Upper for article of footwear

Abstract

An upper of an article of footwear has an outer ply structure and an inner ply structure. An ankle collar is formed at the interconnection between the outer and inner ply structures and completely surrounds the shoe opening. The inner ply structure has a bladder in the heel region, and a heel cup or heel counter insert in the heel region is partially located between the first and second interior surfaces, and an upper portion of the heel cup or heel counter insert is disposed within the bladder. The ankle collar contacts the rearward surface of the bladder. The heel upper insert may also be attached to a multi-layer insole, which is then collectively inserted into the upper.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This patent application incorporates by reference the entire contents of the following applications: International Patent Application No. PCT / US2022 / 046726 filed on October 14, 2022, U.S. Patent Application No. 18 / 199,262 filed on May 18, 2023, U.S. Patent Application No. 18 / 199,250 filed on May 18, 2023, and U.S. Patent Application No. 18 / 199,274 filed on May 18, 2023. Technical Field

[0003] The utility model relates to the technical field of footwear, in particular to a shoe upper and a shoe having the shoe upper. Background Art

[0004] In footwear, existing sock-like upper designs—those formed from a single-piece knitted or woven sock-like material—are renowned for their comfort and snug fit. However, these designs often present challenges for easily donning and doffing the shoe, as they often lack the necessary structure or resilience to remain upright during the process. This lack of support, particularly around the heel area, often necessitates manually maintaining proper opening while inserting the foot. Furthermore, prior art sock-like upper designs are not configured to accommodate the addition of a heel component, nor are they designed to provide dual layers and / or support around the opening of the upper for such a heel component. Utility Model Content

[0005] Aspects of the present invention relate to a novel sock-like construction for a shoe upper comprising a single, elongated, circular knit tube that is subsequently folded inwardly upon itself to form at least a double-layer sock. The folding process creates two consistent sock layers, allowing for a seamless ankle collar that forms the shoe opening.

[0006] Additionally, aspects of the present invention relate to a shoe having a structure that supports easier insertion of a foot.

[0007] In one aspect of the present invention, an upper material is made of a knitted structure. The process of forming the knitted structure includes forming an outer sock structure and an inner sock structure. Each of the outer sock structure and the inner sock structure has a general size similar to a sock. Each of the outer sock structure and the inner sock structure may have a toe region, a midfoot region, a heel region, a sockliner portion, and an upper portion.

[0008] In another aspect of the present invention, the heel counter may include a heel cup. The heel cup may be uniformly molded with an upper portion, a middle portion, and a lower portion, and the upper portion may have a smaller medial-lateral length than the middle portion. The middle portion and the lower portion may form a concave structure configured to accommodate a heel. The upper portion of the heel cup has an overall downward inclination at a first angle relative to a vertical line perpendicular to a horizontal surface of the floor, with the highest portion extending rearward. The upper portion has an upper surface that may have a convexly curved portion along the rearmost vertical section of the heel cup so that the bottom of the heel is guided to slide after the foot is inserted. The convexly curved portion may further bend downward and turn to form a concave structure at the middle portion and the lower portion.

[0009] The upper portion of the heel cup is raised and may extend above the medial collar portion and the lateral collar portion of the upper. The upper may have a horizontal curvature that is relatively coextensive with the medial-lateral curvature of the heel portion of the upper. The length of the horizontal curvature may be configured to receive and at least partially cup at least a portion of the bottom of the heel when the foot is inserted into the shoe.

[0010] The heel cup can be formed from a rigid structure that is capable of being substantially uncompressed after the foot is inserted. In such a configuration, the upper can have an elastic portion that allows the upper to stretch when the foot is inserted into the shoe. As the foot is inserted, pressure is applied to the upper portion of the heel cup. If the heel cup is substantially rigid, this pressure can push the heel cup rearward. The heel cup can be used in conjunction with an elastic portion in the upper to allow the heel cup to move rearward during foot insertion. Following insertion, the rigid heel cup can return to its original position to secure the foot within the shoe and support the foot during use.

[0011] The upper portion of the heel cup can also be compressed during foot insertion, wherein the upper portion can have a first configuration in its natural state and can deform to a second configuration under the load of the user's foot when the user wears the footwear. The heel cup can return to the first configuration after the load of the user's foot is removed. In the second configuration, at least a portion of the upper portion is lowered relative to the first configuration, and the upper portion can return to the first configuration after the load of the user's foot is removed. The middle portion can include a peripheral portion having a first thickness and a central portion having a second thickness, wherein the second thickness is less than the first thickness.

[0012] According to this embodiment, in a first configuration, the upper portion has a downward inclination at a first angle relative to a vertical line perpendicular to a horizontal surface of a floor, and in a second configuration, the upper portion has an inclination at a second angle greater than the first angle. Furthermore, in the second configuration, a lower region of the central portion of the heel cup extends outwardly in a direction away from the shoe opening, causing the shoe opening to widen in the medial-lateral direction.

[0013] The inner foam layer can be a flat material lining covering at least a portion of the inner surface of the heel cup; alternatively, the foam layer can include an area with additional padding. The foam layer provides cushioning and comfort for the foot and can help secure the foot within the shoe upper after insertion. In one embodiment, the foam layer can protrude and extend with a rounded, forward-facing surface. The foam layer can form a U-shaped pad around the heel cup area, contacting the foot above the calcaneal region and around the posterior portion of the subtalar joint or at least a portion of the topmost area of ​​the shoe opening that receives the foot. The foam layer can at least partially surround and extend above the shoe opening that receives the foot. During insertion, the foam layer can be compressed by the user's heel in an unexpanded or first partially compressed state. After the foot is inserted into the shoe, the foam layer can expand to its uncompressed state or a second partially compressed state, where the second partially compressed state is less compressed than the first partially compressed state. This configuration enables the inner foam layer to apply sufficient pressure on or around the user's ankle to secure the foot in the shoe. For example, during activities such as walking or running, the heel bone portion of the foot may not be easily removed from the shoe. In areas where less padding is desired, such as extending to where the foam layer applies pressure around the ankle, the foam layer may have a tapered or flat size.

[0014] The foam layer and heel cup can be constructed as a separately formed heel counter insert, which is then positioned within the shoe upper. The heel counter insert can be covered with a foam covering material. The heel counter insert can have a fixed wing constructed from the foam layer and / or foam covering material, which extends downward at the bottom of the heel counter insert. The heel cup can terminate above the heel wing, or a portion of the heel cup can extend downward within or beside the wing. The fixed wing can be folded into a shape that is roughly perpendicular to the vertical dimension of the heel counter and inserted along the shoe upper, sock lining, or insole of the insole. The fixed wing can be attached to the top surface of the shoe upper, sock lining, insole of the insole, or sole.

[0015] The covering layer may cover a heel counter insert having a heel cup and a foam layer. The covering layer is part of a portion of the inner sock structure that extends above the ankle collar of the shoe and is exposed thereby, and forms part of the outer sock structure. The covering layer may have a front covering portion and a rear covering portion. The front covering portion may cover an inwardly facing surface of the heel counter. The rear covering portion may cover at least a portion of an outwardly facing surface of the heel counter. The covering layer may be formed integrally with the sock, for example knitted or woven integrally with the sock. The one-piece construction eliminates the need for a separate covering layer to construct the heel cup, thereby allowing for more efficient production. Where the covering layer is part of both the outer sock structure and the inner sock structure, the covering layer forms an integral bladder that houses the heel cup insert or the heel counter insert.

[0016] Furthermore, the integrated bladder closely accommodates at least the contours of the upper and / or middle portions of the heel cup or heel counter insert. The integrated bladder can be seamless, thereby providing greater comfort for the foot. It should be noted that a tubular sock with an integrated bladder can also be constructed using woven materials or engineered mesh fabrics or textiles known in the art, as are known to those skilled in the art.

[0017] Because the integrated bladder wraps around the rear-facing surface of the heel cup or heel counter insert, the bladder can extend downward below the level of the ankle collar and down behind the ankle collar and upper to the inner sock layer of the upper. The inner sock layer of the upper can then extend upward to the top of the ankle collar and then wrap over the ankle collar to meet the outer surface of the sock layer.

[0018] The upper may also have an integral ankle collar (which may also be referred to as an integral ankle strap, band, area, wing, extension, or any other term that may be commonly used to define an integral component). The integral ankle collar is a further extension of the sock and extends away from the sock portion that covers the outer heel counter. The ankle collar wraps around the outer cover portion of the cover layer. The ankle collar may include two layers, each layer forming a part of the inner sock structure and the outer sock structure. The rear cover portion of the cover layer and the ankle collar may be integrally connected or formed separately. When integrally connected, the rear cover portion and the ankle collar may be a knitted textile material, an engineered mesh fabric, or a textile known in the art to those of ordinary skill in the art.

[0019] A portion of the outer sock structure and a portion of the inner sock structure may include an integrated ankle collar that may extend around a rearward-facing surface of the integrated bladder and below the level of an upper portion of the heel cup.

[0020] The bladder and ankle collar are integrated into the inner and outer sock structures, allowing for easy assembly of the upper. The outer sock structure and ankle collar can be used to provide external protection for the upper. Furthermore, the ankle collar can be a tension band with elastic properties, allowing the heel cup to move backward during insertion of the foot into the shoe and return to its original position once the foot is inserted.

[0021] In another aspect of the present invention, an insole can be placed through an aperture in the outer sock structure or the inner sock structure and positioned between the engaging surfaces of the outer sock structure and the inner sock structure, primarily in an area corresponding to the insole portion. The outer sock structure can then be attached to the midsole or outsole. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] By way of example only, selected embodiments and aspects of the present invention are described below. Each description refers to an accompanying drawing ("Figure") that illustrates the described content. Some of the figures shown in the drawings or photographs accompanying this description may be for left or right footwear. Each figure includes one or more identifiers for one or more parts or elements of the present invention.

[0023] Various embodiments are described with reference to the accompanying drawings, in which:

[0024] Figure 1 is a front view of the heel cup.

[0025] Figure 2 yes Figure 1 Stereoscopic view of the heel cup.

[0026] Figure 3 yes Figure 1 Side view of the heel cup.

[0027] Figure 4A and Figure 4B yes Figure 1 The heel cup is in compression configuration ( Figure 4A ) and uncompressed configuration ( Figure 4B ) side-by-side front perspective view.

[0028] Figure 4C and Figure 4D yes Figure 1 The compressible heel cup is placed in the shoe in its compression configuration ( Figure 4C ) and its uncompressed configuration ( Figure 4D ) side-by-side top view.

[0029] Figure 5 is a front view of a heel cup configured with a series of intersecting segments.

[0030] Figure 6A yes Figure 1Schematic diagram of a cross section of the arc length of the posteriormost portion of the heel cup.

[0031] Figure 6B It is along Figure 1 The line 6-6 in the Figure 1 Cross-sectional view of the heel cup.

[0032] Figure 7 is a side view of the heel counter with the heel cup located within the interior of the heel counter.

[0033] Figure 8 yes Figure 7 A top view of the heel counter.

[0034] Figure 9 yes Figure 7 A three-dimensional image of the heel counter.

[0035] Figure 10 is a perspective view of a shoe upper having a heel counter including a heel cup.

[0036] Figure 11 Is a Figure 10 Side view of the upper of the shoe.

[0037] Figure 12 Is a Figure 10 Rear view of the upper of the shoe.

[0038] Figure 13 Is a Figure 10 A rear view of the shoe with the upper and the ankle collar pulled down.

[0039] Figure 14 Is a Figure 10 A top view of the upper of the shoe.

[0040] Figure 15 It is along Figure 14 The line 15-15 in the Figure 14 A cross-sectional view of the heel area of ​​a shoe upper.

[0041] Figure 16 is a perspective view of the elongated interfacing surfaces of a knitted structure prior to the eversion process to form a double-layer sock upper.

[0042] Figure 17 is a perspective view of the elongated counterfacing surfaces of a knitted structure prior to the inversion process to form a double-layer sock upper.

[0043] Figure 18 It is cut at the longitudinal center line of the elongated knitted structure Figure 17 sectional view of .

[0044] Figure 19 It is cut at the longitudinal center line of the knitted structure after the inversion process to form the double-layer sock upper Figure 17 sectional view of .

[0045] Figure 20 It is a top view of the multi-layer insole.

[0046] Figure 21 It is along Figure 20 The line 21-21 in the Figure 20 Cross-sectional view of the insole.

[0047] Figure 22 yes Figure 20 Exploded view of the insole.

[0048] Figure 23 It is a bottom view of the multi-layer insole.

[0049] Figure 24 is a cross-sectional view of a shoe having a multi-layer insole.

[0050] Figure 25 is a cross-sectional view of the heel counter insert.

[0051] List of reference numerals:

[0052] 14: sole;

[0053] 16: upper;

[0054] 32: Heel back;

[0055] 34: Heel counter insert

[0056] 46: inner lining;

[0057] 48: Shoe opening;

[0058] 50: central part;

[0059] 52: heel cup;

[0060] 54: lower portion of the heel cup;

[0061] 58: middle part of the heel cup;

[0062] 64: Upper part of the heel cup;

[0063] 66: inner wall;

[0064] 68: Top edge line of the heel cup;

[0065] 70: peripheral portion of the heel cup;

[0066] 84: heel cup collar;

[0067] 86: vertical line (perpendicular to the horizontal surface);

[0068] 88: horizontal surface of the floor;

[0069] 90: midline of the heel cup;

[0070] 92: Foam layer;

[0071] 94: Protrusion

[0072] 102: Knitted structure

[0073] 104: Outer sock layer structure

[0074] 105: Inner sock structure

[0075] 110: First toe area

[0076] 111: Second toe area

[0077] 112: First midfoot area

[0078] 113: Second midfoot area

[0079] 114: First heel area

[0080] 115: Second heel area

[0081] 116: First insole part

[0082] 117: Second insole part

[0083] 118: Orifice

[0084] 122: Inner side

[0085] 123: External side

[0086] 124: First joint surface

[0087] 125: Second joint surface

[0088] 126: First opposing surface

[0089] 127: Second relative surface

[0090] 134: Tongue area

[0091] 135: Perforation

[0092] 136: Insole

[0093] 137: Top inner bottom layer

[0094] 138: Middle inner bottom layer

[0095] 139: Bottom inner bottom layer

[0096] 140: cyst

[0097] 142: Ankle collar

[0098] 144: Upper boundary

[0099] 146: Lower boundary

[0100] 152: Front covering part

[0101] 154: rear covering part

[0102] 162: Fixed wing

[0103] 164: Notch

[0104] 166: Insole support pad

[0105] 168: Exposed Area

[0106] A1: Sloping downward

[0107] A L : the amplitude of the arc of the lower part

[0108] A U : the amplitude of the arc of the upper part

[0109] W U : Width of the upper arc

[0110] W L : The width of the arc of the lower part

[0111] T1: Thickness of the heel cup DETAILED DESCRIPTION

[0112] A shoe may include a sole and an upper. The sole may include an outsole, a midsole, and / or an integrally formed outsole and midsole. The upper may include a toe cap, a vamp, a tongue, an inner shoe waist, an outer shoe waist, and a heel counter. The shoe has a forefoot portion, a rear portion, an inner side, and an outer side. The upper may include an exterior layer, an interior layer or interior structure, and / or an inner lining. The upper may form a shoe opening that accommodates the user's foot when the shoe is worn. These areas are defined conceptually, not as discrete, physically defined segments. As such, the figures of this application depict the approximate locations of these areas and portions.

[0113] The heel counter or rear portion of the upper may include a heel cup, which facilitates insertion of the foot into the shoe opening. The upper portion of the heel cup has an overall downward slope at a first angle relative to a vertical line perpendicular to a horizontal surface of the floor, with the highest portion extending rearward. The upper portion may have an upper surface that may have a convexly curved portion along the rearmost vertical section of the heel cup, guiding the heel bottom to slide after insertion. The convexly curved portion may further curve downward and flex to form a concave configuration at the middle and lower portions of the heel cup.

[0114] The upper portion of the heel cup is raised and may extend above the medial and lateral collar portions of the upper. The upper may have a horizontal curvature that is relatively coextensive with the medial-lateral curvature of the heel portion of the upper. The length of the horizontal curvature may be configured to receive and at least partially cup at least a portion of the bottom of the heel when the foot is inserted into the shoe.

[0115] The heel cup can be formed from a rigid structure that is substantially uncompressed after the foot is inserted. In such a configuration, the upper can have an elastic portion that allows the upper to stretch when the foot is inserted into the shoe. As the foot is inserted, pressure is applied to the upper portion of the heel cup. If the heel cup is substantially rigid, this pressure can push the heel cup rearward. The heel cup can be used in conjunction with an elastic portion in the upper to allow the heel cup to move rearward during foot insertion. Following insertion, the rigid heel cup can return to its original position to secure the foot within the shoe and support the foot during use.

[0116] A heel cup can support easier insertion and removal of the foot. The heel counter, or rear portion, of the upper can allow the shoe's opening, configured to accommodate the foot, to temporarily widen when the user is putting on or removing the shoe. Widening of the shoe opening can be initiated by the user placing a load on the heel counter, or rear portion of the upper. This load can be applied by the user's foot, with little or no assistance from the user's hands. In an exemplary embodiment of the present invention, the heel counter can be compressible and return to its uncompressed state when placed under sufficient load. The heel counter can compress and return to its uncompressed state when sufficient load is applied. The heel counter can have a heel cup that lowers or has a compressible layer that compresses under load, thereby widening the shoe opening and allowing the user's foot to be inserted more easily. Once the foot is inserted into the shoe, the heel counter can have a compressible layer, such as a foam layer or component, that can further secure or improve the foot's position during normal shoe wear.

[0117] Heel cup. Reference Figures 1 to 10In an embodiment, the heel counter 32 may include a compressible heel cup 52, which may be an internal component of the upper 16, a portion of the lining 46, or an attachment adjacent to the lining 46 of the upper 16 so that the heel cup 52 contacts the foot, or a portion of the exterior layer 42 of the upper 16 or an attachment to the exterior surface of the exterior layer 42 of the upper 16.

[0118] refer to Figure 1 4, the shape of the heel cup 52 corresponds substantially to that of the heel cover and its profile resembles a pear shape. The medial-lateral width of the heel cup near the heel cup collar 84 is less than the medial-lateral width of the lower portion 54, as shown in FIG. Figures 1 to 2 shown

[0119] like Figure 2 As shown, the inner wall 66 of the upper portion 64 of the heel cup at the rearmost portion of the heel cup can be tilted downward by 0 to 90 degrees relative to a vertical line 86 perpendicular to a horizontal surface 88 of the floor. In this exemplary embodiment, the inner wall 66 of the upper portion 64 can have a 30-degree downward slope. The inner wall 66 of the upper portion 64 of the heel cup 52 can also have a convex curve facing the shoe opening 48. The top portion of the convex curve has a 30-degree downward slope A1. The lower portion of the convex curve extends directly above the portion of the heel cup 52 that receives the heel. The lower portion of the convex curve can have a downward slope that is less than the downward slope A1 and gradually decreases as it approaches the slope of the vertical line 86. The heel cup 52 has a concave curve that surrounds the rear portion of the heel. The medial and lateral sides of the heel cup 52 can also extend and provide support for a portion of the shoe waist, even as far as the v-joint.

[0120] The thickness of the heel cup 52 may decrease at various locations. A top edge line 68 may gradually narrow the inner and outer surfaces of the heel cup 52. The heel cup 52 may have an increased thickness T1, such as 2 mm to 3 mm, along other peripheral edges. In another exemplary embodiment, the thickness T1 may decrease in certain areas to provide greater flexibility for the heel cup 52 when donning or removing the shoe 12. In one embodiment, the thickness T1 of the heel cup 52 may gradually decrease from the peripheral portion 70, which forms an area at the perimeter of the heel cup 52, toward the central portion or region 50 of the middle portion 58. The minimum thickness T1 in the central region 50 of the middle portion 58 may be approximately (but not limited to) 1 / 4 to 1 / 6 of the thickness of the thickest portion at the perimeter of the heel cup 52, such as 0.5 mm to 1 mm. The thickest area of ​​the top portion may be greater than the thickest area of ​​the bottom portion. The reduced thickness T1 of the central region of the middle portion 58 may allow the heel cup 52 to compress under sufficient load. In alternative embodiments, thickness T1 can be reduced throughout the medial-lateral portion or in multiple areas, such as areas in the middle portion 58 and / or areas in the upper portion 64. The thinner areas can increase the flexibility and flexure of the heel cup 52, which provides the necessary compressibility under the load of a user's foot, such as during wearing of the shoe 12. Such compression can allow the upper portion 64 and / or the middle portion 58 of the heel cup 52 to move rearward and widen the shoe opening 48 to allow the foot to enter more easily. When the user wears the footwear, the heel cup 52 can be deformed from the first configuration in its natural state to the second configuration under the load of the user's foot. For example, the heel cup 52 can be partially compressed so that the upper portion 64 and / or the middle portion 58 of the heel cup 52 are lowered enough to allow the user's foot to be inserted. See, for example, Figure 4A and Figure 4C Once the user's foot is inserted into the shoe 12, the heel cup 52 can return to its uncompressed configuration.

[0121] According to this embodiment, when a user wears the shoe 12, the convexly curved top portion of the heel cup 52 of the shoe 12 or the uppermost section of the heel counter 32 can be lowered and extended rearwardly away from the foot as the heel counter 32 is compressed, as shown in FIG. Figure 4A . This action allows the user's foot to be inserted into the shoe opening 48 with a reduced degree of plantar flexion. During compression of the heel cup 52, portions of the heel cup 52 can move forward in the direction of the forefoot portion. Deformation of the heel cup 52 can include widening of the attached heel counter 32 as the medial and lateral sides of the heel cup move outward, thereby widening the shoe opening. The medial-lateral widening of the shoe opening 48 allows for easier entry of the forefoot portion of the user's foot, such as easier insertion. In one exemplary embodiment, a 7.5 cm shoe opening can be widened to 4 cm or approximately 50%. See Figure 4C and Figure 4D Depending on the size of the shoe and the flexibility of the heel cup, the widening may be smaller or larger. In some shoes, the desired widening may be smaller or larger depending on the needs of fit and use.

[0122] exist Figure 1 In the exemplary embodiment of the heel cup 52 shown in FIG4 , the thickness T1 of the heel cup 52 made of a polymer material (such as DuPont Hytrel) can be between 0.4 mm and 4 mm. Depending on the required elasticity and durability of the material, the thickness T1 of the heel cup can range from thinner to thicker in various areas. For example, the midpoint area can be thinner than the surrounding areas, and in particular, the central portion can be thinner than the peripheral portion, such as Figure 6B The central portion may be spaced apart from the medial and lateral edges, wherein the peripheral edge may have a greater thickness. Other suitable materials may include other thermoplastic elastomers, or other polymers capable of providing compressible properties to the heel cup.

[0123] In another exemplary embodiment, the heel cup may be configured with a series of intersecting segments that form an egg crate-like configuration. Figure 5 An exemplary embodiment is shown with segments arranged in a diagonal configuration. In alternative embodiments, the segments can also be arranged in a vertical and horizontal configuration. The apertures between the segments can be set to a generally uniform size. The size of the segments can be uniform, or the thickness and width of the segments can vary. Thinner or narrower segments can be used to increase flexibility and compressibility in designated locations, while thicker or wider segments can provide varying degrees of rigid support. For example, the segments can be thinner in the middle, particularly in a central portion of the middle portion spaced apart from the edges. The surrounding segments can be thicker than the central portion. The central portion can allow for greater flexibility to deform under load.

[0124] In an exemplary embodiment, the rearmost portion of the heel cup 52 may have an overall vertical cross-sectional shape that generally resembles an S-wave, as shown in FIG. Figure 6A The upper and lower parts of the S wave can be distinguished at a point P1 passing through the horizontal plane, i.e., a center line 90, which is drawn between the upper and lower arc ends of the S wave and intersects the heel counter 52 and the inflection point of the S wave. The amplitude of the arc of the upper part of the S wave (A U ) and width (W U ) may be different from the amplitude of the lower arc of the lower portion of the S wave (A L ) and width (W L ). In an exemplary embodiment, W U Approximately W L 0.44 times of A U Approximately A L1 / 3, wherein the depth of the upper bend is less than that of the lower bend. In one possible embodiment, W U About 2cm, and W L About 4.5cm. U About 3mm, and A L The cross section of the heel cup 52 is approximately 9 mm. U / A L and W U / W L Both are reduced and may consist solely of a lower arc along the medial and lateral sides of heel cup 52. The measurements at the rearmost portion of heel cup 52 of the exemplary embodiment are intended to be exemplary.

[0125] The central region of the middle portion of the heel cup can have a single or multiple openings. Just as the central region of the middle portion can be constructed of less material than the maximum thickness of the collar and / or the maximum thickness of the base, the central region of the middle portion of the heel cup can be constructed of a material that is more flexible than the material forming its perimeter. The net effect of a central region including a single orifice, multiple orifices, a lesser thickness, and / or a more flexible material can facilitate entry and removal of the user's foot from the shoe.

[0126] According to an exemplary embodiment, the heel cup 52 may be attached to at least the foam layer 92, such as Figure 10 The heel cup 52 may be located within the interior of the heel counter 32 of the upper 16, as shown. Figures 7 to 10 As shown, the foam layer 92 can line both the inner wall 66 and the outer wall of the heel cup 52. Around the upper portion and the middle portion, the foam layer 92 can protrude and extend further into the shoe opening 48. The foam layer 92 can be thicker at or near the upper portion 64 and the middle portion 58 of the heel cup 52, thereby forming a portion of the collar of the shoe opening 48. Once the user's foot is inserted into the shoe 12, the thicker foam layer 92 can provide a secure fit because the foam will be positioned over the calcaneal area of ​​the user's foot and extend around at least a portion of the ankle area of ​​the foot. Because the foam is compressible, the foam can be compressed by the heel during insertion or removal of the foot and hold the ankle of the foot in place once the user's foot is inserted.

[0127] In another aspect of the present invention, the heel cup 52 can be uniformly molded with an upper portion 64, a middle portion 58, and a lower portion 54, with the upper portion 64 having a smaller medial-lateral length than the middle portion 58. The middle portion 58 and the lower portion 54 can form a concave structure configured to accommodate a heel. The upper portion 64 of the heel cup 52 has an overall downward inclination at a first angle relative to a vertical line 86 perpendicular to a horizontal surface 88 of the floor, with the highest portion extending rearward. The upper portion 64 has an upper surface that can have a convex curvature along the rearmost vertical section of the heel cup to guide the bottom of the heel in sliding motion after insertion of the foot. The convex curvature can further curve downward and turn to form a concave structure at the middle portion 58 and the lower portion 54.

[0128] The upper portion 64 of the heel cup 52 is raised and can extend above the medial and lateral collar portions of the upper. The upper can have a horizontal curvature that is relatively coextensive with the medial-lateral curvature of the heel portion of the upper. The length of the horizontal curvature can be configured to receive and at least partially cup at least a portion of the bottom of the heel when the foot is inserted into the shoe.

[0129] In another exemplary embodiment of a heel counter, a heel cup 52 having S-wave dimensions similar to those described above can be formed from a rigid structure that is substantially uncompressed after the foot is inserted. In such a configuration, the upper 16 can have an elastic portion that allows the upper to stretch as the foot is inserted into the shoe. As the foot is inserted, pressure is applied to the upper portion 64 of the heel cup 52. If the heel cup is substantially rigid, the pressure can push the heel cup 52 rearward. Following insertion of the foot, the rigid heel cup 52 can return to its original position to secure the foot within the shoe and support the foot during use.

[0130] Depending on the embodiment, the rigid heel cup 52 may have a consistent thickness, or may have varying thickness or lack of material in the middle or lower portion of the heel cup.

[0131] According to this embodiment, in a first configuration, the upper portion 64 has a downward inclination A1 at a first angle relative to a vertical line 86 perpendicular to a horizontal surface 88 of the floor, and in a second configuration, the upper portion 64 has a downward inclination A1 at a second angle greater than the first angle. In addition, in the second configuration, the lower area of ​​the central portion 50 of the heel cup extends outwardly in a direction away from the shoe opening, which widens the shoe opening in the medial-lateral direction.

[0132] The heel cup can be used in conjunction with a foam layer 92, which can be a flat lining of material that covers at least a portion of the inner surface of the heel cup 52, or the foam layer 92 can include areas with additional padding, such as Figure 15. In one embodiment, the foam layer 92 may protrude near the upper and middle portions of the heel cup and have a rounded or substantially tubular shape. The foam layer 92 may form a U-shaped cushion around the area of ​​the heel cup 52, with the foam layer contacting the foot above the calcaneal region and around at least a portion of the topmost region of the shoe opening 48, which receives the foot, around the posterior portion of the subtalar joint. The foam layer 92 may extend at least partially around the shoe opening 48. During insertion, the foam layer 92 may be compressed by the user's heel, placing the foam in an unexpanded state or a first compressed state. After the foot is inserted into the shoe, the foam layer 92 may expand to its fully uncompressed state or a second compressed state, which is less compressed than the first. This configuration enables the inner foam layer 92 to exert sufficient pressure on or around the user's ankle to secure the foot in the shoe. For example, during activities such as walking or running, the calcaneal region of the foot may not be easily removed from the shoe. In areas where less padding is needed, such as extending to areas where the foam layer 92 applies pressure around the ankle, the foam layer 92 can have a tapered or flat size. The raised foam layer also increases the curvature of the lower portion of the upper to better secure the heel portion of the foot.

[0133] The heel cup 52 and the foam layer 92 may form a heel counter insert 34 , which may be constructed separately and inserted between the layers of the upper. Figures 24 to 25, an exemplary embodiment of a heel counter insert 34 is shown in FIG. The heel counter insert 34 can have a foam layer 92 that completely surrounds the heel cup 52 and has a projection 94 on the inner surface of the heel cup, which is located at the upper and middle portions of the heel cup. The projection 94 extends from the rearmost portion of the heel cup and extends along the inner surface of the heel cup, thereby forming a U-shaped dimension. The end of the projection 94 can be tapered to the inside and outside of the heel counter insert 34 and can be vertically tapered above and below the projection 94. The heel counter insert 34 can also have a fixing wing 162, which can be constructed of a foam layer or foam covering material, which can be a mesh fabric, textile, polymer film, or any other material known to those skilled in the art. The heel cup and / or foam layer can terminate above the fixing wing 162. Alternatively, a portion of the heel cup and / or foam layer can extend downward within or beside the wing. The securing fin 162 and all of its components can be folded or bent at an angle that is perpendicular or approximately perpendicular to the wall of the heel cup. The securing fin 162 can also have at least one cutout or notch 164 to allow the securing fin 162 to fold or bend without deforming as it extends around the curve of the heel counter, which in turn surrounds the rear portion of the heel. The securing fin 162 can then be attached, sewn, or bonded to a shoe upper, a sock liner, an insole, one of the layers of a multi-layer insole, or the top surface of a shoe sole.

[0134] The heel counter insert 34 can be positioned within and bonded to both the exterior and interior layers of the upper. The upper portion of the heel counter insert 34 can also be positioned within a bladder portion 140 of the upper, which extends above an ankle collar 142 of the shoe opening. According to embodiments involving bonding the heel counter insert to a sock liner, insole, or sole component, the combined structure can be inserted between two layers of the upper, with the upper portion of the heel counter inserted into the bladder portion of the upper.

[0135] Double sock layer: reference Figures 11 to 19 and Figure 24 In the embodiment of the present invention, the upper 16 includes a knit structure 102 defining an elongated circular knit tube that is subsequently folded inwardly (i.e., turned over) upon itself to form a double-layer sock having two conforming sock layers and a seamless ankle collar 142 that forms the shoe opening 48 for receiving the foot.

[0136] Regions and alignment. The process of forming the knitted structure 102 includes forming an outer sock structure 104 and an inner sock structure 105. Each of the outer sock structure 104 and the inner sock structure 105 can resemble the general dimensions of a sock. Each of the outer sock structure 104 and the inner sock structure 105 can have a toe region, a midfoot region, a heel region, and a sockliner portion. When the knitted structure is folded inward (i.e., turned over) upon itself, these corresponding sections of the outer sock structure 104 and the inner sock structure 105 align. These regions are defined conceptually, not as discrete, physically delineated segments. As such, the figures of this application depict the approximate locations of these regions and portions.

[0137] In one embodiment, the outer sock structure 104 has a first toe region 110 corresponding to the position of the user's toes when the shoe is worn, a first heel region 114 corresponding to the position of the user's heel when the shoe is worn, a first midfoot region 112 between the first toe region 110 and the first heel region 114, and a first sockliner portion 116 corresponding to the bottom side of the user's foot. Similarly, the inner sock structure 105 has a second toe region 111 corresponding to the position of the user's toes when the shoe is worn, a second heel region 115 corresponding to the position of the user's heel when the shoe is worn, a second midfoot region 113 between the second toe region 111 and the second heel region 115, and a second sockliner portion 117 corresponding to the bottom side of the user's foot.

[0138] The upper 16 provided by this embodiment also includes a heel counter 32 or heel counter insert 34 that is disposed between the first heel area 114 and the second heel area 115 when the knitted structure 102 is inverted.

[0139] In an exemplary embodiment, first toe region 110 and second toe region 111 are configured with the potential for relative movement between the corresponding regions, as are first heel region 114 and second heel region 115, and first midfoot region 112 and second midfoot region 113. In other embodiments, after the regions of the various layers are aligned in a particular configuration, some or all of the corresponding regions may be attached to one another.

[0140] refer to Figure 19, the outer sock structure 104 can be substantially aligned with the inner sock structure 105, such that the respective toe regions 110 and 111, midfoot regions 112 and 113, and heel regions 114 and 115 are substantially aligned. The phrase "substantially aligned" should be interpreted to mean that the inner sock structure 105 is primarily contained within the outer sock structure 104. However, this does not preclude the possibility that a portion of the inner sock structure 105 extends beyond the confines of the outer sock structure 104. While the inner sock structure 105 is largely enclosed by the outer sock structure 104, embodiments exist in which a section of the inner sock structure 105 protrudes from or is not aligned with the outer sock structure 104, such as through an opening in the outer sock structure 104. The inner sock structure 105 can be partially exposed from the outer sock structure 104 as desired without departing from their intended positional relationship.

[0141] Knit Construction and Overturning. In an exemplary embodiment, the outer sock structure 104 and the inner sock structure 105 can be knitted as a single tubular knit tube that does not overlap during the knitting process. Alternatively, the process of making a double sock can include joining the outer sock structure 104 and the inner sock structure 105, which are individually tubular knit or flat knit.

[0142] One or both of the outer sock structure 104 and the inner sock structure 105 may include, for example Figures 16 to 18 The orifice 118 ( Figure 18 (The openings are shown in dashed lines.) In an exemplary embodiment, the outer sock structure 104 may include an opening 118 at a location at least partially along the first sockliner portion 116. Once the knitted structure 102 is formed, the opening 118 allows the outer sock structure 104 to be flipped over onto the inner sock structure 105 to form a double sock. The opening 118 can be of any size and location on the sockliner portion 116. It can be a partial slit along at least a portion of the footbed 116 or extend along the length of the sockliner. The opening can also be wider depending on the structural insert placed in the upper or how the upper is lasted or bonded to the sole.

[0143] Once the outer sock structure 104 is flipped over the inner sock structure 105, the outer sock structure and the inner sock structure 105 are interconnected at the top of the seamless ankle collar 142, forming an opening to the foot-receiving cavity. Once the double-layer sock is flipped over and the structural support is inserted, the aperture 118 can be optionally closed, for example by sewing or gluing. The structural support may include a heel counter, heel counter insert, insole, sock liner, shoe last, plate, toe guard, toe cap support, stretch member, strap, instep / eyelet / tongue support, foam, cushioning material, insulating lining, lighting components, electronic equipment, decorative material, portion of the sole, or any other component inserted between the layers of the upper. Once the upper is formed, the outer sock structure 104 can be attached to the upper surface of the sock liner, protective layer, or at least a portion of the sole, or if the sole is already inserted into the upper, only the outer sock structure 104 can be closed.

[0144] In an alternative process to manufacturing a double-layer sock, which involves joining an outer sock structure 104 and an inner sock structure 105, which are either tubular knit or flat knit, the ankle collar 142 that forms the shoe opening 48 may require the addition of a seam that can be sewn around the edges of the ankle collar to stabilize and define the ankle collar. The stitching can include elastic thread that provides elasticity to the ankle collar to allow the heel counter / heel cup to fit more tightly. In addition to the elastic properties provided by the ankle collar, the heel cup can actually have a looser fit around the foot. To further enhance the fit, the inner foam layer of the heel cup can expand after the foot is inserted to further cup the foot and improve the fit of the foot into the shoe upper.

[0145] As best seen before the outer sock structure 104 is turned over onto the inner sock structure 105, the single tubular knit tube has Figure 16 The inner side 122 shown and the Figure 17 105 ). Figure 17As shown, exterior side 123 is thus comprised of a first opposing surface 126 present on outer sock structure 104 and a second opposing surface 127 present on inner sock structure 105. In some embodiments, first engaging surface 124 and second engaging surface 125 can be free to move relative to each other at certain areas of the upper, but can also be anchored or secured to each other (e.g., using stitching or bonding) at other areas, or completely attached to each other except for an insertable component between the two upper layers 104 and 105.

[0146] The stretchability of the upper 16 can also be controlled by the amount of hot melt yarn or the amount of elastic yarn incorporated into the knitted structure 102. Stretchability can also be designed by the type of knitting or the knitting design. Stretchability can include two-way or four-way stretch. The knitting pattern and stitching can be varied to create areas of different stretchability, such as different stretchability in the toe areas 110 and 111, the midfoot areas 112 and 113, the heel areas 114 and 115, and the ankle collar 142. Either or both of the outer sock structure 104 and the inner sock structure 105 can be constructed using a combination of hot melt yarn and elastic yarn. The degree of stretchability of both the outer sock structure 104 and the inner sock structure 105 can be determined by the ratio of the hot melt yarn and elastic yarn used to improve the fit and adaptability of the shoe.

[0147] The exemplary embodiment exhibits increased stretchability of the outer sock structure 104 in the first toe region 110 and the first heel region 114. Areas where the inner sock structure 105 exhibits stretchability may be the second toe region 111, the second heel region 115, and the second midfoot region 113. The ankle collar 142 may also exhibit stretchability to provide elasticity and tension around the ankle.

[0148] In an exemplary embodiment, the thickness of the outer sock structure 104 can be between 0.9 mm and 1.9 mm, inclusive; the thickness of the inner sock structure 105 can be between 0.9 mm and 1.9 mm, inclusive; and the combined thickness of the outer sock structure 104 and inner sock structure 105 can be between 1.9 mm and 2.9 mm, inclusive. This configuration increases the thickness of the upper 16, increasing its structural strength and durability. Furthermore, the upper 16 provides a cushioning and shock-absorbing effect.

[0149] Knitted eyelets or other openings. Additionally, the knitted pattern may include knitted eyelets or openings. In the case of eyelets, the laces can be threaded through without any additional eyelet components, or eyelet supports can be placed over the openings of the eyelets. The eyelets can be integrally embroidered onto the first opposing surface 126 present on the outer sock structure 104. The portion of the laces near the shoe opening 48 can be tied in a bow and securely attached to the outer sock structure 104.

[0150] Other integrally knitted apertures can be located in any area of ​​the upper. This can include apertures in the integral bladder that can allow the heel counter to be inserted into such an opening and / or make the heel counter visible or exposed. The apertures can have a functional role, allowing the material of the heel counter to protrude through upper portions such as drawstrings or heel counters. The openings can also allow portions of the heel counter (such as the smooth surface of the heel cup) to come into direct contact with the foot. The openings can allow portions of the cushioning material or foam layer or the material covering such components (if worn) to come into direct contact with the user's foot or socks. Additional elements (such as an extension of the heel cup) can be added to the heel counter through the apertures in the integral bladder.

[0151] Instep or tongue attachment. A drawstring may be present on a portion of the tongue area 134 and securely attached to the outer sock structure 104. A drawstring may also be present on the rear portion of the ankle collar or integrated bladder. The drawstring may be integral with the sock or added separately. The drawstring may be part of an insert between the layers and located at the instep, and may extend through an aperture at or near the front portion of the ankle collar of the upper.

[0152] Inserts. Inserts at certain locations may be positioned between the outer sock structure 104 and the inner sock structure 105. The first engaging surface 124 and the second engaging surface 125 may be separated by such an insert, including the heel counter 32, the heel cup 52, and / or the insole. Once inserted, the sock may then be attached to the shoe sole.

[0153] Heel Counter and Bladder. In an exemplary embodiment, the heel counter insert 34 having the heel cup 52 is primarily positioned between a first engagement surface 124 at the first heel region 114 and a second engagement surface 125 at the second heel region 115. The heel counter insert 34 having the heel cup 52 is positioned through an aperture 118 in the outer sock structure 104. The inner sock structure 105 includes a specific knit pattern that forms an overlay (here, an integrated bladder 140) that securely accommodates the contours of the upper portion of the heel counter insert 34 or the upper and middle portions of the heel counter insert 34. See, e.g., Figures 16 to 19 、 Figure 24 and Figure 25 .

[0154] The heel counter insert 34 can be bonded to the knit material of the upper using a hot melt thermoplastic material or an adhesive. Alternatively, the insert can be sewn to the knit material or attached by any other common means known in the art. The heel counter insert 34 can be attached to the outer sock structure 104 and / or the inner sock structure 105 using a hot melt thermoplastic material or an adhesive, or it can be sewn to the outer sock structure 104 and / or the inner sock structure 105.

[0155] The integrated bladder 140 has a front cover portion 152 and a rear cover portion 153. The front cover portion 152 can cover the inner surface of the heel counter. The rear cover portion 153 can cover at least a portion of the outer surface of the heel counter. The heel counter insert 34 can include the heel cup 52 and the foam layer 92, and the integrated bladder 140 can cover these components without the presence of a seam or additional stitching.

[0156] The integrated bladder 140 has an interior surface that contacts and surrounds an upper portion of the heel counter insert 34 .

[0157] The integral bladder portion 140 has an exterior surface with a forward portion and a rearward portion.

[0158] The heel counter insert 34 and the integrated bladder 140 extend vertically beyond an upper boundary 144 of the ankle collar 142 , thereby projecting above the highest point of the ankle collar 142 .

[0159] Because the integrated bladder wraps around the rear-facing surface of the heel cup, the bladder can extend downward below the level of the ankle collar and behind the ankle collar. The bladder can extend to the intersection of the bladder and the inner sock layer of the upper, and the inner sock layer extends upward to the top of the ankle collar and wraps over the ankle collar to meet the outer surface of the sock layer. The inner sock layer can also be the inner surface of the ankle collar. In some cases, the integrated bladder can extend further downward as far as the sockliner or insole, which forms a defined unconnected space between the inner sock layer of the upper (or the inner surface of the ankle collar) and the rear-facing surface of the integrated bladder. The unconnected space can provide greater movement between the heel cup and the upper, such as during foot insertion or removal, where the heel cup can move rearward to widen the shoe opening, allowing the foot to have greater ease in moving in and out of the shoe.

[0160] The integrated bladder material can be secured to the heel counter insert (i.e., the heel cup) along with an additional layer, such as a foam layer, to prevent the material from obstructing the ease with which the foot can be put on and taken off the shoe. The surrounding sock upper can have stretch properties that allow the heel counter to temporarily shift rearward as the foot slides along the inner surface of the heel counter. The ankle collar or collar wrapped around the integrated bladder can provide sufficient tension to prevent the heel cup from moving too far rearward, thereby providing a secure fit around the user's heel.

[0161] Ankle Collar. In an exemplary embodiment, the ankle collar 142 forms a band-like structure that encircles the ankle and provides a secure fit. The ankle collar 142 may extend partially or completely around the shoe opening 48. The ankle collar 142 has an upper boundary 144, which is the top edge of the collar, and a lower boundary 146, which is the bottom edge. The upper boundary 146 marks the distinction between the outer sock structure 104 and the inner sock structure 105. However, this distinction does not necessarily indicate a physical separation, as the outer sock structure 104 and the inner sock structure 105 may be integrally formed. In an exemplary embodiment, the seamless ankle collar 142 is visually distinguished from the rest of the shoe upper. The ankle collar 142 may include elastic and tension properties that help to comfortably grip the ankle. The lower boundary 146 may serve as a transition point where the integrated ankle collar or tension band connects to the main body of the sock. The first engagement surface 124 and the second engagement surface 125 may contact each other along at least a portion of the entire circumference of the ankle collar 142, thereby forming at least a double layer looped along the cross-sectional axis, such as Figure 18 As shown. The lower boundary 146 of the ankle collar 142, i.e., the two layers of the ankle collar 142, can be stitched or bonded throughout part or all of its length between the layers forming the loop of the ankle collar 142. The loop of the ankle collar 142 can have a hollow space, or the overlapping layers can be completely knitted together, or the space can be filled with materials that can provide various functions (including tension, padding, firmness, or aesthetics). The construction, fibers, or materials of the ankle collar 142 can be different from those of other areas of the upper. For example, the tension can be greater or less than that of other areas of the upper. The varied construction can involve a high density of fibers or stitches, or the type of stitches used in various areas of the upper, which can increase or decrease the tension. The different fibers or materials can differ in elasticity or stretchability.

[0162] The rear cover portion 154 and the ankle collar 142 of the integral bladder 140 may be integrally connected, spaced apart but of unitary construction, or formed separately.

[0163] The portion of the ankle collar 142 that extends rearward and around the heel counter 32 insert may be similar to an ankle strap. The portion of the ankle collar 142 formed by the opposing surface of the inner sock layer contacts the rearward surface of the integrated bladder.

[0164] The middle and lower portions of the heel cup 52 insert extend vertically below the lower boundary 146 of the ankle collar 142 and are located between the facing surfaces of the outer sock structure 104 and the inner sock structure 105 .

[0165] In an exemplary embodiment, the top of the upper boundary 144 of the ankle collar 142 is lower than the top of the heel counter 32 insert and the bladder 140. Thus, the heel cup 32 insert helps prevent the ankle collar 142 from collapsing under heel pressure, thereby making the shoe donning process easier for the user. Alternatively, the ankle collar can have sufficient tension to prevent the heel cup from moving too far backward, and the ankle collar can help return the heel cup to its original position after the foot is inserted. Such tension can contribute to a more secure fit of the heel cup, whereas without the ankle collar, a looser fit around the foot would be possible. The foam layer surrounding the portion of the user's heel and ankle can further enhance the secure fit as it expands around the foot. The foam layer can even be compressed against the foot by the ankle collar.

[0166] According to this alternative functionality, incorporating the integrated bladder and ankle collar 142 into the outer sock structure 104 and inner sock structure 105 facilitates easier assembly of the upper 16. The outer sock structure 104 and ankle collar 142 can also serve to provide external protection for the upper 16. Either or both of the outer sock structure 104 and the ankle collar can be elastic, allowing the heel cup 52 to move backward during insertion of the foot into the shoe, allowing the ankle collar to function as a tension band or strap. In this manner, the heel cup 52 can return to its original position after the foot is inserted into the shoe. After insertion, the ankle collar can also reduce the heel cup from inadvertently moving backward while the shoe is being used. The tension provided by the ankle collar can prevent or reduce the likelihood of the foot accidentally slipping out of the shoe. This tension can be sufficient to hold the shoe in place while removing the foot from the shoe, as may be required during shoe removal (such as by the user's hands or the user's other foot / shoe).

[0167] The tension of the ankle collar can be adjustable. The ankle collar can be attached to a securing device, such as a strap, laces, a tensioning cord system with a tension dial, or any other securing device known in the art. At least a portion of the securing device can also be inserted between the layers during the formation of the upper. The securing device can extend through an aperture in the outer layer to allow the user to access it to increase the tension. In the case of straps, the tension can be provided by a buckle or Velcro attachment. In the case of laces or cords, they can extend through the instep to tighten the ankle collar and provide support in the instep area. The securing device can extend coextensively with the ankle collar or be configured to pull the ankle collar tighter.

[0168] Insole. In an exemplary embodiment, insole 136 may be disposed between first engagement surface 124 at first midfoot region 112 and second engagement surface 125 at second midfoot region 113. See, e.g. Figures 20 to 24 .

[0169] Insole 136 may be inserted between engagement surfaces 124 and 125 through aperture 118 in outer sockliner structure 104 and positioned primarily between first engagement surface 124 at first sockliner portion 116 and second engagement surface 125 at second sockliner portion 117 .

[0170] The insole 136 can be attached to the knitted structure 102 at one or both of the first engagement surface 124 and the second engagement surface 125, for example, by stitching or gluing. Once the insole 136 is inserted, the aperture 118 along the first insole portion 116 can be closed, for example, by stitching. Once the aperture 118 of the outer sock structure 104 is closed, the upper 16 can then be attached to the sole 14. The midsole can be attached to the first opposing surface 126 at the first insole portion 116, thereby covering the seam of the aperture 118 of the outer sock structure 104. Before the insole is inserted into the upper, it can also be attached to other structures, such as a sock lining, a shoe last, or components associated with the upper, such as a heel cup, heel counter insert, toe cap, straps, or side supports. In one example, the heel counter insert 34 can be attached to the insole 136, and the combined structure can then be inserted between the first engagement surface 124 and the second engagement surface 125. Attachment methods may include any method known in the art, including sewing and / or gluing.

[0171] like Figure 15 and Figures 20 to 24 As shown, an exemplary embodiment of the insole 136 includes a multi-layer construction to enhance comfort and, in some embodiments, also enhance airflow. Specifically, the insole 136 includes three different layers.

[0172] The top inner bottom layer 137, which is in direct contact with the second engagement surface 125, can be made of a viscoelastic material, such as polyurethane foam. Exemplary foams can be characterized by a density range of 130-150 kg / m3 and a hardness rating of 9-15 (measured on the Asker F scale). The top inner bottom layer 137 is approximately 3 mm in thickness.

[0173] According to this embodiment, below the top inner bottom layer 137 is a middle inner bottom layer 138, which is constructed from an example material, such as a thermoplastic elastomer (TPE) base material. This material can be a foam polymer or a material that provides additional cushioning. The middle layer can have a different rigidity or elasticity than the top inner bottom layer. In one embodiment, the rigidity can be greater or the elasticity can be less. The middle inner bottom layer 138 can have any thickness, such as approximately 4 mm.

[0174] According to this embodiment, exposed areas 168 of the TPE intermediate inner bottom layer 138 are intentionally exposed along the inner and outer sides of the insole when viewed from the bottom. These exposed areas can be designed with a curved or beveled profile. Exposed areas 168 facilitate the merging of the insole with the upper surface of the midsole, which typically exhibits curved sidewalls along its perimeter. Furthermore, the exposure of the TPE layer in these areas enhances airflow and reduces moisture within the shoe. In some embodiments, perforations 135 can be located in the beveled areas of the TPE intermediate inner bottom layer 138 to enhance airflow and heat dissipation.

[0175] The bottom inner bottom layer 139 of insole 136 is made of hot melt sheet material and is approximately 1mm thick. This layer is designed to fix the insole in the upper and contact the first engagement surface 124. The bottom inner bottom layer 139 can be completely coextensive with the middle inner bottom layer, or can cover the part of the middle layer. In an exemplary embodiment, the bottom inner bottom layer 139 can be completely coextensive with the heel portion and partially coextensive with the midfoot or forefoot area. The exposed area 168 of the middle layer can be at any position or in an area that allows the middle layer to be more breathable. The exposed area 168 can also be produced after the layers are combined, thereby producing a bevel angle that can be used to allow the insole to better fit in the top surface of the sole, wherein the profile is configured to accommodate the bevel edge of the insole.

[0176] The TPE intermediate inner bottom layer 138 and / or the hot melt bottom inner bottom layer 139 can each be configured with perforations 135 that can extend through both the intermediate layer and the bottom layer. The perforations in one layer can be partially or completely aligned with the perforations in the other layer, or they can also be misaligned. The perforations can be configured to facilitate airflow through the intermediate inner bottom layer and the bottom inner bottom layer. The exposed area 168 can also enhance airflow. The improved airflow improves breathability and reduces moisture accumulation in the shoe. In other exemplary embodiments, perforations can be present in the intermediate inner bottom layer but not in the bottom layer, or vice versa.

[0177] Additionally, an insole support pad 166 can be positioned beneath the heel area of ​​the bottom layer of the insole. The insole support pad 166 can be constructed of ethylene vinyl acetate (EVA), with options for foam and non-foam EVA configurations. Structurally, the insole support pad 166 is characterized by a thicker composition at the rear and gradually tapering toward the front.

[0178] The insole, alone or in combination with a heel counter insert, may be bonded to the upper by adhesive, stitching, hot melt film, or any other means known in the art.

[0179] Support Plate. In one embodiment, the support plate may be disposed between engagement surfaces 124 and 125, either alone or in combination with other components such as an insole. The support plate may also be located on the lower surface of first engagement surface 124 of insole 136 facing midfoot region 112 and may be partially or completely coextensive with the insole. The minimum distance between support plate 138 and first heel region 114 may be smaller than the minimum distance between support plate 138 and first toe region 110. In other words, support plate 138 may be disposed near first heel region 114. Support plate 138 may be attached to the lower surface of insole 136 using an adhesive. The shape of the end of support plate 138 near first heel region 114 may be adapted to the shape of insole 136. Support plate 138 may be constructed of any material that further increases the rigidity or hardness of the insole and may be constructed of any material, including, but not limited to, cardboard, plastic, nylon, and metal.

[0180] The support plate 138 can improve the structural strength of the insole 136. When the upper 16 includes a heel counter 32 insert, the support plate 138 can effectively position the heel counter 32 insert and improve the stability of the heel counter 32 insert.

[0181] Logo. The outer surface of the outer sock structure 104 may be provided with a logo strip. The angle α between the logo strip 150 and the vertical satisfies the following: 0° < α < 90°, meaning that the logo strip 150 is tilted. The logo strip 150 may be provided with text, a pattern, or the like. The logo strip may also be located on the outer surface of the heel cup bladder cover directly above the ankle collar 142.

[0182] Item 1: An upper for an article of footwear, comprising: a first knit layer and a second knit layer; the first knit layer and the second knit layer having corresponding toe, midfoot, and heel regions; the first knit layer having a first interior surface and a first exterior surface; the second knit layer having a second interior surface and a second exterior surface; the first interior surface and the second interior surface substantially facing each other; the first exterior surface and the second exterior surface substantially opposite each other; an ankle collar formed at the interconnection between the first knit layer and the second knit layer and at least partially surrounding an opening of a foot-receiving cavity of the upper; the second knit layer defining an integral bladder in the heel region; a heel cup in the heel region being partially located between the first interior surface and the second interior surface; an upper portion of the heel cup, the upper portion being disposed within the integral bladder; the integral bladder defining a forward-facing surface on a forward covering portion and a rearward-facing surface on a rearward covering portion; and the ankle collar having a portion of the second exterior surface contacting the rearward-facing surface.

[0183] Clause 2: The upper of Clause 1, wherein the upper portion of the heel cup and portions of the integrated bladder extend above the ankle collar.

[0184] Item 3: The shoe upper of Item 1, further comprising an insole positioned between the first interior surface and the second interior surface.

[0185] Item 4: An upper as in Item 1, wherein the heel cup is a structural element comprising an upper rear portion extending rearwardly and sloping downwardly in a direction from the heel toward the toe, the downward inclination having a convex curvature; and the convex curvature having an upper surface facing upwardly and a lower surface facing the opening of the article of footwear.

[0186] Clause 5: The upper of Clause 4, wherein the heel cup is rigid and does not flex downwardly and away from the shoe opening under load.

[0187] Clause 6: The upper of Clause 4, wherein the heel cup flexes downwardly and away from the shoe opening under a load and returns to its original position once the load is removed.

[0188] Clause 7: The upper of Clause 5, wherein the heel cup is temporarily urged rearwardly during foot insertion or removal.

[0189] Clause 8: The upper of Clause 1, wherein the heel cup is part of a heel counter insert, the heel counter insert comprising the heel cup and a foam layer, wherein an upper portion of the heel counter insert, including the upper portion of the heel cup, is located at least within the integral bladder.

[0190] Clause 9: The upper of Clause 6, wherein the foam layer has a protruding portion, the protruding portion being located on the heel cup such that the cushion contacts the foot over the calcaneal region of the foot.

[0191] Item 10: The upper of Item 9, wherein the foam layer is in a first compressed state during foot insertion and removal, and is in a fully uncompressed state after foot removal, and is in either a fully uncompressed state or a second compressed state after foot insertion, wherein the second compressed state is less than the first compressed state.

[0192] Item 11: The shoe upper of Item 3, wherein the insole is multi-layered, the first layer having viscoelastic properties and the second layer having perforations.

[0193] Clause 12: The upper of Clause 8, wherein the heel counter insert has a securing tab that can be connected perpendicular to the heel cup and attached to the sockliner of the upper.

[0194] Item 13: The shoe upper according to Item 12, wherein the sockliner can be a part of the first knitted layer or the second knitted layer, an insole, or a sock lining.

Claims

1. A shoe upper for a footwear article, characterized in that: include: a first knitted layer and a second knitted layer; The first knitted layer and the second knitted layer have corresponding toe areas, midfoot areas, and heel areas; The first knit layer has a first interior surface and a first exterior surface; The second knit layer has a second interior surface and a second exterior surface; the first interior surface and the second interior surface facing each other; the first exterior surface and the second exterior surface are opposite to each other; an ankle collar formed at the interconnection between the first knit layer and the second knit layer and at least partially surrounding an opening of the foot-receiving cavity of the upper; the second knit layer defining an integral bladder in the heel region; a heel cup in the heel region being partially located between the first interior surface and the second interior surface; an upper portion of the heel cup, the upper portion being seated within the integral bladder; The integral bladder portion defines a forward-facing surface on the front cover portion and a rearward-facing surface on the rear cover portion; as well as The ankle collar has a portion of the second exterior surface contacting the rearward-facing surface.

2. The shoe upper according to claim 1, wherein: The upper portion of the heel cup and portions of the integrated bladder extend above the ankle collar.

3. The shoe upper according to claim 1, wherein: Also included is an insole positioned between the first interior surface and the second interior surface.

4. The shoe upper according to claim 1, wherein: The heel cup is a structural element that includes an upper rear portion that extends rearwardly and slopes downwardly in a direction from the heel toward the toes, the downward slope having a convex curve; and the convex curve has an upper surface facing upward and a lower surface facing the shoe opening of the footwear article.

5. The shoe upper according to claim 4, wherein: The heel cup is rigid.

6. The shoe upper according to claim 4, wherein: The heel cup flexes downwardly and away from the shoe opening under load and returns to its original position once the load is removed.

7. The shoe upper according to claim 5, wherein: The heel cup is temporarily urged rearward during foot insertion or removal.

8. The shoe upper according to claim 1, wherein: The heel cup is part of a heel counter insert comprising the heel cup and a foam layer, wherein an upper portion of the heel counter insert, including an upper portion of the heel cup, is located at least within the integral bladder.

9. The shoe upper according to claim 8, wherein: The foam layer has a raised portion and an area including padding, the raised portion being located on the heel cup such that the padding contacts the foot over the calcaneal region of the foot.

10. The shoe upper according to claim 9, wherein: The foam layer is in a first compressed state during foot insertion and removal, and in a fully uncompressed state after foot removal, and in either a fully uncompressed state or a second compressed state after foot insertion, wherein the second compressed state is less than the first compressed state.

11. The shoe upper according to claim 3, wherein: The insole is multi-layered, with a first layer having viscoelastic properties and a second layer having perforations.

12. The shoe upper according to claim 8, wherein: The heel counter insert has a securing tab that can be connected perpendicular to the heel cup and attached to the sockliner of the upper.

13. The shoe upper according to claim 12, wherein: The insole may be a portion of the first knitted layer or the second knitted layer, an insole, or a sock lining.

Images