US-12622481-B2 - Article of footwear incorporating a knitted component with an integral knit ankle cuff

US12622481B2US 12622481 B2US12622481 B2US 12622481B2US-12622481-B2

Abstract

An article of footwear with a knitted component including an upper and an integral knit ankle cuff is provided. The upper and the ankle cuff are formed as a one-piece knit element. The knit element forms a portion of an exterior surface of the upper and an opposite interior surface of the upper, with the interior surface forming a void for receiving a foot. The ankle cuff is formed of unitary knit construction with the upper as a one-piece knit element and extends above a throat area of the upper. The ankle cuff includes malleolus zones on medial and lateral sides to correspond with the ankle bones of a wearer. The knit component further incorporates features to assist with providing entry for a foot of a wear, providing comfort to a wearer, and to assist with orientation of the upper of the article of footwear when being worn.

Inventors

Denis Dekovic
John Droege
Windra Fahmi
Jeongwoo Lee
Daniel A. Podhajny
Karl Seamarks
Doug D. Wilken

Assignees

NIKE, INC.

Dates

Publication Date: 20260512
Application Date: 20220506

Claims (20)

1 . A method of manufacturing a cleated shoe, the method comprising: knitting an upper comprising at least part of a forefoot region, a midfoot region, a heel region, a lateral side, a medial side, and an instep area extending between the lateral side and the medial side, wherein the instep area is joined through knitting to each of the lateral side and the medial side; knitting, in the instep area, a stretch zone, the stretch zone comprising a unitary knit construction with the lateral side, the medial side, and the instep area; knitting an ankle cuff, the ankle cuff comprising a unitary knit construction with at least the instep area of the upper, wherein the ankle cuff comprises a malleolus zone located on the ankle cuff, the malleolus zone comprising a plurality of voids in at least an exterior layer of the ankle cuff, wherein the plurality of voids expose an interior layer of the ankle cuff; and securing a sole structure comprising a plurality of cleat members to the upper to form the cleated shoe.
2 . The method of manufacturing the cleated shoe of claim 1 , wherein the plurality of voids expose an interior surface of the interior layer of the ankle cuff.
3 . The method of manufacturing the cleated shoe of claim 1 , further comprising forming a plurality of lace apertures that extend through the upper, the plurality of lace apertures disposed along the instep area on each of the lateral side and the medial side of the upper.
4 . The method of manufacturing the cleated shoe of claim 3 , wherein the plurality of lace apertures comprise a plurality of outer lace apertures disposed at a first location of the instep area on each of the lateral side and the medial side and a plurality of inner lace apertures disposed at a second location of the instep area on each of the lateral side and the medial side, wherein the second location is located more inward toward a middle of the upper than the first location.
5 . The method of manufacturing the cleated shoe of claim 4 , further comprising: integrating a lace such that the lace extends into an inner lace aperture of the plurality of inner lace apertures on the medial side of the upper, extends along the interior layer of the upper, and then exits the upper through an outer lace aperture of the plurality of outer lace apertures on the medial side of the upper, and then extends across the instep area along the exterior layer of the upper, and then extends into an inner lace aperture of the plurality of inner lace apertures on the lateral side of the upper, extends along the interior layer of the upper, and then exits the upper through an outer lace aperture of the plurality of outer lace apertures on the lateral side of the upper.
6 . The method of manufacturing the cleated shoe of claim 1 , wherein the stretch zone comprises a stretch padding zone configured to provide cushioning in an as-worn configuration.
7 . The method of manufacturing the cleated shoe of claim 6 , wherein: the stretch padding zone has a first width measured between the medial side and the lateral side when in an unstretched condition, and the stretch padding zone has a second width measured between the medial side and the lateral side when in a stretched condition, the second width greater than the first width.
8 . The method of manufacturing the cleated shoe of claim 7 , wherein the second width is 25% to 50% larger than the first width.
9 . The method of manufacturing the cleated shoe of claim 1 , wherein at least a portion of the malleolus zone corresponds with at least one of the lateral and medial malleolus bones of a wearer.
10 . The method of manufacturing the cleated shoe of claim 1 , wherein the ankle cuff is configured to cover an ankle of a wearer when the cleated shoe is in an as-worn configuration.
11 . The method of manufacturing the cleated shoe of claim 1 , wherein a stitch type of the ankle cuff is different than a stitch type of the lateral side, the medial side, and the instep area of the upper.
12 . The method of manufacturing the cleated shoe of claim 1 , wherein the malleolus zone has a first length in an unstretched configuration and a second length in a stretched configuration, wherein the second length is larger than the first length.
13 . The method of manufacturing the cleated shoe of claim 1 , wherein the ankle cuff is joined through knitting to the instep area such that the instep area and the ankle cuff include at least one course in common.
14 . The method of manufacturing the cleated shoe of claim 1 , wherein a material element covers a seam between a lateral heel edge of the upper and a medial heel edge of the upper.
15 . The method of manufacturing the cleated shoe of claim 1 , wherein the upper includes a skin layer at one or more areas of the upper.
16 . A method of manufacturing a cleated shoe, the method comprising: knitting an upper comprising at least part of a forefoot region, a midfoot region, a heel region, a lateral side, a medial side, and an instep area extending between the lateral side and the medial side, wherein the instep area is joined through knitting to each of the lateral side and the medial side; knitting an ankle cuff, the ankle cuff comprising a unitary knit construction with at least the instep area of the upper, wherein the ankle cuff comprises a malleolus zone disposed on the ankle cuff, the malleolus zone comprising a plurality of voids extending through both an exterior surface of the ankle cuff and an interior surface of the ankle cuff; and securing a sole structure comprising a plurality of cleat members to the upper to form the cleated shoe.
17 . The method of manufacturing the cleated shoe of claim 16 , further comprising forming a plurality of lace apertures that extend through the upper, the plurality of lace apertures disposed along the instep area on each of the lateral side and the medial side.
18 . The method of manufacturing the cleated shoe of claim 17 , wherein a boundary region extends substantially continuously around part of the ankle cuff and around the instep area and visually demarcates the ankle cuff and the instep area from the lateral side and the medial side of the upper, wherein the boundary region extends beyond the plurality of lace apertures in a longitudinal direction.
19 . The method of manufacturing the cleated shoe of claim 18 , wherein the boundary region encloses a stretch zone of the instep area.
20 . The method of manufacturing the cleated shoe of claim 19 , wherein the stretch zone comprises a stretch padding zone configured to provide cushioning when in the as-worn configuration.

Description

RELATED APPLICATIONS This application, entitled “Article of Footwear Incorporating a Knitted Component with an Integral Knit Ankle Cuff,” is a Continuation application of U.S. application Ser. No. 16/907,494, filed Jun. 22, 2020, and entitled “Article of Footwear Incorporating a Knitted Component with an Integral Knit Ankle Cuff,” which is a Continuation application of U.S. application Ser. No. 15/961,174, filed Apr. 24, 2018, and entitled “Article of Footwear Incorporating a Knitted Component with an Integral Knit Ankle Cuff,” which issued as U.S. Pat. No. 10,918,155 on Feb. 16, 2021, which is a Continuation application of U.S. application Ser. No. 14/013,446, filed Aug. 29, 2013, entitled “Article of Footwear Incorporating a Knitted Component with an Integral Knit Ankle Cuff,” now abandoned. The entireties of the aforementioned applications are incorporated by reference herein. BACKGROUND Conventional articles of footwear generally include two primary elements, an upper and a sole structure. The upper is secured to the sole structure and forms a void on the interior of the footwear for comfortably and securely receiving a foot. The sole structure is secured to a lower surface of the upper so as to be positioned between the upper and the ground. In some articles of athletic footwear, for example, the sole structure may include a midsole and an outsole. The midsole may be formed from a polymer foam material that attenuates ground reaction forces to lessen stresses upon the foot and leg during walking, running, and other ambulatory activities. The outsole is secured to a lower surface of the midsole and forms a ground-engaging portion of the sole structure that is formed from a durable and wear-resistant material. The sole structure may also include a sockliner positioned within the void and proximal a lower surface of the foot to enhance footwear comfort. The upper generally extends over the instep and toe areas of the foot, along the medial and lateral sides of the foot, and around the heel area of the foot. In some articles of footwear, such as basketball footwear and boots, the upper may extend upward and around the ankle to provide support or protection for the ankle. Access to the void on the interior of the upper is generally provided by an opening in a heel region of the footwear. A lacing system is often incorporated into the upper to adjust the fit of the upper, thereby permitting entry and removal of the foot from the void within the upper. The lacing system also permits the wearer to modify certain dimensions of the upper, particularly girth, to accommodate feet with varying dimensions. In addition, the upper may include a tongue that extends under the lacing system to enhance adjustability of the footwear, and the upper may incorporate a heel counter to limit movement of the heel. Various materials are conventionally used in manufacturing the upper. The upper of athletic footwear, for example, may be formed from multiple material elements. The materials may be selected based upon various properties, including stretch-resistance, wear-resistance, flexibility, air-permeability, compressibility, and moisture-wicking, for example. With regard to an exterior of the upper, the toe area and the heel area may be formed of leather, synthetic leather, or a rubber material to impart a relatively high degree of wear-resistance. Leather, synthetic leather, and rubber materials may not exhibit the desired degree of flexibility and air-permeability for various other areas of the exterior. Accordingly, the other areas of the exterior may be formed from a synthetic textile, for example. The exterior of the upper may be formed, therefore, from numerous material elements that each impart different properties to the upper. An intermediate or central layer of the upper may be formed from a lightweight polymer foam material that provides cushioning and enhances comfort. Similarly, an interior of the upper may be formed of a comfortable and moisture-wicking textile that removes perspiration from the area immediately surrounding the foot. The various material elements and other components may be joined with an adhesive or stitching. Accordingly, the conventional upper is formed from various material elements that each impart different properties to various areas of the footwear. BRIEF SUMMARY OF THE INVENTION Various configurations of an article of footwear may have an upper and a sole structure secured to the upper. A knitted component including an upper and an integral knit ankle cuff is incorporated into the article of footwear. The upper and the integral knit ankle cuff are formed as a one-piece knit element. The knit element defines a portion of an exterior surface of the upper and an opposite interior surface of the upper, with the interior surface defining a void for receiving a foot. The integral knit ankle cuff is formed of unitary knit construction with the upper as a one-piece knit element and extends above