HK1215363B - Article of footwear having heel portion with knitted component - Google Patents

Description

Article of footwear having heel portion with knitted component

Technical Field

The present invention relates to an article of footwear.

Background

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 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. For example, in some athletic footwear, 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 relieve pressure on the foot and leg during walking, running, and other ambulatory activities. The outsole is secured to a lower surface of the midsole and forms a ground-engaging portion of a sole structure that is formed from a durable and wear-resistant material. The sole structure may also include a sockliner positioned within the void and proximate a lower surface of the foot to enhance footwear comfort.

The upper 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. In some articles of footwear, such as basketball footwear and boots, the upper may extend upward and around the ankle to provide support or protection to the ankle. Access to the void on the interior of the upper is typically provided by an ankle opening in the heel region of the footwear. A lacing system is often incorporated into the upper to adjust the fit of the upper, thereby allowing the foot to enter and be removed from the void within the upper. The lacing system also allows the wearer to modify certain dimensions of the upper, particularly girth, to accommodate feet having different dimensions. In addition, 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.

Various materials are commonly utilized in the manufacture of footwear uppers. The upper of athletic footwear, for example, may be formed from multiple material elements. The material may be selected according to various characteristics including, for example, tensile resistance, abrasion resistance, flexibility, air permeability, compressibility, and moisture-proofing (motion-wrapping). With respect to the exterior of the upper, the toe area and the heel area may be formed of leather, synthetic leather, or a rubber material to impart a relatively high degree of wear-resistance. Leather, synthetic leather, and rubber materials may not exhibit the desired degree of flexibility and air-permeability for various other areas of the exterior. Thus, other areas of the outer portion may be formed of, for example, a synthetic textile. Accordingly, the exterior of the upper may be formed from multiple material elements that each impart different properties to the upper. A middle or central layer of the upper may be formed from a lightweight polymer foam material that provides cushioning and enhances comfort. Similarly, the interior of the upper may be formed from a comfortable and moisture-resistant fabric that removes perspiration directly from the area surrounding the foot. The various material elements and other components may be joined using adhesives or stitching. Accordingly, a conventional upper is formed from multiple material elements that each impart different properties to different areas of the footwear.

SUMMARY

An article of footwear is disclosed that includes a sole structure and an upper coupled to the sole structure. The upper includes a lower edge disposed adjacent the sole structure. The upper also includes a collar that defines an opening of a void within the upper. The collar defines an upper edge of the upper spaced from the lower edge. The upper includes a front portion and a heel portion. The heel portion also includes a knitted component having a unitary knit construction. The knitted component at least partially defines an upper edge and a lower edge of the upper. The knitted component includes a first side edge attached to the front portion along a first side. The knitted component also includes a second side edge attached to the front portion along a second side.

The knitted component of the heel portion has a first zone and a second zone, wherein the first zone has a first amount of stretch resistance and the second zone has a second amount of stretch resistance, and wherein the first amount of stretch resistance of the first zone is greater than the second amount of stretch resistance of the second zone.

The upper defines a longitudinal axis, and wherein the second zone is substantially centered about the longitudinal axis.

The knitted component of the heel portion includes the first zone, the second zone, and a third zone, wherein the third zone has a third amount of stretch resistance, wherein the first amount of stretch resistance of the first zone is greater than the second amount of stretch resistance of the second zone, and wherein the second amount of stretch resistance of the second zone is greater than the third amount of stretch resistance of the third zone.

The third zone partially defines the collar of the upper, wherein the second zone extends from the third zone toward the sole structure, and wherein the first zone extends between the third zone, the second zone, the first lateral edge, the second lateral edge, and the sole structure.

The third zone has a width measured between the upper edge and an inner boundary that partially bounds the third zone from the second zone and partially bounds the third zone from the first zone, the width varying across the third zone.

The yarns in the first zone comprise a thermoplastic polymeric material.

Said thermoplastic polymeric material is substantially absent from said second region.

The front portion includes a knitted component having a unitary knit construction.

The first side edge of the heel portion is attached to the forward portion along a medial side of the upper and the second side edge of the heel portion is attached to the forward portion along a lateral side of the upper.

The heel portion has an inner surface that partially defines the cavity, the heel portion also has an outer surface that faces opposite the inner surface, and wherein one of the inner surface and the outer surface includes indicia that visually distinguishes the inner surface from the outer surface.

The upper also includes a strobel coupled to the lower edge.

The first side edge extends from the upper edge to the lower edge, and wherein the second side edge extends from the upper edge to the lower edge.

Further, an article of footwear is disclosed that includes a sole structure and an upper coupled to the sole structure. The upper includes a forward portion formed from a first component and a heel portion formed from a second component, the first component being spaced apart from the second component. The front portion and the heel portion are connected to each other along at least one seam. The heel portion includes a heel knitted component having a unitary knit construction. The heel knitted component has a first knitted region associated with a first amount of stretch resistance and a second knitted region associated with a second amount of stretch resistance. The first amount of stretch resistance of the first woven region is greater than the second amount of stretch resistance of the second woven region.

The upper defines a longitudinal axis, and wherein the second knitted zone is substantially centered on the heel knitted component with respect to the longitudinal axis.

The heel knitted component includes the first knitted zone, the second knitted zone, and a third knitted zone, wherein the third knitted zone is associated with a third amount of stretch resistance, wherein the first amount of stretch resistance of the first knitted zone is greater than the second amount of stretch resistance of the second knitted zone, and wherein the second amount of stretch resistance of the second knitted zone is greater than the third amount of stretch resistance of the third knitted zone.

The at least one seam includes a first seam and a second seam, wherein the third knitted zone partially defines a collar of the upper, the collar defining an opening of a void within the upper, wherein the second knitted zone extends from the third knitted zone toward the sole structure, and wherein the first knitted zone extends between the third knitted zone, the second knitted zone, the first seam, the second seam, and the sole structure.

The at least one seam includes a first seam and a second seam, wherein the forward portion of the upper includes a forward knitted component having a unitary knit construction, the forward knitted component and the heel knitted component being joined at the first seam and the second seam by respective stitches.

The yarns in the first woven region comprise a thermoplastic polymeric material that is substantially absent from the second woven region.

The heel portion cooperates with the forward portion to define a lower edge disposed adjacent the sole structure, the heel portion cooperates with the forward portion to define a collar that defines an opening of a void within the upper, the collar having an upper edge spaced apart from the lower edge, wherein the at least one seam includes a first seam and a second seam, each of the first seam and the second seam extending from the upper edge to the lower edge.

Additionally, an article of footwear is disclosed that includes a sole structure and an upper coupled to the sole structure. The upper includes a lower edge disposed adjacent the sole structure. The upper includes a collar that defines an opening of a void within the upper. The collar defines an upper edge of the upper spaced from the lower edge. The upper also includes a forward portion that includes a forward knitted component having a unitary knit construction. In addition, the upper includes a heel portion that includes a heel knitted component having a unitary knit construction. The heel portion has a first knit region, a second knit region, and a third knit region. The first woven zone is associated with a first amount of stretch resistance, the second woven zone is associated with a second amount of stretch resistance, and the third woven zone is associated with a third amount of stretch resistance. The first amount of stretch resistance is greater than the second amount of stretch resistance, and the second amount of stretch resistance is greater than the third amount of stretch resistance. The third knitted zone partially defines a collar and an upper edge. The first knitted zone partially defines a lower edge. The second woven extent is cooperatively surrounded by the first woven extent and the third woven extent. The heel knitted component includes a first edge that is joined to the front knitted component by stitching on a medial side of the upper. The heel knitted component also includes a second edge that is connected to the front knitted component by stitching on a lateral side of the upper.

Other systems, methods, features and advantages of the disclosure will be, or will become, apparent to one with skill in the art upon examination of the following figures and detailed description. It is intended that all such additional systems, methods, features and advantages be included within this description and this summary, be within the scope of the disclosure, and be protected by the following claims.

Brief description of the drawings

The disclosure can be better understood with reference to the following drawings and description. The components in the figures are not necessarily to scale, emphasis instead being placed upon illustrating the principles of the disclosure. Moreover, in the figures, like reference numerals designate corresponding parts throughout the different views.

FIG. 1 is a lateral side view of an article of footwear according to an example embodiment of the present disclosure;

FIG. 2 is a medial side view of the article of footwear of FIG. 1;

FIG. 3 is a top view of the article of footwear of FIG. 1;

FIG. 4 is a bottom view of an upper of the article of footwear of FIG. 1;

FIG. 5 is a rear view of the article of footwear of FIG. 1;

FIG. 6 is a plan view of the knitted component of the upper of the article of footwear of FIG. 1;

FIG. 7 is a plan view of an exterior surface of a heel knitted component of an upper of the article of footwear of FIG. 1;

FIG. 8 is a plan view of an interior surface of a heel knitted component of an upper of the article of footwear of FIG. 1; and

fig. 9 is a plan view of a heel knitted component according to further embodiments of the present disclosure.

Detailed Description

The following discussion and accompanying figures disclose an article of footwear having an upper that includes at least one knitted component. An article of footwear is disclosed as having a general configuration suitable for walking or running. Concepts associated with the footwear (including the upper) may also be applied to a variety of other athletic footwear types, including baseball shoes, basketball shoes, cross-training shoes, cycling shoes, football shoes, soccer shoes, sprinting shoes, tennis shoes, and hiking shoes, for example. These concepts may also be applied to footwear styles that are generally considered to be non-athletic, including dress shoes, loafers, sandals, and work boots. Accordingly, the concepts disclosed herein may be applied to a variety of footwear types.

Shoe structure

Fig. 1-3 illustrate an exemplary embodiment of an article of footwear 100 (also referred to simply as footwear 100). In some embodiments, article of footwear 100 may generally include sole structure 110 and upper 120.

For purposes of reference, footwear 100 may be generally divided into three general regions along longitudinal axis X: forefoot region 101, midfoot region 102, and heel region 103. Forefoot region 101 generally includes portions of footwear 100 corresponding with the toes and the joints connecting the metatarsals with the phalanges. Midfoot region 102 generally includes portions of footwear 100 corresponding with the arch area of the foot. Heel region 103 generally corresponds with rear portions of the foot, including the calcaneus bone. Footwear 100 also includes a lateral side 104 and a medial side 105 that extend through each of forefoot region 101, midfoot region 102, and heel region 103 and correspond with opposite sides of footwear 100. More particularly, lateral side 104 corresponds with an outer region of the foot (i.e., a surface that faces away from the other foot), and medial side 105 corresponds with an inner region of the foot (i.e., a surface that faces toward the other foot). Forefoot region 101, midfoot region 102, and heel region 103, as well as lateral side 104 and medial side 105 are not intended to demarcate precise areas of footwear 100. Rather, forefoot region 101, midfoot region 102, and heel region 103, as well as lateral side 104 and medial side 105 are intended to represent general areas of footwear 100 to aid in the following discussion. In addition to footwear 100, forefoot region 101, midfoot region 102, and heel region 103, as well as lateral side 104 and medial side 105 may also be independently applicable to sole structure 110, upper 120, and various elements thereof.

Sole structure 110 may be secured to upper 120 and may extend between the foot and the ground when article of footwear 100 is worn. In some embodiments, sole structure 110 may generally include a midsole 111 and an outsole 112.

Midsole 111 may be secured to a lower surface of upper 120 and may be formed from a compressible polymer foam element (e.g., polyurethane or ethylvinylacetate foam) that attenuates ground reaction forces (i.e., provides cushioning) when compressed between the foot and the ground during walking, running, or other ambulatory activities. In additional embodiments, midsole 111 may include plates, moderators, fluid-filled chambers, lasting elements, or motion control members that further attenuate forces, enhance stability, or influence foot motions. Midsole 111 may also be primarily formed from a fluid-filled chamber.

Outsole 112 may be secured to a lower surface of midsole 111. Outsole 112 may also be formed from a wear-resistant rubber material that is textured to impart traction.

In some embodiments, sole structure 110 may also include a sockliner 113. The insole 113 is partially shown in fig. 3. Sockliner 113 may be located within upper 120 and may be positioned to extend below a lower surface of the foot to enhance the comfort of footwear 100.

Although this configuration for sole structure 110 provides an example of a sole structure 110 that may be used with upper 120, a variety of other conventional or nonconventional configurations for sole structure 110 may also be used. Accordingly, in other embodiments, the features of sole structure 110 or any sole structure used with upper 120 may vary.

Upper 120 will now be discussed in general terms. Upper 120 may define a void 117 within footwear 100 for receiving and securing a foot relative to sole structure 110. Void 117 is shaped to accommodate the foot and extends along the lateral side of the foot, along the medial side of the foot, over the foot and toes, around the heel, and under the foot.

Upper 120 may define collar 130 along with upper edge 132 that defines opening 121. Opening 121 may provide access to void 117 for the wearer's foot and may be located at least in heel region 103.

Tongue 140 may be included at the front of collar 130 and may extend longitudinally toward forefoot region 101 and between lateral side 104 and medial side 105. As shown in the illustrated embodiment, tongue 140 may be integrally attached to forefoot region 101, lateral side 104, and medial side 105. In other embodiments, tongue 140 may be separate from lateral side 104 and medial side 105. Accordingly, the tongue may be movably received between lateral side 104 and medial side 105 in the open throat area of upper 120.

In some embodiments, a closure element 122 for selectively securing upper 120 to a wearer's foot may also be included. The closure element 122 may be of any suitable type, such as a lace as shown in the illustrated embodiment. In other embodiments, closure element 122 may also include one or more buckles, straps, or other suitable means for securing upper 120 to the wearer's foot.

In an exemplary embodiment, closure element 122 may be configured to interact with tensile strands 141 to help secure upper 120 to the foot of the wearer. In the illustrated embodiment, upper 120 includes a plurality of tensile strands 141 that extend upward from sole structure 110 along upper 120 and back downward, forming looped ends to provide apertures 143 that receive closure elements 122. Tensile strands 141 suitable for use with Upper 120 may include tensile strands and/or tensile elements disclosed in one or more Of the commonly owned U.S. patent applications entitled "Article Of Footwear Having An Upper that includes a Knitted Component", filed 12-18.2008 and published 24.2010 as U.S. patent application publication No. 2010/0154256, both Of which are incorporated herein by reference in their entirety, and U.S. patent application publication No. 12/338,726 entitled "Article Of Footwear Having An Upper that includes a Knitted Component", filed 3-15.2011 and published 20.20.2012 as U.S. patent application publication No. 2012/0233882, filed 3-15.2012, and U.S. patent application publication No. 13/048,514 entitled "Article Of Footwear Incorporating a Knitted Component", both Of which are incorporated herein by reference in their entirety.

In this embodiment, apertures 143 provided by lines 141 are spaced along axis X between lateral side 104 and medial side 105. Thus, closure elements 122 extend along axis X and alternate between lateral side 104 and medial side 105. By tightening closure element 122, the wearer can modify the dimensions of upper 120 to accommodate the size of the foot. More specifically, closure element 122 may allow the wearer to tighten upper 120 around the foot, and closure element 122 may allow the wearer to loosen upper 120 to facilitate entry and removal of the foot from void 117 through opening 121.

In some configurations, upper 120 may also extend at least partially under the foot of the wearer. For example, sole structure 110 is removed in fig. 4, and as shown, upper 120 may include a strobel 125 attached to lower edge 160 along a perimeter. The strobel 125 may be attached via stitching 162 as shown in the illustrated embodiment, via a fastener, via an adhesive, or via another attachment device. Thus, the strobel 125 extends under the foot of the wearer. As mentioned above, sole structure 110 may include a sockliner 113 and a midsole 111. In these embodiments, footbed 113 may be layered on the upper surface of strobel 125 within cavity 117, and midsole 111 may be attached to the lower surface of strobel 125.

In further configurations, upper 120 may include additional elements. For example, upper 120 may include a toe guard formed of a wear-resistant material in forefoot region 101. Upper 120 may additionally include logos, trademarks, symbols, and placards with care instructions and material information. Those of ordinary skill in the art will appreciate that upper 120 may also include additional elements without departing from the scope of the present disclosure.

Many conventional footwear uppers are formed from multiple material elements (e.g., polymer foam, polymer sheet, leather, synthetic leather) that are joined together by, for example, stitching or bonding. However, in various embodiments discussed herein, upper 120 may be at least partially formed from knitted component 130. Knitted component 130 may extend at least partially through forefoot region 101, midfoot region 102, and/or heel region 103. Knitted component 130 may also extend along lateral side 104, medial side 105 over forefoot region 101, and/or around heel region 103. Additionally, knitted component 130 may at least partially define an exterior surface 119 and an opposite interior surface 115 of upper 120. Interior surface 115 may define at least a portion of void 117 within upper 120, and exterior surface 119 may face in a direction opposite interior surface 115.

As will be discussed, knitted component 130 may provide upper 120 with a reduced weight as compared to other conventional uppers. Moreover, in some embodiments, knitted component 130 may be configured with different zones having different characteristics. For example, one or more predetermined zones may have more stretch resistance than other zones. In addition, knitted component 130 may provide an aesthetically pleasing characteristic and texture to upper 120. Still further, knitted component 130 may provide manufacturing advantages to footwear 100. Other advantages attributed to knitted component 130 will be discussed in detail below.

Knitted component structure

In some embodiments, knitted component 130 may include a plurality of knitted subcomponents independently formed to each have a unitary knit construction. Once formed, these knitted components having unitary knit construction may be joined together to define at least a portion of upper 120.

For example, as shown in the illustrated embodiment, knitted component 130 may include a first knitted component or front knitted component 150 and a second knitted component or heel knitted component 152 that are connected together to cooperatively define knitted component 130. In one embodiment, forward knitted component 150, heel knitted component 152, and strobel 125 may be joined together to cooperatively define upper 120, as shown in fig. 4.

For purposes of clarity, according to an exemplary embodiment, front knitted component 150 and heel knitted component 152 are shown separated and lying substantially flat in fig. 6. As shown, front knitted component 150 is formed of unitary knit construction and heel knitted component 152 is also formed of unitary knit construction.

As used herein, the term "unitary braided structure" means that the respective component is formed as a one-piece element by a braiding process. That is, the knitting process generally forms various features and structures having unitary knit construction without requiring significant additional manufacturing steps or processes. Unitary knit structures may be used to form a knitted component having structures or elements that include one or more courses of yarn or other knitted material that are joined such that the structures or elements include at least one common course (i.e., share a common yarn) and/or include substantially continuous courses between each of the structures or elements. With this arrangement, a one-piece element having a unitary braided construction is provided.

As shown in fig. 6, front knitted component 150 may include a medial side portion 202, a lateral side portion 204, and a front portion 200. The boundaries of front knitted component 150 may be bounded by a first U-shaped perimeter edge 208, a second smaller U-shaped perimeter edge 209, a first back edge 210 extending laterally between edge 208 and edge 209, and a second back edge 212 extending laterally between edge 208 and edge 209.

In addition, heel knitted component 152 may include an upper perimeter edge 220, a lower perimeter edge 222, a first side edge 224 extending laterally between upper perimeter edge 220 and lower perimeter edge 222, and a second side edge 226 extending laterally between upper perimeter edge 220 and lower perimeter edge 222. In some embodiments, edges 224, 226 may be at least partially angled away from each other as edges 224, 226 extend from upper perimeter edge 220 to lower perimeter edge 222.

Front knitted component 150 may be coupled to heel knitted component 152 to define upper 120, as shown in fig. 1-4. For example, first rear edge 210 of front knitted component 150 may be coupled to first side edge 224 of heel knitted component 152 to define first seam 240 of upper 120. In addition, second rear edge 212 of front knitted component 150 may be coupled to second side edge 226 of heel knitted component 152 to define second seam 242 of upper 120.

Front knitted component 150 may be coupled to heel knitted component 152 in any suitable pattern along seams 240 and 242. For example, knitted components 150, 152 may be coupled at seams 240 and 242 via stitching, via an adhesive, via fasteners, or via any other suitable attachment mechanism.

When assembled into upper 120, medial portion 202 of forward knitted component 150 may define a majority of medial side 105 of upper 120. Further, forward portion 200 may define a majority of forefoot region 101 of upper 120. In addition, lateral portion 204 may define a majority of lateral side 104 of upper 120. Heel knitted component 152 may define a majority of heel region 103 of upper 120. In addition, second peripheral edge 209 and upper peripheral edge 220 may cooperate to define upper edge 132 of upper 120, as shown in fig. 1-3. In addition, first peripheral edge 208 and lower peripheral edge 222 may cooperate to define lower edge 160 of upper 120, as shown in fig. 4. Additionally, first seam 240 may extend from upper edge 132 to lower edge 160 on medial side 105 of upper 120, as shown in fig. 2, 3, and 4. In addition, second seam 242 may extend from upper edge 132 to lower edge 160 on lateral side 105 of upper 120, as shown in fig. 1,3, and 4.

In some embodiments, front knitted component 150 may include multiple zones having one or more different physical properties. In the illustrated embodiment, the boundaries of these regions are indicated by dashed lines. For example, as best illustrated in fig. 3 and 6, front knitted component 150 may include a first zone 214, a second zone 216, and a third zone 218. As shown in the illustrated embodiment, the third zone 218 may be U-shaped and substantially centrally located between the inner portion 202 and the outer portion 204, adjacent the second peripheral edge 209. Thus, the inner boundary 163 of the third zone 218 can be positioned approximately at a uniform distance spaced from the second peripheral edge 209 so as to be generally concentric with the second peripheral edge 209, as shown in the plan view of fig. 6. Further, the second zone 216 may extend longitudinally forward from the third zone 218 toward the front portion 200, and the second zone 216 may include an inboard branch 219 extending between the front portion 200 and the inboard portion 202. The first portion 221 of the first zone 214 extends between the third zone 218, the first back edge 210, the perimeter edge 208, and the second zone 216. The second portion 223 of the first zone 214 extends between the third zone 218, the second back edge 212, the perimeter edge 208, and the second zone 216.

The first region 214, the second region 216, and the third region 218 may have one or more different physical properties. For example, the first zone 214 may have a greater degree or amount of stretch resistance than the second zone 216, and the second zone 216 may have a greater degree or amount of stretch resistance than the third zone 218. In other words, the first zone 214 may be stiffer than the second zone 216, and the second zone 216 may be stiffer than the third zone. Accordingly, third zone 218 may stretch easily to allow the passage of the wearer's foot through collar 123 of upper 120, while first zone 214 may be more tensile such that first zone 214 provides support to the wearer's foot. In addition, second region 216 may be sufficiently stretchable to allow upper 120 to comfortably conform to the foot of the wearer.

Similarly, in some embodiments, heel knitted component 152 may include multiple regions having one or more different physical properties. In the illustrated embodiment, the boundaries of these regions are indicated by dashed lines. For example, as best illustrated in fig. 6, heel knitted component 152 may include a first zone 228, a second zone 230, and a third zone 232.

In an exemplary embodiment, one or more different zones 228, 230, 232 may be associated with different portions of heel knitted component 152. By providing different portions of heel knitted component 152 with zones having varying physical properties, the fit, comfort, and/or support provided by heel knitted component for upper 120 may be varied as desired.

In one embodiment, third zone 232 may be provided along a peripheral edge of knitted component 152 associated with collar 132 and adjacent to opening 121 of upper 120. The inner boundary of the third zone 232 is shown in phantom in fig. 6, and partially bounds the third zone 232 from the first zone 228 and partially bounds the third zone 232 from the second zone 230. As shown in fig. 6, the third zone 232 may have a substantially constant width and may extend along the upper perimeter edge 220. Accordingly, the inner boundary 161 of the third zone 232 can be positioned approximately at a uniform distance from the upper peripheral edge 220 so as to be substantially concentric with the upper peripheral edge 220, as shown in the plan view of fig. 6.

In an exemplary embodiment, second zone 230 may be provided at a location along a portion of knitted component 152 corresponding with a heel and/or an achilles tendon of a wearer's foot. In this embodiment, second zone 230 may be located approximately in the middle of knitted component 152 along the lateral direction. By providing second region 230 with a configuration that imparts a variety of physical properties, portions of knitted component 152 corresponding with the heel and/or achilles tendon of the wearer's foot may have a desired fit, comfort, and/or support.

In various embodiments, the second region 230 can have any suitable shape. In one embodiment, the second region 230 may have a substantially symmetrical geometry. For example, in this embodiment, the second region 230 may be polygonal. As shown in fig. 6, the second region 230 can include an inverted triangular portion 231 and a diamond-shaped portion 233 arranged end-to-end and extending from the third region 232 toward the lower perimeter edge 222. Second zone 230 may also be substantially symmetrical and centered with respect to axis X of upper 120. Further, the first region 228 may extend between the third region 232, the first side edge 224, the lower perimeter edge 222, the second side edge 226, and the second region 230.

The first, second, and third regions 228, 230, 232 may have one or more different physical properties. For example, the first zone 228 may have a greater degree or amount of stretch resistance than the second zone 230, and the second zone 230 may have a greater degree or amount of stretch resistance than the third zone 232. In other words, the first region 228 may be stiffer than the second region 230, and the second region 230 stiffer than the third region 232.

In some embodiments, first region 228 of heel knitted component 152 may have similar physical properties to first region 214 of front knitted component 150. In addition, second region 230 of heel knitted component 152 may have similar physical properties as second region 216 of forward knitted component 150. Additionally, third zone 232 of heel knitted component 152 may have similar physical properties as third zone 218 of front knitted component 150. Thus, for example, the first zones 228, 214 may have substantially the same tensile resistance or stiffness, the second zones 230, 216 may have substantially the same tensile resistance or stiffness, and the third zones 232, 218 may have substantially the same tensile resistance or stiffness.

The different stretch resistances of each zone 214, 216, 218, 228, 230, 232 may be achieved in a variety of ways. For example, in some cases, each zone 214, 216, 218, 228, 230, 232 may have a different stitching pattern. Additionally, each zone 214, 216, 218, 228, 230, 232 may include different types of yarns or threads. More specifically, in one embodiment, the third zones 218, 232 may be formed using a half-gauge knit to provide a ribbed appearance, and the third zones 218, 232 may be formed at least in part using one or more elastomeric yarns, such as spandex (spandex). The second zones 216, 230 may be formed using a full gauge knit and may be formed using one or more elastomeric yarns, such as spandex. In further embodiments, the second zones 216, 230 may have a grid-type appearance for increased breathability. Further, the first zones 214, 228 may be formed using full gauge knitting and may include yarns made of thermoplastic polymeric material. These yarns may be less elastic than the yarns included in second and third zones 216, 230, 218, 232, and these yarns may partially melt and fuse to impart additional stiffness to respective zones 214, 228 after application of heat to upper 120. It will be appreciated that these thermoplastic yarns may not be present in the second and third zones 216, 230, 218, 232. It will also be appreciated that the yarns of each zone 214, 216, 218, 228, 230, 232 may be knitted and controlled by known intarsia knitting processes. Further, zones 214, 216, 218, 228, 230, 232 may be formed and encompassed in accordance with the teachings of U.S. patent application serial No. 13/691,316 entitled "Article of Footwear Incorporating a Knitted Component," filed on day 11, 30, 2012, of Podhajny et al, which is hereby incorporated by reference in its entirety.

It will be appreciated that knitted component 130 of upper 120 may provide weight reduction to article of footwear 100. In addition, knitted component 130 may provide different physical properties in different zones 214, 216, 218, 228, 230, 232 such that upper 120 may be comfortable, may provide localized support to the wearer's foot, and may be easily donned and removed. Additionally, the knitting process used to produce knitted component 130 may reduce waste, may reduce manufacturing time, and/or may provide other manufacturing advantages.

Furthermore, as discussed above, knitted component 130 may be formed from multiple subcomponents, namely, a forward knitted component 150 and a heel knitted component 152. Accordingly, the properties of knitted component 130 may be highly controlled during manufacturing. For example, it will be appreciated that heel region 103 of upper 120 may be important to provide support to the heel of the wearer without uncomfortable sliding or rubbing against the wearer's skin. Accordingly, heel knitted component 152 may include a relatively stiff first region 228 for providing suitable support. Heel knitted component 152 may also include a more elastic second region 230, and this second region 230 may be substantially centered on heel knitted component 152 such that this second region 230 may stretch and conform comfortably against the heel of the wearer. Second zone 230 may also stretch and accommodate as the wearer's heel flexes during walking, running, and otherwise moving. Accordingly, heel knitted component 152 may provide an important balance of stiff support and flexion such that a separate heel counter may not be necessary in article of footwear 100.

Moreover, because front knitted component 150 and heel knitted component 152 are separate and independent and each have a unitary knit construction, portions of upper 120 may be tailored and adjusted for specific uses, for specific wearers, or for other purposes. For example, if heel region 103 of upper 120 is to have different desired physical properties, e.g., is to be made stiffer, then forward knitted component 150 may be joined to a different heel knitted component that is provided with a second region that is smaller than second region 230. Alternatively, if heel region 103 is to be made more flexible, forward knitted component 150 may be connected to a different heel knitted component that is provided with a second region that is larger than second region 230.

The manufacture of knitted components 150, 152 and upper 120 will now be discussed. As mentioned, knitted components 150, 152 may be formed to have a one-piece unitary knit construction. For example, the knitted components 150, 152 may be knitted on a flat knitting machine. Further, in some embodiments, heel knitted component 152 may be knitted such that upper perimeter edge 220 is formed first, and additional courses may be added until lower perimeter edge 222 is formed. In this way, upper peripheral edge 220 may have a neat and finished appearance, and raw lower peripheral edge 222 may be eventually covered and bonded by sole structure 110. Likewise, front knitted component 150 may be formed such that second perimeter edge 209 is formed first, and courses may be added until first perimeter edge 208 is formed.

Knitted components 150, 152 may then be joined at seams 240, 242, as discussed above. To facilitate this assembly process, heel knitted component 152 may include indicia 254, such as an "X" shown in fig. 8, that distinguishes inner surface 250 of heel knitted component 152 from outer surface 252 of heel knitted component 152. It should be noted that outer surface 252 of heel knitted component 152 shown in fig. 7 does not include logo 254. Thus, even if heel knitted component 152 is substantially symmetrical, the manufacturer may distinguish between inner and outer surfaces 250, 252 to help orient heel knitted component 152 for attachment to front knitted component 150.

It should also be noted that interior surface 250 may partially define void 117 of upper 120, and exterior surface 252 may face outward. Accordingly, when upper 120 is fully assembled, indicia 254 as shown in fig. 8 may be less readily visible to the wearer or others. However, it will be understood that the outer surface 252, rather than the inner surface 250, may include indicia 254. Additionally, indicia 254 may be formed by yarns or cords included in the overall knit construction of heel knitted component 152, or indicia 254 may be marked separately from the overall knit construction of heel knitted component 152. Additionally, indicia 254 may be located at any suitable location on heel knitted component 152. For example, as shown in fig. 8, indicia 254 may be substantially centered on heel knitted component 152 and may be adjacent lower peripheral edge 222.

Once knitted components 150, 152 are connected at seams 240, 242, strobel 125 may be attached to lower edge 160, as shown in fig. 4. Sole assembly 110 may then be attached as discussed above.

Referring now to fig. 9, an alternative embodiment of heel knitted component 352 is illustrated in accordance with further teachings of the present disclosure. Heel knitted component 352 may be substantially similar to the embodiments discussed above. For example, heel knitted component 352 may include first zone 328, second zone 330, and third zone 332 similar to the embodiments discussed above. However, heel knitted component 352 may define an inner boundary 361, which inner boundary 361 delimits the third zone from first zone 328 and second zone 330, unlike the embodiment of fig. 7. More specifically, although the inner boundary 161 is positioned approximately at a consistent distance from the upper peripheral edge 220 in the embodiment of fig. 6-8, the curvature of the boundary 361 may be inverted relative to the upper peripheral edge 320 such that portions of the inner boundary 361 may be spaced apart from the upper peripheral edge 320 by varying distances. For example, the portion disposed closer to the inner boundary 361 of the second zone 330 may be spaced apart from the upper peripheral edge 320 by a greater distance than other portions. Thus, the width of the third zone 332 between the upper peripheral edge 320 and the inner boundary 361 can vary across the third zone 332 in the plan view of fig. 9. This may allow heel knitted component 352 to closely conform to the wearer's heel for increased comfort and support.

In general, footwear 100 may provide several advantages. Footwear 100 may be comfortable to wear. Footwear 100 may provide support for a foot of a wearer. Footwear 100 may also flex with the foot of the wearer and may flexibly conform to the foot of the wearer. The physical properties may vary across different areas of footwear 100 to further enhance performance.

While various embodiments of the disclosure have been described, the description is intended to be exemplary, rather than limiting and it will be apparent to those of ordinary skill in the art that many more embodiments and implementations are possible that are within the scope of the disclosure. Accordingly, the disclosure is not to be restricted except in light of the attached claims and their equivalents. Furthermore, various modifications, combinations, and alterations of the features described herein may be made within the scope of the appended claims.

Claims (19)

1. An article of footwear comprising:

a sole structure; and

an upper having a longitudinal axis, wherein the upper is coupled to the sole structure, the upper including a lower edge disposed adjacent the sole structure, the upper further including:

a collar having an upper perimeter edge, the collar defining an opening of a cavity within the upper;

a front portion and a heel portion;

wherein, when the forward portion and the heel portion are assembled into the upper, the collar circumferentially surrounds an entire opening of the void, the collar being defined by the upper perimeter edge and an inner boundary that is consistently spaced apart from the upper perimeter edge of the upper;

the heel portion comprises a knitted component having a unitary knit construction, wherein the knitted component of the heel portion has a first zone and a second zone, wherein the first zone has a first amount of stretch resistance and the second zone has a second amount of stretch resistance, and wherein the first amount of stretch resistance of the first zone is greater than the second amount of stretch resistance of the second zone, wherein the second zone is substantially centered on the longitudinal axis and substantially centered within the first zone;

wherein the collar comprises a third amount of stretch resistance and wherein the third amount of stretch resistance of the collar is less than the second amount of stretch resistance of the second zone; and is

Wherein the knitted component includes a first side edge attached to the front portion along a first side and a second side edge attached to the front portion along a second side.

2. The article of footwear recited in claim 1, wherein the knitted component of the heel portion includes the first zone, the second zone, and a third zone, wherein the third zone has the third amount of stretch resistance, wherein the first amount of stretch resistance of the first zone is greater than the second amount of stretch resistance of the second zone, and wherein the second amount of stretch resistance of the second zone is greater than the third amount of stretch resistance of the third zone.

3. The article of footwear recited in claim 2, wherein the third zone partially defines the collar of the upper, wherein the second zone extends from the third zone toward the sole structure, and wherein the first zone extends between the third zone, the second zone, the first lateral edge, the second lateral edge, and the sole structure.

4. The article of footwear of claim 3, wherein the third zone has a width measured between the upper peripheral edge and the inner boundary, the inner boundary partially demarcating the third zone from the second zone and partially demarcating the third zone from the first zone, the width varying across the third zone.

5. The article of footwear recited in claim 1, wherein the yarns in the first zone include a thermoplastic polymer material.

6. The article of footwear of claim 5, wherein the thermoplastic polymeric material is substantially absent from the second zone.

7. The article of footwear of claim 1, wherein the forward portion includes a knitted component having a unitary knit construction.

8. The article of footwear of claim 7, wherein the first side edge of the heel portion is attached to the forward portion along a medial side of the upper and the second side edge of the heel portion is attached to the forward portion along a lateral side of the upper.

9. The article of footwear of claim 1, wherein the heel portion has an inner surface that partially defines the cavity, the heel portion further having an outer surface that faces opposite the inner surface, and wherein one of the inner surface and the outer surface includes indicia that visually distinguishes the inner surface from the outer surface.

10. The article of footwear of claim 1, wherein the upper further includes a strobel coupled to the lower edge.

11. The article of footwear of claim 1, wherein the first side edge extends from the upper perimeter edge to the lower edge, and wherein the second side edge extends from the upper perimeter edge to the lower edge.

12. An article of footwear comprising:

a sole structure; and

an upper coupled to the sole structure, the upper comprising:

a front portion formed by a first component and a heel portion formed by a second component, the first component being spaced apart from the second component;

the front portion and the heel portion are connected to each other along at least one seam;

a collar circumferentially surrounding an opening of a void formed by the upper when the forward portion and the heel portion are connected, the collar having an upper perimeter edge and an inner boundary that is consistently spaced apart from and concentric with the upper perimeter edge;

the heel portion includes a heel knitted component having a unitary knit construction, the heel knitted component having a first knit region associated with a first amount of stretch resistance and a second knit region associated with a second amount of stretch resistance; and is

Wherein the first amount of stretch resistance of the first woven region is greater than the second amount of stretch resistance of the second woven region.

13. The article of footwear recited in claim 12, wherein the upper defines a longitudinal axis, and wherein the second knitted region is substantially centered on the heel knitted component on the longitudinal axis.

14. The article of footwear of claim 12, wherein the heel knitted component includes the first knitted zone, the second knitted zone, and a third knitted zone, wherein the third knitted zone is associated with a third amount of stretch resistance, wherein the first amount of stretch resistance of the first knitted zone is greater than the second amount of stretch resistance of the second knitted zone, and wherein the second amount of stretch resistance of the second knitted zone is greater than the third amount of stretch resistance of the third knitted zone.

15. The article of footwear recited in claim 14, wherein the at least one seam includes a first seam and a second seam, wherein the third knitted zone partially defines the collar of the upper, the collar defining the opening of the void within the upper, wherein the second knitted zone extends from the third knitted zone toward the sole structure, and wherein the first knitted zone extends between the third knitted zone, the second knitted zone, the first seam, the second seam, and the sole structure.

16. The article of footwear recited in claim 12, wherein the at least one seam includes a first seam and a second seam, wherein the forward portion of the upper includes a forward knitted component having a unitary knit construction, the forward knitted component and the heel knitted component being joined at the first seam and the second seam by respective stitches.

17. The article of footwear recited in claim 12, wherein yarns in the first knitted zone include a thermoplastic polymer material that is substantially absent from the second knitted zone.

18. The article of footwear of claim 12, wherein the heel portion cooperates with the forward portion to define a lower edge disposed adjacent the sole structure, the heel portion cooperates with the forward portion to define the collar, the collar defining the opening of the void within the upper, the collar having an upper edge spaced apart from the lower edge, wherein the at least one seam includes a first seam and a second seam, each of the first seam and the second seam extending from the upper edge to the lower edge.

19. An article of footwear comprising:

a sole structure; and

an upper having a longitudinal axis, wherein the upper is coupled to the sole structure, the upper including a lower edge disposed adjacent the sole structure, the upper including a collar defining an opening of a void within the upper, the collar defining an upper edge of the upper spaced apart from the lower edge, the upper further including:

a front portion comprising a front knitted component having a unitary knit construction; and

a heel portion comprising a heel knitted component having a unitary knit construction, the heel portion having a first knit region associated with a first amount of stretch resistance, a second knit region associated with a second amount of stretch resistance, and a third knit region associated with a third amount of stretch resistance;

wherein the first amount of stretch resistance is greater than the second amount of stretch resistance, and the second amount of stretch resistance is greater than the third amount of stretch resistance;

wherein the third knit zone partially defines the collar and is formed between the upper edge and an inner boundary that is consistently spaced from and concentric with the upper edge, wherein the first knit zone partially defines the lower edge, wherein the second knit zone is cooperatively surrounded by the first knit zone and the third knit zone, and wherein the second knit zone is substantially centered on the longitudinal axis and substantially centered within the first knit zone; and is

The heel knitted component includes a first edge joined to the forward knitted component by stitching on a medial side of the upper, and a second edge joined to the forward knitted component by stitching on a lateral side of the upper.