Shoe upper with integrated construction

Abstract

A shoe has an outer sock layer structure and an inner sock layer structure. An ankle cuff is formed at the interconnection between the outer sock layer structure and the inner sock layer structure and completely surrounds the shoe opening. The inner sock layer structure has a pocket in the heel region and a heel cup or heel counter insert in the heel region is partially located between the first interior surface and the second interior surface and an upper portion of the heel cup or heel counter insert is situated within the pocket. The ankle cuff contacts a rearward facing surface of the pocket. The heel counter insert may also be attached to multilayer insole which are then collectively inserted into the upper.

We claim: 
     
         1 . An upper of an article of footwear comprising:
 a first knit layer and a second knit layer;
 the first knit layer and second knit layer having corresponding toe, midfoot, and heel regions; 
 the first knit layer having a first interior surface and a first exterior surface; 
 the second knit layer having a second interior surface and a second exterior surface;
 the first interior surface and the second interior surface generally facing toward each other; 
 the first exterior surface and the second exterior surface generally opposing each other; 
 
   an ankle cuff formed at the interconnection between the first knit layer and the second knit layer and at least partially surrounding the opening of the foot receiving cavity of the upper;
 the second knit layer defining an integrated pocket in the heel region; a heel cup in the heel region partially located between the first interior surface and the second interior surface; 
   an upper portion of the heel cup situated at least partially within a cover portion of the integrated pocket;   
       the integrated pocket defining a forward facing surface the cover portion and a rearward facing surface of the cover portion; and
 the ankle cuff having a portion of the second exterior surface contacting the rearward facing surface. 
 
     
     
         2 . The upper of  claim 1  wherein the upper portion of the heel cup and portions of the integrated pocket extend above the ankle cuff. 
     
     
         3 . The upper of  claim 1  further comprising an insole situated between the first interior surface and the second interior surface. 
     
     
         4 . The upper of  claim 1  wherein the heel cup is a structural element comprising an upper rear portion extending rearward and inclined downward in a direction from the heel toward the direction of the toe, the downward incline having a convex curvature; and the convex curvature having an upper surface facing upward and lower surface facing an opening of the article of footwear. 
     
     
         5 . The upper of  claim 4  wherein the heel cup is rigid. 
     
     
         6 . The upper of  claim 4  wherein the heel cup is capable of bending downward and away from the shoe opening under load and returns to its original position once the load is removed. 
     
     
         7 . The upper of  claim 5  wherein the heel cup is configured to temporarily move rearward during foot insertion or removal. 
     
     
         8 . The upper of  claim 1  wherein the heel cup is part of a heel counter insert comprising the heel cup and a foam layer wherein at least an upper portion of the heel counter insert which includes the upper portion of the heel cup is located within the integral pocket. 
     
     
         9 . The upper of  claim 8  wherein the foam layer has a protruding portion that is located on the heel cup such that the padding contacts the foot above the calcaneus region of the foot. 
     
     
         10 . The upper of  claim 9  wherein the foam layer is in a first compressed state during foot insertion and foot removal, in a fully uncompressed state after foot removal, and either in the fully uncompressed state or in a second compressed state after foot insertion, wherein the second compressed state is less compressed than the first compressed state. 
     
     
         11 . The upper of  claim 3  wherein the insole is multilayered with a first layer having viscoelastic properties and a second layer having perforations. 
     
     
         12 . The upper of  claim 8  wherein the heel counter insert has a securing flap that is connected perpendicular to the heel cup and that is attached to a footbed of the upper. 
     
     
         13 . The upper of  claim 12  wherein the footbed may be either a portion of the first knit layer or second knit layer, an insole, or a sockliner. 
     
     
         14 . An upper of an article of footwear comprising:
 a first knit layer and a second knit layer;
 the first knit layer and second knit layer having corresponding toe, midfoot, and heel regions; 
   an ankle cuff formed at an interconnection between the first and second knit layers and an upper boundary of the ankle cuff defining an opening of the footwear;
 the second knit layer defining an integrated pocket in the heel region; 
   a heel cup situated at least partially within a cover portion of the integrated pocket;   the integrated pocket defining a forward facing surface on a front cover portion and a rearward facing surface on a rear cover portion; and   the ankle cuff contacting the rearward facing surface, and   wherein an upper portion of the heel cup and the integrated pocket extend beyond the height of the opening of the footwear.   
     
     
         15 . The upper of  claim 14 , further comprising a foam layer at least partially surrounding the heel cup and extending beyond the height of the opening of the footwear. 
     
     
         16 . The upper of  claim 14 , wherein the ankle cuff comprises a density of fibers or stitches compared to other regions of the upper to enhance tension and wherein the ankle cuff comprises elastic yarns integrated into the knit structure to increase degree of elasticity and tension around the heel cup region of the upper compared to other regions of the upper. 
     
     
         17 . An upper of an article of footwear comprising:
 a first knit layer and a second knit layer;
 the first knit layer and second knit layer having corresponding toe, midfoot, and heel regions; 
   an ankle cuff formed at an interconnection between the first and second knit layers and an upper boundary of the ankle cuff defining an opening of the footwear;
 the second knit layer defining an integrated pocket in the heel region; 
   a heel cup;   wherein an upper portion of the heel cup is situated at least partially within a cover portion of the integrated pocket;   
       the ankle cuff having an elasticity and providing tension against a heel cup positioned within the footwear, wherein the elasticity allows rearward movement of the heel cup during foot insertion and the tension facilitates return of the heel cup toward its original state after insertion. 
     
     
         18 . The upper of  claim 17 , further comprising a foam layer at least partially surrounding the heel cup and extending beyond the height of the opening of the footwear. 
     
     
         19 . The upper of  claim 1 , wherein the cover portion extends above a rearmost portion of the ankle cuff. 
     
     
         20 . The upper of  claim 8  wherein the heel counter insert further comprises a securing flap connected perpendicular to and materially separate from the heel cup and that is attached to a footbed of the upper.