Patent Application
20240324724
This application claims the benefit of U.S. Provisional Patent Application No. 63,492,295, filed on Mar. 27, 2023, the entirety of which is hereby incorporated by reference.
Aspects herein are directed to a knitted upper and an article of footwear made therefrom that include a heel portion configured to move between two wear configurations and/or raised structures of varying heights.
A variety of articles, including footwear, are formed of textiles, which are often formed by weaving or interlooping (e.g., knitting) a yarn or a plurality of yarns. In particular, an upper for an article of footwear may be formed from a knitted textile. Additionally, footwear wearers occasionally want to wear footwear without moving the heel portion over the wearer's heel, a tendency that may be more prevalent in knitted uppers due to the relatively flexible nature of the knitted material. However, because conventional footwear having a heel portion is typically not constructed to be worn with the heel portion pushed down, such use can cause the knitted upper to wear more quickly and can be uncomfortable.
Additionally, footwear formed of knitted textiles may include raised structures to provide cushioning or a visual indicator of comfort. However, these raised textiles may interfere with securely joining the upper to a sole structure.
Examples of aspects herein are described in detail below with reference to the attached drawing figures, wherein:
A variety of articles, including footwear, are formed of textiles, which are often formed by weaving or interlooping (e.g., knitting) a yarn or a plurality of yarns. In particular, an upper for an article of footwear may be formed from a knitted textile. Additionally, footwear wearers occasionally want to wear footwear without moving the heel portion over the wearer's heel, a tendency that may be more prevalent in knitted uppers due to the relatively flexible nature of the knitted material. However, because conventional footwear having a heel portion is typically not constructed to be worn with the heel portion pushed down, such use can cause the knitted upper to wear more quickly and can be uncomfortable.
At a high level, aspects herein are directed to a knitted upper and articles of footwear configured to move between a first wear configuration where a heel portion is generally upright and a second wear configuration where the heel portion extends into the foot-receiving void. The material and/or knit construction of the heel portion may help bias the heel portion to fold along folding areas between the heel portion and midfoot portions while maintaining structural integrity to the footwear and comfort to the wearer. More specifically, the knitted component may include a first folding area between the heel portion and the lateral midfoot portion and a second folding area between the heel portion and the medial midfoot portion, where the knitted component folds along the first and second folding areas when moving between the different wear configurations. The first and second folding areas each extend diagonally from the biteline up towards the throat region of the upper.
The entire heel portion may have a greater elasticity than the lateral midfoot portion adjacent the first folding area and the medial midfoot portion adjacent the second folding area. For example, the heel portion may be formed entirely from elastic yarn(s), while the lateral midfoot portion adjacent the first folding area and the medial midfoot portion adjacent the second folding area may be formed at least partially from yarn(s) having less elastic than yarn(s) in the heel portion. In some aspects, this include the lateral and medial midfoot portions adjacent the folding areas having no elastic yarns. Each course or substantially each course within the heel portion may include a plurality of tuck stitches between the first and second surfaces of the heel portion. More particularly, each course or substantially each course may include interlocking tuck stitches in some examples. Further, the lateral midfoot portion adjacent the first folding area and the medial midfoot portion adjacent the second folding area may include no tuck stitches or a lower density of tuck stitches than the heel portion. The tuck stitches, either alone or in combination with the elastic yarn(s) provides resiliency to the heel portion that enables the heel portion to fold inward for the second wear configuration while maintaining structural integrity. As described herein, the wear caused when depressing down a heel portion on traditional footwear reduces comfort, durability, and the ability of the heel portion to return to an upright position easily without user manipulation. In contrast, aspects of the heel portion disclosed herein have an increased resiliency that enables the heel portion to quickly and easily move between depressed and upright positions without changing the shape of the heel portion or causing structural deformation.
Additionally, other aspects of this disclosure relate to raised structures within the knitted component. Generally, footwear may be formed of raised structures to provide cushioning or a visual indicator of comfort, but such structures may interfere with securely joining the upper to a sole structure. As such, aspects herein include a first loft region with first raised structures and a second loft region with second raised structures that are shorter than the first loft region. The second loft region is positioned between the first loft region and an outer perimeter of the knitted component. For example, the second loft region may be positioned between the first loft region and a biteline. Having shorter raised structures adjacent the biteline may allow a more secure joining of the upper with the sole structure. Further, the knitted component may include a non-loft region without raised structures adjacent the second loft region, where the second loft region may be positioned between the first loft region and the non-loft region. The non-loft region may have a smooth or non-planar construction and extend at least partially underfoot to secure the upper to the sole structure.
As used herein, the term “article of footwear” generally includes 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. As used herein, the term “upper” refers to a footwear component that 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 to form a void for receiving a wearer's foot. Illustrative, non-limiting examples of uppers may include uppers incorporated into 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. Further, in other aspects, the upper may also be incorporated into a non-athletic shoe, such as a dress shoe, a loafer, and a sandal. Accordingly, the concepts disclosed with respect to articles of footwear apply to a wide variety of footwear types.
As used herein, the article of footwear and/or the knitted upper may be divided into different general regions. A forefoot region generally includes portions of the article of footwear and/or upper that corresponds to the toes and joints connecting the metatarsals with the phalanges. A midfoot region generally includes portions of the article of footwear and/or upper corresponding with an arch area and an instep area of the foot. A heel region generally corresponds with rear portions of the foot including the calcaneus bone. The upper and article of footwear described herein may include a lateral side, which corresponds with an outside area of the foot (i.e., the surface that faces away from the other foot), and a medial side, which corresponds with an inside area of the foot (i.e., the surface that faces toward the other foot). The different regions and sides described above are intended to represent general areas of footwear to aid in the following discussion and are not intended to demarcate precise areas. The different regions and sides may be applied to the article of footwear as a whole, to the upper, and to the sole structure.
The term “exterior” as used herein means a surface of the upper or article of footwear that faces the external environment. In some aspects, the outer surface may mean the outermost surface of the upper or article of footwear. The term “interior” as used herein means a surface of the upper or article of footwear that faces a void for receiving the wearer's foot. In some aspects, the interior surface may mean the innermost surface of the upper or article of footwear.
The term “knitted component” or “knitted upper” refers to a textile piece that is formed from at least one yarn that is manipulated (e.g., with a knitting machine) to form a plurality of intermeshed loops that define courses and wales. The term “course,” as used herein, refers to a predominantly horizontal row of knit loops (in an upright textile as-knit) that are produced by adjacent needles during the same knitting cycle. The course may comprise one or more stitch types, such as a knit stitch, a held stitch, a float stitch, a tuck stitch, a transfer stitch, a rib stitch, and the like, as these terms are known in the art of knitting. The term “knit stitch,” as used herein, refers to the basic stitch type where the yarn is cleared from the needle after pulling a loop of the yarn from the back to the front of the textile through a previous stitch and may be referred to herein as a “knit loop.” The term “wale,” as used herein, is a predominantly vertical column of intermeshed or interlooped knit loops, generally produced by the same needle at successive (but not necessarily all) courses or knitting cycles. Knitted components described herein may include weft-knitted or warp-knitted components.
The term “integrally knit,” as used herein, may mean a knit textile having a yarn from one or more knitted courses in one area being interlooped with one or more knitted courses of another area. The interlooping may be through a simple knit stitch, a tuck stitch, a held stitch, a float or miss stitch, and the like. In this way, areas that are integrally knit together have a seamless transition.
Additionally, there are various measurements provided herein. Unless indicated otherwise, all measurements provided herein are taken when the upper and/or article of footwear is at standard ambient temperature and pressure (298.15 K and 100 kPa) and is in a resting (non-tensioned) state. Unless indicated otherwise, the term “about” or “substantially” with respect to a measurement means within ±10% of the indicated value.
The article of footwear 100 (and/or its components) can be divided into one or more regions (which can also be referred to as “areas,” or “portions”). For example, in an anterior-to-posterior direction, the article of footwear 100 (and/or its components) can be divided into (and/or include) a forefoot region 108, a midfoot region 110, and a heel region 112. The forefoot region 108 of the article of footwear 100 can correspond to anterior portions of a foot, including toes and joints connecting metatarsal bones with phalanx bones of the foot. The midfoot region 110 of the article of footwear 100 can correspond with an arch area of the foot. The heel region 112 of the article of footwear 100 can correspond with posterior portions of the foot, including a calcaneus bone. In a medial-to-lateral direction, the article of footwear 100 (and/or its components) can be divided into a lateral side 114 and a medial side 116, both of which extend through the forefoot region 108, the midfoot region 110, and the heel region 112. More particularly, the lateral side 114 corresponds with an outside area of the foot (i.e., the side that faces away from the other foot) when the article of footwear 100 is worn, while the medial side 116 corresponds with an inside area of the foot (i.e., the side that faces towards the other foot) when the article of footwear 100 is worn. These regions 108, 110, and 112 and sides 114 and 116 are not intended to demarcate precise areas of the article of footwear 100 but, rather, are intended to represent general areas of the article of footwear 100 to aid in understanding the various descriptions provided herein.
The sole structure 102 generally extends between the foot and the ground when the article of footwear 100 is worn. The sole structure 102 may include multiple components, such as an outsole, a midsole, and an insole or sockliner. Various materials may be used to form the sole structure 102, such as rubber, ethylene vinyl acetate (EVA), thermoplastic polyurethane (TPU), thermoplastic elastomer (e.g., polyether block amide), and the like. The sole structure 102 may also include various other elements, such as a heel counter and a toe cap. The sole structure 102 may include various other features to attenuate forces, enhance stability, and/or provide traction, such as treads, as understood by one skilled in the art.
The upper 104 defines a void within the article of footwear 100 for receiving and securing a foot relative to the sole structure 102. Access to the foot-receiving void is provided by an ankle opening 125 located in at least the heel region 112. The upper 104 includes a throat region 126 disposed in the midfoot region 110 between the ankle opening 125 and the forefoot region 108. The throat region 126 may be configured to cover a top side of the wearer's foot and, therefore, form part of a top side (or overfoot region) of the upper 104 between the lateral side 114 and the medial side 116.
The article of footwear 100 depicted in the figures is intended to be used with a right foot; however, it should be understood that the following discussion may also apply to a mirror image of the article of footwear 100 that is intended for use with a left foot. Although an article of footwear is shown, it should be understood that other articles of wear are also contemplated by the present disclosure, including but not limited to apparel (e.g., shirts, jerseys, pants, shorts, gloves, glasses, socks, hats, caps, jackets, undergarments, or other apparel) and containers (e.g., backpacks, bags, or other containers). As such, various aspects disclosed herein may be incorporated into such other articles of wear.
In example aspects, at least a portion of the upper 104 may be formed from at least one knitted component 130. The knitted component 130 may be formed by a weft-knitting process on a flat knitting machine, for example. In some aspects, the entire or substantially the entire upper 104 may be formed of the knitted component 130.
The knitted component 130 may incorporate various types of yarn that impart different properties to separate areas of the upper 104. That is, one area of the knitted component 130 may be formed from a first type of yarn that imparts a first set of properties, and another area of the knitted component 130 may be formed from a second type of yarn that imparts a second set of properties. In this way, properties may vary throughout the upper 104 by selecting specific yarns for different areas of the knitted component 130. The properties that a particular type of yarn will impart to an area of the knitted component 130 partially depend upon the materials that form the various filaments and fibers within the yarn. Cotton, for example, provides a soft hand, natural aesthetics, and biodegradability. Elastane and stretch polyester each provide substantial stretch and recovery, with stretch polyester also providing recyclability. Rayon provides high luster and moisture absorption. Wool also provides high moisture absorption, in addition to insulating properties and biodegradability. Nylon is a durable and abrasion-resistant material with relatively high strength. Polyester is a hydrophobic material that also provides relatively high durability.
In addition to materials, other aspects of the yarns selected for the knitted component 130 may affect the properties of the upper 104. For example, a yarn forming the knitted component 130 may be a monofilament yarn or a multifilament yarn. As such, unless otherwise specified, the term “yarn,” as used herein, does not require multiple filaments or fibers. The yarn may also include separate filaments that are each formed of different materials. In addition, the yarn may include filaments that are each formed of two or more different materials, such as a bicomponent yarn with filament(s) having a sheath-core configuration or two halves formed of different materials. Different degrees of twist and crimping, as well as different deniers, may also affect the properties of the upper 104. Accordingly, both the materials forming the yarn and other aspects of the yarn may be selected to impart a variety of properties to separate areas of the upper 104. Additional properties of yarn(s) used in various aspects of this disclosure are described in further detail below.
The knitted component 130 may be formed as a single integral one-piece element during a knitting process, such as weft knitting, warp knitting, or any other suitable knitting process. Additional elements, such as an underfoot portion and/or a heel element (including, but not limited to the heel portion 140 described herein) may be integrally formed with the upper 104 as a one-piece unitary structure. Alternatively, one or more such additional elements may be formed separately from the upper 104 and then later attached, secured, or otherwise assembled as necessary. Forming the upper 104 with the knitted component 130 may provide the upper 104 with advantageous characteristics including, but not limited to, a particular degree of elasticity, breathability, bendability, strength, moisture absorption, weight, abrasion resistance, and/or a combination thereof. For example, aspects of this knitted component 130 may enable the upper 104 to change between a first wear configuration to a second wear configuration due to properties in the heel region 112 and portions of the midfoot region 110. Further, forming the upper 104 from an integrally knit knitted component may form various features and structures of the upper 104 without the need for significant additional manufacturing steps or processes, thereby increasing production efficiency.
Aspects of the upper 104 can be adjusted between at least two different wear configurations so that the article of footwear 100 may be worn in different manners. For example, a first wear configuration of the upper 104 is shown in
In the first wear configuration, the heel portion 140 of the knitted component 130 is in an upright position. It should be understood that the term “upright position” as used herein to refer to the heel portion 140 in the first wear configuration contemplates that the heel portion 140 may curve and/or slant such that it is not strictly perpendicular to a ground-contacting surface. Rather, the heel portion 140 may be considered in an upright position when it extends away from the sole structure 102. In another way, the heel portion 140 may be considered in an upright position when it generally defines the rear portion of the foot-receiving void such that an interior surface 133 (shown in
To move from the first wear configuration in
When in the second wear configuration of
When the article of footwear 100 is in the second wear configuration, the ankle opening 125 of the upper 104 is no longer defined by the first edge 142 of the heel portion 140. Rather, the ankle opening 125 may be defined by the rearward edge 128 of the throat region 126 and either by the biteline 106 between the upper 104 and the sole structure 102 or, in aspects in which part of the knitted component 130 remains upright, by a lower part 143 of the knitted component 130 in the heel region 112. In this way, the ankle opening 125 changes from a first configuration when the heel portion 140 is extended upwards and a second configuration when the heel portion 140 is extended inwards. The ankle opening 125 may be larger in the second configuration than in the first configuration.
In some embodiments, the sole structure 102 is shaped to aid in easy access of the foot when the article of footwear 100 is in the second wear configuration. For example, in some aspects, a top surface of the sole structure 102 has a concave portion forming a depression 105. The depression 105 is located in the heel region 112. The top surface of the sole structure 102 at the depression 105 is lower than or positioned inferior to the top surface of the midsole in the regions immediately adjacent the depression 105, such as a lateral elevated or raised surface 103 of the midsole positioned laterally of the depression 105 and a similar medial elevated or raised surface positioned medially of the depression 105. In some aspects, the depression 105 is centrally located in the heel region 112 between the lateral side 114 and the medial side 116 and may align with a heel seam 122, described further below. The width of the depression 105 may be measured as a distance between the lateral raised surface 103 and the medial raised surface, and the width may be at least five centimeters in some aspects, at least 6.5 centimeters in some aspects, or at least 8 centimeters in some aspects. As such, the depression 105 may be wide enough to provide unobstructed access to the ankle opening 125 when the heel portion 140 is pushed inwards. In this way, a wearer can easily slide the wearer's foot into the article of footwear 100 when it is in the second wear configuration.
Returning to the knitted component 130, the heel portion 140 is integrally knit with the lateral and medial midfoot portions 120a and 120b along the first and second folding areas 132 and 134, respectively. As such, the upper 104 has seamless transitions between the heel portion 140 and the first and second folding areas 132 and 134, between the first folding area 132 and the lateral midfoot portion 120a, and between the second folding area 134 and the medial midfoot portion 120b.
The first folding area 132 and the second folding area 134 each extends diagonally from the rearward edge 128 of the throat region 126 (which may also be considered a forward edge of the ankle opening 125) towards the lower part 143 of the heel portion 140. In some aspects, the first and second folding areas 132 and 134 each extend to the biteline 106. Further, in some aspects, a lateral part and a medial part of the heel portion 140 are joined by the heel seam 122, and the first and second folding areas 132 and 134 may each extend to the heel seam 122. When in the first wear configuration, the first folding area 132 extends downward from a lateral midpoint 127 of the ankle opening 125, while the second folding area 134 extends downward from a medial midpoint 129 of the ankle opening 125. In some embodiments, the lateral midpoint 127 is the lowest-most point of the ankle opening 125 on the lateral side 114, and the medial midpoint is the lower-most point of the ankle opening 125 on the medial side 116. In some aspects, the lateral midpoint 127 and the medial midpoint 129 may each be closer to the back end of the ankle opening 125 than the front end of the ankle opening 125.
The knitted component 130 may be biased to fold along the first and second folding areas 132 and 134 when a force is applied to the exterior surface 135 of the knitted component to push the heel portion 140 into the foot-receiving void of the upper 104. This biasing may be achieved by varying the type of yarn between the heel portion 140 and the lateral and medial midfoot portions 120a and 120b that are adjacent the first and second folding areas 132 and 134. Additionally or alternatively, the biasing may be achieved by varying the knit construction between the heel portion 140 and the lateral and medial midfoot portions 120a and 120b that are adjacent the respective first and second folding areas 132 and 134.
For example, in some examples, the heel portion 140 has a higher elasticity than the lateral midfoot portion 120a (or at least the part of the lateral midfoot portion 120a that abuts the first folding area 132) and a higher elasticity than the medial midfoot portion 120b (or at least the part of the medial midfoot portion 120b that abuts the second folding area 134). In one aspect, the heel portion 140 has a greater concentration or density of elastic yarn than the portions of the lateral and medial midfoot portions 120a and 120b that abut the respective folding areas 132 and 134. All of the yarns forming the heel portion 140 may be elastic yarn(s), which may refer to yarn(s) having elastane, while the lateral and medial midfoot portions 120a and 120b may contain non-elastic yarns or yarns having less elastane than yarns in the heel portion 140. In some aspects, the lateral and medial midfoot portions 120a and 120b may contain some elastic yarns in combination with non-elastic yarns, but nonetheless have less elastic yarns or yarns with lower elastic concentration than yarn(s) forming the heel portion 140. In one example, the lateral and medial midfoot portions 120a and 120b each have one or more non-elastic yarns forming courses on one surface and one or more elastic yarns forming courses on the opposite surface. In contrast, the heel portion 140 may have elastic yarns forming both surfaces while having no non-elastic yarns. In one example, at least one non-elastic yarn used to form the lateral and midfoot portions 120a and 120b is polyester.
Aspects of the heel portion 140 may also include goring or wedging to create three-dimensional shaping or curvature to the heel portion 140. In this way, the heel portion 140 may be shaped to fit around the contours of a wearer's heel to avoid slippage when the article of footwear 100 is in the first wear configuration. The combination of the elastic yarns forming the heel portion 140 and the goring may help to maintain the proper fit of the heel portion 140 around the wearer's heel when in the first wear configuration. This may be particularly important when the footwear 100 does not include traditional support structures for the heel (e.g., heel counter reinforcements), as such structures could interfere with the ability of the heel portion 140 to fold down into the second wear configuration and/or the comfort of the footwear 100 in the second wear configuration. In some aspects, the exterior surface 135 of the heel portion 140 may include support and/or cushioning elements as described with respect to
Further, in some aspects, the heel portion 140 has courses forming a first surface and courses forming a second surface (where these are collectively referred to herein as a set of courses). The heel portion 140 has a higher density of tuck stitches of yarns between courses on the first surface and courses on the second surface (e.g., tuck stitches formed between the front and back knitting beds) compared to the density of tuck stitches in the lateral midfoot portion 120a (or at least the part of the lateral midfoot portion 120a that abuts the first folding area 132) and a higher density of tuck stitches compared to the density of tuck stitches in the medial midfoot portion 120b (or at least the part of the medial midfoot portion 120b that abuts the second folding area 134).
In some aspects, the heel portion 140 includes tuck stitches formed on every needle in the front and back needle beds. Every set of courses in the heel portion 140 may include tuck stitches. Further, in some aspects, the heel portion 140 has interlocking tuck stitches where a first set of tuck stitches intersects with a second set of tuck stitches as the yarn extends between front and back beds. An example stitch diagram showing the interlocking tuck stitches is described further herein with respect to
The resiliency of the heel portion 140, through the higher elasticity and/or the higher density of tuck stitches, enables the article of footwear 100 to move between the first and second wear configurations with ease and comfort while maintaining structural integrity. When heel portions on traditional footwear are depressed (such as something similar to the second wear configuration), the heel portions undergo structural deformation and, as a result, fail to return to an upright position without significant wearer manipulation of the heel portion. The structural deformation also results in reduced comfort and durability. However, the resiliency of aspects of the heel portion 140 disclosed herein enables the heel portion 140 to return from a depressed position (first wear configuration) to an upright configuration (second wear configuration) without changing the shape of the heel portion 140 or reducing the structural integrity, even after multiple wears and/or long-term wear in the second wear configuration. Additionally, the increased resiliency of the heel portion 140 enables the heel portion 140 to return more quickly from the second wear configuration to the first wear configuration. For example, the heel portion 140 may be configured to remain in a depressed position for the second wear configuration once the heel portion 140 is pressed down, such as by a wearer's foot, but it can return to an upright position for the first wear configuration by minimal force from the wearer, such as a simple flick of the heel portion 140 that causes the heel portion 140 to quickly return to the upright position.
In various aspects, the first folding area 132 and the second folding area 134 each comprise a knitted tubular structure.
In areas adjacent the first and second folding areas 132 and 134 (e.g., the heel portion 140 and either the lateral midfoot portion 120a or the medial midfoot portion 120b), the knitted component 130 may include a single layer. Alternatively, the knitted component 130 in these areas adjacent the first and second folding areas 132 and 134 may include multiple layers where at least one yarn extends between the two layers to keep the yarns integrated together (i.e., not separable). Further, in some aspects, the first layer 502 and second layer 504 of the tubular structures in the first and second folding areas 132 and 134 may each be formed with one or more elastic yarns. In some aspects, all of the yarns forming the first and second folding areas 132 and 134 are elastic.
These tubular structures may each extend along the lengths of the respective folding areas 132 and 134. As such, the tubular structures may extend diagonally from the rearward edge 128 of the throat region 126 to the biteline 106 in a rearward part of the heel region 112, which may be the heel seam 122. In some aspects, while the tubular structures extend along the folding areas 132 and 134, tubular structures may be absent from the heel portion 140 of the knitted component 130.
Further, the upper 104 may include a tensioning element 150 that extends through the channel 506 in the first folding area 132 and in the second folding area 134. The tensioning element 150 may comprise one or more strands of a yarn comprising any material suitable for applying tension for the article of footwear 100, such as nylon, polyester, or cotton. The tensioning element 150 may be one of various types of cables, such as a braided cable, with a greater diameter than any single strand of yarn forming the knitted component 130. The tensioning element 150 may also have a higher tenacity and/or tensile strength than any strand of yarn forming the knitted component 130. Further, the tensioning element 150 may comprise polyester, nylon, or other high-tenacity materials. In some examples, the tensioning element 150 also includes elastane.
The tensioning element 150, in some examples, comprises a single cable having any of the above properties that extends through both the first folding area 132 and the second folding area 134. In aspects that have the tensioning element 150 extending through the channel 506, the knitted component 130 may be biased to fold between the heel portion 140 and the tensioning element 150 within the channel 506 in the first folding area 132 and in the second folding area 134 to switch between the first and second wear configurations. The presence of the tensioning element 150 within the channel 506 may aid in the knitted component 130 being biased to fold between the heel portion 140 and the tensioning element 150.
While the fold may occur between the tensioning element 150 and the heel portion 140 in some parts of the first folding area 132 and the second folding area 134, the fold may occur in different locations for other parts, such as the posterior portion of the upper 104.
In any of these examples, the fold in the posterior aspect of the heel region 112 may occur slightly above the top surface of the sole structure 102 (for example, at the depression 105). For example, the lower part 143 of the knitted component 130 and, in some aspects, at least part of the first and second folding areas 132 and 134 remain upright when the heel portion 140 is folded inward to form a ridge along the ankle of the ankle opening 125. Such a ridge may help keep a wearer's foot nestled in place without inadvertently sliding out when the footwear 100 is worn in the second wear configuration. Alternatively, the knitted component 130 may fold so that the knitted component 130 is substantially flush with the depression 105 of the sole structure 102 when in the second wear configuration. Some embodiments of the upper 104 includes the channel 506 in each of the first folding area 132 and the second folding area 134, but does not include the tensioning element 150.
As described, the tensioning element 150 is positioned around the entire or substantially the entire ankle opening 125 in the second wear configuration, and as such, the tensioning element 150 helps ensure a proper fit and secures the upper 104 around an ankle of the wearer when in the second wear configuration. Further, when in the first wear configuration, the tensioning element 150 extends around at least the anterior portion (or anterior boundary) of the ankle opening 125 and extends from the throat region 126 at the ankle opening 125 down to the lower part 143 of the knitted component 130 adjacent the biteline in the posterior aspect of the heel region 112. This placement of the tensioning element 150 also helps to secure the wearer's heel (and therefore the wearer's foot) in the upper 104 when the footwear is in the first wear configuration. Aspects of the upper 104 may lack other fastening or tensioning components, such as laces, in the throat region 126. Further, the tensioning element 150 in the first and second folding areas 132 and 134 may be the only source of tension for fastening the footwear 100 around the wearer's foot.
While some of the tensioning element 150 extends between first and second layers 502 and 504 of the knitted component 130, the tensioning element 150 may also include an exposed segment 152 that is outside of the knitted component 130. The exposed segment 152 may extend out from the knitted component 130 through an opening at the end of the tubular structure of the first folding area 132 and an opening at the end of the tubular structure of the second folding area 134. The exposed segment 152 of the tensioning element 150 may be positioned in the throat region 126 and may be near the ankle opening 125. The length of the exposed segment 152 may be increased or decreased to adjust the tension of the tensioning element 150 and, therefore, adjust the fit of the knitted component 130 around the wearer at the ankle opening 125 when the footwear 100 is in either the first wear configuration or the second wear configuration. As illustrated in the figures, the upper 104 may include a toggle 154 or other adjustment mechanism around the exposed segment 152 of the tensioning element 150.
In some aspects, the tensioning element 150 is a single continuous cable extending through both the first folding area 132 and the second folding area 134. However, it is contemplated that the first and second folding areas 132 and 134 may contain distinct tensioning elements, which may either join together (through a tie or fastening structure, for example) or may remain separate from one another. Further, there may be multiple tensioning elements 150 within a single channel in the first folding area 132 and/or the second folding area 134.
Although not shown, the article of footwear 100 may optionally include a tongue that is at least partially detached from the rest of the knitted component 130 and eye stays adapted to receive a lace, which may be in addition to or instead of the tensioning element 150.
Turning to
Row 602 represents the yarn 610 forming knit loops (e.g., knit loop 612) being knit primarily on needles on the first needle bed (e.g., a front needle bed). In some aspects, at the beginning and/or at the end of row 602, the yarn 610 may be knit to form stitches, such as knit loops) on the second needle bed, but the majority of the stitches represented in row 602 are made on the first needle bed. Row 604 represents the yarn 610 forming a first set of tuck stitches (e.g., tuck stitch 614) that alternate between needles on the first needle bed and needles on the second needle bed. Row 604 may also include one or more knit loops of the yarn 610 formed on either the first needle bed or the second needle bed at the beginning and/or end of the row 604. Row 606 represents the yarn 610 forming knit loops being knit primarily on needles on the second needle bed (e.g., a back needle bed). The beginning and/or the end of row 606 may include stitches, such as knit loops, of the yarn 610 formed on the first needle bed, but the majority of the stitches represented in row 606 are made on the second needle bed. Row 608 represents the yarn 610 forming a second set of tuck stitches that alternate between needles on the first needle bed and the second needle bed. The front and back tuck stitches in the second set of tuck stitches in row 608 may be offset from the front and back tuck stitches, respectively, in the first set of tuck stitches in row 604 such that, where the yarn 610 is tucked on a front needle in row 604, the yarn is tucked on a back needle in row 608 and vice versa. As such, the first set of tuck stitches in row 604 and the second set of tuck stitches in row 608 may be considered as collectively forming interlocking tuck stitches because the yarn 610 crosses over itself as these two sets of tuck stiches cross between the front and back surfaces of the knitted component being formed. Row 608 may also have the yarn 610 forming one or more knit loops on either the first needle bed or the second needle bed at the beginning and/or end of the row 608.
These two sets of interlocking tuck stitches shown in
Further, the additional heel component 700 may include a cushion structure to provide additional cushioning underneath the wearer's heel when the article of footwear 100 is in the second wear configuration. This cushion structure may be on the interior surface 133 of the heel portion 140 or on the exterior surface 135. Such an additional heel component 700 may provide anti-slippage benefits in the first wear configuration when it is placed on the interior surface 133 and in the second wear configuration when it is placed on the exterior surface 135. Some aspects of the upper 104 include an additional component on both the interior surface 133 and the exterior surface 135. In one aspect, the article of footwear 100 includes a cushion structure in the form of a foam component covered by a textile component and heat pressed to the interior surface 133 of the heel portion 140.
Some aspects of the article of footwear 100 include integrally knit raised structures. The integrally knit raised structures are formed such that they extend outward on the exterior side of the knitted component 130. Various aspects of the disclosure include the knitted component 130 having raised structures of different heights in different regions of the upper 104.
The first loft region 802 having the first set of raised structures 182 is located in the throat region 126. The first loft region 802 may extend from the forefoot region 108 of the upper 104 towards the ankle opening 125. As such, the first loft region 802 may extend through the midfoot region 110 and into at least part of the heel region 112. Some portions of the first loft region 802 extend at least halfway down the lateral side 114 between the throat region 126 and the biteline 106 and at least halfway down the medial side 116 between the throat region 126 and the biteline 106. The second loft region 804 may be positioned between the first loft region 802 and an outer perimeter 810 of the knitted component. When the knitted component 130 is incorporated into the article of footwear 100, the second loft region 804 may extend adjacent the biteline 106 on the lateral side 114 and the medial side 116. The second loft region 804 may extend from the forefoot region 108 of the upper 104 towards the ankle opening 125. As such, the second loft region 804 may extend through the midfoot region 110 and into at least part of the heel region 112.
Further, in aspects having the non-loft region 806, the non-loft region 806 may be adjacent the outer perimeter 810 of the knitted component 130 and may extend from the forefoot region 108 of the upper 104 through midfoot region 110 and the heel region 112. The second loft region 804 be positioned between the first loft region 802 and the non-loft region 806. The non-loft region 806 at least partially extends underneath the foot when the knitted component 130 is folded into the shape of the upper 104 and may extend over a superior-facing surface of the sole structure 102. As such, the non-loft region 806 is secured to the sole structure 102, and the non-loft region 806 may be fully or at least partially obscured from view when the upper 104 is secured to the sole structure 102.
Having a larger raised structure 182 of the first loft region 802 located throughout the throat region 126 and, in some aspects, throughout the majority of the overfoot portion of the upper 104, may create increased cushioning and provides a strong visual indicator of comfort. At the same time, the non-loft region 806 with a smoother texture adjacent the outer perimeter 810 of the knitted component 130 provides a more planar surface to which the sole structure 102 can secure, which helps the joining process be more efficient and enables a more secure connection between the upper 104 and the sole structure 102. Further, positioning the second loft region 804 between the first loft region 802 and the non-loft region 806 creates a transition between the larger raised structures 182 and the smoother, more planar surface of the non-loft region 806. This transition may be more aesthetically pleasing than a drastic change between the first loft region 802 and the non-loft region 806. Additionally, in some aspects, the second loft region 804 extends to the biteline 106 when the upper 104 is secured to the sole structure 102, and positioning smaller raised structures 184 adjacent the biteline 106 instead of the larger raised structures 182 allows a smoother joining of the upper 104 and the sole structure 102 at the biteline 106.
Further, while this disclosures utilizes the article of footwear 100 as an example article for incorporating the knitted component 130 with raised structures 182 and 184, it should be understood that aspects of this disclosure may apply to other articles, such as articles of apparel. As such, embodiments may include an article of apparel, such as a shirt or pair of shorts, that has a first loft region with taller raised structures, similar to the first loft region 802; a second loft region with shorter raised structures, similar to the second loft region 804; and a non-loft region without raised structures, similar to the non-loft region 806, where the non-loft region may be adjacent an edge (e.g., neckline, hem, etc.) of the article of apparel, and the second loft region may be positioned between the non-loft region and the first loft region to serve as a transition between the textures of the two regions.
A first raised structure 182a within the first loft region 802 has a first height 912a extending between the first surface 902 and the second surface 904, and a second raised structure 182b within the first loft region 802 has a height 912b between the first surface 902 and the second surface 904. The first height 912a is greater than the second height 912b. In some aspects, the first height 912a is at least 25% greater than the second height 912b, at least 50% greater than the second height 912b, or at least 150% greater than the second height 912b.
Further, the raised structure 184 in the second loft region 804 has a height 914 between the first surface 902 and the second surface 904. Generally, in exemplary aspects, each of the raised structures 182 within the first loft region 802 are taller than each of the raised structures 184 in the second loft region 804. As such, heights 912a and 912b are each greater than height 914. For brevity, the height of any given raised structure within the first loft region 802 may be referred to as 912. In some aspects, the height 912 of a raised structure 182 in the first loft region 802 is at least 100% greater than the height 914 of a raised structure 184 in the second loft region 804, at least 150% greater than the height 914, or at least 200% greater than the height 914.
In some aspects, the raised structures 182 and 184 are formed by a first knit layer 932 and a second knit layer 934, with yarn extending between the first and second knit layers 932 and 934. For instance, the first surface 902 may be formed by the first knit layer 932 and the second surface 904 may be formed by the second knit layer 934. In areas corresponding to the raised structures 182 and/or 184, the first and second knit layers 932 and 934 are unsecured to each other to create a cavity 936 where the first and second knit layers 932 and 934 are separable. Adjacent the raised structures 182 and 184, the knitted component 130 includes secured areas 906 where the first and second knit layers 932 and 934 are secured together such that they are not separable from one another. In some embodiments, the first and second knit layers 932 and 934 are secured together in secured areas 906 by at least one yarn forming one of the layers interlooped with yarn forming the other layer. Further, in some aspects, the first and second knit layers 932 and 934 are secured together in secured areas 906 by using elastic yarns, which may further enhance the degree to which the first and second layers 932 and 934 are secured together.
The first knit layer 932 may be formed by at least a first yarn, and the second knit layer 934 may be formed by at least a second yarn. Within the cavity 936 of each raised structure 182 or 184, a third yarn 938 (or plurality of third yarns or strands) may float between the first and second knit layers 932 and 934. The third yarn 938 may be an expandable yarn such that, when the third yarn 938 is knitted within the first and second knit layers 932 and 934 in the secured areas 906, the third yarn 938 has a first diameter, and when the third yarn 938 is unsecured and floating between the first and second knit layers 932 and 934 in the cavities 936 of the raised structures 182 or 184, the third yarn 938 has a second diameter that is greater than the first diameter. In this way, the third yarn 938 may expand within the cavity to cause the first knit layer 932 and/or the second knit layer 934 to extend outward, thereby creating the raised structures 182 and 184. In some aspects, there is a single end of the third yarn 938 floating within the cavity 936 of the raised structures. Alternatively, there may be multiple third yarns 938 (of either the same or different yarn type) floating within the cavity 936.
In some aspects, at least within the raised structures 182 and 184, the second knit layer 934 is formed by a yarn having a higher elasticity than the yarn forming the first knit layer 932. In some aspects, a majority of the surface area of the portion of second knit layer 934 that corresponds to the raised structures 182 and 184 is formed from one or more elastic yarns or at least yarn having a higher elasticity than yarn forming the first knit layer 932. In some aspects, the entire portion of the second knit layer 934 that corresponds to the raised structures 182 and 184 is formed from one or more elastic yarns or at least yarn having a higher elasticity than yarn forming the first knit layer 932. In this way, the second knit layer 934 is more elastic than the first knit layer 932 within the raised structures 182 and 184. Having a higher elasticity in the second knit layer 934 keeps the second knit layer 934 from expanding outward due to the floating third yarn(s) 938, and instead, all or substantially all of the loft created by the third yarn(s) 938 pushes out the first knit layer 932.
It should be understood that aspects of this disclosure may apply to knitted components, and articles (including articles of apparel and articles of footwear) having the knitted component 130, where the knitted component 130 includes the raised structures (e.g., raised structures 182 and/or 184) described herein without including features of the heel portion 140 and first and second folding areas 132 and 134. Further, some aspects of this disclosure apply to knitted components and articles of footwear having the knitted component 130 with the disclosed heel portion 140 and first and second folding areas 132 and 134 without having the raised structures 182 and 184. Further, some aspects of the disclosure include knitted components and articles of footwear with the heel portion 140, first and second folding areas 132 and 134, and the raised structures 182 and 184.
The following clauses represent example aspects of concepts contemplated herein. Any one of the following clauses may be combined in a multiple dependent manner to depend from one or more other clauses. Further, any combination of dependent clauses (clauses that explicitly depend from a previous clause) may be combined while staying within the scope of aspects contemplated herein. The following clauses are examples and are not limiting.
Clause 1: An article of footwear comprising: an upper comprising a knitted component comprising a heel portion, a lateral midfoot portion, and a medial midfoot portion, the heel portion being integrally knit with the lateral midfoot portion along a first folding area and integrally knit with the medial midfoot portion along a second folding area, the knitted component being biased to fold inward along the first folding area and the second folding area when force is applied to an exterior side of the heel portion so that the heel portion is folded down and extends inwards into a foot-receiving void defined by the upper.
Clause 2: The article of footwear of clause 1, wherein the knitted component defines an ankle opening of the upper, the ankle opening having a first configuration when the heel portion is extended upwards and a second configuration when the heel portion is extended inward.
Clause 3: The article of footwear of clause 2, wherein, in the first configuration, the ankle opening has a lateral midpoint and a medial midpoint, wherein the first folding area extends downward from the lateral midpoint of the ankle opening, and the second folding area extends downward from the medial midpoint of the ankle opening.
Clause 4: The article of footwear of clause 3, wherein the lateral midpoint is the lower-most point of the ankle opening on the lateral side, and the medial midpoint is the lower-most point of the ankle opening on the medial side.
Clause 5: The article of footwear of any of clauses 1-4 further comprising a sole structure secured to the upper, and a biteline where the sole structure meets the upper.
Clause 6: The article of footwear of clause 5, wherein the first folding area and the second folding area each extends diagonally upward from the biteline.
Clause 7: The article of footwear any of clauses 1-6, wherein the first folding area and the second folding area each comprises a first layer and a second layer integrally knit together, the first layer and the second layer being partially unsecured to form a channel between the first layer and the second layer.
Clause 8: The article of footwear of clause 7, further comprising a tensioning element extending through the channel.
Clause 9: The article of footwear of clause 8, wherein the knitted component is biased to fold along the first folding area and the second folding area between the tensioning element and the heel portion.
Clause 10: An article of footwear comprising: an upper having a heel region comprising an interior surface and an exterior surface; the upper comprising a knitted component comprising a heel portion, a lateral midfoot portion, and a medial midfoot portion, the heel portion forming at least part of the interior surface and at least part of the exterior surface in the heel region of the upper, the heel portion being integrally knit with the lateral midfoot portion and with the medial midfoot portion, the entire heel portion of the knitted component having a greater elasticity than the lateral midfoot portion and the medial midfoot portion.
Clause 11: The article of footwear of clause 10, wherein the heel portion of the knitted component comprises courses forming the interior surface and courses forming the exterior surface opposite the interior surface, and a plurality of tuck stiches securing courses forming the interior surface to courses forming the exterior surface.
Clause 12: The article of footwear of any of clauses 10-11, wherein the upper includes a first folding area between the heel portion and the lateral midfoot portion and a second folding area between the heel portion and the medial midfoot portion.
Clause 13: The article of footwear of clause 12, wherein the first folding area and the second folding area each include a knitted tubular structure extending between a first knit layer and a second knit layer.
Clause 14: The article of footwear of any of clauses 10-13, wherein the heel portion consists of one or more elastic yarns.
Clause 15: The article of footwear of any of clauses 10-14, further comprising a sole structure secured to the upper, wherein the heel portion is integrally knit with the lateral midfoot portion along a first folding area and integrally knit with the medial midfoot portion along a second folding area, wherein in a first configuration, the heel portion extends upward away from the sole structure, and when in a second configuration, the heel portion extends into a foot-receiving void defined by the upper.
Clause 16: An article of footwear comprising a knitted component, the knitted component comprising: a first knit layer forming a first surface and a second knit layer forming a second surface; a plurality of secured areas where at least one yarn is interlooped in the first knit layer and interlooped in the second knit layer; a plurality of raised structures where the first knit layer is unsecured to and extends away from the second knit layer; a first loft region comprising first raised structures from the plurality of raised structures, each first raised structure extending a height between the first surface and the second surface; and a second loft region comprising second raised structures from the plurality of raised structures, each second raised structure extending a height between the first surface and the second surface, the height of each second raised structure being less than the height of each first raised structure, wherein the second loft region is positioned between the first loft region and an outer perimeter of the knitted component.
Clause 17: The article of footwear of clause 16, wherein the knitted component forms at least a portion of an upper and the article of footwear further comprises a sole structure secured to the upper.
Clause 18: The article of footwear of clause 17, wherein the second loft region extends along portions of a biteline where the upper meets the sole structure.
Clause 19: The article of footwear of any of clauses 17-18, wherein the knitted component comprises a non-loft region where the first knit layer remains secured to the second knit layer, the non-loft region is positioned between the second loft region and the outer perimeter of the knitted component, and the non-loft region extends over a superior-facing surface of the sole structure.
Clause 20: The article of footwear of any of clauses 17-19, wherein the knitted component comprises one or more strands that, in the plurality of secured areas, are interlooped with yarn in at least one of the first knit layer and the second knit layer and that, in the plurality of raised structures, float within a cavity between the first knit layer and the second knit layer.
Clause 21: An article of footwear comprising: an upper comprising a knitted component comprising a heel portion, a lateral midfoot portion, and a medial midfoot portion, the heel portion being integrally knit with the lateral midfoot portion along a first folding area and integrally knit with the medial midfoot portion along a second folding area, the knitted component defining an ankle opening of the upper, and the knitted component being configured to move between a first wear configuration where the heel portion extends upwards and a second wear configuration where the heel portion is extended inwards into a foot-receiving void of the upper, wherein the ankle opening defined by the knitted component is larger in the second wear configuration than in the first wear configuration.
Clause 22: The article of footwear of clause 21, wherein, in the first wear configuration, the ankle opening has a lateral midpoint and a medial midpoint, wherein the first folding area extends downward from the lateral midpoint of the ankle opening, and the second folding area extends downward from the medial midpoint of the ankle opening.
Clause 23: The article of footwear of clause 22, wherein the lateral midpoint is the lower-most point of the ankle opening on the lateral side, and the medial midpoint is the lower-most point of the ankle opening on the medial side.
Clause 24: The article of footwear of any of clauses 21-23, further comprising a sole structure secured to the upper along a biteline, wherein the first folding area and the second folding area each extends diagonally upward from the biteline.
Clause 25: The article of footwear of any of clauses 21-24, wherein the heel portion has a greater elasticity than each of the lateral midfoot portion and the medial midfoot portion.
Clause 26: The article of footwear of any of clauses 21-25, wherein the heel portion has a greater density of tuck stitches than the lateral midfoot portion and the medial midfoot portion.
Clause 27: The article of footwear of any of clauses 21-26, wherein the first folding area and the second folding area each comprises a first layer and a second layer integrally knit together, the first layer and the second layer being partially unsecured to form a channel between the first layer and the second layer, wherein a tensioning element extends through the channel.
Clause 28: The article of footwear of any of clauses 21-27, wherein the knitted component is biased to fold along the first folding area and the second folding area between the tensioning element in the channel and the heel portion.
Clause 29: An article of footwear, an upper comprising a knitted component comprising: a heel portion, a lateral midfoot portion, and a medial midfoot portion; a first knitted tubular structure integrally knitted with and positioned between the heel portion and the lateral midfoot portion; and a second knitted tubular structure integrally knitted with and positioned between the heel portion and the medial midfoot portion, wherein the knitted component lacks knitted tubular structures within the heel portion.
Clause 30: The article of footwear of clause 29, wherein the only yarn forming the heel portion is elastic yarn.
Clause 31: The article of footwear of any of clauses 29-30, wherein the knitted component includes courses forming a first surface and courses forming a second surface opposite the first surface, wherein the heel portion includes a first density of tuck stitches securing courses forming the first surface to courses forming the second surface, wherein the lateral midfoot portion and the medial midfoot portion each includes a second density of tuck stitches securing courses forming the first surface to courses forming the second surface, wherein the first density is greater than the second density.
Clause 32: The article of footwear of any of clauses 29-31, wherein the first knitted tubular structure and the second knitted tubular structure each have a channel and a tension element extending through the channel.
Clause 33: The article of footwear of any of clauses 29-32, wherein the first knitted tubular structure and the second knitted tubular structure each extends upward diagonally from a biteline between the upper and the sole structure to a throat region of the upper.
Clause 34: The article of footwear of any of clauses 29-33, wherein the first knitted tubular structure forms a first folding area and the second knitted tubular structure forms a second folding area, wherein when force is applied to an exterior side of the heel portion, the knitted component is biased to fold at the first folding area and the second folding area so that the heel portion is folded down and extends into a foot-receiving void defined by the upper.
Clause 35: A knitted component for an upper, the knitted component comprising: a heel portion and a midfoot portion, a first layer and a second layer defining a channel extending around at least an anterior boundary of an ankle opening, a tensioning element extending through the channel.
Clause 36: The knitted component of clause 35, wherein the channel and the tensioning element extend from the ankle opening to a lower part of the heel portion.
Clause 37: The knitted component of clause 36, wherein the channel and the tensioning element extend from the lower part of the heel portion on a medial side of the upper to the anterior boundary of the ankle opening and down to the lower part of the heel portion on the lateral side of the upper.
Clause 38: The knitted component of any of clauses 35-37, wherein the channel is a single continuous channel.
Clause 39: The knitted component of any of clauses 35-38, wherein the tensioning element extending through the channel is a single continuous tensioning element.
Clause 40: The knitted component of any of clauses 35-39, wherein the tensioning element is a cable.
Clause 41: The knitted component of any of clauses 35-40, wherein the knitted component is biased to fold inward along a first folding area between the heel portion and a lateral midfoot portion and along a second folding area between the heel portion and a medial midfoot portion when force is applied to an exterior side of the heel portion.
Clause 42: An article of footwear comprising the upper at least partially formed by the knitted component of any of clauses 35-41 and a sole structure secured to the upper.
Clause 43: An article of footwear comprising: an upper comprising a knitted component comprising a heel portion, a lateral midfoot portion, and a medial midfoot portion, the heel portion being integrally knit with the lateral midfoot portion along a first folding area and integrally knit with the medial midfoot portion along a second folding area, and a sole structure secured to the upper, wherein a top side of the sole structure includes a depression in a central posterior portion of the sole structure, wherein the knitted component is configured to move from a first wear configuration where the heel portion is upright and a second wear configuration where the heel portion is folded down along the first folding area and the second folding area and extends inwards into a foot-receiving void defined by the upper.
Clause 44: The article of footwear of clause 43: wherein in the second wear configuration, a top surface of the midsole in the depression is positioned inferior to the heel portion of the upper.
Clause 45: The article of footwear of any of clauses 43 to 44, wherein the upper comprises a heel seam joining a lateral side of the upper and a medial side of the upper, wherein the depression of the sole structure aligns with the heel seam.
Clause 46: The article of footwear of any of clauses 43 to 45, wherein the sole structure is a midsole.
Clause 47: The article of footwear of any of clauses 43 to 46, wherein the depression of the sole structure is between a lateral raised surface and a medial raised surface, wherein the distance across the depression between the lateral raised surface and the medial raised surface is at least five centimeters.
| Number | Date | Country | |
|---|---|---|---|
| 63492295 | Mar 2023 | US |
