HK1233872B - Article of footwear incorporating a knitted component with an integral knit ankle cuff - Google Patents

Description

Article of footwear comprising a knitted component with an integral knitted ankle collar

This application is a divisional application of an application filed on August 28, 2014, with application number 201410433503.8, and invention name “Footwear comprising a knitted component with an integral knitted ankle collar”.

Technical Field

The present application relates to articles of footwear.

background

Conventional footwear generally includes two main components: an upper and a sole structure. The upper is fixed to the sole structure and forms a cavity on the interior of the footwear for comfortably and securely accommodating the foot. The sole structure is fixed to the lower surface of the upper to be positioned between the upper and the ground. In some sports footwear, for example, the sole structure may include a midsole and an outsole. The midsole may be formed from a polymer foam material that attenuates ground reaction forces during walking, running, and other ambulatory activities to reduce pressure on the foot and leg. The outsole is fixed to the lower surface of the midsole and forms a ground-engaging portion of the sole structure. The outsole is formed from a durable and wear-resistant material. The sole structure may also include an insole positioned within the cavity and proximate to the lower surface of the foot to enhance footwear comfort.

The upper generally extends over the instep area and toe area of the foot, along the medial and lateral sides of the foot, and around the heel area of the foot. In some footwear articles (such as basketball shoes and boots), the upper can extend upward and around the ankle to provide support or protection for the ankle. The entrance to the cavity on the inside of the upper is generally provided through an opening in the heel area 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 move out of the cavity in the upper. The lacing system also allows the wearer to modify certain dimensions of the upper, particularly girth, to accommodate feet of different sizes. In addition, the upper may include a tongue that extends below the lacing system to enhance the adjustability of the footwear, and the upper may include a heel counter to limit the movement of the heel.

A variety of materials are conventionally used to make shoe uppers. For example, the shoe uppers of athletic footwear can be made of multiple material elements. The materials can be selected based on a variety of properties, including, for example, stretch resistance, wear resistance, flexibility, air permeability, compressibility, and hygroscopicity. Regarding the exterior of the shoe upper, the toe area and the heel area can be made of leather, synthetic leather, or rubber materials to impart a relatively high degree of wear resistance. For various other areas of this exterior, leather, synthetic leather, and rubber materials may not exhibit the required degree of flexibility and air permeability. Therefore, for example, other areas of this exterior can be made of synthetic fabrics. Therefore, the exterior of the shoe upper can be made of many material elements, each of which imparts different properties to the shoe upper. The middle layer or center layer of the shoe upper can be made of a lightweight polymer foam material, which can provide cushioning and enhance comfort. Similarly, the interior of the shoe upper can be made of a comfortable and hygroscopic fabric that removes sweat from the area that closely surrounds the foot. The various material elements and other components can be connected by adhesives or stitching. As a result, conventional uppers are formed from multiple material elements that impart different properties to various areas of the footwear.

Summary of the Invention

Various configurations of footwear may include an upper and a sole structure secured to the upper. A knitted component comprising the upper and an integral knitted ankle collar is incorporated into the footwear. The upper and the integral knitted ankle collar are formed as a one-piece knitted element. The knitted element defines a portion of the upper's exterior surface and a portion of an opposing interior surface of the upper, wherein the interior surface defines a cavity for accommodating the foot. The integral knitted ankle collar is formed as a one-piece knitted element along with the upper from a unitary knitted structure and extends over the throat area of the upper. The knitted component includes features that help provide access for the wearer's foot, provide comfort for the wearer, and assist in orienting the upper of the footwear when worn.

In one aspect, the present invention provides an article of footwear having an upper and a sole structure fixed to the upper, the upper including a knitted component formed of a unitary knitted structure, the knitted component including: a foot region forming substantially a majority of the upper, the foot region extending through a forefoot region, a midfoot region, and a heel region of the article of footwear, the foot region including an instep area extending between a lateral side and a medial side of the upper; an ankle region forming a portion of the upper extending above the foot region, the ankle region including an ankle collar defining a throat opening to a cavity within the upper for accommodating a foot; wherein the ankle collar is formed of a unitary knitted structure together with at least the instep region of the foot region and portions of the foot region arranged on the medial and lateral sides in the heel region; and wherein the ankle collar also includes at least one ankle region arranged on at least one of the medial and lateral sides of the upper, the at least one ankle region including a plurality of recesses on the outer surface of the ankle collar.

In one embodiment, the ankle collar comprises at least two knit layers; and wherein a first knit layer comprises a majority of an exterior surface of the ankle collar, and a second knit layer comprises a majority of an interior surface of the ankle collar.

In one embodiment, the plurality of notches are formed by cavities in the first knit layer that expose the second knit layer.

In one embodiment, the cavity in the first knit layer comprises at least one of a 1×1 simulated mesh knit structure and a 2×2 simulated mesh knit structure.

In one embodiment, the at least one ankle region on the ankle collar is disposed at a location corresponding to an ankle of a wearer's foot.

In one embodiment, the knitted component further includes a lace receiving hole formed into at least one of the instep area and the ankle collar, the lace receiving hole being configured to receive a loose end of a tied lace within the interior of the upper.

In one embodiment, the instep area further includes a stretch padding zone, which is arranged between the medial side and the lateral side of the upper along the upper portion of the footwear; the stretch padding zone is configured to stretch across the footwear in a lateral direction between an unstretched condition and a stretched condition; and wherein the stretch padding zone has a first thickness in the unstretched condition and a second thickness in the stretched condition, the first thickness being greater than the second thickness.

In another aspect, the present invention provides an article of footwear having an upper and a sole structure fixed to the upper, the upper including a knitted component formed of an integral knitted structure, the knitted component including: a foot region forming substantially the majority of the upper, the foot region extending through a forefoot region, a midsole region, and a heel region of the article of footwear, the foot region including an instep region extending between a lateral side and a medial side of the upper; an ankle region forming a portion of the upper extending above the foot region, the ankle region including an ankle collar defining an opening leading to an inner portion of the upper the shoe throat opening having a cavity for accommodating a foot; the instep area further comprising a stretch padding area, which together with the instep area is surrounded by and formed by an integral knitted structure, the stretch padding area being arranged between the medial side and the lateral side of the upper along the upper portion of the footwear; the stretch padding area being configured to stretch across the footwear in a lateral direction between an unstretched condition and a stretched condition; and wherein the stretch padding area has a first thickness in the unstretched condition and a second thickness in the stretched condition, the first thickness being greater than the second thickness.

In one embodiment, the stretch pad area is formed from a first knit structure and the remainder of the instep area is formed from a second knit structure, the first knit structure being different from the second knit structure.

In one embodiment, the second knit structure includes at least one of a plain knit structure and a double jersey knit structure.

In one embodiment, the knitted component further includes a plurality of lace holes configured to receive a shoelace, the plurality of lace holes being arranged in a longitudinal direction along the upper on each of the medial side and the lateral side of the instep area.

In one embodiment, the stretch pad zone extends between the plurality of lace apertures on each of the medial side and the lateral side of the instep area.

In one embodiment, the stretch padding area is formed of unitary knit construction with the ankle collar such that the stretch padding area includes at least one course in common with the ankle collar.

In one embodiment, the ankle collar is formed of an integral knitted structure together with at least the instep area of the foot region and the portion of the foot region arranged on the medial side and the lateral side in the heel area; and wherein the ankle collar further comprises at least one ankle region, the at least one ankle region being arranged on at least one of the medial side and the lateral side of the upper, the at least one ankle region comprising a plurality of recesses on the outer surface of the ankle collar.

In one embodiment, the knitted component further includes a lace receiving hole formed into at least one of the instep area and the ankle collar, the lace receiving hole being configured to receive a loose end of a tied lace within the interior of the upper.

In another aspect, the present invention provides an article of footwear having an upper and a sole structure fixed to the upper, the upper including a knitted component formed from an integral knitted structure, the knitted component including: a foot region forming substantially a majority of the upper, the foot region extending through a forefoot region, a midsole region, and a heel region of the article of footwear, the foot region including an instep region extending between a lateral side and a medial side of the upper; an ankle region forming a portion of the upper extending above the foot region, the ankle region including an ankle collar defining a throat opening to a cavity within the upper for accommodating the foot; and wherein the knitted component also includes a lace-receiving hole formed into at least one of the instep region and the ankle collar, the lace-receiving hole being configured to receive a loose end of a tied lace in an interior of the upper.

In one embodiment, the knitted component includes a knitted element having two sides, including a first side forming substantially the majority of the outer surface of the upper and a second side arranged opposite the first side, the second side forming substantially the majority of the inner surface arranged within the interior of the upper; wherein the lace-receiving hole defines a hole extending through the first side and the second side of the knitted element; and wherein the loose end of the tied lace is configured to be placed along the inner surface within the interior of the upper when arranged through the hole of the lace-receiving hole.

In one embodiment, the lace-receiving aperture comprises a buttonhole trace in the knitted component.

In one embodiment, the ankle collar is formed of an integral knitted structure together with at least the instep area of the foot region and the portion of the foot region arranged on the medial and lateral sides in the heel area, and wherein the ankle collar further comprises at least one ankle region arranged on at least one of the medial and lateral sides of the upper, and the at least one ankle region comprises a plurality of recesses in the outer surface of the ankle collar.

In one embodiment, the instep area further includes a stretch padding zone, which is arranged between the medial side and the lateral side of the upper along the upper portion of the footwear; the stretch padding zone is configured to stretch across the footwear in a lateral direction between an unstretched condition and a stretched condition; and wherein the stretch padding zone has a first thickness in the unstretched condition and a second thickness in the stretched condition, the first thickness being greater than the second thickness.

Other systems, methods, features and advantages of the present invention will be or will become apparent to one of ordinary skill in the art upon examination of the following drawings and detailed description. All such additional systems, methods, features and advantages are intended to be included within this description and this summary of the invention, to be included within the scope of the present invention, and to be protected by the following claims.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention may be better understood with reference to the following drawings and descriptions. The components in the drawings are not necessarily to scale, but emphasis is placed on illustrating the principles of the present invention. In addition, in the drawings, like reference numerals indicate corresponding parts throughout the different views.

FIG1 is an isometric view of an exemplary embodiment of an article of footwear;

FIG2 is a medial side view of an exemplary embodiment of an article of footwear;

FIG3 is a lateral view of an exemplary embodiment of an article of footwear;

FIG4 is a top view of an exemplary embodiment of an article of footwear;

FIG5 is a top view of an exemplary embodiment of a knitted component included in an upper of an article of footwear;

FIG6 is an enlarged front view of an exemplary embodiment of a knitted collar for an article of footwear;

FIG7 is an enlarged front view of an exemplary embodiment of a knitted shoe collar including holes for receiving tied shoe laces;

FIG8 is an enlarged front view of an exemplary embodiment of a knitted shoe collar including holes for receiving tied shoe laces;

FIG9 is an enlarged front view of an exemplary embodiment of a knitted shoe collar including holes for receiving tied shoe laces shown in phantom;

FIG10 is an enlarged lateral view of a knit shoe collar including an exemplary embodiment of an ankle region;

FIG11 is a cross-sectional view of an exemplary embodiment of the ankle region taken along the line in FIG10;

FIG12 is an enlarged lateral view of a knit shoe collar including an exemplary embodiment of an ankle region;

FIG13 is an enlarged lateral view of a knitted shoe collar including an exemplary embodiment of an ankle region undergoing stretching;

FIG14 is an exemplary embodiment of an article of footwear including a knitted collar having an ankle region;

FIG15 is an exemplary embodiment of an article of footwear including a knitted collar having an ankle region, wherein the article of footwear has a wearer's foot inserted therein;

16 is an exemplary embodiment of an article of footwear including a knitted collar having an ankle region with a wearer's foot positioned within the article of footwear.

FIG17 is an enlarged front view of a knitted shoe collar including features to assist in orientation of the shoe upper;

FIG18 is an enlarged front view of a knit shoe collar including an exemplary embodiment of a stretch padding area in an unstretched condition;

FIG. 19 is an enlarged front view of a knit shoe collar including an exemplary embodiment of a stretch padding area in a stretched condition; and

20 is a schematic diagram of an exemplary loop diagram for making a knit component including a stretch padding area.

DETAILED DESCRIPTION

The following discussion and accompanying drawings disclose various concepts about the manufacture of knitted components and knitted components. Although knitted components can be used in various products, a footwear article comprising one of the knitted components is disclosed below as an example. Figures 1 to 20 show exemplary embodiments of footwear articles comprising knitted components, which include an upper and an integrated knitted ankle collar. The individual features of the knitted components described herein can be used in combination or can be provided separately in different configurations for footwear articles. In addition, any one of the features can be optional and may not be included in any specific embodiment of the knitted component.

Figures 1 to 4 illustrate an exemplary embodiment of an article of footwear 100 (also referred to simply as article 100). In some embodiments, article of footwear 100 may include a sole structure 110 and an upper 120. Although article 100 is shown as having a general configuration suitable for a soccer ball, the concepts associated with article 100 may also be applied to various other types of athletic footwear, including, for example, baseball shoes, basketball shoes, cycling shoes, rugby shoes, tennis shoes, running shoes, training shoes, walking shoes, and hiking boots. The concepts may also be applied to types of footwear that are generally considered non-athletic, including dress shoes, casual shoes, sandals, and work boots. Thus, the concepts disclosed with respect to article 100 may be applied to a wide variety of footwear types.

For reference purposes, as shown in Figures 1, 2, and 3, article 100 can be divided into three general regions: a forefoot region 10, a midfoot region 12, and a heel region 14. Forefoot region 10 generally includes the portion of article 100 corresponding to the toes and the joints connecting the phalanges with the metatarsal bones. Midfoot region 12 generally includes the portion of article 100 corresponding to the arch area of the foot. Heel region 14 generally corresponds to the rear portion of the foot, including the calcaneus. Article 100 also includes a lateral side 16 and a medial side 18, which extend through each of forefoot region 10, midfoot region 12, and heel region 14 and correspond to opposite sides of article 100. More specifically, lateral side 16 corresponds to the outside area of the foot (i.e., the surface facing away from the other foot), while medial side 18 corresponds to the inside area of the foot (i.e., the surface facing the other foot). Forefoot region 10, midfoot region 12, heel region 14, and lateral side 16, medial side 18 are not intended to delineate precise areas of article 100. Rather, forefoot region 10, midfoot region 12, heel region 14, and lateral side 16, medial side 18 are intended to represent general areas of article 100 to facilitate the discussion below. In addition to article 100, forefoot region 10, midfoot region 12, heel region 14, and lateral side 16, medial side 18 may also apply to sole structure 110, upper 120, and individual components thereof.

In an exemplary embodiment, sole structure 110 is secured to upper 120 and extends between the foot and the ground when article 100 is worn. In some embodiments, sole structure 110 may include one or more components, including a midsole, an outsole, and/or a sockliner or insole. In an exemplary embodiment, sole structure 110 may include an outsole 112 secured to a base portion and/or a lower surface of upper 120, the base portion and/or the lower surface of upper 120 being configured to secure sole structure 110 to upper 120. In one embodiment, outsole 112 may be formed from a wear-resistant rubber material that is textured to provide frictional traction. In this embodiment, outsole 112 includes a plurality of cleat members 114 configured to provide frictional traction with the ground. While this configuration for sole structure 110 provides an example of a sole structure that may be used in conjunction with upper 120, various other conventional or non-conventional 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.

For example, in other embodiments, the sole structure 110 may include a midsole and/or an insole. The midsole may be secured to the lower surface of the upper and, in some cases, 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 motions. In other cases, the midsole may include a plate, an adjuster, a fluid-filled chamber, a lasting element, or a motion control member that further attenuates forces, enhances stability, or influences foot motion. In yet other cases, the midsole may be primarily formed from a fluid-filled chamber located within the upper and positioned to extend below the lower surface of the foot to enhance the comfort of the article.

In some embodiments, upper 120 defines a cavity within article 100 for receiving a foot and securing the foot relative to sole structure 110. The cavity 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, around the ankle, and below the foot. Upper 120 includes an exterior surface 121 and an opposing interior surface 122. Exterior surface 121 faces outward and away from article 100, while interior surface 122 faces inward and defines a majority or relatively large portion of the cavity within article 100 for accommodating the foot. Furthermore, interior surface 121 can be placed against the foot or a sock covering the foot. Access to the cavity is provided by throat opening 140, which is located in at least heel region 14. More specifically, the foot can be inserted into upper 120 through throat opening 140, and the foot can be exited from upper 120 through throat opening 140. In some embodiments, instep region 150 extends from ankle opening 140 in heel region 14 over an area corresponding to the instep of the foot to an area adjacent forefoot region 10 .

A lace 154 extends through various eyelets in upper 120 and allows the wearer to modify the size of upper 120 to accommodate the proportions of the foot. More specifically, lace 154 allows the wearer to tighten upper 120 around the foot, and lace 154 allows the wearer to loosen upper 120 to facilitate entry and removal of the foot from the cavity (i.e., through throat opening 140). In addition, a portion of upper 120 in instep area 150 extends under lace 154 to enhance the comfort of article 100. In other configurations, upper 120 may include additional elements, such as (a) a heel counter in heel area 14 to enhance stability, (b) a toe guard formed of a wear-resistant material in forefoot area 10, and (c) a logo, trademark, and label with care instructions and material information.

In some embodiments, shoelace 154 can extend through pairs of eyelets arranged along either side of instep area 150. In an exemplary embodiment, the eyelet pairs can include a plurality of outer eyelets 152 and a plurality of inner eyelets 153. The plurality of outer eyelets 152 can be arranged at a first position along instep area 150. The plurality of inner eyelets 153 can be arranged at a second position along instep area 150, with the inner eyelets 153 positioned further inward toward the middle of upper 120 than the outer eyelets 152 on each of lateral side 16 and medial side 18. Furthermore, the positions of outer eyelets 152 and inner eyelets 153 can be offset in the longitudinal direction along instep area 150. With this configuration, shoelace 154 can pass through inner eyelets 153, extend along inner surface 122, under knitted component 130, and exit knitted component 130 through outer eyelets 152 to continue along outer surface 121. In this manner, lace 154 may continue throughout instep area 150 through plurality of apertures 152 , 153 .

Many conventional footwear uppers are formed by various material elements (e.g., textiles, polymer foams, polymer sheets, leather, synthetic leather), which are connected, for example, by stitching or tying. In some embodiments, the major part of the upper 120 is formed by a knitted component 130, which will be discussed in more detail below. For example, the knitted component 130 can be manufactured by a flat knitting process and passes through each of the forefoot area 10, the midfoot area 12, and the heel area 14, along both the lateral side 16 and the medial side 18, on the forefoot area 10 and around the heel area 14 and extend. In an exemplary embodiment, the knitted component 130 forms substantially all of the upper 120, including a major part or a relatively large part of the inner surface 122 and the outer surface 121, thereby defining a part of the cavity in the upper 120. In some embodiments, the knitted component 130 can also extend under the foot. However, in other embodiments, a strobel sock, or a thin, sole-shaped piece of material, is secured to knitted component 130 to form a base portion of upper 120 that extends under the foot for attachment to sole structure 110. Additionally, as depicted in FIG4 , a seam extends vertically through heel region 14 to connect the edges of knitted component 130.

Additionally, while the knitted component 130 forms part of both the outer surface 121 and the inner surface 122, in some embodiments, a polymer layer or skin layer may be bonded to areas of the knitted component 130, as disclosed in U.S. Patent No. 13/079,653 to Dua, entitled “Article Of Footwear Having A Knit Upper With A Polymer Layer,” which was filed on April 4, 2011 and published on October 4, 2012 as U.S. Patent Application Publication No. 2012/0246973, the disclosure of which is incorporated herein by reference in its entirety.

In some embodiments, article 100 may include an integral knitted ankle collar 160 for covering at least a portion of the wearer's ankle. Thus, in addition to covering the foot, upper 120 extends upward and covers a portion of the ankle. For reference purposes, as shown in Figures 1, 2, and 3, upper 120 can be divided into two general regions: foot region 20 and ankle region 30. Foot region 20 extends through each of forefoot region 10, midfoot region 12, and heel region 14 and generally includes the portion of upper 120 corresponding to the foot. In many configurations of article 100, foot region 20 corresponds to the portion of upper 120 intended to be positioned beneath the wearer's lateral and medial malleolus (i.e., the bony protrusions on each side of the ankle). Ankle region 30 is primarily located in heel region 14 and generally includes the portion of upper 120 corresponding to the ankle. In many configurations of article 100 , ankle region 30 corresponds to the portion of upper 120 intended to cover and extend over the lateral and medial malleolus.

In an exemplary embodiment, border region 200 separates foot region 20 from ankle region 30. In this embodiment, border region 200 defines a portion of upper 120 where ankle collar 160 begins extending upward from foot region 20. In some embodiments, border region 200 may demarcate portions of knitted component 130 where the properties of the knit structure associated with ankle collar 160 (e.g., stitch type, yarn type, or properties associated with different stitch types or yarn types, including aesthetics, stretch, thickness, breathability, and wear resistance) may differ from the remainder of upper 120. It should be understood that in some cases, border region 200 may be visibly displayed on upper 120 by virtue of a difference in knit structure or other indicia. However, in other cases, border region 200 may not be visible on upper 120, and the portions of upper 120 associated with foot region 20 and ankle region 30 may have a continuous appearance.

Ankle collar 160 is located in ankle region 30 and forms the ankle portion of knitted component 130. The remaining portion of knitted component 130 located in foot region 20 forms the foot portion of knitted component 130. When article 100 is worn, the foot portion of knitted component 130 covers the wearer's foot, while the ankle portion of knitted component 130, including ankle collar 160, covers the wearer's ankle. Furthermore, ankle collar 160 and the ankle portion of knitted component 130 can be formed of a unitary knit structure along with the foot portion of knitted component 130.

Although a seam may be present in the ankle collar 160, the ankle portion of the knitted component 130 has a continuous structure that extends around the wearer's ankle as a whole. With reference to the top view of Figure 4, the ankle collar 160 forms a circular, oval or otherwise continuous and arched throat opening 140, which provides the entrance to the cavity in the upper 120. The throat opening 140 can have a relatively large size that allows the foot to pass through and enter the cavity. In some embodiments, the throat opening 140 can be stretched to accommodate the foot. In addition, the ankle collar 160 can have a size that is smaller than the average ankle diameter. Therefore, once the foot is located in the cavity, the ankle collar 160 can remain slightly stretched and firmly placed against the ankle. Therefore, the other parts of the ankle collar 160 and the knitted component 130 in the ankle area 30 can be formed to have stretch properties.

In some embodiments, knitted component 130 may include one or more features to help provide access for the wearer's foot, provide comfort to the wearer, and assist in the orientation of upper 120 of article 100 when worn. In an exemplary embodiment, ankle collar 160 may include features configured to correspond to the wearer's lateral and medial malleolus. In one embodiment, ankle collar 160 includes an ankle region 164 disposed on each of lateral side 16 and medial side 18 of upper 120. As described in more detail below, ankle region 164 provides a knitted structure on ankle collar 160 that allows for increased stretch and comfort for the wearer of article 100. Furthermore, by covering the wearer's ankle and fitting snugly to the wearer's ankle, ankle region 164 may help maintain the orientation of upper 120 on the wearer's foot.

In some embodiments, knitted component 130 may also include lace-receiving apertures 162. In an exemplary embodiment, lace-receiving apertures 162 may be located on portions of instep region 150 and/or ankle collar 160 that are near or adjacent to boundary region 200 between foot region 20 and ankle region 30. With this configuration, the lace-receiving apertures may be positioned approximately where lace apertures 152, 153 terminate at the top of the lacing area of upper 120. In one embodiment, lace-receiving apertures 162 may be configured to receive tied and knotted laces, such as lace 154.

Knitted component 130 extends in the whole vamp 120 and forms the major part of inner surface 122, thereby defining a part of the cavity in vamp 120. Although seams may exist in knitted component 130, the major part of knitted component 130 has a generally seamless configuration. In addition, knitted component 130 can be formed by an integral knitted structure. As used herein, when formed as a one-piece element by a knitting process, a knitted component (e.g., knitted component 130) is defined as being formed by an "integral knitted structure". That is, the knitting process generally forms the various features and structures of knitted component 130 without the need for significant additional manufacturing steps or processes. Integral knitted structure can be used to form a knitted component having a structure or element of one or more courses (courses) comprising yarn or other knitted materials, the one or more courses being connected so that the structure or element includes at least one common course (i.e., sharing a common yarn) and/or a generally continuous course between each of the structure or element. Through this structure, a one-piece element of an integral knitted structure is provided.

Although portions of the knitted component 130 may be connected to one another after the knitting process (e.g., edges of the knitted component 130 may be connected together), the knitted component 130 remains formed of a unitary knitted structure because it is formed as a one-piece knitted element. Furthermore, when other elements (e.g., laces, logos, trademarks, labels with care instructions and material information, structural elements) are added after the knitting process, the knitted component 130 remains formed of a unitary knitted structure.

Examples of various configurations of knitted components that can be used for knitted component 130 are disclosed in the following documents: U.S. Patent No. 6,931,762 to Dua; U.S. Patent No. 7,347,011 to Dua et al.; U.S. Patent Application Publication 2008/0110048 to Dua et al.; U.S. Patent Application Publication 2010/0154256 to Dua; and U.S. Patent Application Publication 2012/0233882 to Huffa et al., the disclosures of each of which are incorporated herein by reference in their entirety.

The main elements of knitted component 130 are knitted element 131 and inlaid thread 132. Knitted element 131 is formed by at least one yarn, which is manipulated (e.g., by a knitting machine) to form a plurality of loops that are intertwined with each other, defining various courses and wales. In other words, knitted element 131 has the structure of a knitted fabric. Inlaid thread 132 extends through knitted element 131 and passes between the various loops within knitted element 131. Although inlaid thread 132 generally extends along the courses within knitted element 131, inlaid thread 132 can also extend along the wales within knitted element 131. The advantages of inlaid thread 132 include providing support, stability, and structure. For example, inlaid thread 132 helps secure upper 120 around the foot, limits deformation in the area of upper 120 (e.g., imparts stretch resistance), and works together with shoelace 154 to enhance the fit of article 100. U.S. Patent Application Publication 2012/0233882 to Huffa et al., referenced above and incorporated herein, provides a discussion of the manner in which the knitted component 130 may be formed, including the process of inlaying or otherwise positioning the inlaid strand 132 within the knitted element 131 .

In some embodiments, inlaid strand 132 can extend upward through knitted element 131 from sole structure 110 toward instep area 150. In an exemplary embodiment, inlaid strand 132 can extend between each inner lace hole 153 and each outer lace hole 152, and can extend downward from instep area 150 back toward sole structure 110. For example, inlaid strand 132 can form a loop around outer lace hole 152, while inner lace hole 153 is located outside of the loop. With this configuration, inlaid strand 132 can reinforce outer lace hole 152.

Furthermore, when article 100 is provided with a lace 154, the inlaid thread 132 extending around the outer shoelace eyelets 152 can help provide support and/or stability to the wearer's foot. In some embodiments, the inlaid thread 132 can be tensioned when the shoelace 154 is tightened, and the inlaid thread 132 resists stretching in the upper 120. Furthermore, the inlaid thread 132 helps secure the upper 120 around the foot and works together with the shoelace 154 to enhance the fit of the article 100. For example, in embodiments where the shoelace 154 passes through the inner shoelace eyelets 153 into the knitted component 130 and exits the knitted component 130 through the outer shoelace eyelets 152, the shoelace 154 is arranged through the loop formed by the inlaid thread 132, allowing the fit of the upper 120 to be adjusted by pulling the shoelace 154. In one embodiment, the inlaid thread 132 can extend around the outer shoelace eyelets 152 while remaining within the knitted element 131. That is, inlaid strand 132 may extend through knitted component 130 within one or more courses and/or wales of knitted element 131. However, in other embodiments, inlaid strand 132 may exit knitted element 131 at one or more portions so as to be exposed on outer surface 121 and/or inner surface 122.

In an exemplary embodiment, the instep area 150 extending between the medial side 18 and the lateral side 16 can be formed by an integral knitted structure together with the upper 120 and the ankle collar 160. As shown in Figure 4, the portion of the knitted component 130 that forms the instep area 150 can be substantially continuous with the rest of the knitted component that forms the upper 120 and the ankle collar 160. In this embodiment, the instep area 150 is connected to the upper 120 along each of the lateral side and the medial side of the instep area 150 by knitting, so that the instep area 150 and the upper 120 include at least one common horizontal row and/or include substantially continuous horizontal rows. In addition, the instep area 150 is connected to the ankle collar 160 in front of the throat opening 140 by knitting, so that the instep area 150 and the ankle collar 160 include at least one common horizontal row and/or include substantially continuous horizontal rows.

With reference now to Fig. 5, the exemplary embodiment of knitted component 130 is shown with plane or flat configuration.In this embodiment, knitted component 130 has the configuration that is roughly Y-shaped that is outlined by outer perimeter.In this embodiment, this outer perimeter comprises front perimeter edge 510, outer perimeter edge 500 and medial perimeter edge 502 that is arranged relatively with outer perimeter edge 500. The outer perimeter edge of knitted component 130 also comprises a pair of heel edges, comprises outer heel edge 504 and medial heel edge 506.In an exemplary embodiment, knitted component 130 may also comprise the inner perimeter that will be associated with shoe throat opening 140 described above and define shoe throat opening 140.In this embodiment, the inner perimeter of knitted component 130 comprises inner perimeter edge 508. When incorporated into an article of footwear, including footwear 100, front peripheral edge 510, lateral peripheral edge 500, medial peripheral edge 502, and at least a portion of lateral heel edge 504 and medial heel edge 506 rest against an upper surface of sole structure 110 and may be connected to a strobel insole or sockliner. Furthermore, lateral heel edge 504 and medial heel edge 506 are connected to one another and extend vertically in heel region 14 of article 100. In some embodiments of the article of footwear, a material element may cover the seam between lateral heel edge 504 and medial heel edge 506 to reinforce the seam and enhance the aesthetic appeal of the footwear.

As described above, knitted component 130 may include an instep area 150 formed of a unitary knitted structure along with the remainder of upper 120 and ankle collar 160. In some embodiments, instep area 150 includes a plurality of lace holes 152, 153 arranged in knitted component 130. As described above, lace holes 152, 153 may extend through knitted component 130 and be configured to receive shoelaces, including shoelace 154. In an exemplary embodiment, lace holes 152, 153 are knitted directly into knitted component 130. However, in other embodiments, lace holes 152, 153 may include additional reinforcing elements added to knitted component 130. In some embodiments, instep area 150 may also include lace-receiving holes 162. As described above, lace-receiving holes 162 may be arranged in portions of instep area 150 and/or ankle collar 160 that are proximate to or adjacent to border region 200. In an exemplary embodiment, lace-receiving holes 162 may also be formed in a similar manner as lace holes 152, 153. In one embodiment, lace-receiving holes 162 may be formed directly into knitted component 130 using a button-hole stitch or other suitable stitch type. In other embodiments, lace-receiving holes 162 are optional and may be omitted.

5 , each of lateral side 16 and medial side 18 can be associated with a single inlaid strand 132 that alternately passes through knitted element 131 and extends beyond knitted element 131 at various portions of knitted component 130. In this embodiment, inlaid strand 132 exits knitted element 131 at various portions of knitted component 130 along each of lateral peripheral edge 500 and medial peripheral edge 502 before extending back into knitted element 131. With this configuration, a single inlaid strand 132 can be used for each of lateral side 16 and medial side 18 of upper 120. However, in other embodiments, additional inlaid strands can be provided at various portions of knitted component 130.

In various embodiments, a knitted component can include multiple types of yarns that impart different properties to separate areas of the upper. For example, one area of knitted component 130 can be formed from a first type of yarn that imparts a first set of properties, while another area of knitted component 130 can be formed from a second type of yarn that imparts a second set of properties. In this configuration, by selecting specific yarns for different areas of knitted component 130, the properties can be varied throughout upper 120.

The characteristics of the area that a particular type of yarn will impart to a knitted component depend in part on the material forming the multiple filaments and fibers in the yarn. For example, cotton provides a soft feel, natural beauty, and biodegradability. Elastane and stretch polyester each provide a large amount of stretching and recovery, with stretch polyester also providing recyclability. Rayon provides high gloss and hygroscopicity. In addition to insulating properties and biodegradability, wool also provides high hygroscopicity. Nylon is a durable and wear-resistant material with relatively high strength. Polyester is a hydrophobic material that also provides relatively high durability.

In addition to material, other aspects of the yarn selected for knitted components may affect the properties of the upper. For example, the yarn forming knitted component 130 may be a monofilament yarn or a multifilament yarn. The yarn may also include a separate filament formed of different materials. In addition, the yarn may include a filament formed of two or more different materials, such as a bicomponent yarn, which has a sheath-core configuration or two halves formed of different materials. Different degrees of twisting and curling and different deniers may also affect the properties of the upper 120. Therefore, the material forming the yarn and other aspects of the yarn may be selected to give various properties to the separate area of the upper 120.

In some embodiments, an integral knit ankle collar 160 can extend rearward from the instep area 150 of the knitted component 130 to the inner peripheral edge 508 and can also extend across to the lateral heel edge 504 and the medial heel edge 506. In an exemplary embodiment, the ankle collar 160 is formed of a unitary knit structure with the upper 120 at the rear portion of the instep area 150 of the knitted component 130 and along the border region 200 of each of the lateral side 16 and the medial side 18 of the upper 120. That is, the ankle collar 160 is knitted to the upper 120 at the rear portion of the instep area 150 so that the ankle collar 160 of the upper 120 and the instep area 150 of the upper 120 include at least one common course and/or include a substantially continuous course between the ankle collar 160 and the upper 120. Similarly, the ankle collar 160 is connected by knitting approximately along the border area 200 extending around the upper 120, including along each side of the upper 120 at the lateral heel edge 504 and the medial heel edge 506. It should be noted that in some configurations of the knitted component 130, although a dotted line is used to separate and define the location on the knitted component 130 where the ankle collar 160 begins, the dotted line may be used for reference and not be visible.

In some embodiments, an ankle collar 160 forms a circular or tubular structure in the upper 120 that corresponds to the throat opening 140 of the article 100. When the article 100 is worn, the ankle collar 160 extends around or around the wearer's ankle and can be placed against the ankle. In some embodiments, the ankle collar 160 can exhibit a greater stretchability than the rest of the upper 120. An advantage of imparting a relatively low resistance to stretching (i.e., allowing stretching) to the ankle collar 160 is that when the foot is inserted into and exited from the throat opening 140 formed by the ankle collar 160, this area of the knitted component 130 will elongate or otherwise stretch. Furthermore, when the article 100 is worn, the ankle collar 160 can remain in a partially stretched state and placed against the ankle, thereby preventing dirt, stones, and other debris from entering the article 100 through the throat opening 140.

In an exemplary embodiment, ankle collar 160 may include an ankle region 164 disposed on each of lateral side 16 and medial side 18. As described in more detail with reference to Figures 10 through 17, ankle region 164 provides a knit structure on ankle collar 160 that allows for increased stretch and comfort for the wearer of article 100. Additionally, ankle region 164 may help maintain the orientation of upper 120 on the wearer's foot by covering and fitting closely against the wearer's ankle.

Referring now to Figures 6 through 9, an exemplary embodiment of lacing receiving holes 162 is shown on ankle collar 160. In some embodiments, lacing receiving holes 162 may be located in instep region 150 or ankle collar 160. The location of lacing receiving holes 162 may be selected to correspond to the uppermost group of lacing holes 152, 153 or to correspond to a position slightly above the uppermost group of lacing holes 152, 153. In this embodiment, the uppermost group of lacing holes 152, 153 is arranged on each of lateral side 16 and medial side 18, proximate to upper edge 602 of throat opening 140. With this configuration, once shoelace 154 is extended through the uppermost group of lacing holes 152, 153, the tied and knotted shoelace can be inserted through hole 600 defined by lacing receiving holes 162. As shown in Figure 6, hole 600 extends through upper 120 from exterior surface 121 to interior surface 122.

7 to 9 illustrate an exemplary process of using lacing receiving holes 162 to insert the loose end of the tied and knotted lace into hole 600 so that the loose end of the tied and knotted lace is arranged inside the interior of the upper 120. As shown in FIG7, by using a lace 154 arranged through lacing holes 152, 153, article 100 can be selectively tightened to a desired amount of tightness around the foot inside the upper 120. Once the lace 154 reaches the desired amount of tightness, the lace 154 can then be tied and tied into a bow 700. However, it should be understood that the bow 700 is shown for exemplary purposes and that in other embodiments, different mechanisms can be used to securely hold the lace 154 in a tightened configuration.

Next, as shown in FIG8 , the loose ends of the bow 700 (including the lace loop and the trailing lace end) can begin to be placed through the aperture 600 formed by the lacing receiving aperture 162. In an exemplary embodiment, the portion of the knitted component surrounding the lacing receiving aperture 162 that forms the ankle collar 160 and/or instep area 150 can be stretched to help tuck the loose ends of the bow 700 into the aperture 600. Finally, as shown in FIG9 , the loose ends of the bow 700 have been fully inserted through the aperture 600 of the lacing receiving aperture 162, such that the loose ends of the bow 700 of the shoelace 154 are placed against the inner surface 122 of the knitted component 130 within the interior of the upper 120. In this embodiment, the knot of the bow 700 remains outside the aperture 600 on the outer surface 121. However, in other embodiments, the lacing receiving aperture 162 can be configured to accommodate the entirety of the bow 700, including the loose ends and the knot.

By placing the loose ends of bow 700 within holes 600 of lacing receiving apertures 162, the trailing ends of shoelace 154 and the lacing loops of bow 700 move within upper 120, keeping outer surface 121 relatively consistent. This configuration helps reduce the likelihood that the trailing ends of shoelace 154 and/or the lacing loops of bow 700 may interfere with article 100 when worn. For example, in embodiments where article 100 is a soccer shoe, lacing receiving apertures 162 can be used to provide a generally consistent outer surface 121 for use in playing soccer. With this configuration, the loose ends of bow 700 (including the lacing loops of bow 700 and/or the trailing ends of shoelace 154) are protected within the interior of upper 120 and can be prevented from flapping and interfering when contacting a soccer ball.

Referring now to Figures 10-17, an exemplary embodiment of an integral knitted ankle collar 160 is illustrated. In some embodiments, the ankle collar 160 can include features configured to correspond to the wearer's lateral and medial malleolus. In one embodiment, the ankle collar 160 includes an ankle region 164 disposed on each of the lateral side 16 and the medial side 18 of the upper 120. Exemplary embodiments of the knitted structure forming the ankle region 164 are described below.

In an exemplary embodiment, knit element 131 includes at least two knit layers that interlock with one another at one or more portions to form knit component 130. In this embodiment, first knit layer 1000 forms a majority of a first side of knit component 130. In some embodiments, first knit layer 1000 may be associated with a majority of exterior surface 121. Second knit layer 1010 forms a majority of a second side of knit component 130, the second side of knit component 130 being disposed opposite the first side. In some embodiments, second knit layer 1010 may be associated with a majority of interior surface 122.

10 , in this embodiment, the ankle region 164 may include a plurality of notches 1020 in the exterior surface 121 of the ankle collar 160. The plurality of notches 1020 are cutouts or cavities in the first knit layer 1000 that allow the second layer 1010 to be exposed to the exterior of the knitted component 130. That is, in this embodiment, the exterior surface 121 includes portions of the first knit layer 1000 and the second knit layer 1010 that are disposed within the bottoms of the plurality of notches 1020.

11 , a cross-sectional view of the ankle region 164 is shown to illustrate the knit structure including a first knit layer 1000 and a second knit layer 1010, in which embodiment each of the plurality of notches 1020 has a depth approximately equal to the thickness of the first layer 1000. By knitting the knit element 131 such that the first layer 1000 includes selectively placed notches or cavities, the second layer 1010 can be exposed to form the plurality of notches 1020.

In some embodiments, the ankle region 164 is formed by knitting the ankle collar 160 of the knitted component 130 together with a knitted structure forming a plurality of recesses 1020 during the knitting process. Suitable knitting structures for forming the ankle region 164 include a 1×1 simulated mesh knitting structure or a 2×2 simulated mesh structure. Compared to a mesh knitting structure that can be used to form a hole that extends completely through the knitted element 131 (including a first knitting layer 1000 and a second knitting layer 1010), the simulated mesh knitting structure forms recesses in the first knitting layer 1000, as depicted in Figure 11. In addition to improving the aesthetics of the article 100, the simulated mesh knitting structure can improve flexibility and reduce the total mass of the knitted component 130. Compared to the 1×1 simulated mesh knitting structure, the 2×2 simulated mesh knitting structure forms larger recesses in the first knitting layer 1000. Depending on the desired size of the plurality of notches 1020 associated with the ankle region 164, a 1×1 simulated mesh knit structure or a 2×2 simulated mesh knit structure may be used. In other embodiments, larger simulated mesh knit structures may be similarly formed. Furthermore, in other embodiments, a combination of a 1×1 simulated mesh knit structure, a 2×2 simulated mesh knit structure, or larger simulated mesh knit structures may be used together to form the ankle region 164.

Suitable simulated mesh knit structures with accompanying loop patterns for knitting such simulated mesh knit structures for use in the present embodiment are described in US Patent Application Publication No. 2012/0233882 to Huffa et al., referenced above and incorporated herein.

In an exemplary embodiment, an ankle region 164 disposed on lateral side 16 and medial side 18 provides additional stretch to ankle collar 160. As shown in FIG12 and FIG13 , ankle collar 160 is shown with ankle region 164 subjected to stretch. FIG12 shows ankle collar 160 in an unstretched condition. In this embodiment, ankle region 164 includes a plurality of recesses 1020, including a first recess 1200 and a second recess 1202. First recess 1200 and second recess 1202 are disposed at opposite ends of ankle region 164, with first recess 1200 disposed rearwardly on ankle collar 160 toward heel region 14, and second recess 1202 disposed forwardly on ankle collar 160 toward forefoot region 10.

In one embodiment, the first notch 1200 and the second notch 1202 can be separated by a first length L1 on the ankle collar 160. In this embodiment, the first length L1 represents the widest part of the ankle region 164. However, in other embodiments, the ankle region 164 can have different shapes associated with larger or smaller lengths. In addition, in this embodiment, the ankle region 164 is associated with a plurality of notches 1020 arranged in an approximately hexagonal configuration. However, in other embodiments, the arrangement of the plurality of notches 1020 associated with the ankle region 164 (including the number and/or position of the notches) can be varied. For example, in other embodiments, the arrangement of the plurality of notches 1020 can be associated with any geometric or non-geometric shape (including circular, oval, square, triangle, rectangle) and other desired arrangements. In an exemplary embodiment, the arrangement of the plurality of notches 1020 associated with the ankle region 164 can be selected to approximately conform to the shape of the wearer's ankle.

Referring now to FIG. 13 , an ankle collar 160 is shown subjected to stretching. In one embodiment, when the ankle collar 160 is under stretching (e.g., as may occur when a foot is inserted into the upper 120 through the throat opening 140), the ankle region 164 is configured to help provide stretch to the ankle collar 160. In this embodiment, the first notch 1200 and the second notch 1202 may be separated by a second length L2 on the ankle collar 160. In this embodiment, the second length L2 represents the stretching condition of the ankle region 164. The second length L2 may be greater than the first length L1. In some cases, the second length L2 may be significantly greater than the first length L1. For example, depending on the type of knit structure and the type of yarn selected to form the ankle region 164, the ankle region 164 may be subjected to a significant amount of stretch compared to the rest of the ankle collar 160, such that the second length L2 may be at least 50% greater than the first length L1. In other embodiments, the second length L2 may be 25% to 50% greater than the first length L1. In other embodiments, the second length L2 may be more than 50% greater than the first length L1.

14-16 illustrate an exemplary process for inserting a wearer's foot 1400 into upper 120 of article 100, wherein article 100 is provided with ankle collar 160 including ankle region 164. As shown in FIG14 , article 100 is configured to receive wearer's foot 1400 within the interior void of upper 120 through throat opening 140 defined by ankle collar 160. Foot 1400 includes an ankle bone 1402, also referred to as the lateral malleolus, which is shown on lateral side 16. Similarly, foot 1400 also includes a medial malleolus 1404 (shown in FIG17 ), which is disposed opposite the lateral malleolus.

Referring now to FIG. 15 , a diagram illustrates the insertion of a foot 1400 through the throat opening 140. As described above, the ankle collar 160, including the ankle region 164, can help stretch the ankle collar 160 during insertion of the foot 1400 into the article 100. Furthermore, as shown in FIG. 15 , and as will be described further below, the instep region 150 can also be configured to stretch to accommodate the entry of the foot 1400 into the upper 120. FIG. 16 illustrates the situation once the foot 1400 has been inserted into the upper 120 of the article 100. In this embodiment, the ankle region 164 approximately corresponds to the location of the ankle bone 1402 on the foot 1400. Similarly, the ankle region 164 disposed on the medial side 18 of the ankle collar 160 can also correspond to the location of the medial malleolus 1404 of the foot 1400. By providing the ankle collar 160 with additional stretch features, the ankle collar 160 can be snugly aligned with and encircle the foot 1400 over the ankle bone 1402. With this configuration, upper 120 may fit tightly and securely to the wearer's foot 1400 .

16 , upper 120 also provides additional comfort for the wearer's foot 1400 by accommodating and allowing ankle collar 160 to stretch at ankle region 164. In this embodiment, a protruding portion of ankle bone 1402 may project outwardly of ankle collar 160 at ankle region 164. With this configuration, since ankle region 164 may have a reduced resistance to stretching compared to the remainder of ankle collar 160, ankle region 164 reduces pressure on ankle bone 1402 and allows ankle collar 160 to comfortably surround the wearer's foot 1400.

Furthermore, by covering and fitting snugly against the wearer's lateral and medial malleolus, ankle region 164 can also help maintain the orientation of upper 120 on the wearer's foot. As shown in FIG17 , a front view of article 100 is shown with foot 1400 positioned within article 100. In this embodiment, lateral malleolus 1402 and medial malleolus 1404 are covered by ankle region 164 of ankle collar 160. By allowing each of lateral malleolus 1402 and medial malleolus 1404 to bulge outward at ankle region 164, ankle collar 160 can help maintain a desired orientation of upper 120.

In this embodiment, vertical axis 1700 and lateral axis 1702 are shown intersecting at an approximate midpoint 1704. Midpoint 1704 can be positioned a first distance D1 from a lateral malleolus end 1710, associated with the lateral malleolus 1402 of the foot 1400, extending outwardly through an ankle region 164 on the lateral side 16 of the ankle collar 160. Similarly, midpoint 1704 can be positioned a second distance D2 from a medial malleolus end 1712, associated with the medial malleolus 1404 of the foot 1400, extending outwardly through an ankle region 164 on the medial side 18 of the ankle collar 160. In this embodiment, first distance D1 and second distance D2 are approximately equal, such that midpoint 1704 is approximately equidistant from each of lateral malleolus end 1710 and medial malleolus end 1712.

Because the portion of ankle collar 160 associated with each ankle region 164 has a smaller or reduced amount of stretch resistance than the remainder of ankle collar 160, lateral malleolus 1402 and medial malleolus 1404 of foot 1400 will tend to remain within the corresponding ankle region 164. With this arrangement, midpoint 1704 can remain generally oriented in the same position on upper 120. Thus, upper 120 can generally maintain a desired orientation on the wearer's foot. For example, in embodiments where article 100 is a soccer shoe, ankle region 164 can help maintain the orientation of upper 120, thereby providing a generally smooth exterior surface 121 for playing soccer.

In various embodiments, the ankle region 164 having the plurality of recesses 1020 can provide additional aesthetic features to the ankle collar 160. For example, by selecting yarns having different colors for each of the first knit layer 1000 and the second knit layer 1010, a contrasting or coordinated visual effect can be provided on the ankle collar 160. For example, team colors or user-selected colored yarns forming each of the first knit layer 1000 and the second knit layer 1010 can be selected such that the color of the second knit layer 1010 is visible on the plurality of recesses 1020 of the ankle region 164.

In some embodiments, knitted component 130 may include additional features on upper 120 that provide comfort and/or cushioning for the wearer's foot. In an exemplary embodiment, knitted component 130 may include a stretch padding area arranged in instep area 150 that is configured to stretch to help the foot enter the upper 120 and provide cushioning once the foot has been inserted. An exemplary embodiment of a stretch padding area 1800 arranged across instep area 150 of upper 120 is shown in Figures 18 to 20. As shown in Figure 18, the stretch padding area extends from medial edge 1802 to lateral edge 1804 approximately in the middle of upper 120, adjacent to eyelets 152, 153, between lateral side 16 and medial side 18 of upper 120. In this embodiment, the stretch padding area 1800 may have a shape that is approximately an oblong oval or diamond, including an upper edge 1806 disposed in a direction toward the throat opening 140 and a lower edge disposed opposite the upper edge 1806 in a direction away from the throat opening 140 and toward the forefoot region 10. It should be noted that although dashed lines are used to separate and define the stretch padding areas 1800 on the knitted component 130, the dashed lines may be for reference only and may not correspond to any visible lines on the knitted component 130.

In an exemplary embodiment, stretch padding area 1800 can be formed by knitting using a knit structure that provides cushioning in an unstretched state and flexibility in a stretched state. In one embodiment, stretch padding area 1800 can include a stretch knit structure 1810 that is formed from a unitary knit structure along with the remainder of upper 120 (including instep area 150 and ankle collar 160). In an exemplary embodiment, stretch padding area 1800 can be surrounded by the remainder of upper 120 having a different knit structure than stretch knit structure 1810. Stretch knit structure 1810 can be a knit structure having a reduced or lesser amount of stretch resistance than the remainder of upper 120. For example, stretch padding area 1800 can include stretch knit structure 1810, as described below and shown by loop diagram 2000 in FIG. In one embodiment, the portion of upper 120 surrounding stretch padding area 1800 may include a jersey knit structure or a double jersey knit structure. For example, stretch knit structure 1810 may be used to knit stretch padding area 1800 so that stretch padding area 1800 can stretch in a lateral direction from medial edge 1802 to lateral edge 1804 while maintaining relative stretch resistance between upper edge 1806 and lower edge 1808 in a longitudinal direction.

Additionally, in some embodiments, the stretch properties of stretch padding area 1800 can be further enhanced or increased by using elastic yarn to form stretch knit structure 1810. With this configuration, the combination of the reduced resistance to stretch provided by stretch knit structure 1810 and the reduced resistance to stretch provided by the elastic yarn can provide an increased or greater amount or degree of stretch to stretch padding area 1800. For example, such an increased or greater amount of stretch can assist a wearer in inserting their foot into upper 120.

Figure 18 illustrates stretch padding area 1800 in an unstretched condition. In this configuration, stretch padding area 1800 may have a first width W1 extending across upper 120 between medial edge 1802 and lateral edge 1804. Additionally, in the unstretched condition, stretch padding area 1800 may have a first thickness T1 between outer surface 121 and inner surface 122 in the region of knitted component 130. In an exemplary embodiment, first thickness T1 may be provided to help cushion and/or pad the instep of a foot of a wearer of article 100. For example, in an embodiment where article 100 is a soccer shoe, first thickness T1 of stretch padding area 1800 may help cushion or provide padding for the wearer's foot during contact with a soccer ball.

Referring now to FIG. 19 , stretch padding area 1800 is illustrated in a stretched condition. In this embodiment, for example, during entry of a foot into upper 120, upper 120 may be stretched in the lateral direction between lateral side 16 and medial side 18. In the stretched condition, stretch padding area 1800 is configured to stretch in the lateral direction between medial edge 1802 and lateral edge 1804. In an exemplary embodiment, stretch knit structure 1810 is configured such that stretch padding area 1800 flattens and lengthens in the lateral direction to provide flexibility during insertion of the foot into upper 120. As shown in FIG. 19 , during the stretched condition, stretch padding area 1800 may have a second width W2 extending across upper 120 between medial edge 1802 and lateral edge 1804. In one embodiment, second width W2 may be greater than first width W1. For example, in some cases, second width W2 may be at least 25% greater than first width W1. In other cases, second width W2 may be 25% to 50% greater than first width W1. In other cases, the second width W2 can be more than 50% greater than the first width W1.

Furthermore, in the stretched condition, stretch padding area 1800 can have a second thickness T2 between outer surface 121 and inner surface 122 in the area of knitted component 130. In an exemplary embodiment, second thickness T2 can be less than first thickness T1. Once the stretched condition ends and stretch padding area 1800 returns to the unstretched condition, stretch padding area 1800 will again have the first thickness T1 in the area of knitted component 130. With this configuration, stretch padding area 1800 can assist in inserting the wearer's foot into upper 120 while providing cushioning and/or padding to the instep of the foot once it has been inserted.

Referring now to FIG20 , an exemplary embodiment of a loop diagram 2000 for knitting a stretch knit structure 1810 is shown. In this embodiment, loop diagram 2000 illustrates the sequence of stitches and movements performed by a knitting machine (e.g., a flat knitting machine) to form stretch knit structure 1810, which forms part of stretch padding region 1800. As shown in FIG20 , the spaced dots represent needles of the knitting machine, and the steps illustrated represent the direction of movement of the yarn or thread between the needles of each of the front and rear needle beds of the knitting machine. In a first step 2002, the yarn or thread is passed between each of the front and rear needle beds in an alternating manner, with a knit stitch performed on the rear needle bed and a tuck stitch performed on the front needle bed.

Next, in the second step 2004, the yarn or thread is passed between the front needle bed and the rear needle bed in an alternating manner, wherein a drop stitch is performed on the front needle bed at the needles arranged between the needles having the pattern performed in the first step 2002. Similarly, in the second step 2004, a drop stitch is performed on the rear needle bed at the needles arranged between the needles having the drop stitch performed in the first step 2002. In the third step 2006, a drop stitch is performed on the rear needle bed at the same needle holding the yarn or thread from the pattern performed in the second step 2004. Furthermore, in the third step 2006, a drop stitch is performed on the front needle bed at the same needle as the needle having the drop stitch performed in the second step 2004.

Finally, in the fourth step 2008, the yarn or thread is knitted on the front needle bed using the same needles as those used for knitting in the first step 2002, and the yarn or thread is knitted on the rear needle bed using the same needles as those used for knitting in the first step 2002. Through such a configuration, the portion of the stretch pad area 1800 having the stretch knit structure 1810 can be formed.

It should be understood that the portion of the stretch cushioning area 1800 that can be manufactured with the stretch knit structure 1810 according to the loop diagram 2000 shown in Figure 20 is merely exemplary. A stretch cushioning area 1800 having a desired size can be formed using a substantially similar process shown in the loop diagram 2000 to knit a knit structure having a width associated with a selected number of stitches and a length associated with a selected number of courses.

Although various embodiments of the present invention have been described, this description is intended to be illustrative rather than restrictive, and it will be apparent to those skilled in the art that many more embodiments and implementations within the scope of the present invention are possible. Therefore, the present invention is not limited except in accordance with the appended claims and their equivalents. Furthermore, various modifications and variations may be made within the scope of the appended claims.

Claims (16)

1. A footwear article having an upper including a knitted component, said knitted component comprising: The foot area extends through the forefoot area, midfoot area, and heel area of the footwear article, and includes a back area extending between the outer and inner sides of the upper. An ankle region, which forms a portion of the upper extending above the foot region, the ankle region including an ankle collar, the ankle collar defining a throat opening leading to a cavity within the upper, the cavity being configured to receive the foot; The ankle collar, together with at least the instep region of the foot region and the portion of the foot region located on the inner and outer sides of the heel region, is formed by an integral knitted structure. The ankle collar includes at least two knitted layers that interlock with each other within at least one portion of the ankle collar. The ankle collar further includes at least one ankle area, which is disposed on at least one of the inner and outer sides of the shoe upper. The at least one ankle area includes a plurality of notches in a first knit layer of the at least two knit layers, the first knit layer comprising the outer surface of the ankle collar. The plurality of notches are gaps in the first knitted layer, which allow a second knitted layer of the at least two knitted layers to be exposed to the outside of the knitted component. 2. The footwear article of claim 1, wherein the second knitted layer includes the inner surface of the ankle collar. 3. The footwear article of claim 2, wherein the plurality of notches are formed by the gaps in the first knitted layer that expose the second knitted layer. 4. The footwear article of claim 3, wherein the notch in the first knitted layer comprises at least one of a 1×1 simulated mesh knitted structure and a 2×2 simulated mesh knitted structure. 5. The footwear article of claim 1, wherein the at least one ankle area on the ankle collar is arranged at a position corresponding to the ankle of the wearer's foot. 6. The footwear article of claim 1, wherein the knitted component further comprises a lacing receiving hole formed in at least one of the instep region and the ankle collar, the lacing receiving hole being configured to receive the loose end of a tied lace inside the upper. 7. The footwear article of claim 1, wherein the instep region further comprises a stretch padding area disposed along the upper part of the footwear article between the inner and outer sides of the upper; The stretch padding area is configured to stretch across the footwear in a lateral direction between an unstretched and stretched state; and The stretch pad area has a first thickness in the unstretched state and a second thickness in the stretched state, wherein the first thickness is greater than the second thickness. 8. A footwear article having an upper including a knitted component, said knitted component comprising: The foot area extends through the forefoot area, midfoot area, and heel area of the footwear article, and includes a back area extending between the outer and inner sides of the upper. An ankle region, forming a portion of the upper extending above the foot region, the ankle region including an ankle collar defining a throat opening leading to a cavity within the upper, the cavity configured to receive the foot, wherein the ankle collar includes at least two knitted layers that interlock with each other within at least a portion of the ankle collar; and The ankle collar further includes a region containing a plurality of notches, the plurality of notches being gaps in a first knitted layer forming the outer surface of the ankle collar, the gaps allowing a second knitted layer to be exposed to the outside of the knitted component, and wherein the plurality of notches formed in the ankle collar are not in the foot region. 9. The footwear article of claim 8, wherein the knitted component further comprises a plurality of lacing holes configured to receive laces, the plurality of lacing holes being arranged longitudinally along the upper on each of the inner and outer sides of the instep region. 10. The footwear article of claim 8, wherein the ankle collar, together with at least the instep region of the foot region and portions of the foot region disposed on the inner and outer surfaces of the heel region, are formed by an integral knitted structure. 11. The footwear article of claim 8, wherein the knitted component further comprises a lacing receiving hole formed in at least one of the instep region and the ankle collar, the lacing receiving hole being configured to receive the loose end of a tied lace inside the upper. 12. A footwear article having an upper including a knitted component, said knitted component comprising: The foot area extends through the forefoot area, midfoot area, and heel area of the footwear article, and includes a back area extending between the outer and inner sides of the upper. An ankle region, forming a portion of the upper extending above the foot region, the ankle region including an ankle collar defining a throat opening leading to a cavity within the upper, the cavity configured to receive the foot, wherein the ankle collar includes a first knit layer and a second knit layer, the first knit layer forming the outer surface of the upper, and wherein the first knit layer and the second knit layer interlock with each other in at least a portion of the ankle collar; and The ankle collar further includes a region of a notch formed in the first knit layer of the ankle collar, wherein the yarn of the first knit layer in the region of the notch is different from the yarn of the second knit layer in the region of the notch, and wherein the notch is a gap in the first knit layer that allows the second knit layer to be exposed to the outside of the knitted part. The knitted component further includes a lacing receiving hole formed in at least one of the instep area and the ankle collar, the lacing receiving hole being configured to receive the loose end of the tied lace inside the upper. 13. The footwear article of claim 12, wherein the second knitted layer is arranged opposite to the first knitted layer, and the second knitted layer forms the inner surface of the upper; The shoelace receiving holes define holes extending through the first knit layer and the second knit layer; and The loose end of the tied shoelace is configured to be positioned along the inner surface of the shoe upper when arranged through the hole of the shoelace receiving hole. 14. The footwear article of claim 12, wherein the yarn of the first knitted layer in the region of the notch is different from the yarn of the second knitted layer, based on a selected characteristic including at least one of differences in color, transparency, denier, tensile resistance, breathability, durability, water resistance and the number of threads constituting the yarn. 15. The footwear article of claim 12, wherein the ankle collar, together with at least the instep region of the foot region and portions of the foot region disposed on the inner and outer surfaces of the heel region, is formed by an integral knitted structure; and The area of the notch formed in the first knit layer is disposed on at least one of the inner and outer sides of the ankle collar. 16. The footwear article of claim 12, wherein the instep region further comprises a stretch padding area disposed along the upper portion of the footwear article between the inner and outer sides of the upper. The stretch padding area is configured to stretch across the footwear in a lateral direction between an unstretched and stretched state; and The stretch pad area has a first thickness in the unstretched state and a second thickness in the stretched state, wherein the first thickness is greater than the second thickness.