knitted component <NUM> secured thereto, may be placed into a steaming mechanism, such as a steam chamber or unit. The knitted component <NUM> may then be subjected to a predetermined temperature of steam heat for a predetermined period of time. When subjected to this steam, the thermoplastic polymer material present in the knitted component <NUM>, such as the thermoplastic polymer material included with a yarn (i.e., the second yarn <NUM> described above, for example), may at least partially melt. As a result, the material originally forming separate yarns of the upper <NUM> may become bonded and/or continuous to form a fused area. In addition the thermoplastic polymer material may at least partially melt with one or more portions of the inlaid component <NUM> (<FIG>) incorporated into the knitted component <NUM>. Therefore, any one or more areas where the upper <NUM> contains thermoplastic polymer material, and where that material is subjected to a suitable process (such as the steaming process described herein), it is contemplated that at least one fused area will be formed. Once the upper <NUM> reaches a predetermined temperature (e.g., enough to activate the fusible yarn, for example) and/or when the upper <NUM> has been subjected to the steaming process for a pre-determined amount of time, the jig <NUM> may be removed from the steam exposure. While steaming and heat-pressing processes are described herein, any other suitable process may be used to form the fused areas.

In the case of a heat pressing process, such as during post-treatment of the heel element <NUM>, the jig <NUM> may be closed (the top section placed over the bottom section <NUM>) and placed into the heat press. The heat press may be preheated to between about l00°C and about <NUM> (or any other suitable temperature range). The press may then be activated. In one process, the heat press may apply approximately <NUM>,<NUM> kPa (<NUM>/cm<NUM>) of pressure at between about <NUM> and about <NUM> for a period of <NUM> seconds. When subjected to this heat and pressure, the thermoplastic polymer material of the knitted component <NUM> which may form the heel element <NUM>, such as the thermoplastic polymer material included with a yam (i.e., the fifth yarn <NUM> described above), may at least partially melt. As a result, the material originally forming separate yams of the heel element <NUM> may become bonded and/or continuous to form at least one, or a plurality of fused area(s). Therefore, any one or more areas where the knitted component <NUM> or <NUM> contains thermoplastic polymer material, and where that material is subjected to a suitable process (such as the heat-pressing process described herein), it is contemplated that a fused area will be formed. The melting of the thermoplastic polymer material to one or more adjacent portions of the inlaid component <NUM> may also serve to hold, secure or lock the inlaid component in place, once cooled. A thermocouple (not shown) may measure the temperature of the knitted component <NUM> or <NUM> during this process. Once the knitted component <NUM> or <NUM> reaches a predetermined temperature (e.g., between about <NUM> and about <NUM>), the heat press may open, and the knitted component <NUM> or <NUM> may be removed. While a heat-pressing process is described, any other suitable process may be used to form the fused areas of the heel element <NUM>.

Next, after steaming (the upper <NUM>) and/or heat-pressing (the heel element <NUM>), the heated knitted component <NUM> and/or <NUM> may be shaped or formed. In one example, the heel element <NUM> formed from the second knitted component <NUM> may be formed on a last or other similar device in order to shape the heel element <NUM> into a concave, three-dimensional structure that would preferably generally confirm to the shape of a heel of a wearer.

Further, after steaming and/or heating (and shaping, if desired) the knitted component <NUM> and/or <NUM> may begin to cool. During cooling, the knitted component <NUM> that forms the upper <NUM>, for example, may remain positioned on the jig <NUM> in its stretched condition. As it cools, the thermoplastic material present in any one of the yarns, such as the second yam <NUM> present in the knitted component <NUM>, may at least partially fuse together with adjacent yams in its proximity to within the knitted component <NUM>. Once cooled, the fusible yam may also enhance one or more mechanical properties of the knitted component <NUM> and/or <NUM> (such as strength and/or rigidity) at least in select locations and/or have the effect of securing or locking the relative positions of the yarns within the knitted component. Because the fusible yarn cooled when the knitted component <NUM> (forming the body <NUM> of the upper <NUM>) is in its stretched condition, the knitted component may therefore remain in this stretched and expanded condition. Likewise, after cooling of the fusible yarn (i.e., the fifth yarn <NUM>) within the knitted component <NUM> (forming the heel element <NUM>) the heel element may therefore have greater stiffness, durability and ability to retain shape, for example.

By stretching the knitted component <NUM> of the upper from a first unstretched condition (<FIG>) to a second stretched condition (<FIG>) and steaming it on the jig <NUM> in the stretched condition, the fusible yams (such as the second yarn <NUM>) may at least partially melt and infiltrate the adjacent and surrounding yarns (such as the first yarn <NUM> and third yarn <NUM>). Upon cooling, the fusible yams can then lock the surrounding yarns into the stretched condition such that this process provides an ability to remove at least a portion, at least half of, substantially all or all of the mechanical stretch of the knitted component <NUM>, as necessary or desired, before it is ultimately removed from the jig <NUM> and later formed into an upper <NUM>.

As an alternative to natural cooling, the knitted component <NUM>, <NUM> may go through a cooling process, such as a cold-pressing process. The cooling process may set the fused area(s) or otherwise bring the fused area into a state other than a melted state. In one example, the knitted component <NUM>, <NUM> may be placed in a cold press. A silicon pad (which may be any other suitable material) may be placed on one or both sides of the knitted component <NUM>, <NUM>, and particularly over the heated and/or partially melted areas, to ensure even pressure. The cold press may include a refrigeration system, but in some processes the cold press is at or about at room temperature. When activated, in one non-limiting example, the cold press may apply approximately <NUM>,<NUM> to <NUM>,<NUM> MPa (<NUM>-<NUM>/cm<NUM>) of pressure for about <NUM> seconds. During the cold-pressing process, the release paper may remain attached to the knitted component <NUM>, <NUM> to prevent the knitted component <NUM>, <NUM> from sticking to the cold press, though this is not required. The cold press can be used in conjunction with a jig similar to the jig <NUM> described with respect to the steaming and/or heat-pressing process.

In some versions, a heat pressing process may be used to attach an auxiliary component, such as the auxiliary interior element <NUM> described above, to the upper <NUM>. While not shown, the auxiliary component <NUM>, which may include a thermoplastic polymer material, may be placed in contact with the upper <NUM> such that it at least partially melts and thereby adheres to the upper <NUM> during a steaming and/or a heat pressing process. Alternatively, or in addition, an auxiliary component <NUM> may be substantially free of a thermoplastic polymer and may be bonded to the upper <NUM> by placing the auxiliary component <NUM> in contact with the heated thermoplastic polymer of the upper <NUM>. This may be done in conjunction with the process of forming the fused areas or may be done at a different time.

While the embodiments and other features are described generally herein with reference to an upper <NUM> for an article of footwear, those features could additionally or alternatively be incorporated into another type of article. For example, the features described herein may be included in articles of apparel (e.g., shirts, pants, socks, footwear, jackets and other outerwear, briefs and other undergarments, hats and other headwear), containers (e.g., backpacks, bags), and upholstery for furniture (e.g., chairs, couches, car seats).

Claim 1:
An article of footwear (<NUM>) having an upper (<NUM>) and a sole structure (<NUM>) secured to the upper, the upper being at least partially formed of a knitted component (<NUM>), the knitted component (<NUM>) comprising:
an outer surface (<NUM>) and an opposite-facing inner surface (<NUM>);
the knitted component (<NUM>) extending through at least a portion of each of a forefoot region, midfoot area (<NUM>), and a heel area (<NUM>) of the article of footwear (<NUM>),
wherein the upper (<NUM>) comprises a knitted body (<NUM>) being formed at least in part from a first yam (<NUM>) having a tenacity of at least <NUM> cN per tex or greater, and wherein the upper comprises a first collar opening (<NUM>), and
wherein the knitted component (<NUM>) further comprises a heel element (<NUM>) located in the heel area (<NUM>) extending from a lateral side (<NUM>) to a medial side (<NUM>) of the upper (<NUM>),
the article of footwear (<NUM>) being characterized in that an outer surface (<NUM>) of the heel element (<NUM>) is adjacent to the inner surface (<NUM>) of the upper (<NUM>), and wherein the heel element (<NUM>) comprises a second collar opening (<NUM>) that extends above the first collar opening (<NUM>).