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.

What 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 2 , wherein the spacer knit structure comprises one or more yarns in the first knit layer and/or the second knit layer that comprise the thermoplastic polymer material. 
     
     
         4 . The knitted component of  claim 3 , wherein each yarn of the one or more yarns is formed entirely of the thermoplastic polymer material. 
     
     
         5 . The knitted component of  claim 3 , wherein each yarn of the one or more yarns comprises a multi-component yarn comprising the thermoplastic polymer material. 
     
     
         6 . The knitted component of  claim 5 , wherein the multi-component yarn comprises a core and a sheath, and wherein the sheath comprises the thermoplastic polymer material. 
     
     
         7 . The knitted component of  claim 1 , 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  claim 1 , 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  claim 1 , 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  claim 1 , 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 11 , 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 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 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  claim 14 , 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  claim 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 20 , further comprising incorporating the upper into an article of footwear. 
     
     
         22 . The method of  claim 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.