Patentable/Patents/US-20250325072-A1
US-20250325072-A1

Shoe Upper with Integrated Construction

PublishedOctober 23, 2025
Assigneenot available in USPTO data we have
Inventorsnot available in USPTO data we have
Technical 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.

Patent Claims

Legal claims defining the scope of protection, as filed with the USPTO.

1

2

. The upper ofwherein the upper portion of the heel cup and portions of the integrated pocket extend above the ankle cuff.

3

. The upper offurther comprising an insole situated between the first interior surface and the second interior surface.

4

. The upper ofwherein 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 ofwherein the heel cup is rigid.

6

. The upper ofwherein 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 ofwherein the heel cup is configured to temporarily move rearward during foot insertion or removal.

8

. The upper ofwherein 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 ofwherein 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 ofwherein 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 ofwherein the insole is multilayered with a first layer having viscoelastic properties and a second layer having perforations.

12

. The upper ofwherein 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 ofwherein 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:

15

. The upper of, 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, 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.

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. The upper of, 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, wherein the cover portion extends above a rearmost portion of the ankle cuff.

20

. The upper ofwherein 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.

Detailed Description

Complete technical specification and implementation details from the patent document.

This patent application incorporates by reference the following applications in their entirety: International Patent Application No. PCT/US2022/046726, filed on Oct. 14, 2022, U.S. patent application Ser. No. 18/199,262, filed on May 18, 2023, U.S. patent application Ser. No. 18/199,250, filed on May 18, 2023, and U.S. patent application Ser. No. 18/199,274, filed on May 18, 2023.

The invention relates to the technical field of footwear, in particular, to a shoe upper and a shoe having the same.

Existing sock upper designs, uppers formed by unitarily knit or woven sock, in footwear are known for their comfort and close fit. Yet, these designs often pose a challenge in slipping on the shoes effortlessly, as they tend to lack the necessary structure or resilience to stay upright during the process. This lack of support, especially around the heel area, frequently necessitates the use of hands to keep the shoe properly open while the foot is being inserted. Furthermore, prior art sock upper designs are not configured to receive added heel components, nor are they designed to provide dual layers and/or support for such heel components around the opening of the upper.

Aspects of this invention relate to a novel sock-like construction for a shoe upper comprising a singular, elongated, circular knit tube which is subsequently folded inward upon itself to form at least a double-layered sock. This folding process creates two congruent sock layers which allows for a seamless ankle collar that forms a shoe opening.

Additionally, aspects of this invention relate to a shoe that has a structure capable to support easier foot insertion.

In one aspect of the invention, an upper material is made of a knit structure. A process of forming the knit structure includes forming an outer sock layer structure and an inner sock layer structure. Each of the outer sock layer structure and inner sock layer structure resembles the general dimensions of a sock. Each of the outer sock layer structure and inner sock layer structure may have a toe region, a midfoot region, a heel region, a footbed portion, and an upper portion.

In another aspect of the invention, a heel counter may include a heel cup. The heel cup may be uniformly molded with an upper portion, midportion, and lower portion, and the upper portion has a smaller mediolateral length than the midportion. The midportion and lower portion may form a concave structure configured to receive the heel. The upper portion of the heel cup has an overall downward incline with a first angle relative to a vertical line that is normal to a horizontal surface of the floor with the highest portion extending rearward. The upper portion has an upper surface that may have a convex curved portion along the rearmost vertical cross-section of the heel cup such that a heel bottom is directed to slide upon insertion of the foot. The convex curved portion may further curve downward and inflect to form the concave structure at the midportion and lower portion.

The upper portion of the heel cup rises may extend above the medial and the lateral collar portions of the upper. The upper portion may have a horizontal curvature that is relatively coextensive to the mediolateral curvature of the heel portion of the upper. The length of the horizontal curvature may be configured to receive and at least partially cup at least a portion of the bottom of the heel as the foot is inserted into the shoe.

The heel cup may be formed of a rigid structure capable of not being substantially compressed upon insertion of the foot. In such configurations, the upper may have elastic portions that allow the upper to stretch as the foot is inserted into the shoe. As the foot is inserted, a pressure is applied to the upper portion of the heel cup. If the heel cup is substantially rigid, the pressure may push the heel cup rearward. The heel cup may be used in combination with elastic portions in the upper to allow the heel cup to move rearward during foot insertion. Following foot insertion, the rigid heel cup may return to its original position to secure the foot within the shoe and support of the foot during use.

The upper portion of the heel cup may also be compressed during foot insertion wherein the upper portion may have a first configuration in its native state and is capable of distorting into a second configuration under a load of a user's foot when the user is donning the footwear. The heel cup is capable of returning to the first configuration after the load of the user's foot is removed. In the second configuration, at least part of the upper portion is lowered relative to the first configuration and the upper portion is capable of returning to the first configuration after the load of the user's foot is removed. The midportion may include a peripheral portion having a first thickness and a central portion having a second thickness, and the second thickness is less than the first thickness.

Further to this embodiment, in the first configuration, the upper portion has a downward incline with a first angle relative to a vertical line that is normal to a horizontal surface of the floor, and the upper portion in the second configuration has an incline with a second angle greater than the first angle. Additionally, in the second configuration, a lower region of a central portion of the heel cup extends outward in a direction away from the shoe opening that causes the shoe opening to widen along the mediolateral direction.

An interior foam layer may be a flat material lining covering at least a portion of an inner surface of the heel cup; or the foam layer may include regions with additional padding; foam layer functions to provide cushion and comfort to the foot and may assist in securing the foot within the upper after foot insertion. In one embodiment, the foam layer may be protruding and elongated with a rounded front facing surface. The foam layer may form a U-shaped padding around the region of the heel cup such that the padding contacts the foot above the calcaneus region of the foot and around the rear portion of the subtalar joint or at least a portion of the topmost region of the foot receiving shoe opening. The foam layer may extend at least partially around and over the foot receiving shoe opening. The foam layer may be compressed by the user's heel during foot insertion in an unexpanded or first partially compressed state. After the foot is inserted into the shoe, the foam layer may be expanded to its uncompressed state or a second partially compressed state wherein the second partially compressed state is less compressed than the first partially compressed state. Such a configuration enables the interior foam layer to exert sufficient pressure on or around the user's ankle in order to secure the foot into the shoe. For example, the calcaneus portion of foot may not be easily removed from the shoe during such activities as walking or running. The foam layer may have a tapered, or flattened dimension in regions where less padding is needed such as regions extending where the foam layer exerts pressure around the ankle of the foot.

The foam layer and heel cup may be constructed as a separately formed heel counter insert which is then positioned within the upper. The heel counter insert may be covered with a foam covering material. The heel counter insert may have a securing flap constructed of the foam layer and/or foam covering material which extends downward at the bottom the heel counter insert. The heel cup may terminate above the heel flap, or a portion of the heel cup may extend downward within or alongside the flap. The securing flap may be folded to be approximately perpendicular to the heel counter's vertical dimension and inserted along the footbed of the upper, sockliner, or insole. The securing flap may be affixed to the footbed of the upper, sockliner, insole or top surface of the sole.

A cover layer may cover a heel counter insert having a heel cup and foam layer. The cover layer is part of a portion of the inner sock layer structure which extends above an ankle collar of the shoe and thus is exposed and forms part of the outer sock layer structure. The cover layer may have a front cover portion and a rear cover portion. The front cover portion may cover the inner facing surface of the heel counter. The rear cover portion may cover at least a portion of the outer facing surface of the heel counter. The cover layer may be formed integrally with the sock as being integrally knit or woven with the sock. The unitary construction eliminates the need for constructing a separate cover layer of the heel cup thereby allowing for more efficient production. With the cover layer being part of the outer sock layer structure and inner sock layer structure, the cover layer forms an integrated pocket which receives the heel cup insert or heel counter insert.

Furthermore, the integrated pocket snugly accommodates at least the contours of the upper and/or mid portion of the heel cup or heel counter insert. The integrated pocket may be seamless and thus provide more comfort to the foot. It should be noted that tubular sock with the integrated pocket may also be constructed using woven material or engineered mesh or textile commonly known in the art by an ordinary person skilled in the art.

As the integrated pocket wraps around a rear facing surface of the heel cup or heel counter insert, the pocket may extend downward below the level of the ankle collar and behind the ankle collar and the upper down to the inner sock layer of the upper. The inner sock layer of the upper may then extend upward to the top of the ankle collar and then wrap over the ankle collar to meet the junction of the outer surface of the sock layer.

The shoe upper may also have an integrated ankle cuff (or may be referred to as an integrated ankle band, strap, region, flap, extension, or any other term that may be used to commonly define the integrated component). The integrated ankle cuff is a further extension of the sock and extends away from the sock portion that covers the outer heel counter. The ankle cuff wraps around the outer cover portion of the cover layer. The ankle cuff may comprise two layers, each layer forming a portion the inner sock layer structure and the outer sock layer structure, respectively. The rear cover portion of the cover layer and the ankle cuff may be integrally connected or separately formed. When integrally connected, the rear cover portion and the ankle cuff may be a knit, woven material, engineered mesh or textile commonly known in the art by an ordinary person skilled in the art.

A portion of the outer sock layer structure and a portion of the inner sock layer structure may comprise an integrated ankle cuff that may extend around the rearward facing surface of the integrated pocket and below the level of the upper portion of the heel cup.

The integration of the pocket and ankle cuff into the inner and outer sock layer structures enables case of assembly of the upper. The outer sock layer structure and ankle cuff may serve to provide outer protection of the upper. Further, the ankle cuff may be a tension band with elastic properties such that the heel cup may move rearward during a foot insertion into the shoe, and the heel cup may return to its original state once after foot insertion.

In another aspect of the invention, an insole may be placed through an aperture in the outer sock layer structure or the inner sock layer structure and situated primarily between the interfacing surfaces of the outer sock layer structure and the inner sock layer structure in the area corresponding to the footbed portion. The outer sock layer structure may thereafter be attached to the midsole or outsole.

A shoe may comprise a sole and an upper. The sole may comprise an outsole, a midsole, and/or an integrally formed outsole and midsole. The upper may comprise a toe box, a vamp, a tongue, a medial quarter, a lateral quarter, and a heel counter. The shoe has a forefoot portion, a rear portion, a medial side and a lateral side. The upper may comprise an exterior layer, interior layers or interior structure, and/or an inner lining. The upper may form a shoe opening that can receive a user's foot when the user is donning the shoe. These regions are defined conceptually rather than as discrete, physically demarcated sections. As such, the figures of the present application depict approximate locations of these regions and portions.

The heel counter or rear portion of the upper may comprise a heel cup that enables easier insertion of the foot into the shoe opening. The upper portion of the heel cup has an overall downward incline with a first angle relative to a vertical line that is normal to a horizontal surface of the floor with the highest portion extending rearward. The upper portion has an upper surface that may have a convex curved portion along the rearmost vertical cross-section of the heel cup such that a heel bottom is directed to slide upon insertion of the foot. The convex curved portion may further curve downward and inflect to form the concave structure at a midportion and at a lower portion of the heel cup.

The upper portion of the heel cup rises and may extend above the medial and the lateral collar portions of the upper. The upper portion may have a horizontal curvature that is relatively coextensive to the mediolateral curvature of the heel portion of the upper. The length of the horizontal curvature may be configured to receive and at least partially cup at least a portion of the bottom of the heel as the foot is inserted into the shoe.

The heel cup may be formed of a rigid structure not substantially compressed upon foot insertion. In such configurations, the upper may have elastic portions that allow the upper to stretch as the foot is inserted into the shoe. As the foot is inserted, a pressure is applied to the upper portion of the heel cup. If the heel cup is substantially rigid, the pressure may push the heel cup rearward. The heel cup may be used in combination with elastic portions in the upper to allow the heel cup to move rearward during foot insertion. Following foot insertion, the rigid heel cup may return to its original position to secure the foot within the shoe and support the foot during use.

The heel cup may support both the easier insertion and easier removal of the foot. The heel counter or rear portion of the upper may allow for a transient widening of the opening of the shoe configured to receive the foot when the user is donning or removing the shoe. The widening of the shoe opening may be initiated by the user placing a load on the heel counter or rear portion of the upper that may be exerted by the user's foot with minimal to no assistance by the user's hands. In one exemplary embodiment of the invention, the heel counter may be compressible when placed under sufficient load and return to its uncompressed stated. The heel counter may have a heel cup that lowers or has compressible layers that compress under load, widening the shoe opening and allowing easier insertion of the user's foot. Once a foot is inserted into the shoe, the heel counter may have a compressible layer, such as a foam layer or component, that may further secure or enhance securement of the foot during user's normal wear of the shoe.

Heel Cup. Referring to the embodiments ofa heel countermay comprise a compressible heel cupwhich may be an interior component of the upper, a portion of the inner liningor an attachment adjacent to the inner liningof the uppersuch that the heel cupmakes contact with the foot, or a portion of the exterior layerof the upperor an attachment of an outer surface of the exterior layerof the upper.

Referring to the exemplary embodiment of, the heel cuphas a shape substantially corresponding to a heel covering and has a profile resembling a pear-like shape. The heel cup has a mediolateral width near the heel cup collarthat is less than the mediolateral width of the lower portionas shown in

As shown in, the inner wallof the upper portionof the heel cup at the rearmost portion of the heel cup may have a downward incline of between 0 to 90 degrees relative to a vertical linethat is normal to the horizontal surfaceof the floor. In this exemplary embodiment, the inner wallof the upper portionmay have a downward incline of 30 degrees. The inner wallof the upper portionof the heel cupmay also have a convex curvature facing toward the shoe opening. The top portion of the convex curvature has the downward incline Aof 30 degrees. The lower portion of the convex curvature extends just above the portion of the heel cupthat receives the heel. The lower portion of the convex curvature may have a downward incline less than the downward incline of Aand gradually decreases as it approaches an incline equal to the vertical line. The heel cuphas a concave curvature that surrounds the rear portion of the heel. The medial and lateral sides of the heel cupmay also extend and form support of part of the quarter and even as far as the vamp.

The thickness of the heel cupmay be reduced at various locations. The top edge linemay have a tapering of the inner surface of the heel cupand outer surface of the heel cup. The heel cupmay have increased thickness Talong the other perimeter edges, such as 2 to 3 mm. In another exemplary embodiment, the thickness Tmay be reduced in certain areas to provide greater flexibility to the heel cupwhen donning or removing the shoe. In one embodiment, the thickness Tof the heel cupmay decrease gradually from a peripheral portionforming an area at the periphery of the heel cuptoward the central portion or regionof the mid-portion. The minimum thickness Tin the central regionof the mid-portionmay be approximately, but not limited to ¼ to ⅙ the thickness relative to the thickest portions at the periphery of heel cup, such as 0.5 to 1 mm. The thickest region of the top portion may be greater than the thickest region of the bottom portion. The reduced thickness Tof the central region of the mid-portionmay allow for the heel cupto compress under sufficient load. In an alternate embodiment, the thickness Tmay be reduced across the entire mediolateral portion or in multiple regions such as regions in the mid-portionand/or regions of the upper portion. The thinner regions may provide increased flexibility and bending of the heel cupwhich provides the necessary compressibility under the load of a user's foot such as during the donning of a shoe. Such compression may allow the upper portionand/or the mid-portionof the heel cupto move rearward and widen the shoe openingto allow easier entry of the foot. The heel cupcan distort a first configuration in its native state, to a second under a load of a user's foot when the user is donning the footwear. For example, the heel cupmay be partially compressed such that the upper portionand/or mid-portionof the heel cupis lowered sufficiently to allow the insertion of the user's foot. See for example. Once the user's foot is inserted into the shoe, the heel cupmay return to its uncompressed configuration.

Further to this embodiment, when a user dons the shoe, the top portion of the convex curvature of the heel cupor the uppermost segment of the heel counterof the shoemay be lowered and extend backward away from the foot as the heel counteris compressed as shown in. This action allows the user's foot to be inserted into the shoe openingwith a reduced degree of plantar flexion. During compression of the heel cup, portions of the heel cupmay move forward toward the direction of the forefoot portion. The distortion of the heel cupmay include the attached heel counterwidening with the medial and lateral sides of the heel cup moving outward thereby widening the opening of the shoe. The mediolateral widening of the shoe openingallows easier entry such as easier insertion of the forefoot portion of the user's foot. In one exemplary embodiment, the shoe opening of 7.5 cm may widen up to 4 cm or about 50%. See. The widening may be less or more depending on the size of the shoe and the flexibility of the heel cup. In some shoes, the desired widening may be less or greater depending on the needs of securement and use.

In an exemplary embodiment of the heel cupas shown in, the thickness Tof a heel cupmade of a polymer material, such as Dupont Hytrel, may range from 0.4 mm to 4 mm. The range of thickness Tof the heel cup may be thinner or thicker at various regions depending on the desired elastic and durable properties of the material. For example, the midpoint region may be thinner than the surrounding regions, and in particular, a central portion may be thinner than the peripheral portion as shown in. The central portion may be spaced away from the medial and lateral edges wherein the peripheral edges may have a greater thickness. Other suitable materials may include other thermoplastic elastomers or other polymers capable of providing the compressible characteristics of the heel cup.

In another exemplary embodiment, the heel cup may be configured to have a series of crisscross beams that form an egg crate like configuration.shows an exemplary embodiment with beams that are in a diagonal configuration. In an alternate embodiment, the beams may also be in a vertical and lateral configuration. The apertures between the beams may be approximately uniformly sized. The beams may be uniform in dimensions or vary in thickness and width. Beams that are thinner or less wide may be used to enhance flexibility and compressibility in designated locations while thicker or wider beams provide varying degrees of rigid support. For example, the beams may be thinner in the mid-portion, and in particular, the central portion of the mid-portion that is spaced away from the edges. The surrounding beams may be thicker than the central portion. The central portion may allow for greater flexibility in order to distort under a load.

In an exemplary embodiment, the rearmost portion of the heel cupmay have an overall vertical cross-sectional shape that resembles approximately an S wave as shown on a cross-sectional diagram of. The upper and lower portions of the S wave may be differentiated at the point Pthrough a horizontal plane, i.e. the midline, which is drawn between the upper arc and lower arc ends of the S wave and intersects the heel counterand the inflection point of the S wave. The amplitude (A) and width (W) of arc of the upper portion of the S wave may be different than the amplitude (A) and width (W) of the lower arc of the lower portion of the S wave. In the exemplary embodiment, the Wis approximately 0.44 times that of the W. The Ais approximately ⅓ that of the A, wherein the upper curvature has less depth than the lower curvature. In one possible embodiment, the Wis approximately 2 cm and the WI, is approximately 4.5 cm. The Ais roughly 3 mm and the Ais roughly 9 mm. The S configuration decreases both in A/A, and W/Win the cross-sections in the areas extending from the rearmost portion's cross-section of the heel cupand may only consist of the lower portion arc along the medial and lateral sides of the heel cup. The measurements at the rearmost portion of the heel cupof the exemplary embodiment are intended to be exemplary.

The central region of the mid-portion of the heel cup may have a single aperture or a plurality of apertures. Just as the central region of the mid-portion may be constructed with less material than the maximum thickness of the collar and/or the maximum thickness of the base, the central region of the mid-portion of the heel cup may be constructed with a material of greater flexibility than the material forming its periphery. The resulting effects of the central region comprising a single aperture, a plurality of apertures, a lesser thickness, and/or a material of greater flexibility, may serve to facilitate entry and removal of the user's foot from the shoe.

Further to the exemplary embodiment, the heel cupmay be attached at least to an foam layer, as shown in. The heel cupmay be located in the interior of the heel counterof the upperas shown in. The foam layermay line both the inner wallof the heel cupand outer wall of the heel cup. Around the upper portion and mid-portion, the foam layermay protrude and extend further into the shoe opening. The foam layermay be thicker at or adjacent to the upper portionand mid-portionof the heel cupthereby forming part of the cuff of the shoe opening. The thicker foam layermay provide securement of the user's foot once inserted within the shoeas the foam would be located above the calcaneus bone region of the user's foot and extend around at least portions of the ankle region of the foot. Since the foam is compressible, the foam may be compressed by the heel during foot insertion or removal and hold the ankle of the user's foot once the foot is inserted.

In another aspect of the invention, a heel cupmay be uniformly molded with an upper portion, midportion, and lower portion, and the upper portionhas a smaller mediolateral length than the midportion. The midportionand lower portionmay form a concave structure configured to receive the heel. The upper portionof the heel cuphas an overall downward incline with a first angle relative to a vertical linethat is normal to a horizontal surfaceof the floor with the highest portion extending rearward. The upper portionhas an upper surface that may have a convex curved portion rearmost vertical cross-section of the heel cup such that a heel bottom is directed to slide upon insertion of the foot. The convex curve may further curve downward and inflect to form the concave structure at the midportionand lower portion.

The upper portionof the heel cuprises and may extend above the medial and the lateral collar portions of the upper. The upper portion may have a horizontal curvature that is relatively coextensive to the mediolateral curvature of the heel portion of the upper. The length of the horizontal curvature may be configured to receive the bottom of the heel and at least partially cup at least a portion of the bottom of the heel as the foot is inserted into the shoe.

In another exemplary embodiment of the heel counter, the heel cup, having the similar S wave dimensions as presented above, may be formed of a rigid structure capable of not being substantially compressed upon insertion of the foot. In such configurations, the uppermay have clastic portions on the medial and/or lateral sides of the upper that allow the upperto stretch as the foot is inserted into the shoe. As the foot is inserted, a pressure is applied to the upper portionof the heel cup. If the heel cup is substantially rigid, the pressure may push the heel cuprearward as the foot slides down the upper portion into the shoe. Following foot insertion, the rigid heel cupmay return to its original position to secure the foot within the shoe and support the foot during use.

Further to this embodiment, the rigid heel cupmay have a uniform thickness or have varying thicknesses or lack of material in the midportion or lower portion of the heel cup.

Further to this embodiment, in the first configuration, the upper portionhas a downward incline Awith a first angle relative to a vertical linethat is normal to a horizontal surfaceof the floor, and the upper portionin the second configuration has a downward incline Awith a second angle greater than the first angle. Additionally, in the second configuration, a lower region of a central portionof the heel cup extends outward in a direction away from the shoe opening that causes the shoe opening to widen along the mediolateral direction.

The heel cup may be used in combination with a foam layerwhich may be a flat material lining covering at least a portion of an inner surface of the heel cupor the foam layermay include regions with additional padding such as the embodiment shown in. In one embodiment, the foam layermay be protruding and rounded or substantially tubular near the upper and midportion of the heel cup, and the foam layermay form a U-shaped padding around the region of the heel cupwherein the foam layer contacts the foot above the calcaneus region of the foot and around the rear portion of the subtalar joint or at least a portion of the topmost region of the foot receiving shoe opening. The foam layermay extend at least partially around and over the foot receiving shoe opening. The foam layermay be compressed by the user's heel during foot insertion such that the foam is in an unexpanded or in a first compressed state. After the foot is inserted into the shoe, the foam layermay be expanded to its fully uncompressed state or a second compressed state wherein the second compressed state is less compressed than the first compressed state. Such a configuration enables the interior foam layerto exert a sufficient pressure on or around the user's ankle in order to secure the foot into the shoe. For example, the calcaneus portion of foot may not be easily removed from the shoe during such activities as walking or running. The foam layermay have a tapered, or flattened dimension in regions where less padding is needed such as regions extending where the foam layerexerts pressure around the ankle of the foot. The protruding foam layer also increases the curvature of the lower portion of the upper to better secure the heel portion of the foot.

The heel cupand foam layermay form a heel counter insertthat may be separately constructed and inserted in between the layers of an upper. An exemplary embodiment of a heel counter insertis shown in. The heel counter insertmay have the foam layerfully surrounding the heel cupand have a protruding portionon the interior surface of the heel cup and located at the upper portion and midportion of the heel cup. The protruding portionextends from the rear most portion of the heel cup and extends along the interior surface of the heel cup thereby forming a U-shaped dimension. The ends of the protruding portionmay taper to the medial and lateral sides of the heel counter insertand may taper vertically above and below the protruding portion. The heel counter insertmay also have a securing flapwhich may be constructed of the foam layer or a foam covering material which may be mesh, textile, polymer film, or any other material known to an ordinary person skilled in the art. The heel cup and/or foam layer may terminate above the securing flap. Alternatively, a portion of the heel cup and/or foam layer may extend downward within or alongside the flap. The securing flapand all components of the securing flapare able to be folded or bent at an angle that is or approximate to a perpendicular angle with respect to the walls of the heel cup. The securing flapmay also have at least one cut or notchto allow the securing flapto fold or bend without buckling as it extends around the curvature of the heel counter around the rear portion of the heel. The securing flapmay then be affixed, stitched or bonded to footbed of the upper, sockliner, insole, one of the layers of a multilayer insole, or the top surface of the sole.

The heel counter insertmay be located and bonded within outer and inners layers of the upper. The upper portion of the heel counter insertmay be further located within a pocketof the upper that extends above the ankle cuffof the shoe opening. Further to embodiments involving bonding the heel counter insert into a sockliner, insole, or sole component, the combined structure may be inserted between a double layer upper with the upper portion of the heel counter inserted into a pocket of the upper.

Double Sock Layer: Referring to the embodiments of, a shoe uppercomprising a knit structuredefining an elongated, circular knit tube that is subsequently folded inward (i.e., inverted) upon itself to form a double-layered sock with two congruent sock layers and a seamless ankle cuffthat forms the foot receiving shoe opening.

Regions and Alignment. A process of forming the knit structureincludes forming an outer sock layer structureand an inner sock layer structure. Each of the outer sock layer structureand inner sock layer structureresembles the general dimensions of a sock. Each of the outer sock layer structureand inner sock layer structuremay have a toe region, a midfoot region, a heel region, and a footbed portion. These corresponding segments of the outer sock layer structureand inner sock layer structureare aligned when the knit structure is folded inward (i.e., inverted) upon itself. These regions are defined conceptually rather than as discrete, physically demarcated sections. As such, the figures of the present application depict approximate locations of these regions and portions.

In one embodiment, the outer sock layer structurehas a first toe regioncorresponding to the location of the user's toes after the shoe donned, a first heel regioncorresponding to the location of the user's heel after the shoe is donned; a first midfoot regionbetween the first toe regionand the first heel region, and a first footbed portioncorresponding to the underside of the users foot. Similarly, the inner sock layer structurehas a second toe regioncorresponding to the location of the user's toes after the shoe donned; a second heel regioncorresponding to the location of the user's heel after the shoe donned; a second midfoot regionbetween the second toe regionand second heel region; and a second footbed portioncorresponding to the underside of the user's foot.

The shoe upperprovided by this embodiment further includes a heel counteror a heel counter insertdisposed between the first heel regionand the second heel regionwhen the knit structureis inverted.

In the exemplary embodiment, the first toe regionand the second toe regionare configured with the potential for relative movement between the corresponding regions, as are the first heel regionwith the second heel region, and the first midfoot regionwith the second midfoot region. In other embodiments, some or all areas of the corresponding regions may be affixed to one another after the regions of the layers are aligned in a particular configuration.

Referring to, the outer sock layer structuremay be substantially aligned with the inner sock layer structuresuch that the respective corresponding toe regions, midfoot regions, and heel regionsare substantially aligned. The phrase “substantially aligned” should be interpreted to mean that the inner sock layer structureis predominantly contained within the outer sock layer structure. This, however, does not preclude the possibility of a portion of the inner sock layer structureextending beyond the confines of the outer sock layer structure. While the inner sock layer structureis largely enveloped by the outer sock layer structure, there may be embodiments where a segment of the inner sock layer structureprotrudes from or does not align with the outer sock layer structure, such as through the opening of the outer sock layer structure. The inner sock layer structurecan partially emerge from the outer sock layer structureif necessary, without departing from the scope of their intended positional relationship.

Patent Metadata

Filing Date

Unknown

Publication Date

October 23, 2025

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Cite as: Patentable. “SHOE UPPER WITH INTEGRATED CONSTRUCTION” (US-20250325072-A1). https://patentable.app/patents/US-20250325072-A1

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