HK40027712A - Article of footwear having a knitted component with a forefoot portion and a heel portion - Google Patents

Description

Article of footwear having a knitted component with a forefoot portion and a heel portion

RELATED APPLICATIONS

This application claims the benefit of U.S. provisional application No. 62/541,495 filed on 8/4/2017, which is hereby incorporated by reference in its entirety.

Background

Conventional articles of footwear generally include two primary elements: an upper and a sole structure. The upper is generally secured to the sole structure and may form a void within the article of footwear for comfortably and securely receiving a foot. The sole structure is generally secured to a lower surface of the upper so as to be positioned between the upper and the ground. For example, in some articles of athletic footwear, the sole structure may include a midsole and an outsole. The midsole may be formed from a polymer foam material that attenuates ground reaction forces to relieve stresses placed on the foot and leg during walking, running, and other ambulatory activities. The outsole may be secured to a lower surface of the midsole and may form a ground-engaging portion of the sole structure that is formed of a durable and wear-resistant material.

The upper of the article of footwear generally extends over instep and toe areas of the foot, along medial and lateral sides of the foot, and around a heel area of the foot and, in some cases, under the foot. Access to the void in the interior of the upper is typically provided through an ankle opening in the heel region of the footwear and/or adjacent to the heel region of the footwear. A lacing system is often incorporated into the upper to adjust the fit of the upper and thereby facilitate entry and removal of the foot from the void within the upper. In addition, the upper may include a tongue that extends under the lacing system to enhance adjustability of the footwear, and the upper may incorporate other structures, such as, for example, a heel counter (heel counter), to provide support for the heel and to limit movement of the heel.

Description of the drawings

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

Fig. 1 is a diagram illustrating an article of footwear with a knitted component in accordance with certain aspects of the present disclosure.

Fig. 2 is a diagram showing a side cut-away view along line 2-2 of fig. 1.

Fig. 3 is a diagram illustrating a knitted component for an article of footwear that may occur after a knitting process according to certain aspects of the present disclosure.

Fig. 4 is an illustration showing a knitted component for an article of footwear including a forefoot extension extending from a toe region, according to certain aspects of the present disclosure.

Fig. 5A is an illustration showing an article of footwear with a forefoot extension forming a toe box (toe cap), according to certain aspects of the present disclosure.

Fig. 5B is a diagram illustrating the embodiment of fig. 5A when the toe cap is turned over (inverted) after the knitting process.

Fig. 6 is a diagram illustrating an article of footwear with side extensions (side extensions) according to certain aspects of the present disclosure.

Detailed Description

Aspects are described below with reference to the drawings, in which like elements are generally identified by like numerals. The relationship and functioning of the various elements of the aspects may be better understood by reference to the following detailed description. However, the aspects are not limited to those illustrated in the figures or described explicitly below. It should also be understood that the drawings are not necessarily to scale and that, in some instances, details that are not necessary for an understanding of the aspects disclosed herein, such as conventional manufacturing and assembly, may have been omitted.

Certain aspects of the present disclosure relate to an upper configured for use in an article of footwear and/or other article (such as an article of apparel). When referring to an article of footwear, the present disclosure may describe basketball shoes, running shoes, cycling shoes, cross-training shoes, football shoes, golf shoes, hiking shoes and boots, ski and snowboard boots, soccer shoes, tennis shoes, and/or walking shoes, as well as types of footwear that are generally considered to be non-athletic, including but not limited to dress shoes, loafers (loafers), and sandals.

In one aspect, the present disclosure provides a knitted component. The knitted component may have a forefoot portion having a top layer and a bottom layer, wherein a cavity is formed between the top layer and the bottom layer, and wherein the top layer is secured to the bottom layer via at least one common knit structure. The heel region may extend in a lengthwise direction from the bottom layer of the forefoot portion and may be secured to the bottom layer of the forefoot portion via at least one common knit structure. The at least one extension may extend from the heel region in a second direction, the second direction being different than the lengthwise direction.

In another aspect, the present disclosure provides an article of footwear. An article of footwear may include a forefoot portion having a top layer and a bottom layer, with a cavity formed between the top layer and the bottom layer. The heel region may be secured to a bottom layer of the forefoot portion, and the heel region may form a first portion of the collar. At least one extension may extend from the heel region, wherein the at least one extension is secured to an edge of the top layer of the forefoot portion, and wherein the extension forms at least a second portion of the collar.

In another aspect, the present disclosure provides a method. The method can include forming a forefoot portion of a knitted component on a knitting machine, the forefoot portion having a top layer and a bottom layer, wherein a cavity is formed between the top layer and the bottom layer, and wherein the top layer is secured to the bottom layer via at least one common knit structure. The method may also include forming a heel region of the knitted component on the knitting machine, the heel region being secured to the bottom layer of the forefoot portion via at least one common knit structure. The method may also include forming at least one extension of the knitted component on the knitting machine, the at least one extension attached to the heel region, and securing the extension to an edge of the top layer of the forefoot portion.

In another aspect, the present disclosure provides an article of footwear having a knitted component with a heel region. The heel region may include a medial side, a lateral side, and a rear portion between the medial side and the lateral side, wherein at least one of the medial side and the lateral side of the knitted component includes a concave region on an outer surface of the knitted component.

In another aspect, the present disclosure provides an article of footwear having a knitted component with a heel region. The heel region may include a medial side, a lateral side, and a rear portion between the medial side and the lateral side, wherein at least one of the medial side and the lateral side of the knitted component includes a convex region on a medial surface of the knitted component, the medial surface defining a cavity.

Fig. 1 is a diagram illustrating an article of footwear 100 according to certain aspects of the present disclosure. Referring to fig. 1, article of footwear 100 may include upper 102. Alternatively, upper 102 may be formed generally as a textile component (textile). The textile component can be any suitable type of textile, and in some embodiments, it can be formed as a knitted component 104. As shown, upper 102 may be secured to sole structure 106. Upper 102 may include a lateral side 108 and a medial side 110. The area where the sole structure 106 joins the upper 102 may be referred to as a bite line (biteline) 112. Upper 102 may be fixedly attached to sole structure 106 using any suitable technique, such as by using an adhesive, by stitching, or the like. Upper 102 may extend partially or completely around a foot of a wearer and/or may be integral with sole structure 106, and a sockliner may or may not be used. In some embodiments, sole structure 106 may include a midsole and an outsole.

The upper 102 may also include a throat area 114 extending from the ankle opening 116 to the void 118, and a collar 120 may at least partially surround the ankle opening 116. The void 118 of the article of footwear 100 may be configured (e.g., sized and shaped) to receive and accommodate a human foot. Throat area 114 may be generally disposed in midfoot area 122 of upper 102. Midfoot region 122 of upper 102 may be located between heel region 124 and toe region 126. In some embodiments, tongue 128 may be at least partially disposed in throat area 114. If included, tongue 128 may be any type of tongue, such as a lined tongue (gassed tongue) or a purse-roll tongue (burrito tongue). If tongue 128 is not included, lateral and medial sides of throat area 114 may be joined together.

Although upper 102 is described herein as being formed primarily of knitted component 104, the knitted component is optional, and it may alternatively or additionally include textile components formed by processes other than knitting (e.g., weaving) and may also include other materials, including but not limited to leather, plastic, rubber, and any other material. Forming upper 102 with knitted component 104 may provide advantageous properties to upper 102 including, but not limited to, a particular degree of elasticity (e.g., in young's modulus), breathability, flexibility, strength, hygroscopicity, weight, wear-resistance, and/or combinations thereof. These properties may be achieved by selecting a particular single or multi-layer knit structure (e.g., rib knit structure), single plain knit structure (single jersey knit structure), or double plain knit structure (double jersey knit structure), by varying the size and tension of the knit structure, by using one or more yarns formed from a particular material (e.g., a polyester material, a relatively inelastic material, or a relatively elastic material such as spandex), by selecting a particular size (e.g., denier) of yarn, and/or combinations thereof. Knitted component 104 may also provide desirable aesthetic characteristics by incorporating yarns having different colors, textures, or other visual properties arranged in a particular pattern.

Moreover, the yarns themselves and/or the knit structure of knitted component 104 may differ at different locations such that knitted component 104 has two or more portions with different properties (e.g., the portion forming throat area 114 of upper 102 may be relatively elastic while another portion may be relatively inelastic). Additionally or alternatively, in some embodiments, knitted component 104 may incorporate one or more materials having properties that change in response to a stimulus (e.g., temperature, humidity, electrical current, magnetic field, or light). For example, knitted component 104 can include a yarn formed from one or more thermoplastic polymer materials (including material combinations) that transitions from a solid state to a softened or liquid state when subjected to certain temperatures at or above its melting point and then transitions back to a solid state upon cooling. The thermoplastic polymer material may provide the ability to heat and then cool a portion of knitted component 104 to thereby form regions of bonded or continuous material (referred to herein as "fused regions") that exhibit certain advantageous properties, including, for example, a relatively high degree of rigidity, strength, and water resistance. Non-limiting examples of thermoplastic polymer materials are polyurethanes, polyamides, polyolefins, and/or certain nylons.

Knitted component 104 of article of footwear 100 may include forefoot portion 130 with top layer 132 and bottom layer 134, and may form cavity 118 between top layer 132 and bottom layer 134. Thus, in forefoot portion 130, bottom layer 134 may form a lower portion associated with a plantar surface (also referred to as a ball or bottom of the foot) of the foot, and top layer 132 may form an upper portion (over portion) associated with an instep surface (also referred to as a top surface of the foot) of the foot. Bottom layer 134 may extend immediately above sole structure 106 and/or be secured to sole structure 106. In some embodiments, the top layer 132 and the bottom layer 134 may meet at the bite line 112, but this is optional and they meet at a boundary 136 above the bite line 112 in fig. 1.

The knitted component may also include a heel portion 140. The bottom side of heel portion 140 may be secured to sole structure 106. As described in more detail below, heel portion 140 may be secured to bottom layer 134 of forefoot portion 130 via a common knit structure, and first extension 142 and/or second extension 144 may extend from heel portion 140 and be secured to top layer 132 of forefoot portion 130 (e.g., via stitching). Heel portion 140 may form a first collar portion 146 of collar 120, and first extension 142 and second extension 144 may form respective second collar portion 148 and third collar portion 150 of collar 120 on medial and lateral sides of first collar portion 146.

In some embodiments, first extension 142 and/or second extension 144 may extend from heel region 124 toward throat region 114, and in some embodiments may extend to a location adjacent throat 152. Seam 154 may secure first extension 142 to forefoot portion 130, and in particular to top layer 132 of forefoot portion 130. Alternatively, the seam 154 may extend from adjacent the throat to proximate the bite line 112, although other seam orientations/locations are contemplated. As described in more detail below, the seam 154 may be formed after forming the knitted component on the knitting machine.

Fig. 2 shows a side cutaway view of article of footwear 100 along line 2-2 of fig. 1. As shown in fig. 2, knitted component 104 may include forefoot portion 130 with at least two separable layers: a top layer 132 and a bottom layer 134. The top layer 132 and the bottom layer 134 can have different, oppositely facing surfaces. For example, first surface 156 of top layer 132 may form an exterior surface of article of footwear 100, and second surface 158 of top layer 132 may face cavity 118. With respect to bottom layer 134, third surface 160 may face cavity 118, and fourth surface 162 may face sole structure 106 (shown in fig. 1).

A cavity 118 may be formed between the top layer 132 and the bottom layer 134. The top layer 132 and the bottom layer 134 can be formed together on a knitting machine and can converge at a boundary 136 (e.g., at a stitched seam as described in more detail below). The attachment at the boundary 136 may be provided by a common knit structure, such as a common course, stitch, wale, and/or yarn extending between the top layer 132 and the bottom layer 134, and when the top layer 132 and the bottom layer 134 are formed, the common knit structure may be formed on the knitting machine. Other attachment means and/or methods are also contemplated (e.g., the top layer 132 and the bottom layer 134 can be sewn together after the knitting process, secured via adhesive, etc.).

Fig. 3 shows knitted component 104 as it may appear after knitting (e.g., on a flat knitting machine), but in the depicted article of footwear 100 of fig. 1-2, knitted component 104 is in an expanded state before being lasted or otherwise manipulated into a wearable shape. To form the multi-layer knitted component 104, the top layer 132 can be formed primarily on the front needle bed of the knitting machine and the bottom layer 134 can be formed primarily on the back needle bed (or vice versa), and the boundary 136 can be formed where the knit structure crosses between the front needle bed and the back needle bed. If the top layer 132 and the bottom layer 134 are separable and define a pocket (cavity 118) therebetween, the layer formed on the front needle bed and/or the layer formed on the back needle bed can have a single plain knit with needles from only one needle bed.

Other knitting techniques may additionally or alternatively be used to form the multilayer structure. For example, it is contemplated that during the knitting process, both layers may utilize needles from each needle bed to enhance the ability to integrate functional and/or visual features within each layer. For example, one or more consecutive courses of top layer 132 may utilize needles from two needle beds to provide a particular multi-bed knit structure to top layer 132. Then, before or during knitting of one or more courses of the bottom layer 134, all of the stitches of the top layer 132 may be transferred to the first needle bed to release the needles on the second needle bed to form the bottom layer 134 (and prevent the top layer 132 from bonding to the bottom layer 134). The bottom layer 134 may then be knitted solely on the second needle bed, or may utilize needles on both needle beds (particularly where the top layer 132 leaves some needles on the first needle bed unoccupied). If the bottom layer 134 is formed on both needle beds, once it is time to restore the knitted course of the top layer 132, all of the stitches associated with the bottom layer 134 can be transferred to the second needle bed to free the first needle bed for forming the top layer 132 again (and to prevent the bottom layer 134 from bonding with the top layer 132). This process can be repeated as needed.

If desired, when knitting the top layer 132 and/or the bottom layer 134, some of the needles on each needle bed may be skipped by the top layer 132 and/or the bottom layer 134 to leave some of the unused needles for knitting another layer. Accordingly, the top layer 132 and/or the bottom layer 134 may have a reduced needle count and/or stitch density when compared to a full gauge portion (e.g., such as the heel portion 140 described in more detail below). In some embodiments, the number of needles (gauge) (defined as the ratio of the number of needles used to the total number of needles available) of the top layer 132 and/or the bottom layer 134 may be at least 25% less, at least 50% less, or even less than the number of needles of the heel portion 140. In one non-limiting embodiment, the top layer 132 and the bottom layer 134 have a stitch count that is about 50% of the stitch count of the heel portion 140.

Additionally or alternatively, the top layer 132 and the bottom layer 134 may include yarns referred to as "fusible yarns," which in this disclosure refer to yarns having a thermoplastic polymer material with a melting point less than 120 ℃. In one exemplary embodiment, the fusible yarns of the top layer 132 and the bottom layer 134 can be yarns having polyester yarns surrounded by a thermoplastic polymer material or composite material having a melting point below 100 ℃ (e.g., about 60 ℃). After the knitting process, knitted component 104 may be heated and then cooled such that the thermoplastic polymer material fuses and hardens to provide sufficient structure (e.g., rigidity) to top layer 132 and bottom layer 134, particularly when the number of needles in top layer 132 and/or bottom layer 134 is relatively low. In some embodiments, at least one of the top layer 132 and the bottom layer 134 can include a second yarn therein that is not configured to melt or fuse when subjected to the aforementioned heating (e.g., where the melting point or decomposition point of the second yarn is above the highest processing temperature of the knitted component 104). The second yarn may be any type of yarn, such as a polyester yarn suitable for providing comfort-related properties and/or desired visual properties. Furthermore, it may be advantageous to use relatively thin yarns so that the top layer 132 and/or the bottom layer 134 have a desired net-like appearance (at least in the low needle count areas), which may be made possible by the inclusion of the above-described fusible yarns.

Heel portion 140 may extend in a lengthwise direction 166 from bottom layer 134 of forefoot portion 130. Thus, when the knitted component 104 is initially removed from the knitting machine, the heel portion 140 may be indirectly attached to the top layer 132 only through the bottom layer 134. Heel portion 140 may be secured to a bottom layer of forefoot portion 130 via at least one common knit structure (e.g., at least one common connecting row).

Knitted component 104 may also include first extension 142 and second extension 144 extending from heel portion 140. First extension 142 and second extension 144 may extend from heel portion 140 at least partially in a second direction 168 (at least where knitted component 104 is forced into a flattened state), where second direction 168 is different from lengthwise direction 166. For example, the second direction 168 may be approximately perpendicular to the lengthwise direction 166 (e.g., within 30% of true perpendicular, or less, such as within 15%). More specifically, when knitted component 104 is incorporated into article of footwear 100, first extension 142 may extend in a lateral direction with respect to the foot and second extension 144 may extend in a medial direction with respect to the foot (or vice versa). The first extension 142 and the second extension 144 can be formed on the knitting machine with the rest of the knitted component 104, and thus they can share a common knit structure with the heel portion 140. When the knitted component 104 is initially removed from the knitting machine, the first extension 142 and the second extension 144 may be indirectly secured to the bottom layer 134 by way of the heel portion 140 and to the top layer 132 by way of the heel portion 140 and the bottom layer 134.

When knitted component 104 is knitted generally in lengthwise direction 166, heel portion 140 may be knitted substantially before the formation of top layer 132 and bottom layer 134 of forefoot portion 130 or substantially after the formation of top layer 132 and bottom layer 134 of forefoot portion 130. The same applies to the first extension 142 and the second extension 144. Advantageously, this may provide the heel portion 140 and extensions 142, 144 with the opportunity to utilize the full needle count of both needle beds of the knitting machine during its formation. Accordingly, heel portion 140 and extensions 142, 144 may be formed entirely or primarily of a double plain knit structure. In this context, a "double plain knit structure" is generally defined as any knit structure formed on two needle beds and utilizing at least one needle from each needle bed. Utilizing two needle beds of a flat knitting machine to provide a double plain knit structure can enhance the ability to include certain knit or non-knit features, particularly because utilizing two needle beds (rather than one needle bed) significantly enhances the ability to selectively include visual designs, physical properties, and other features formed by a particular knit structure, a particular yarn or combination of yarns, or a combination thereof. To illustrate, one yarn type (e.g., thermoplastic polymer material yarn used to form the rigidly fused regions) may be located on the outward facing surface, and a different yarn type (e.g., polyester yarn) may be located on the oppositely facing surface (i.e., the inner surface) to provide comfort-related characteristics.

Still referring to fig. 3, first extension 142 may include a first edge 184, which first edge 184 may be located on a side thereof closest to forefoot portion 130. The first edge 184 can be a free edge when the knitted component 104 is initially removed from the knitting machine. Similarly, the second extension 144 may include a second edge 186. After the knitting process, first edge 184 and/or second edge 186 may be manipulated such that they are adjacent to third edge 188 of top layer 132 of forefoot portion 130. The first edge 184 and/or the second edge 186 may then be secured to the third edge 188. The fixation may be achieved by any suitable means, such as by stitching, bonding via an adhesive, or the like. In some embodiments, this securing may occur when knitted component 104 is positioned on a last (supporting foot-shaped last) of the foot shape for support during the lasting process. One example of a lasting process is described in U.S. patent application serial No. 12/848, 352 filed on 2/8/2010 and issued to U.S. patent No. 8,595,878, which is incorporated herein by reference in its entirety.

Once the securing is complete (or possibly before the securing), knitted component 104 may be attached to other components of article of footwear 100. For example, referring back to fig. 2, sole structure 106 may be attached to bottom surface 162 of bottom layer 134, and midsole 190 may be placed within cavity 118. If a midsole 190 is included, the midsole 190 may be within the cavity 118 and in contact with the top surface 160 of the bottom layer 134 during normal use, but the midsole 190 may be freely removable by the user. However, midsole 190 may alternatively be secured to the top surface of bottom layer 134 via any suitable means or method (e.g., stitching or adhesive bonding).

Referring to fig. 4, in some embodiments, knitted component 104 may include forefoot extension 192 extending from toe region 126 of forefoot portion 130. Forefoot extension 192 may share a common knit structure (e.g., a common course, stitch, wale, and/or yarn) with forefoot portion 130, and in particular with at least one of top layer 132 and bottom layer 134. In some embodiments, forefoot extension 192 may be secured to forefoot portion 130 at boundary 136 of top layer 132 and bottom layer 134. Advantageously, if the knitting direction is in the lengthwise direction 166, forefoot extension 192 can be formed just before or after the formation of forefoot portion 130, such that both needle beds of the knitting machine are focused on forefoot extension 192. Thus, the formation of forefoot extension 192 may utilize the full needle count of both needle beds of the knitting machine when forming, which may provide forefoot extension 192 with the ability to have enhanced complexity for providing certain physical and/or visual characteristics (e.g., a relatively strong, inelastic, and durable structure). Forefoot extension 192 may include, for example, a double knit structure. Optionally, forefoot extension 192 may include at least one pocket 138 (e.g., formed from two separable knit layers) for receiving other elements, such as a cushioning element (not shown). It is contemplated that the pocket 138 may have at least one inlaid floating yarn with a relatively high degree of softness to provide cushioning. As will be understood by those skilled in the art, such an embodiment may be achieved when two needle beds are available, which is an advantage provided by the layout of knitted component 104.

As shown in fig. 4, the forefoot extension may optionally be configured to form a tongue 128 of the article of footwear 100, and may additionally or alternatively include a toe box portion 129, the toe box portion 129 serving to provide additional protection to the user's toes. As knitted component 104 is manipulated into its wearable shape, forefoot portion 130 of forefoot extension 192 may be pulled back (e.g., toward heel portion 140) to form an upper end 194 of tongue 128 (also shown in fig. 1). As depicted in fig. 1 (and as described in more detail below), when the knitted component 104 is in its wearable orientation, the knitted component 104 can be flipped relative to its orientation depicted in fig. 4. Thus, referring to fig. 4, forefoot extension 192, which forms tongue 128, may be located at least partially outside of cavity 118 immediately after the knitting process, but when in its wearable orientation, forefoot extension 192 may be located within cavity 118 between top layer 132 and bottom layer 134. Advantageously, tongue 128 may provide additional protection to the toes of the foot and may prevent the lace from chafing the foot when the lacing system is used. The user may also pull on a tongue 128 placed on the article of footwear 100 to help ensure a proper fit. Although tongue 128 is primarily described herein as being part of knitted component 104, tongue 128 may alternatively be formed separately and then secured to knitted component 104 after knitted component 104 is formed on the knitting machine.

When the knitted component 104 is turned, the step of turning the knitted component 104 can occur after the knitted component 104 is removed from the knitting machine, but before the first extension 142 and/or the second extension 144 are secured to the top layer 132 at the seam 154 (illustrated by the arrow). Advantageously, the relatively flexible knitted component 104 (prior to forming the seam) may be more easily turned over and less easily damaged by the turning over. However, in other embodiments, the seam 154 may be formed prior to inverting. This may be advantageous when the outer portions of seam 154 entangle to other residues occurring during its formation, which are initially more easily isolated from the outside, but may turn inside out so that they are not wearable when knitted component 104 is manipulated into its wearable state.

In some embodiments, and as depicted in the embodiment of fig. 4, top layer 132 of forefoot portion 130 may include a throat opening 196 in throat region 114. The throat opening 196 can be formed during the knitting process, or the knit material can be cut from the top layer 132 after the knitting process. One or more apertures 198 may be located on the respective lateral side 108 and medial side 110 of throat opening 196 for receiving a fastening element, such as a lace. Advantageously, throat opening 196 may enhance the ability of top layer 132 to adjust around the foot (e.g., in response to, for example, pulling a lace). Tongue 128 is formed by forefoot extension 192, which tongue 128 may still remain to provide complete protection for the top of the foot. Optionally, the tongue may be secured (e.g., via stitching) along its medial and lateral sides such that the tongue remains in place when the article of footwear 100 is not being worn, although this is not required. In addition, in other embodiments (whether with or without a tongue), the throat opening may not be present, and top layer 132 may substantially cover the top of the foot when worn.

Forefoot extension 192 may additionally or alternatively form an element other than a tongue. For example, referring to fig. 5A and 5B, forefoot extension 192 may be a knitted extension forming two separable layers of toe cap 206, where toe cap 206 has an upper layer 208 and a lower layer 210. When forefoot extension 192 includes separable layers (shown in fig. 5A), the two layers may be formed using any suitable technique, such as any of the techniques described above with respect to knitting top layer 132 and bottom layer 134 of forefoot portion 130. After the knitting process and referring to fig. 5B, the toe cap 206 may be flipped relative to its orientation in fig. 5A such that the upper foot layer 208 overlies and is coextensive with the toe area of the top layer 132 and such that the lower foot layer 210 overlies and is coextensive with the toe area of the bottom layer 134. The toe cap 206 may then be secured to the top layer 132 and/or the bottom layer 134 using any suitable device or method (e.g., stitched seam, adhesive, by heat treating thermoplastic polymer yarns to fuse the two components together, etc.). Advantageously, the toe cap 206 may provide additional knit structures for protecting the wearer's toes and/or providing other desired functions associated with the additional knit layers. Alternatively, knitted component 104 may be flipped over (as described in more detail above) such that toe cap 206 moves into cavity 118 between top layer 132 and bottom layer 134. In other embodiments, the toe cap 206 may remain outside of the cavity 118.

Figure 6 is a diagram illustrating knitted component 104 having side extensions 212. Similar to the forefoot extensions described above, side extensions 212 may extend from the boundary where top layer 132 and bottom layer 134 meet. Thus, when knitting in the lengthwise direction 166, the side extensions 212 will extend beyond the needles used to form the top layer 132 and the bottom layer 134 on the needle beds, and thus the side extensions 212 can be formed with the full needle count of both needle beds, which is associated with the advantages described above. As shown, the side extensions 212 may be in the form of strips 214. The straps 214 may be configured to wrap around the wearer's foot to provide tightening (e.g., instead of laces) and/or additional medial-to-lateral support. When knitted component 104 is turned over, side extensions 212 may move from outside of cavity 118 to inside of cavity 118 (or vice versa). Thus, the band 214 may be within the cavity when the knitted component 104 is in its wearable state. It is also contemplated that the side extension 212 may be formed as a tubular structure with components inserted therein. When formed into a tubular structure, it is also contemplated that the strap may be pulled from outside the cavity 118 into the cavity 118 through its end 216 while flipping the extension 212 over on itself. Advantageously, the strip 214 may thus be knitted outside the cavity 118, pulled into the cavity 118, and then removed again from the cavity 118 when the top layer 132 and the bottom layer 134 are turned over during the post-knitting process.

As described above, the knitted component 104 may have regional properties (zonal properties). For example, in one non-limiting exemplary embodiment, the top layer 132 of the forefoot portion may have a first region 202 in the throat area 114 and a second region 204 adjacent to the first region 202. First zone 202 and second zone 204 may have different knit structures such that first zone 202 stretches less than second zone 204 when subjected to the same stretching force. The difference in elasticity can be tested by applying equal tension on the two regions and then measuring the displacement (per initial length unit). For example, the first zone 202 may have a knit structure with a higher stitch count than the second zone 204, such that it has a higher stitch density (i.e., loops of knitting per unit area), which may provide lower elasticity.

Additionally or alternatively, the first zone 202 may be formed of yarns having different materials, or may be treated differently during post-knitting processing to provide a first zone having lower elasticity. For example, the first region 202 may include a thermoplastic polymer material having a relatively low melting point that melts upon application of heat and then cools to a fused state upon cooling, thereby forming a relatively rigid structure. The thermoplastic polymer material in first zone 202 may be the same thermoplastic polymer material as described above with respect to the "fusible yarns," but alternatively it may be a different thermoplastic polymer material provided by separate yarns and having a different (e.g., higher) melting point (and in such embodiments, the fusible yarns need not be excluded from first zone 202 or second zone 204). For example, in one non-limiting exemplary embodiment, both first zone 202 and second zone 204 include the fusible yarns described above. The first zone 202 may additionally include an amount of a second thermoplastic polymer, which may be a thermoplastic polyurethane having a melting point between about 80 ℃ and about 200 ℃, such as from about 100 ℃ to about 125 ℃ based on atmospheric pressure at sea level. The second thermoplastic polymer material may provide a relatively high stiffness after heat treatment. Any suitable amount of the second thermoplastic polymer material may be included. Although the zone properties are primarily described with respect to the depicted zones 202, 204 of the top layer 132, other zones of the knitted component 104 may additionally or alternatively include different zones having different physical and/or visual properties.

Another advantage of forming heel portion 140 on two needle beds (as described above) is the ability to provide heel portion 140 with a natural tendency to bend due to the particular knitting structure. For example, heel portion 140 of knitted component 104 may include medial heel side 170, lateral heel side 172, and a rear portion 174 between medial heel side 170 and lateral heel side 172, wherein at least one of medial heel side 170 and lateral heel side 172 includes a convex area on a medial surface 176 of knitted component 104. For example, as shown, medial heel side 170 includes a first convex region 180 on medial surface 178, and lateral heel side 172 includes a second convex region 182 on medial surface 178. Conversely, medial heel side 170 and lateral heel side 172 each include a concave region relative to the outer surface (which is hidden in fig. 6). As a result, medial heel side 170 and lateral heel side 172 may at least partially enclose the wearer's achilles tendon, which may enhance the fit of article of footwear 100 for providing more support, less slippage, and overall better footwear performance. Rear portion 174 may include a concave area 185 on inner surface 178 and a convex shape on the outer surface, which matches the natural contour of the achilles tendon on a typical wearer's heel.

The tendency to bend can be formed using any suitable knitting process. For example, in one embodiment, and with reference to medial heel side 170 and lateral heel side 172 (opposite rear portion 174), more tension may be included on the exterior surface of heel portion 140 than on interior surface 178 during the knitting process. This may be a result of changing the tension in the respective yarns/loops with a tension-affecting component of the knitting machine, forming more loops on the inner surface 178 than on the outer surface (e.g., in a double needle bed knitting structure) by using yarns of different elasticity and/or denier, or the like. Specific examples of methods of forming knitted structures having a natural tendency to bend include in U.S. patent application No. 15/454,034 filed on 3/9/2017, which is incorporated herein by reference in its entirety. Furthermore, the tendency to bend may be enhanced by certain post-processing steps (such as steaming, which may, for example, tighten the yarns of knitted component 104), which may enhance the effect of the difference between the amounts of tension on the respective surfaces of knitted component 104.

All of the structures and methods disclosed and claimed herein can be made and executed without undue experimentation in light of the present disclosure. While this disclosure may be embodied in many different forms, specific aspects of the disclosure are described in detail herein. The present disclosure is an exemplification of the principles of the disclosure and is not intended to limit the disclosure to the particular aspects illustrated. Furthermore, unless explicitly stated to the contrary, use of the terms "a" or "an" is intended to include "at least one" or "one or more". For example, "one yarn (a yarn)" is intended to include "at least one yarn" or "one or more yarns".

Any ranges given in absolute terms or in approximate terms are intended to encompass both, and any definitions used herein are intended to be illustrative and not limiting. Notwithstanding that the numerical ranges and parameters setting forth the broad scope of the disclosure are approximations, the numerical values set forth in the specific examples are reported as precisely as possible. Any numerical value, however, inherently contains certain errors necessarily resulting from the standard deviation found in their respective testing measurements. Moreover, all ranges disclosed herein are to be understood to encompass any and all subranges (including all fractional and integer values) subsumed therein.

Moreover, the present disclosure encompasses any and all possible combinations of some or all of the various aspects described herein. It should also be understood that various changes and modifications to the aspects described herein will be apparent to those skilled in the art. Such changes and modifications can be made without departing from the spirit and scope of the present disclosure and without diminishing its intended advantages. It is therefore intended that such changes and modifications be covered by the appended claims.

Claims (20)

1. A knitted component, the knitted component comprising:

a forefoot portion having a top layer and a bottom layer, wherein a cavity is formed between the top layer and the bottom layer, and wherein the top layer is secured to the bottom layer via at least one common knit structure;

a heel region extending in a lengthwise direction from the bottom layer of the forefoot portion and secured to the bottom layer of the forefoot portion via at least one common knit structure; and

at least one extension extending from the heel region in a second direction when the knitted component is in an expanded state, the second direction being different than the lengthwise direction.

2. The knitted component of claim 1, wherein the at least one extension includes a first edge for securing to a second edge of the top layer of the forefoot portion.

3. The knitted component recited in claim 1, wherein a first extension and a second extension extend from the heel region for securing to at least one edge of the top layer of the forefoot portion, wherein the first extension extends in a lateral direction from the heel region, and wherein the second extension extends in a medial direction from the heel region.

4. The knitted component recited in claim 1, wherein the heel region includes knit structures that have a greater density than respective knit structures of the top layer and the bottom layer of the forefoot portion.

5. The knitted component of claim 1, further comprising a knitted forefoot extension that extends from a boundary between the top layer and the bottom layer of the forefoot portion.

6. The knitted component of claim 5 wherein the knitted forefoot extension has a plurality of separable layers.

7. The knitted component of claim 5, wherein the knitted forefoot extension is at least partially coextensive with the top layer and the bottom layer.

8. The knitted component of claim 1, wherein the top layer of the forefoot portion includes a throat opening.

9. The knitted component of claim 1, wherein the knitted component includes side extensions that extend from a boundary between the top layer and the bottom layer of the forefoot portion.

10. The knitted component recited in claim 9, wherein the side extensions form a band for encircling a wearer's foot when incorporated into an article of footwear.

11. An article of footwear, comprising:

a forefoot portion having a top layer and a bottom layer, wherein a cavity is formed between the top layer and the bottom layer;

a heel region secured to the bottom layer of the forefoot portion, the heel region forming a first portion of a collar; and

at least one extension extending from the heel region,

wherein the at least one extension is secured to an edge of the top layer of the forefoot portion, an

Wherein the extension forms at least a second portion of the collar.

12. The article of footwear recited in claim 11, wherein the at least one extension extends to a throat area of the article of footwear.

13. The article of footwear of claim 11, further comprising a knitted component, wherein the knitted component includes the forefoot portion and the heel region.

14. The article of footwear recited in claim 13, wherein the heel region is secured to the bottom layer of the forefoot portion via a common knit structure.

15. The article of footwear of claim 13, wherein the at least one extension is secured to the edge of the top layer via a stitched seam.

16. The article of footwear of claim 13, wherein the knitted component is inverted relative to its shape after being formed on the knitting machine.

17. The article of footwear of claim 11, wherein a first extension extends in a lateral direction from the heel region, wherein a second extension extends in a medial direction from the heel region, and wherein both the first extension and the second extension are secured to the edge of the top layer.

18. The article of footwear of claim 11, further comprising a forefoot extension extending from the toe region.

19. The article of footwear of claim 18, wherein the forefoot extension is at least partially located within the cavity and forms a tongue.

20. A method, the method comprising:

forming a forefoot portion of a knitted component on a knitting machine, the forefoot portion having a top layer and a bottom layer, wherein a cavity is formed between the top layer and the bottom layer, and wherein the top layer is secured to the bottom layer via at least one common knit structure;

forming a heel region of the knitted component on the knitting machine, the heel region being secured to the bottom layer of the forefoot portion via at least one common knit structure; and

forming at least one extension of the knitted component on the knitting machine, the at least one extension being attached to the heel region; and

securing the extension to an edge of the top layer of the forefoot portion.