Patent Description:
<CIT> discloses a shoe with a textile upper consisting at least partially of an at least two-layer textile material. In the area of the inner instep, the heel and/or the outer instep there is an interrupted structure of separate pads made of two-layer textile material arranged next to one another. An elastic structure is embedded therein with a thickness that exceeds the added thickness of the two textile layers.

<CIT> discloses a knitted component formed of multiple knitted component portions. The knitted component is formed of unitary knit construction and includes multiple tubular rib structures. An article of footwear may include an upper incorporating the knitted component. The upper may comprise areas with tubular rib structures arranged in different orientations over the forefoot region, the midfoot region, the vamp region, and the heel region of the article of footwear. Some regions of the upper may have a greater number of tubular rib structures than other regions, and some tubular rib structures can include tensile elements.

<CIT> discloses an article of footwear having an upper and a sole structure secured to the upper. Interior layer features are provided, including collar portions and a heel pad that extends along the heel region of the knitted component from a sockliner to an opening on an ankle cuff of the knitted component.

The objective technical problem to be solved may be considered to consist in overcoming or at least reducing the disadvantages according to the prior art. The problem is solved by the subject matter of the independent claim. In one aspect, an article of footwear is provided according to the subject matter of claim <NUM>. The knitted component has a first exterior surface and a second interior surface. The knitted component has at least one integrally knitted cushion region located on the second surface. The cushion region includes a plurality of non-planar structures that project away from the second surface of the knitted upper by at least <NUM> (for example, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, or greater depth), and the cushion region is located in a rearfoot region of the upper. The cushion region may be at least partially located in a calcaneus region, and/or at least partially located in an Achilles region. The cushion region may have a shape with an area of at least <NUM>,<NUM><NUM>, for example <NUM>,<NUM><NUM>, <NUM>,<NUM><NUM>, <NUM>,<NUM><NUM>, <NUM>,<NUM><NUM>, <NUM>,<NUM><NUM>, or greater area. The cushion region may have a geometric shape, such as a rectangle, a square, a trapezoid, a rhombus, an oval, a circle, a conic section (e.g., a hyperbolic shape), and other geometric shapes. Or, the cushion region may have a non-geometric shape. The plurality of non-planar structures may be separated by a plurality of base portions, which may be at least partially formed from one or more elasticated yarns. The plurality of non-planar structures includes one or more tubular rib structures, in an orientation that is parallel to a heel centerline of the upper. The plurality of non-planar structures may include at least <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, or a greater number of non-planar structures. The knitted component may be formed by a number of different materials. For example, the knitted component may include a thermoplastic polymer (e.g., a thermoplastic polyurethane) that makes up at least <NUM>%, <NUM>%, or greater percentage of the weight of the knitted component. The upper may include a second plurality of knitted elements that project from the first surface.

An article of footwear not according to the claimed invention may have a cushion region which may begin at or within <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM> or greater distance from a bite line where the upper meets the sole structure. In such examples, the tension zone may be located adjacent to a collar region of the upper, for example in a sub-ankle region of the upper.

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

The present disclosure can be better understood with reference to the following drawings and description. The components in the figures are not necessarily to scale, emphasis instead being placed upon illustrating the principles of the present disclosure.

<FIG> illustrates an upper <NUM> for an article of footwear. When incorporated into an article of footwear, the upper <NUM> may generally provide a comfortable and secure covering for wearer's foot. The upper <NUM> may be divided into a forefoot region <NUM>, a midfoot region <NUM>, and a rearfoot region <NUM>. Referring to <FIG> in conjunction with <FIG>, when the upper <NUM> is incorporated into an article of footwear, the forefoot region <NUM> generally includes portions that correspond with the toes and the joints connecting the metatarsals with the phalanges. The midfoot region <NUM> generally includes portions of the upper <NUM> that correspond with an arch area of the foot. The rearfoot region <NUM> includes portions of the upper <NUM> that correspond with rear portions of the foot, including areas that cover the calcaneus bone (which forms a portion of a wearer's heel). Additionally, the rearfoot region <NUM> may cover some or all of the wearer's malleoli and talus (which form a portion of the ankle), and may extend forward of those areas. The upper <NUM> also includes a lateral side <NUM> and a medial side <NUM>, which extend through each of forefoot region <NUM>, midfoot region <NUM>, and rearfoot region <NUM>. More particularly, the lateral side <NUM> corresponds with an outside area of the foot (i.e., the surface that faces away from the other foot), and the medial side <NUM> corresponds with an inside area of the foot (i.e., the surface that faces toward the other foot). The forefoot region <NUM>, midfoot region <NUM>, and rearfoot region <NUM> and lateral side <NUM> and medial side <NUM> are not intended to demarcate precise areas of the upper <NUM>. Rather, they are intended to represent general areas of the upper <NUM> to aid in the following discussion.

Referring still to <FIG>, at least a portion of upper <NUM>, and potentially substantially the entirety of upper <NUM>, is formed of a knitted component <NUM>. The knitted component <NUM> may be formed as an integral one-piece element during a knitting process, such as a weft knitting process (e.g., with a flat knitting machine with one, two, or more needle beds, or with a circular knitting machine), a warp knitting process, or any other suitable knitting process. That is, the knitting process on the knitting machine may substantially form the knit structure of the knitted component <NUM> without the need for significant post-knitting processes or steps. Alternatively, two or more portions of the knitted component <NUM> may be formed separately as two or more distinct knitted components (each of which being integrally knit), and may be joined following the knitting process. The knitted component <NUM> includes an interior surface <NUM> that may eventually face an interior void or face a wearer's foot when the knitted component is incorporated into an article of footwear. The knitted component <NUM> includes an exterior surface <NUM> that may face away from the void of an article of footwear. In some embodiments, e.g., embodiments with separable layers, the knitted component <NUM> may include one or more internal surfaces.

Generally, forming an upper at least partially with a knitted component may provide advantageous characteristics including, but not limited to, a particular degree of stretch (for example, as expressed in terms of Young's modulus), breathability, bendability, strength, moisture absorption, weight, abrasion resistance, and/or a combination thereof. These characteristics may be accomplished by selecting a particular single layer or multi-layer knit structure (e.g., a ribbed knit structure, an interlock structure, a single jersey knit structure, a double jersey knit structure, additional knit structures, or any combination thereof), by varying the size and tension of the knit structure, by using one or more yarns formed of a particular material (e.g., a polyester material, a relatively inelastic material, or a relatively elastic material such as elastane), by selecting yarns of a particular size (e.g., g/m corresponding to denier), and/or a combination thereof. A knitted component may also provide desirable aesthetic characteristics by incorporating yarns having different colors, textures or other visual properties arranged in a particular pattern. The yarns themselves and/or the knit structure(s) formed by one or more of the yams of the knitted component may be varied at different locations such that the knitted component has two or more portions with different properties (e.g., a portion forming the throat area of the upper may be relatively elastic while another portion may be relatively inelastic). In some embodiments, a knitted component may incorporate one or more materials with properties that change in response to a stimulus (e.g., temperature, moisture, electrical current, magnetic field, or light). For example, a knitted component may include yarns formed of at least one thermoplastic polymer material or material composition (e.g., at least one polyurethane, polyamide, polyolefin, and/or nylon) 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 the solid state when cooled. For example, at least a portion of a knitted component may include a first thermoplastic polymer. Or, at least half of the knitted component may include the first thermoplastic polymer. Or, a majority of the knitted component or substantially all of the knitted component may include the first thermoplastic polymer. As one non-limiting example, a knitted component may include a higher percentage by weight (mass) of a resin that makes up a first thermoplastic polymer type. As such, at least <NUM>% (e.g., <NUM>%, <NUM>%, etc.) of the weight (mass) of the knitted component is the resin that makes up the first thermoplastic polymer. It will be appreciated that the first thermoplastic polymer may be present in higher or lower amounts (%) as necessary or desired.

As shown in <FIG>, the knitted component <NUM> may be knitted in a two-dimensional configuration (e.g., through a flat knitting process), which may be subsequently formed into the shape of a wearer's foot through post-knitting methods, e.g., lasting. In other embodiments, the knitted component may be knitted in a three-dimensional configuration by which the knitting process (e.g., a flat or a circular knitting process) knits the upper substantially into the shape of a wearer's foot. Such a three dimensionally-knitted component may include an opening for receiving a wearer's foot within an overfoot portion. The overfoot portion may be joined with an underfoot portion as a result of the knitting process, e.g., around a perimeter of the underfoot portion. Such a three dimensionally-knitted component may resemble a bootie or a sock following the knitting process. However, it shall be understood that the shapes of the knitted components shown in the figures are merely exemplary, as other knitted components embodying the constructions disclosed herein may be knitted in different configurations. For example, a knitted component may be knitted substantially in a two-dimensional U-shape, a C-shape, another one-piece shape with one or more edges in different locations, or a multi-piece configuration. Accordingly, as used herein, the term "knitted component" is not intended to limit said knitted component to a particular shape, manufacturing process, or particular edge configuration.

In any embodiment discussed herein, a knitted component may include any number of integrally knitted features on an exterior surface. For example, the knitted component <NUM> of <FIG> includes non-planar structures <NUM> that are integrally knitted with the knitted component <NUM> and extend away from the exterior surface <NUM>, e.g., to enhance durability and/or to provide an appealing aesthetic. Such non-planar structures <NUM> may together resemble a separate component (e.g., a cage) that surrounds the upper <NUM>, although the non-planar structures <NUM> may be integrally knitted with the upper <NUM> and may form part of the exterior surface <NUM>. Additionally and as shown in <FIG>, a knitted component <NUM> may include one or more channels <NUM> comprising two textile layers that are freely-separable in certain locations, wherein the channels <NUM> may extend away from an exterior surface <NUM>, such as to provide channels for laces or other materials. Additionally and as shown in <FIG>, a knitted component <NUM> may include knitted indicia <NUM> on an exterior surface <NUM>. Additionally and as shown in <FIG>, a knitted component <NUM> may include one or more pillow like, cloud-like, or quilt-like loft portions <NUM> on an exterior surface <NUM> that provide cushioning and appealing aesthetic, such as those as described in U. Patent Application <CIT>. Additionally and as shown in <FIG>, a knitted component <NUM> may include one or more knitted recesses <NUM> in an exterior surface <NUM>, at least one of which recesses <NUM> may or may not reveal one or more floating yarns <NUM>, such as those as described in U. Patent Application <CIT>. Additionally, a knitted component may include one or more knitted structures as described in U. Patent Application No. <CIT>. The foregoing integrally knitted features are merely exemplary and intended to show a subset of the numerous potential knitted features that may be found on an exterior surface of the knitted components described herein.

Referring to <FIG> and <FIG>, the rearfoot region <NUM> of the upper <NUM> includes one or more cushion regions <NUM> that are integrally knitted with the knitted component <NUM> and project away from the interior surface <NUM> (i.e., the surface that may eventually face a wearer's foot and/or the interior of an article of footwear). Generally, the structure, shape, dimensions, and other properties of the cushion region(s) may vary between embodiments; however, the cushion region(s) are generally integrally knitted with the knitted component (i.e., substantially formed from the same knitting process that forms the knitted components, without significant post processing steps), project away from the interior surface of the knitted component, and are configured to provide cushioning and support to the rear portion of a wearer's foot, for example the heel (including the calcaneus bone) and/or the Achilles tendon (see <FIG>). Although the cushion regions disclosed herein may vary in terms of area, each cushion region may generally have an area of at least approximately <NUM>,<NUM><NUM>; in some embodiments, each cushion region may have an area of at least <NUM>,<NUM><NUM>, <NUM>,<NUM><NUM>, <NUM>,<NUM><NUM>, <NUM>,<NUM><NUM>, <NUM>,<NUM><NUM>, or greater area. It is expressly contemplated in this application that a knitted component may have a single cushion region or a plurality of cushion regions. Although the following disclosure generally discusses cushion regions in singular form, it shall be appreciated that this does not in any way limit the number of cushion regions that may be integrally knitted with a knitted component.

In conventional footwear construction, the interior surface of the upper (and any knitted component that forms part of the upper) is relatively smooth and free of elements that might project away from an interior surface and toward a wearer's foot, out of concern for maximizing comfort. In contrast to this traditional construction, the cushion regions described herein project away from the interior surface of the knitted component, but due to their knitted construction, shape, size, location, and materials, will not cause the wearer discomfort, but will instead advantageously cushion the wearer's foot when the knitted component is incorporated into an article of footwear. By projecting away from an interior surface of the knitted component in a location that corresponds with a rear portion of a wearer's foot, the cushion region may advantageously prevent the wearer's foot from slipping upwards and outwards from the article of footwear. Additionally, in some embodiments, the cushion region may obviate the need for traditional heel counters and other components when the knitted component is incorporated into an article of footwear, thereby reducing weight and cost. Still further, in some embodiments, the cushion region may be formed from one or more materials that are similar or identical to other materials utilized in the knitted component, thereby improving recyclability of the knitted component.

Referring again to <FIG>, <FIG>, and <FIG>, in some embodiments the cushion region <NUM> may be at least partially located in a calcaneus region <NUM> of the knitted component <NUM>, i.e., a location that may eventually correspond with at least a portion of a wearer's calcaneus bone when the knitted component <NUM> is incorporated into an article of footwear. This application contemplates that the calcaneus region <NUM> of the knitted component <NUM> may eventually correspond with any aspect of the wearer's calcaneus bone, for example an upper portion, a lower portion, a rear portion, a medial portion, and a lateral portion of the calcaneus bone. Generally, when an upper is incorporated into an article of footwear, the calcaneus region may begin approximately at a bite line where the upper meets a sole structure, and may end approximately <NUM>-<NUM> above the bite line. Similarly, the calcaneus region may begin approximately <NUM>-<NUM> above a lower edge or outer edge of a knitted component, and may end approximately <NUM>- <NUM> above the lower or outer edge. The calcaneus region <NUM> may coincide with a heel centerline <NUM> of the knitted component <NUM>, although its precise boundaries may not be apparent in the knitted component <NUM> itself. The calcaneus region <NUM> may extend in a medial and a lateral direction away from the heel centerline <NUM> by up to approximately <NUM>, <NUM>, <NUM> or more. In another dimension, the calcaneus region <NUM> may extend toward and/or to an outer edge <NUM> and/or a collar edge <NUM> of the knitted component.

In various embodiments, the cushion region may cover none of the calcaneus region, part of the calcaneus region, or substantially all of the calcaneus region. In this application, the cushion region may cover "substantially all" the calcaneus region if it covers an area of at least approximately <NUM><NUM> that is positioned within approximately <NUM> of either side of the heel centerline. For example, in <FIG> and <FIG>, the knitted cushion region <NUM> covers substantially all of the calcaneus region <NUM> by extending approximately <NUM>-<NUM> from either side of the heel centerline <NUM> and extending approximately <NUM>-<NUM> in a direction parallel to the heel centerline <NUM>. In other, similar embodiments, the horizontal and vertical dimensions may each vary from approximately <NUM> to approximately <NUM> or greater. In the embodiment of <FIG> and <FIG>, a cushion region <NUM> on an interior surface <NUM> covers a portion of a calcaneus region <NUM> because the curved edge <NUM> covers only an upper portion of the calcaneus region <NUM>, although the cushion region <NUM> extends in the medial and lateral directions by approximately <NUM>-<NUM> on either side of a heel centerline <NUM>. In the example of <FIG> and <FIG> not according to the claimed invention, a first cushion region <NUM> on an interior surface <NUM> covers a portion of a calcaneus region <NUM>. In the example of <FIG> and <FIG> not according to the claimed invention, a trapezoidal cushion region <NUM> on an interior surface <NUM> substantially covers a calcaneus region <NUM>. In the example not according to the claimed invention of <FIG> and <FIG>, a cushion region <NUM> on an interior surface <NUM> does not cover any part of a calcaneus region <NUM>.

Additionally, the cushion region(s) in some embodiments may be at least partially located in an Achilles region of the knitted component, i.e., a location that may eventually correspond with at least a portion of a wearer's Achilles tendon when the knitted component is incorporated into an article of footwear. This may provide additional cushion and protection for the wearer's Achilles tendon. Referring to <FIG>, an Achilles region <NUM> of the knitted component <NUM> may be located along the heel centerline <NUM> and closer to the collar edge <NUM> than the calcaneus region <NUM>. Not all knitted components may have an Achilles region. In those that do, the degree to which the cushion region may be located in the Achilles region, if at all, may vary between embodiments. For example, in the embodiment of <FIG> and <FIG>, the knitted component <NUM> includes a high collar region <NUM> that covers an Achilles region <NUM>. In this embodiment, the cushion region <NUM> extends along the interior surface <NUM> from the calcaneus region <NUM> to a collar edge <NUM>, thereby occupying at least a portion of the Achilles region <NUM>. In other examples not according to the claimed invention, such as in <FIG> and <FIG>, a second cushion region <NUM> may extend only partially into an Achilles region <NUM>, while the cushion region <NUM> covers at least part of the calcaneus region <NUM>. In still other examples not according to the claimed invention, such as in <FIG> and <FIG>, the cushion region <NUM> may extend away from a heel centerline <NUM> in an Achilles region <NUM> along a lateral and/or medial side of a interior surface of a knitted component, for example to provide increased Achilles support.

As noted above, the size and shape of the cushion region may vary between embodiments. The shape that circumscribes the cushion region may have a geometric or non-geometric shape, and may be symmetrical or asymmetrical. Exemplary geometric shapes include rectangles, squares, trapezoids, rhombuses, ovals, circles, conic sections (e.g., hyperbolic shapes), and other geometric shapes. Non-geometric shapes may include organic shapes such as kidney shapes and other contoured shapes, such as those that may correspond with the anatomy of a wearer's foot. The area of the two-dimensional shape that circumscribes the cushion region may vary between embodiments, for example from approximately <NUM><NUM> to approximately <NUM>,<NUM><NUM> or greater. By comparison, the cushion region may have a surface area that exceeds the area of the two-dimensional shape that circumscribes the cushion region due to the presence of non-planar structures, discussed below. For example, the cushion region <NUM> of <FIG> and <FIG> has a rectangular shape with a width, w, <NUM> of approximately <NUM>-<NUM> and a vertical height, h, <NUM> in a direction parallel to the heel centerline <NUM> of approximately <NUM>-<NUM>. In similar embodiments, the horizontal and vertical dimensions may each vary from approximately <NUM> to approximately <NUM> or greater. In the embodiment of <FIG> and <FIG>, the cushion region <NUM> has a non-geometric shape that extends from an upper portion of the calcaneus region <NUM> into the Achilles region <NUM>, extending to the collar edge <NUM>. The cushion region <NUM> also extends in the medial and lateral directions by approximately <NUM>-<NUM> on either side of the heel centerline <NUM>. In the example of <FIG> and <FIG> not according to the claimed invention, the first cushion region <NUM> has an organic non-geometric shape with a first height, h<NUM>, <NUM> along a heel centerline <NUM>. The height of the first cushion region <NUM> increases to a second height, h<NUM>, <NUM> at other locations that are spaced away from the heel centerline <NUM>, e.g., to better conform to the shape of a wearer's foot. In the embodiment of <FIG> and <FIG>, the cushion region <NUM> has a trapezoidal shape with a wider first width, w<NUM>, <NUM> and a narrower second width, w<NUM>, <NUM>. The foregoing shapes and dimensions are merely exemplary and not intended to limit the number of potential shapes and dimensions that the cushion region may reflect, but rather to exhibit the breadth of potential shapes, dimensions, and locations of the cushion region(s).

In any embodiment, the cushion region includes multiple non-planar structures that enhance cushioning and provide volume to the cushion region by extending away from the interior surface of the knitted component. For example, the cushion region <NUM> of <FIG> and <FIG> includes approximately twenty non-planar structures <NUM>, although other embodiments may include a greater or fewer number of non-planar structures, e.g., two, four, five, ten, twenty-five, thirty, or more non-planar structures. In the embodiment of <FIG> and <FIG>, the cushion region <NUM> includes a plurality of non-planar structures <NUM> that each have a different height. In the example of <FIG> and <FIG> not according to the claimed invention, the first and second cushion regions <NUM>, <NUM> each include a plurality of non-planar structures <NUM>, <NUM>, respectively. In the example of <FIG> and <FIG> not according to the claimed invention, the cushion region <NUM> includes a plurality of horizontal non-planar structures <NUM>. In the example not according to the claimed invention of <FIG> and <FIG>, the cushion region <NUM> includes a plurality of non-planar structures <NUM> formed as loft portions. Referring to the section view of <FIG>, a knitted component <NUM> includes an integrally knitted cushion region <NUM>, which has a plurality of non-planar structures <NUM> that project away from a surface <NUM>. Each non-planar structure <NUM> may extend away from the surface <NUM> by a depth, d, <NUM> which may be at least approximately <NUM>, for example <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, or greater depth. When the knitted component <NUM> is incorporated into an article of footwear, the non-planar structures <NUM> extend into the void formed by the knitted component <NUM>, i.e., toward a wearer's foot. In the embodiment of <FIG>, each non-planar structure <NUM> extends away from the surface <NUM> by the same depth, d, <NUM>. However, as shown in the alternative section view of <FIG>, a knitted component <NUM> may include a cushion region <NUM> with non-planar structures <NUM> that extend away from a surface <NUM> by different distances d<NUM> (<NUM>) and d<NUM> (<NUM>), for example to form a more ergonomic contour.

Referring again to <FIG>, the non-planar structures may be spaced apart by base portions <NUM>, which may be formed of similar or dissimilar materials as the non-planar structures <NUM>. In such embodiments, each base portion <NUM> has a width, w<NUM>, <NUM> that affects the spacing between the non-planar structures <NUM>. In some embodiments, each base portion may have a very small width, e.g., <NUM>-<NUM>, which may correspond with a single course of yam or a small number of courses. In such embodiments, the non-planar structures may be so closely spaced so that adjacent non-planar structures nearly touch each other or actually touch each other. In other embodiments, such as shown in the section view of <FIG> and also potentially in embodiments where the non-planar structures have an orientation that is not parallel with the heel centerline, a base portion <NUM> may have a greater width, w<NUM>, <NUM> so that the non-planar structures are spaced apart by a greater distance. In all embodiments, the cushion region may include base portions having one or more widths.

Generally suitable non-planar structures may include solid rib structures, tubular rib structures, and loft portions. Rib structures may be linear or non-linear. Referring again to <FIG>, generally, the non-planar structures <NUM> may be a tubular rib structure, which may be an area of a knitted component constructed with two or more integrally knit and overlapping knitted portions <NUM>, <NUM> that form a tube or tunnel. Although the sides or edges of the knitted portions <NUM>, <NUM> may be secured to the other layer, a central area is generally unsecured to form the hollow tube or tunnel. One exemplary type of tubular rib structure is an ottoman structure. For example, the cushion region <NUM> of the knitted component <NUM> of <FIG> includes a plurality of elongate, tubular, non-planar structures <NUM> that extend away from the interior surface <NUM>. Hollow rib structures may generally offer improved cushioning over solid rib structures because each hollow tubular rib structure may compress in response to a force, e.g., the force of a wearer's heel. In some cases, tubular rib structures may include one or more additional components that are disposed within the tube, for example to increase cushioning or loft, such as one or more yarns or strands.

In other examples, a cushion region may include other suitable non-planar structures as described in U. Patent Application <CIT>. Such non-planar structures may include one or more integrally knitted cloud-like, quilt-like, or pillow-like loft portions formed by knitting voids between freely separable knit layers, and also by knitting a material (e.g., a monofilament strand) into the voids in order to impart cushioning or loft to the knitted structure. Such a non-planar structure is shown in the example not according to the claimed invention of <FIG> and <FIG>, wherein the cushion region <NUM> includes a plurality of non-planar structures <NUM> that are loft portions. Referring to the section view' of <FIG>, a loft portion <NUM> may include a portion of a first knit layer <NUM> that extends away from an underlying portion of a second knit layer <NUM>, and a material <NUM> that is knitted in between the first and second layers <NUM>, <NUM>. Generally, within each loft portion, the first layer may extend away from the second layer by a distance of about <NUM>-<NUM>, about <NUM>-<NUM>, about <NUM>-<NUM>, about <NUM>-<NUM>, or a greater distance. In other words, the cushion region may project away from an interior surface of the knitted component by <NUM>-<NUM>, about <NUM>-<NUM>, about <NUM>-<NUM>, or a greater distance. Such loft portions may have an approximately geometric shape such as a circle, a triangle, a square, a rectangle, a rhombus, a pentagon, a hexagon, a curve (e.g., a sinusoid or other curve), etc. In still other embodiments, a cushion region may include one or more pods as described in U. Patent Application <CIT>.

Generally, the non-planar structures may be knitted in an array, a pattern, a mosaic, a lattice, or other arrangement to enhance cushion, to improve the interface between the upper and a wearer's heel region, for improved aesthetics, or for other advantage. For example, the plurality of tubular non-planar structures <NUM> of <FIG> and <FIG> are knitted in a closely-spaced parallel array, with each tubular non-planar structure <NUM> being oriented parallel to the heel centerline <NUM> of the knitted component (a "vertical" orientation). The vertical orientation of the tubular non-planar structures <NUM> of <FIG> may correspond with a course-wise direction of the knitted component <NUM>, but may alternatively correspond with a wale-wise direction in other embodiments. The vertical orientation of the tubular non-planar structures <NUM> of <FIG> also corresponds with the orientation of a wearer's Achilles tendon, which may advantageously enable each tubular non-planar structure <NUM> to conform independently to a wearer's heel and/or Achilles tendon. However, in other embodiments, the non-planar structures may have one or more non-vertical orientations. For example, in the example not according to the claimed invention of <FIG> and <FIG>, the non-planar structures <NUM> are loft portions that are knitted in quilt-like pattern.

The cushion region of the knitted component may be knitted from a variety of materials. Given that the cushion region is located where it is likely to contact a wearer's foot when the knitted component is incorporated into an article of footwear, it may be desirable to knit at least part of the non-planar structures with one or more materials having a relatively soft hand. It may also be desirable to knit at least part of the non-planar structures from relatively durable yarns that will withstand repeated ingress and egress of a wearer's foot into an article of footwear and constant friction forces without degradation. Such yarns may exhibit a minimum tensile strength, for example approximately <NUM> N, <NUM> N, <NUM> N, <NUM> N (corresponding to <NUM> kgf, <NUM> kgf, <NUM> kgf, <NUM> kgf), or greater tensile strength. The yarns may also have a minimum tenacity, for example approximately <NUM>,<NUM> cN/dtex, <NUM>,<NUM> cN/dtex, <NUM>,<NUM> cN/dtex, <NUM>,<NUM> cN/dtex, <NUM>,<NUM> cN/dtex (corresponding to <NUM>/denier, <NUM>/denier, <NUM>/denier, <NUM>/denier, <NUM>/denier), or greater tenacity. For example, the non-planar structures may be knitted from one or more synthetic yarns formed at least partially from polyester (e.g., yarns having at least <NUM>%, <NUM>%, <NUM>%, <NUM>%, <NUM>%, <NUM>%, or greater polyester content). Because the cushion region may exhibit better performance if it conforms better to a wearer's foot, it may be desirable to knit at least part of the cushion region from one or more elasticized yams, which may impart resiliency to the knit structure. For example, at least some non-planar structures and/or base portions may be knitted from yams having elastane fibers that comprise at least <NUM>%, <NUM>%, <NUM>%, <NUM>%, or greater portion of the yam, such that the yarn can achieve at least approximately <NUM>%, <NUM>%, <NUM>% or greater elongation without breaking. For example, base portions located adjacent the heel centerline may include yarns having elastane fibers to improve the conformance of the cushion region to a wearer's foot.

In any of the embodiments described herein, it may be desirable to knit part or substantially all of the knitted component (including any cushion region) from recyclable materials, e.g., thermoplastic polymer materials that may be melted and re-formed. Given this, the cushion region may be formed with alternative yams that substantially comprise recyclable materials that exhibit similar physical properties as described above. For example, the knitted component may include yarns formed of at least one thermoplastic polymer material or material composition (e.g., at least one polyurethane, polyamide, polyolefin, and/or nylon) 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 the solid state when cooled. For example, at least a portion, at least half, a majority, or substantially all of the knitted component may include a first thermoplastic polymer. As one non-limiting example, at least <NUM>%, <NUM>%, or greater percentage of the weight of the knitted component may include the resin that makes up the first thermoplastic polymer.

The foregoing uppers include one or more optional tension zones that help the cushion region retain a wearer's foot when the knitted component is incorporated into an article of footwear. More specifically, the tension zone forms part of the same integrally-knit knitted component as the cushion region, and therefore is connected with the cushion region through one or more courses of yarn. The tension zone includes one or more elasticated yarns as described above, which may facilitate the ingress and egress of a wearer's foot when the knitted component is incorporated into an article of footwear by elongating slightly under tensile loads. The tension zone may be located near the cushion region on a lateral or medial side of the knitted component. For example, the knitted component <NUM> of <FIG> includes first and second tension zones <NUM>, <NUM> in a lateral collar region <NUM> and a medial collar region <NUM>, respectively. In other embodiments, the tension zone(s) may be additionally located in a lateral or medial ankle region, or a sub-ankle region. For example, the knitted component <NUM> of <FIG> includes first and second tension zones <NUM>, <NUM> located in lateral and medial sub-ankle regions <NUM>, <NUM>, respectively. In other examples, the tension zone(s) may extend toward or to an outer edge of the knitted component, and may also extend toward or to a collar edge.

When the knitted component is incorporated into an article of footwear and when a wearer inserts a foot into the article, the yarns in the tension zone may experience a tension force. Because interlooped courses of yarn connect the cushion region and the tension zone, the tensile force experienced in the tension zone may pull the cushion region forward, thereby causing the cushion region to conform to the wearer's heel. This anatomical conformance may help secure the wearer's foot during ambulatory activities such as walking, running, and athletics.

The knitted components and uppers described herein may be incorporated into articles of footwear. <FIG> illustrate an article of footwear <NUM> that includes an upper <NUM> that is at least partially formed from a knitted component <NUM>. As shown, the upper <NUM> may be secured to at least one sole structure <NUM>. The article <NUM> is disclosed as having a general configuration suitable for walking, running, athletics, and other ambulatory activities. Concepts associated with footwear, including the upper <NUM> and knitted component <NUM>, may also be applied to a variety of other athletic footwear types including but not limited to baseball shoes, basketball shoes, cross-training shoes, cycling shoes, football shoes, soccer shoes, sprinting shoes, tennis shoes, and hiking boots. The concepts may also be applied to footwear types that are generally considered to be non-athletic, including dress shoes, loafers, sandals, and work boots. The concepts disclosed herein apply, therefore, to a wide variety of footwear types. Furthermore, the concepts disclosed herein may apply to articles beyond footwear, such as accessories or apparel.

As shown in <FIG>, the upper <NUM> may generally provide a comfortable and secure covering for a foot of a wearer. As such, the wearer may insert a foot through an opening <NUM> formed in the upper <NUM> and into a void to effectively secure the foot within the article <NUM> or otherwise unite the foot and article <NUM>. The opening <NUM> is bordered by a collar <NUM>. Moreover, the sole structure <NUM> may be secured to a lower area of the upper <NUM> and extend between the foot and the ground to cushion the foot, provide traction, enhance stability, and influence the motions of the foot.

As with the uppers and knitted components described above, articles of footwear may generally be divided into three general regions: a forefoot region, a midfoot region, and a rearfoot region. Referring still to <FIG>, a rearfoot region <NUM> may secure the wearer's heel within the article <NUM> and may also protect the wearer's heel from abrasion and shock. The rearfoot region <NUM> of the article <NUM> may include components of the upper <NUM> (including the knitted component <NUM>) and the sole structure <NUM>, and may additionally interact with other systems within the article <NUM> (e.g., a tension system and/or a closure system) to improve functionality and performance. Notably, the rearfoot region <NUM> need not be visually distinct from a midfoot region <NUM> (for example, distinguished by an edge, seam, or other structure). Rather, the two regions <NUM> and <NUM> may continuously transition, as through a common and continuous knit structure formed during a single knitting process.

Referring still to <FIG>, the rearfoot region <NUM> may extend from a medial border region <NUM>, around a heel portion <NUM>, to a lateral border region <NUM>. Additionally, the rearfoot region <NUM> may extend upward to the <NUM> opening and collar <NUM>, and may extend downward to the ground, encompassing all structure present in that space, including portions of the upper <NUM> and the sole structure <NUM>. Additionally, the rearfoot region <NUM> of the article <NUM> may include more than one layer of material, for example an interior knit layer of the knitted component <NUM> that is configured to face a wearer's foot, and an exterior knit layer of the knitted component <NUM> that faces outward from the void. In such cases, the layers may, but need not be, physically separable. The rearfoot region <NUM> may further include other components, such as components positioned between knit layers of the upper <NUM> to provide cushioning.

Referring still to <FIG>, along with the section view of <FIG>, the rearfoot region <NUM> of the article <NUM> includes a rectangular cushion region <NUM> having a plurality of non-planar structures <NUM> that are integrally knitted with the knitted component <NUM> and projects away from an interior surface <NUM> of the knitted component <NUM> and into the void. The knitted component <NUM> also includes knitted non-planar structures <NUM> on an exterior surface <NUM>. In this embodiment, the knitted non-planar structures <NUM> resemble a cage, although this is merely exemplary and the exterior surface of other knitted components could have different structures and appearances. However the embodiment of <FIG> illustrates that the knitted component <NUM> may include integrally knitted non-planar structures on both the interior and exterior surfaces <NUM>, <NUM>. The cushion region <NUM> is located in a calcaneus region <NUM> and wraps forward along a medial side <NUM> and a lateral side <NUM> of the upper <NUM>. With reference to the section view of <FIG>, the plurality of non-planar structures <NUM> are knitted in a vertical orientation, i.e., parallel to a heel centerline <NUM> of the article <NUM>. In this embodiment, the cushion region <NUM> begins at a bite line <NUM>, although in other embodiments, the cushion region may begin within <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM> or greater distance from a bite line. The cushion region <NUM> has a vertical height (i.e., in the direction of the heel centerline <NUM>) of approximately <NUM>-<NUM>, and a width of approximately <NUM>-<NUM>, although the dimensions of alternative embodiments may differ as discussed above with respect to knitted components. The article <NUM> also includes a first tension zone <NUM> located a lateral collar region <NUM> and a second tension zone <NUM> located in a medial collar region <NUM>, both tension zones <NUM>, <NUM> being at least partially formed from elasticated yarns to impart stretch to the knitted component <NUM> and also to pull the cushion region <NUM> against a wearer's heel.

In the example article of footwear <NUM> of <FIG> not according to the claimed invention, an upper <NUM> includes a knitted component <NUM> having an ergonomic, non-geometrically shaped cushion region <NUM> that extends away from an internal surface <NUM> of the knitted component <NUM> in a void <NUM> formed by the upper <NUM>. The cushion region <NUM> includes a plurality of non-planar structures <NUM> comprising ottomans. In this example, the upper <NUM> extends high into an Achilles region <NUM>. The cushion region <NUM> is located in a calcaneus region <NUM> and extends into the Achilles region <NUM> toward a collar edge <NUM>. With reference to the section view of <FIG>, the non-planar structures <NUM> are knitted with a horizontal orientation, i.e., perpendicular to a heel centerline <NUM>.

In the example of <FIG> not according to the claimed invention, an article of footwear <NUM> includes an upper <NUM> at least partially formed from a knitted component <NUM>. The knitted component <NUM> includes an ergonomic, non-geometrically shaped cushion region <NUM> that includes a plurality of non-planar structures <NUM> formed as loft portions. The cushion region <NUM> is located in a calcaneus region <NUM>, but does not extend into an Achilles region <NUM>. The non-planar structures <NUM> are knitted in a quilted pattern in order to improve conformity with the wearer's heel.

<FIG> illustrates a non-limiting knitting sequence not according to the claimed invention that may be utilized to form knitted components (such as for an upper for an article of footwear) having a first surface and an opposite-facing second surface, and an integrally-knitted cushion region as described above. The knitted component may be formed through a weft knitting process (e.g., with a flat knitting machine with one, two, or more needle beds). Tire sequence of <FIG> is illustrated on a weft knitting machine having a first needle bed <NUM> and a second needle bed <NUM>.

In a first step <NUM>, the knitting machine knits a base portion of a cushion region. More specifically, the knitting machine knits courses of a first yam <NUM> and a second yarn <NUM> on the first and second needle beds <NUM>, <NUM> in order to form a relatively strong knitted area. The number of courses knitted in the first step <NUM> generally correlates with the width of a base portion of the cushion region. In other words, knitting a greater number of courses in the first step <NUM> would create a base portion having a greater width, and vice versa. Although some courses of the first yam <NUM> utilize tuck stitches in <FIG>, other examples may utilize different knit structures in this step, e.g., a double jersey or a rib knit structure. The first step <NUM> includes a course of the second yarn <NUM> on the second needle bed <NUM> in preparation for the next step, in which the knitting machine knits a non-planar structure. The knitting machine then knits a course of the first yarn <NUM> on the first needle bed <NUM>. The first and second yams <NUM>, <NUM> may be the same or different. For example, the first and second yams <NUM>, <NUM> may include one or more non-elasticated yams having a tensile strength of at least approximately <NUM> N, <NUM> N, <NUM> N, <NUM> N (corresponding to <NUM> kgf, <NUM> kgf, <NUM> kgf, <NUM> kgf), or greater tensile strength, and which may include at least <NUM>%, <NUM>%, <NUM>%, <NUM>%, <NUM>%, <NUM>% or greater percentage (by weight) of a particular base chemistry. The first and/or second yarns <NUM>, <NUM> may include elasticated yams in order to impart stretch and resiliency to the knitted component.

In a second step <NUM>, the knitting machine knits a portion of a non-planar structure of the cushion region, the non-planar structure extending away from a second surface of the knitted component. More particularly, the knitting machine knits a plurality of partial courses of a third yam <NUM> on the second needle bed <NUM>. The knitting length of the partial courses may generally correspond to one dimension of the resulting non-planar structure, e.g., the height (if the courses are eventually oriented parallel to a heel centerline of an upper). For example, the partial courses of the second step <NUM> have a knitting length of approximately twenty-two needles. In other examples, knitting partial courses with a shorter knitting length (e.g., fewer than twenty-two needles) would produce a non-planar structure with a shorter height. The number of partial courses knitted in the second step <NUM> may correspond with the depth by which the resulting non-planar structure extends away from the second surface of the knitted component. In other words, a greater number of courses knitted in the second step <NUM> may create a non-planar structure that has a greater depth, i.e., extends further away from the inner surface of the knitted component. For example, the second step <NUM> of <FIG> includes eight courses of the second yarn, which may produce a non-planar structure that extends away from a base portion by approximately <NUM>-<NUM> depending on the yarn selection. The converse is also true, i.e., a fewer number of courses knitted in the second step <NUM> would create a non-planar structure having a lesser depth, all else equal. The third yam <NUM> may be formed from the same or different materials as the first and second yams <NUM>, <NUM>.

In a third step <NUM>, the knitting machine knits a plurality of additional courses of the first yarn <NUM> on the first and second needle beds <NUM>, <NUM>, although the number of courses may vary in different examples. More specifically, in tire third step <NUM>, the knitting machine closes the non-planar structure knitted during the second step <NUM> and knits another base portion by knitting additional courses of the first and second yams <NUM>, <NUM> utilizing a combination of single-bed and double-bed knit structures. Additionally, the knitting machine knits at least one course of the second yarn <NUM> on the second needle bed in preparation to knit the next non-planar structure.

Following the first through third steps <NUM>, <NUM>, <NUM>, the foregoing sequence may be repeated as desired in order to form additional non-planar structures and base portions, i.e., to expand the cushion region. For example, in a fourth step <NUM>, the knitting machine forms another non-planar structure from the third yarn <NUM> as described above with respect to the second step <NUM>. In a fifth step <NUM>, the knitting machine completes the non-planar structure knitted in the fourth step <NUM>, similar to the third step <NUM> described above.

<FIG> illustrates another non-limiting knitting sequence not according to the claimed invention that may be utilized to form knitted components (such as for an upper for an article of footwear) having an integrally-knitted cushion region. The resulting knitted component may have a different visual appearance and physical properties (e.g., a different stretch level) than the knitted component produced by the knitting sequence of <FIG>.

In a first step <NUM>, the knitting machine forms a base portion comprising fifteen courses by knitting a plurality of courses of a first yam <NUM> on a first needle bed <NUM>. With fifteen courses, the base portion knitted by the first step <NUM> of <FIG> has a greater width than the twelve-course base portion knitted by the third step <NUM> of <FIG>, all else equal. The first yam <NUM> may include an elasticated yarn as described above, for example yarns having elastane fibers that comprise at least <NUM>%, <NUM>%, <NUM>%, <NUM>%, or greater portion of the yam, such that the yarn can achieve at least approximately <NUM>%, <NUM>%, <NUM>%, or greater elongation without breaking. The courses of the first yam <NUM> may include a plurality of interlocking courses knitted on the first needle bed <NUM> and a second needle bed <NUM>, which may help impart stretchiness to the knitted component.

In a second step <NUM>, the knitting machine knits a portion of a non-planar structure of the cushion region that extends away from a second surface of the knitted component. More particularly, the knitting machine knits eleven partial courses of a second yarn <NUM> on the second needle bed <NUM>. With eleven courses, the non-planar structure knitted by the second step <NUM> of <FIG> will project further away from the surface of the knitted component as compared to the non-planar structure knitted by the second step <NUM> of <FIG>, all else equal. Furthermore, each partial course of the second yarn <NUM> has a knitting length of seventeen needles. As a result, the non-planar structure knitted by the second step <NUM> of <FIG> will have a shorter height than the twenty-two needle non-planar structure knitted by the second step <NUM> of <FIG>, all else equal. The second yam <NUM> may be formed from the same or different materials as the first yarn <NUM>.

In a third step <NUM>, the knitting machine closes the non-planar structure knitted during the second step <NUM> and forms a second base portion from the first yarn <NUM>, similar to the first step <NUM>. Following the third step, <NUM> the foregoing sequence may be repeated as necessary' to form additional non-planar structures and base portions, i.e., to expand the knitted cushion region.

Claim 1:
An article of footwear (<NUM>) having an upper (<NUM>, <NUM>, <NUM>) and a sole structure (<NUM>) associated thereto, the upper (<NUM>, <NUM>, <NUM>) forming a void, the upper (<NUM>, <NUM>, <NUM>) comprising:
a knitted component (<NUM>, <NUM>, <NUM>, <NUM>, <NUM>) having a first exterior surface (<NUM>, <NUM>, <NUM>) and a second interior surface (<NUM>, <NUM>, <NUM>), wherein the knitted component (<NUM>, <NUM>, <NUM>, <NUM>, <NUM>) comprises at least one integrally knitted cushion region (<NUM>, <NUM>, <NUM>, <NUM>, <NUM>) located on the second interior surface (<NUM>, <NUM>, <NUM>);
wherein the cushion region (<NUM>, <NUM>, <NUM>, <NUM>, <NUM>) comprises a plurality of non-planar structures (<NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>) that project away from the second interior surface (<NUM>, <NUM>, <NUM>) of the knitted component (<NUM>, <NUM>, <NUM>, <NUM>, <NUM>) by at least <NUM> into the void;
wherein the cushion region (<NUM>, <NUM>, <NUM>, <NUM>, <NUM>) is located in a rearfoot region (<NUM>, <NUM>) of the upper (<NUM>, <NUM>, <NUM>) such that the non-planar structures (<NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>) are configured to contact a wearer's heel,
wherein the knitted upper (<NUM>, <NUM>, <NUM>) comprises a tension zone (<NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>) configured to pull the cushion region (<NUM>, <NUM>, <NUM>, <NUM>, <NUM>) against the wearer's heel, wherein the tension zone (<NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>) is connected to the cushion region (<NUM>, <NUM>, <NUM>, <NUM>, <NUM>) through one or more courses of yarn,
wherein the plurality of non-planar structures (<NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>) comprises tubular rib structures,
wherein the article of footwear (<NUM>) is characterized in that the tension zone (<NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>) comprises one or more elasticated yarns, wherein the plurality of tubular non-planar structures (<NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>) are knitted in a closely-spaced parallel array, and wherein each tubular non-planar structure (<NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>) is oriented vertically and parallel to a heel centerline (<NUM>, <NUM>, <NUM>) of the knitted component (<NUM>, <NUM>, <NUM>, <NUM>, <NUM>).