U.S. patent application number 11/496714 was filed with the patent office on 2008-02-07 for athletic shoe having a segmented upper.
Invention is credited to David Lacorazza.
Application Number | 20080028640 11/496714 |
Document ID | / |
Family ID | 39027732 |
Filed Date | 2008-02-07 |
United States Patent
Application |
20080028640 |
Kind Code |
A1 |
Lacorazza; David |
February 7, 2008 |
Athletic shoe having a segmented upper
Abstract
An athletic shoe having an improved upper, and method of
manufacture are presented herein. The upper is generally comprised
of a forefoot panel extending over a portion of the sole
corresponding to a forward area of a wearer's foot, a mid-section
panel extending over a portion of the sole corresponding to a
midfoot area of the wearer's foot, and a rear panel extending over
a portion of the sole corresponding to a rearfoot area of the
wearer's foot. The upper further comprises a first expansion joint
joining the forefoot panel to the mid-section panel, and a second
expansion joint joining the mid-section panel to the rearfoot
panel.
Inventors: |
Lacorazza; David; (Canton,
MA) |
Correspondence
Address: |
STERNE, KESSLER, GOLDSTEIN & FOX P.L.L.C.
1100 NEW YORK AVENUE, N.W.
WASHINGTON
DC
20005
US
|
Family ID: |
39027732 |
Appl. No.: |
11/496714 |
Filed: |
August 1, 2006 |
Current U.S.
Class: |
36/97 ;
36/45 |
Current CPC
Class: |
A43B 3/26 20130101; A43B
23/0255 20130101; A43B 23/025 20130101; A43B 23/027 20130101; A43B
23/0295 20130101 |
Class at
Publication: |
36/97 ;
36/45 |
International
Class: |
A43B 23/00 20060101
A43B023/00; A43B 3/26 20060101 A43B003/26 |
Claims
1. An article of footwear having a sole and an upper attached to
the sole, wherein the upper is comprised of: a forefoot panel
extending over a portion of the sole corresponding to a forward
area of a wearer's foot; a mid-section panel extending over a
portion of the sole corresponding to a midfoot area of the wearer's
foot; a first expansion joint joining the forefoot panel to the
mid-section panel; a rearfoot panel extending over a portion of the
sole corresponding to a rear area of the wearer's foot; and a
second expansion joint joining the mid-section panel to the
rearfoot panel; wherein the first expansion joint and the second
expansion joint are formed of a material with a greater stretch
characteristic than that of the forefoot panel, mid-section panel,
and rearfoot panel.
2. An article of footwear as defined in claim 1, wherein one of the
expansion joints comprises a two-way expandable material.
3. An article of footwear as defined in claim 1, wherein one of the
expansion joints comprises a four-way expandable material.
4. An article of footwear as defined in claim 1, wherein one of the
expansion joints comprises a spandex material.
5. An article of footwear as defined in claim 1, wherein one of the
expansion joints comprises a spandex material having a polyurethane
coating.
6. An article of footwear as defined in claim 1, wherein an end of
the forefoot panel is spaced about 3 to 4 millimeters from a first
end of the mid-section panel and a second end of the mid-section
panel is spaced about three to four millimeters from an end of the
rearfoot panel.
7. An article of footwear as defined in claim 1, wherein one of the
expansion joints is comprised of a material having a stretch
retention of less than about 15%.
8. An article of footwear as defined in claim 1, wherein one of the
expansion joints is comprised of a material having a stretch
retention of less than about 5%.
9. An article of footwear as defined in claim 1, wherein one of the
expansion joints is entirely on a medial side of the article of
footwear.
10. An article of footwear as defined in claim 1, wherein one of
the expansion joints is entirely on a lateral side of the article
of footwear.
11. An article of footwear as defined in claim 1, wherein one of
the expansion joints extends from a medial side of the article of
footwear to a lateral side of the article of footwear.
12. An article of footwear having a sole and an upper attached to
the sole, wherein the upper is comprised of: a first panel
extending over a portion of the sole corresponding to a forward
area of the wearer's foot; a second panel extending over a portion
of the sole corresponding to a rear area of the wearer's foot with
respect to the first panel, wherein the first and second panels are
formed of a material having a stretch retention of greater than
about 15%; and an expansion joint joining the first panel and
second panel, wherein the expansion joint is formed of a material
having a stretch retention of less than about 15%.
13. An article of footwear as defined in claim 12, wherein the
expansion joint comprises a two-way expandable material.
14. An article of footwear as defined in claim 12, wherein the
expansion joint comprises a four-way expandable material.
15. An article of footwear as defined in claim 12, wherein the
expansion joint comprises a spandex material.
16. An article of footwear having a sole and an upper attached to
the sole, wherein the upper is comprised of: a stretch material
having a stretch retention of less than about 15%; and a
non-stretch material overlaying the stretch material, wherein the
non-stretch material has a stretch retention of greater than about
15%.
17. An article of footwear as defined in claim 16, wherein the
stretch material is a two-way expandable material.
18. An article of footwear as defined in claim 16, wherein the
stretch material is a four-way expandable material.
19. An article of footwear as defined in claim 16, wherein the
stretch material is a spandex material.
20. A method for manufacture of an upper for an article of
footwear, comprising: securing a portion of a first expansion joint
to a portion of a forefoot panel; securing a mid-section panel to a
portion of the first expansion joint and a first portion of a
second expansion joint; and securing a second expansion joint to a
portion of the mid-section panel; and securing a rearfoot panel to
a second portion of the second expansion.
21. A method according to claim 20, wherein the panels are secured
respectively by being sewn together.
22. A method according to claim 20, wherein the panels are secured
respectively by an RF welding technique.
23. A method according to claim 20, wherein the panels are secured
respectively using a zig-zag stitch technique.
24. A method according to claim 20, further comprising attaching
the upper to a sole.
25. A method according to claim 20, wherein a portion of an end of
the forefoot panel is spaced about three to four millimeters from a
portion of a first end of the mid-section panel, and a portion of a
second end of the mid-section panel is spaced about three to four
millimeters from a portion of an end of the rearfoot panel.
Description
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to athletic footwear, and more
specifically to an improved upper for an athletic shoe.
[0003] 2. Background Art
[0004] Athletic footwear must provide stable and comfortable
support for the foot. Specifically, it is important that the
footwear be comfortable while providing adequate support during
various foot movements associated with athletic activity. Athletic
footwear typically includes an upper and a sole, and is sold in a
variety of sizes according to the length and width of the foot.
However, even feet of similar length do not have the same geometry.
Therefore, a conventional upper must be adjustable to provide
support to various foot contours. Many different products and
designs have focused on the need for adjustable upper support. For
example, the upper may include an ankle portion which encompasses a
portion of the ankle region of the foot and thereby provides
support thereto. Other products have incorporated air bladders in
the upper for adjustable support. The standard upper, however, is
typically constructed of one mesh material, with minimal
stretch.
[0005] In addition, it is well known to adjust the size of a shoe
through lacing or through one or more straps reaching across the
throat of a typical shoe. Lacing alone, however, suffers from
several disadvantages, for example, when the shoe laces or straps
are drawn too tightly, the fastening system can cause pressure on
the instep of the foot. Such localized pressure is uncomfortable to
the wearer and can make it difficult for the shoe to be worn for
prolonged periods of time. Furthermore, while lacing allows the
upper of the shoe to be adjustable to accommodate varying foot and
ankle configurations, it does not mold the shoe to the contour of
the foot. Moreover, there are areas of the foot which are not
supported by the upper, due to the irregular contour of the
foot.
[0006] The human foot is a complex bone structure, capable of
withstanding and dissipating many impact forces. FIG. 1 shows a
skeletal depiction of the foot 100. There are three main divisions
to the foot. Portions of the foot include rear foot 102, midfoot
104, and forefoot 106. The rear foot 102 includes the talus 108 and
the calcaneus 110. The midfoot 104 includes three cuneiforms 112,
cuboid 114 and navicular 116. The forefoot 106 includes metatarsal
118, proximal phalanges 120, and distal phalanges 122.
[0007] While the three main divisions of the foot are linked to
each other, it is not uncommon for the three main divisions to move
relative to each other during athletic activity. Although many
products are designed to accommodate the shape of a foot when the
foot is static, the problems associated with the fit of an upper
during dynamic movement of the foot have not been adequately
addressed. Specifically, the standard design of an athletic shoe,
which includes only a continuous upper structure, does not provide
adequate mobility between the three main divisions of the foot,
i.e., rearfoot 102, midfoot 104, and forefoot 106.
BRIEF SUMMARY OF THE INVENTION
[0008] Presented herein is an article of footwear having a sole and
an upper attached to the sole, wherein the upper is comprised of a
forefoot panel extending over a portion of the sole corresponding
to a forward area of a wearer's foot, a mid-section panel extending
over a portion of the sole corresponding to a midfoot area of the
wearer's foot, and a rearfoot panel extending over a portion of the
sole corresponding to a rear area of the wearer's foot. The upper
further comprises a first expansion joint joining the forefoot
panel to the mid-section panel, and a second expansion joint
joining the mid-section panel to the rearfoot panel. The first
expansion joint and the second expansion joint are formed of a
material with a greater stretch characteristic than that of the
forefoot panel, mid-section panel, and rearfoot panel. The
expansion joints may be formed of a two-way expandable material.
Alternatively, the expansion joints may be formed of a four-way
expandable material. For example, the expansion joints may be
formed of a spandex material, or a spandex material having a
polyurethane coating. Further, in one aspect of the invention, an
end of the forefoot panel is spaced about 3 to 4 millimeters from a
first end of the mid-section panel and a second end of the
mid-section panel is spaced about three to four millimeters from an
end of the rearfoot panel. Also, in another aspect of the
invention, the expansion joints are comprised of a material having
a stretch retention of less than about 15%, and more preferably a
material having a stretch retention of less than about 5%. The
expansion joints may be entirely on a medial side of the article of
footwear, entirely on a lateral side of the article of footwear, or
extend from a medial side of the article of footwear to a lateral
side of the article of footwear.
[0009] In accordance with an alternative aspect of the invention,
the upper is comprised of a first panel extending over a portion of
the sole corresponding to a forward area of the wearer's foot, a
second panel extending over a portion of the sole corresponding to
a rear area of the wearer's foot with respect to the first panel,
wherein the first and second panels are formed of a material having
a stretch retention of greater than about 15%, and an expansion
joint joining the first panel and second panel, wherein the
expansion joint is formed of a material having a stretch retention
of less than about 15%. In accordance with an alternative aspect of
the invention, the upper is comprised of a stretch material having
a stretch retention of less than about 15%, and a non-stretch
material overlaying the stretch material, wherein the non-stretch
material has a stretch retention of greater than about 15%.
[0010] Further disclosed herein is a method for manufacture of an
upper for an article of footwear comprising: a) securing a portion
of a first expansion joint to a portion of a forefoot panel; b)
securing a mid-section panel to a portion of the first expansion
joint; c) securing a second expansion joint to a portion of the
mid-section panel; and d) securing a rearfoot panel to a second
portion of the second expansion. The joints and panels may be
secured to one another by being sewn together, by an RF welding
technique, or using a zig-zag stitch technique. The upper is then
preferably attached to a sole of an athletic shoe. In an
alternative method presented herein, a portion of an end of the
forefoot panel is spaced about three to four millimeters from a
portion of a first end of the mid-section panel, and a portion of a
second end of the mid-section panel is spaced about three to four
millimeters from a portion of an end of the rearfoot panel.
BRIEF DESCRIPTION OF THE DRAWINGS/FIGURES
[0011] The accompanying figures, which are incorporated herein and
form part of the specification, illustrate an athletic shoe.
Together with the description, the figures further serve to explain
the principles of the athletic shoe described herein and thereby
enable a person skilled in the pertinent art to make and use the
athletic shoe.
[0012] FIG. 1 shows a skeletal depiction of the foot.
[0013] FIG. 2 shows an athletic shoe having an upper in accordance
with one embodiment of the present invention.
[0014] FIG. 3 shows an athletic shoe having an upper in accordance
with an alternative embodiment of the present invention.
[0015] FIG. 4 shows an athletic shoe having an upper in accordance
with yet another embodiment of the present invention.
[0016] FIG. 5 shows an athletic shoe having an upper in accordance
with another embodiment of the present invention.
[0017] FIG. 6 shows an athletic shoe having an upper in accordance
with still another embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0018] Preferred embodiments of an athletic shoe are described
below with reference to the figures where like reference numbers
indicate identical or functionally similar elements. Also in the
figures, the left most digit of each reference number corresponds
to the figure in which the reference number is used. While specific
configurations and arrangements are discussed, it should be
understood that this is done for illustrative purposes only. A
person skilled in the relevant art will recognize that other
configurations and arrangements can be used without departing from
the spirit and scope of the appended claims.
[0019] FIG. 2 shows an athletic shoe 200. Shoe 200 is comprised of
an outsole 202, a midsole 204, and an upper 206. An insole is
typically included within the shoe, but is not shown in the figure.
Outsole 202 is typically comprised of a wear-resistant rubber
material. Midsole 204 is typically comprised of an ethylene-vinyl
acetate (EVA) material. Alternatively, midsole 204 may be comprised
of alternative materials. The shoe is completed with a tongue
portion 208 and shoelaces 210. Tongue portion 208 and shoelaces
210, are optional as would be known to one of skill in the art.
Further, the materials comprising outsole 202 and midsole 204 may
be chosen as deemed fit by one of skill in the art.
[0020] Upper 206, as shown in FIG. 2, is comprised of a forefoot
panel 212, a mid-section panel 214, and a rearfoot panel 216.
Forefoot panel 212 extends over a portion of the sole corresponding
to a forefoot area of the wearer's foot. Mid-section panel 214
extends over a portion of the sole corresponding to a midfoot area
of the wearer's foot. Rearfoot panel 216 extends over a portion of
the sole corresponding to a rearfoot area of the wearer's foot.
Upper 206 also includes a first expansion joint 218. First
expansion joint 218 joins forefoot panel 212 to mid-section panel
214. Upper 206 also includes a second expansion joint 220. Second
expansion joint 220 joins mid-section panel 214 to rearfoot panel
216. Optionally, a comfort padding 222 is added to upper 206.
[0021] The number of panels that comprise upper 206 is not
restricted to just three panels. Any number of panels between two
and about seven may be used. The objective of the panels is to
mimic the relative movement of the different areas of the foot. For
that reason, three panels are preferred because the foot is
generally divided into three main divisions; specifically the
forefoot, midfoot, and rearfoot. In this manner, upper 206 can move
with the foot. In a typical shoe, the lack of stretch and mobility
in the upper creates relative movement between the foot and the
upper, which in turn creates blisters and sore spots. In contrast
to a typical shoe, the mobility between panels 212, 214, and 216 in
upper 206 works to prevent blisters and sore spots.
[0022] The expansion joints are preferably formed of a synthetic
material. For example, the expansion joints may be formed of a
midbacker coated with polyurethane. The midbacker can be a material
such as spandex. Alternatively, the expansion joints may be
straight textile spandex. Preferably, the expansion joints are
formed of a four-way stretch material. In alternative embodiments
the expansion joints may be formed of a two-way stretch material.
Further, the expansion joints are preferably formed of a material
having a greater stretch characteristic than that of the panels.
For example, under an Elastic Gore Retention test, a preferred
material for the expansion joints would have a maximum stretch
retention of less than 15%, and more preferably a maximum stretch
retention of less than 5%.
[0023] The expansion joints are typically attached to the panels
through a zig-zag stitch between the panels. After stitching, the
panels may be overlaid with a synthetic material. In a preferred
embodiment, the panels are separated from each other by a gap of
about three to four millimeters. In alternative embodiments, the
expansion joints may be sewn on, RF welded, or attached to the
panels by any other attachment operation known to the art.
[0024] FIG. 3 shows an athletic shoe 300, in accordance with an
alternative embodiment of the present invention. Shoe 300 is
different from shoe 200 of FIG. 2 by having an alternative upper
306. Upper 306 is comprised of forefoot panel 312, mid-section
panel 314, and rearfoot panel 316. An expansion joint 318 joins
forefoot panel 312 to mid-section panel 314. A second expansion
joint 320 joins mid-section panel 314 to rearfoot panel 316.
Expansion joint 320 of shoe 300 differs from the expansion joint
220 of shoe 200 in that expansion joint 320 extends from the back
of the shoe to the midsole 304. Such an embodiment adds design
flexibility, while still functioning in accordance with the
objectives of the present invention.
[0025] FIG. 4 shows an athletic shoe 400, in accordance with an
alternative embodiment of the present invention. Shoe 400 differs
from the previously described shoes in that shoe 400 does not
include multiple expansion joints. Instead, shoe 400 includes a
single expansion joint 424, which is one integral unit that forks
in two directions. As such, each panel (forefoot panel 412,
mid-section panel 414, and rearfoot panel 416) is attached to a
portion of expansion joint 424. In the embodiment shown in FIG. 4,
mid-section panel 414 does not correlate exactly with the midfoot,
but instead correlates with a portion of the foot between the
forefoot panel 412 and the rearfoot panel 416. The design of shoe
400, however, does not depart from the objectives of the present
invention. Shoe 400 still allows relative mobility of the
individual portions of upper 406, which in turn correspond to the
relative movement of the different parts of a wearer's foot.
[0026] FIG. 5 shows an athletic shoe 500 in accordance with another
embodiment of the present invention. Athletic shoe 500 differs from
the previously described shoes in that expansion joint 526 forms
one integral unit with a central opening. As such, each panel
(forefoot panel 512, mid-section panel 514, and rearfoot panel 516)
is attached to a portion of expansion joint 526. Specifically,
mid-section panel 514 is disposed within the central opening of
expansion joint 526. The design of shoe 500, however, does not
depart from the objectives of the present invention. Shoe 500 still
allows relative mobility of the individual portions of upper 506,
which in turn correspond to the relative movement of the different
parts of a wearer's foot.
[0027] FIG. 6 shows an athletic shoe 600 in accordance with another
embodiment of the present invention. Athletic shoe 600 differs from
the previously described shoes in design, but not in function. The
alternative design of shoe 600 does not depart from one objective
of the present invention; that being to provide a kinetic fit for a
shoe that provides adequate support while also providing adequate
flexibility to mirror the movement of the various skeletal sections
of a user's foot. Shoe 600 comprises an upper 606 formed of a
stretch mesh material 630 extending throughout the shoe. A
non-stretch synthetic material 640, such as for example a synthetic
leather, is provided throughout the upper to provide adequate
support. In one embodiment, non-stretch material 630 is laid over
stretch mesh material 630 and attached to stretch mesh material 630
by conventional means. In one embodiment, non-stretch material 640
has a plurality of "fingers" 642 that extend upward from the bottom
of upper 606. In between fingers 642 is stretch material 630. As
such, stretch material 630 serves as expansion joints between
fingers 642.
[0028] The shoes described above may be manufactured by a method
comprising: a) securing a portion of a first expansion joint to a
portion of a forefoot panel; b) securing a mid-section panel to a
portion of the first expansion joint; c) securing a second
expansion joint to a portion of the mid-section panel; and d)
securing a rearfoot panel to a second portion of the second
expansion. The panels may be secured to one another by being sewn
together, by an RF welding technique, or using a zig-zag stitch
technique. The upper is then preferably attached to a sole of an
athletic shoe. In an alternative method presented herein, a portion
of an end of the forefoot panel is spaced about three to four
millimeters from a portion of a first end of the mid-section panel,
and a portion of a second end of the mid-section panel is spaced
about three to four millimeters from a portion of an end of the
rearfoot panel.
[0029] The shoes described above may also be manufactured by the
alternative method of: a) providing one unitary upper formed of a
stretch material; and b) securing onto the stretch material a
second material, which is less stretchable than said stretch
material.
[0030] Although it is acknowledged that all materials are
stretchable to a certain extent, as used herein the terms "stretch
material," "stretchable material," "non-stretch material," and
"non-stretchable material" are terms of art. More specifically, the
term "stretch" or "stretchable" is intended to refer to materials
which have a maximum stretch retention of less than 15%, and more
preferably a maximum stretch retention of less than 5%, under an
Elastic Gore Retention test. In such a test, a swatch of material
is first measured in an unloaded and neutral state. The material is
then stretched or extended to, for example, one and a half times
its original length and/or width. The material is then measured
again in an unloaded and neutral state. The second measurement is
intended to determine the material's ability to return to its
original size. A material that returns to within 15% of its
original size, may be considered a "stretch" or "stretchable"
material. However, materials that either fail during extension, or
do not return to within 15% of its original size, may be considered
a "non-stretch" or "non-stretchable" material.
[0031] While various embodiments of an athletic shoe have been
described, it should be understood that they have been presented by
way of example, and not limitation. For example, the illustrated
design and direction of the expansion joints were not intended to
be limiting. Further, the forefoot, mid-section, and rearfoot
panels may take on any form or configuration desirable to a
designer. Further, the terms "forefoot," "mid-section," "midfoot,"
and "rearfoot" are not intended to be limited to the exact bone
structure of a wearer's foot, or the bone structure shown in FIG.
1. Instead, the terms are used solely to designate a forward area
of the foot, a middle area of the foot, and a rear area of the
foot, respectively. Also, FIGS. 2-6 show a medial view of an
athletic shoe. It would be apparent to one of skill in the art that
a lateral view of the athletic shoe would be the mirror image of
that shown. In alternative embodiments, however, expansion joints
can be included in the medial side of the shoe only, the lateral
side of the shoe only, or both the medial and lateral side of the
shoe. The number, location, design, and direction of the expansion
joints may be altered in any fashion as would be deemed fit by a
designer. Further, although an athletic shoe is described, the
presented invention and methods may be employed in any article of
footwear such as a boot, dress shoe, sandal, etc.
[0032] It will be apparent to a person skilled in the relevant art
that various changes in form and detail can be made therein without
departing from the spirit and scope of the appended claims. Thus
the present invention should not be limited by any of the
above-described exemplary embodiments, but should be defined only
in accordance with the following claims and their equivalents.
* * * * *