U.S. patent application number 13/631375 was filed with the patent office on 2013-04-04 for footwear having a woven portion.
This patent application is currently assigned to CROCS, INC.. The applicant listed for this patent is Crocs, Inc.. Invention is credited to Dale Bathum, Stefano del Biondi.
Application Number | 20130081307 13/631375 |
Document ID | / |
Family ID | 47991299 |
Filed Date | 2013-04-04 |
United States Patent
Application |
20130081307 |
Kind Code |
A1 |
del Biondi; Stefano ; et
al. |
April 4, 2013 |
FOOTWEAR HAVING A WOVEN PORTION
Abstract
An article of footwear is constructed from moldable foam and
includes a sole portion and an upper. The upper includes a woven
portion that is constructed by interweaving a number of vertical
bands with a number of horizontal bands. The vertical bands can
have beveled edges to reduce a bulging effect resulting from the
interwoven bands.
Inventors: |
del Biondi; Stefano;
(Padova, IT) ; Bathum; Dale; (Boulder,
CO) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Crocs, Inc.; |
Niwot |
CO |
US |
|
|
Assignee: |
CROCS, INC.
Niwot
CO
|
Family ID: |
47991299 |
Appl. No.: |
13/631375 |
Filed: |
September 28, 2012 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61541851 |
Sep 30, 2011 |
|
|
|
Current U.S.
Class: |
36/83 ;
12/146B |
Current CPC
Class: |
A43B 1/04 20130101; B29D
35/126 20130101; A43B 3/0036 20130101; A43B 3/02 20130101; A43B
23/0245 20130101 |
Class at
Publication: |
36/83 ;
12/146.B |
International
Class: |
A43B 3/00 20060101
A43B003/00 |
Claims
1. A footwear product, comprising: a sole portion; and an upper
having a woven portion, the woven portion comprising: (1) a first
set of bands, wherein the first set of bands is formed as part of a
shell molded from a foam material; and (2) a second set of bands,
formed from the foam material, that is interwoven with the first
set of bands.
2. The footwear product of claim 1, wherein the woven portion
extends at least partially between a lower opening defined in the
upper and an upper opening defined in the upper.
3. The footwear product of claim 1, wherein each of the first set
of bands has a width that is approximately the same as a width of
each of the second set of bands.
4. The footwear product of claim 1, wherein each of the first set
of bands has a width that is different than a width of each of the
second set of bands.
5. The footwear product of claim 1, the woven portion further
comprising a plurality of gaps.
6. The footwear product of claim 1, wherein the first set of bands
is oriented in a first diagonal direction and the second set of
bands is oriented in a second diagonal direction.
7. The footwear product of claim 1, wherein the first set of bands
is oriented in a vertical direction and the second set of bands is
oriented in a horizontal direction.
8. The footwear product of claim 1, wherein the woven portion
comprises an over one-under one type of weave.
9. The footwear product of claim 1, wherein the woven portion
comprises an over one-under two type of weave.
10. The footwear product of claim 1, wherein each of first set of
bands includes a beveled edge.
11. The footwear product of claim 1, wherein the footwear product
comprises at least one of a shoe, a boot, and a sandal.
12. A method of creating a footwear product, the method comprising:
molding a shell having a sole portion and an upper, wherein the
upper includes a plurality of vertical bands; molding a plurality
of horizontal bands; and interweaving the plurality of vertical
bands with the plurality of horizontal bands.
13. The method of claim 12, wherein the upper includes a plurality
of vertical grooves defining a plurality of vertical-band portions,
the method comprising separating the plurality of vertical-band
portions to create the plurality of vertical bands.
14. The method of claim 13, wherein each of the plurality of
vertical grooves comprises a webbing extending between adjacent
vertical-band portions to facilitate beveling of edges of each of
the plurality of vertical bands.
15. The method of claim 12, wherein molding the plurality of
horizontal bands comprises molding a single, continuous piece
having horizontal grooves disposed between adjacent horizontal-band
portions, the method further comprising separating the plurality of
horizontal-band portions to create the plurality of horizontal
bands.
16. The method of claim 12, wherein molding the plurality of
horizontal bands comprises molding a plurality of individual
horizontal bands.
17. The method of claim 12, further comprising attaching a trim
portion to a top edge of the upper.
18. A footwear product comprising: a sole portion; and an upper
having a woven portion, the woven portion comprising: (1) a
plurality of vertical bands, wherein the plurality of vertical
bands are formed by separating a plurality of vertical-band
portions from one another, wherein the plurality of vertical-band
portions are formed as part of a shell molded from a foam material;
and (2) a plurality of horizontal bands, formed from the foam
material, that are interwoven with the plurality of vertical
bands.
19. The footwear product of claim 18, wherein each of plurality of
vertical bands includes a beveled edge.
20. The footwear product of claim 18, wherein the woven portion
comprises at least one of an over one-under one type of weave and
an over one-under two type of weave.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional
Application No. 61/541,851, filed on Sep. 30, 2011, the entirety of
which is incorporated herein by reference.
BACKGROUND
[0002] Traditional textile and leather footwear products have
included woven components. Molded articles, for example foam
injection molded and/or articles made from ethylene vinyl acetate
(EVA) foam, often do not include woven components, because the
appearance of woven components can often be molded directly into a
one-piece non-woven component. However, such faux woven patterns
often do not have the same appearance or performance as footwear
products that feature components that are actually woven
together.
SUMMARY
[0003] This summary is provided to introduce a selection of
concepts in a simplified form that are further described below in
the Detailed Description. This summary is not intended to identify
key features or essential features of the claimed subject matter,
nor is it intended to be used, in isolation, as an aid in
determining the scope of the claimed subject matter. At a high
level, embodiments of the invention relate to a molded-foam
footwear product having a partially-woven construction.
[0004] While multiple embodiments are disclosed, still other
embodiments of the present invention will become apparent to those
skilled in the art from the following detailed description, which
shows and describes illustrative embodiments of the invention.
Accordingly, the drawings and detailed description are to be
regarded as illustrative in nature and not restrictive.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] The present invention is described in detail below with
reference to the attached drawing figures, wherein:
[0006] FIG. 1 is a side view of a boot in accordance with
embodiments of the invention;
[0007] FIG. 2A depicts a cross-sectional view of a vertical band in
accordance with embodiments of the invention;
[0008] FIG. 2B depicts a cross-sectional view of a vertical band
interwoven with a horizontal band in accordance with embodiments of
the invention;
[0009] FIG. 3A is a perspective view of part of the outside of a
woven portion of the boot of FIG. 1 in accordance with embodiments
of the invention;
[0010] FIG. 3B is a perspective view of part of the inside of a
woven portion of the boot of FIG. 1 in accordance with embodiments
of the invention;
[0011] FIG. 4 is a side view of a flat in accordance with
embodiments of the invention;
[0012] FIG. 5A is a first side view of a boot shell in accordance
with embodiments of the invention;
[0013] FIG. 5B is a second side view of the boot shell of FIG. 5A
in accordance with embodiments of the invention;
[0014] FIG. 5C is a rear perspective view of the boot shell of FIG.
5A in accordance with embodiments of the invention;
[0015] FIG. 5D is a side perspective view of a part of the boot
shell of FIG. 5A in accordance with embodiments of the
invention;
[0016] FIG. 5E is a bottom perspective view of the boot shell of
FIG. 5A in accordance with embodiments of the invention;
[0017] FIG. 6A is a side view of a set of horizontal-band portions
in accordance with embodiments of the invention;
[0018] FIG. 6B is a top perspective view of the set of
horizontal-band portions of FIG. 6A in accordance with embodiments
of the invention;
[0019] FIG. 6C is a side view of the set of horizontal-band
portions of FIG. 6A, showing the set of horizontal-band portions
disposed over a shaft portion of the boot shell of FIG. 5A in
accordance with embodiments of the invention;
[0020] FIG. 7A is a top perspective view of a part of a boot in
accordance with embodiments of the invention;
[0021] FIG. 7B is a bottom perspective view of a part of the boot
of FIG. 7A in accordance with embodiments of the invention;
[0022] FIG. 7C is a bottom view of the boot of FIG. 7A in
accordance with embodiments of the invention;
[0023] FIG. 7D is a side view of the boot of FIG. 7A and a
perspective view of an liner in accordance with embodiments of the
invention;
[0024] FIG. 8 is a flowchart depicting a method of constructing a
boot in accordance with embodiments of the invention; and
[0025] FIG. 9 is a flowchart depicting a method of constructing a
flat in accordance with embodiments of the invention.
DETAILED DESCRIPTION
[0026] The subject matter of embodiments of the invention is
described with specificity to meet statutory requirements. However,
the description itself is not intended to limit the scope of this
patent. Rather, the inventors have contemplated that the claimed
subject matter might also be embodied in other ways, to include
different steps or features or combinations of steps or features
similar to the ones described in this document, in conjunction with
other technologies. Moreover, although aspects of methods of
constructing products according to embodiments of the invention are
described with reference to "blocks," the term "block" should not
be interpreted as implying any particular order among or between
various aspects unless the order of individual aspects is
explicitly described.
[0027] Additionally, the terms "vertical" and "horizontal," as the
terms are used herein, refer to a general orientation and are not
meant to specifically refer to a perfectly vertical and horizontal
orientation, respectively. Rather, the terms "vertical" and
"horizontal," as used herein, are used to convey a relative
orientation with respect to what is commonly understood to be the
bottom (e.g., the portion nearest the ground when the article is
being worn by a wearer that is standing) and top (e.g., the portion
farthest from the ground when the article is being worn by a wearer
that is standing) of an article of footwear, as well as with
respect to each other.
[0028] Embodiments of the invention include a molded-foam footwear
product having a partially-woven construction. The footwear product
can be a shoe, a boot, a sandal, or any other type of footwear
product having at least one woven portion. Embodiments of the
invention can include different combinations of the features and
components described herein, additional features or components that
are not described herein, and components made from different
materials or combinations of materials than those described herein.
All such implementations are considered to be within the ambit of
the invention.
[0029] FIG. 1 depicts a boot 1 having a partially-woven
construction in accordance with embodiments of the invention. As
illustrated in FIG. 1, the boot 1 includes a sole assembly 10 and
an upper 12 disposed on top of the sole assembly 10. The sole
assembly 10 includes a sole body 14 defined by an outsole 16, a
sole periphery 18 that extends generally upwardly along the
periphery of the outsole 16, and an insole (not illustrated in FIG.
1 for the purposes of clarity and brevity of description). In
embodiments, the outsole 16 includes a sole base 20 having a number
of recesses 26 and 28 configured to receive a corresponding number
of outsole inserts 30 and 32. In some embodiments, the outsole 16
can be a single, solid piece. According to embodiments, a shank 34
is disposed between the recesses 26 and 28 and provides support to
the wearer's arch.
[0030] The upper 12 includes a vamp 40 disposed on top of the sole
assembly 10 and configured to cover a wearer's foot. In
embodiments, the vamp 40 has a generally solid construction,
thereby providing a continuous surface 42 enclosing the wearer's
foot. In other embodiments, the vamp 40 can include any number of
openings that can, for example, provide ventilation to the inside
of the boot 1. As is illustrated in FIG. 1, the vamp 40 includes an
upper opening 46.
[0031] A shaft 50 extends generally upwardly from the upper opening
46 of the vamp 40. The shaft 50 includes a woven portion 52
disposed between a lower opening 54 and an upper opening 58, which
is defined by an upper edge 60. According to embodiments, the woven
portion 52 extends the entire distance between the lower opening 54
and the upper opening 58. In other embodiments, the shaft 50
includes one or more non-woven portions (not illustrated) disposed
at any position of the shaft 50. In embodiments, the vamp 40 and
the shaft 50 are coupled by way of a continuous construction, as is
described in more detail below.
[0032] The woven portion 52 of the shaft 50 includes a number of
horizontal bands 70 that are interwoven with a number of vertical
bands 72. According to various embodiments of the invention, the
woven portion 52 can include any number of horizontal bands 70 and
vertical bands 72. Additionally, the horizontal bands 70 and
vertical bands 72 can be constructed of any desired width. In some
embodiments, for example, the horizontal bands 70 have
approximately the same width as the vertical bands 72, while in
other embodiments, the horizontal bands 70 have a different width
than the vertical bands 72. Additionally, as shown in FIG. 1, the
configuration of the weave of the horizontal bands 70 and vertical
bands 72 is such that gaps 71 are formed in the woven portion 52 of
the shaft 50. According to embodiments, the horizontal 70 bands
and/or the vertical bands 72 can be sized such that the size of the
gaps 71 is increased or decreased. For instance, larger gaps 71 in
the woven portion 52 can be utilized to facilitate ventilation of
the boot 1.
[0033] In some embodiments, the woven portion 52 of the shaft 50
can be constructed according to a diagonal configuration. For
example, in an embodiment, a first set of bands is oriented in a
first diagonal direction with respect to the horizontal (assuming
that the outsole 16 is resting on a horizontal surface), while a
second set of bands is oriented in a second diagonal direction with
respect to the horizontal. In some embodiments, additional sets of
bands can be interwoven with the first two sets of bands, as
well.
[0034] According to various embodiments, the weave of the bands can
have any number of different configurations. For example, in FIG.
1, the weave of the bands can be referred to as an "over one-under
one" type of weave. That is, each horizontal band 70 passes over a
vertical band 72, then under the next vertical band 72, then over
the next vertical band 72, and so on. In another embodiment, the
weave is an "over one-under two" type of weave, in which each
horizontal band 70 passes over a vertical band 72, then under the
next two vertical bands 72, then over the next one vertical band
72, and so on. Any other configuration of weave is also considered
to be within the ambit of the invention.
[0035] It should be recognized by individuals having skill in the
relevant arts that interweaving the horizontal bands 70 with the
vertical bands 72 can cause a bulging effect at each location where
one type of band crosses the other. To minimize this bulging
effect, in embodiments of the invention, each vertical band
includes a beveled edge 73 along each side. According to
embodiments of the invention, the horizontal bands 70, rather than
the vertical bands 72 include beveled edges to achieve the desired
effect. In further embodiments, both sets of bands 70 and 72
include beveled edges. However, for the purposes of clarity and
brevity of description, only vertical bands 72 with beveled edges
73 are illustrated herein.
[0036] FIGS. 2A, 2B, 3A and 3B illustrate the beveled edges 73.
FIG. 2A depicts a cross-sectional view of a vertical band 72 for
the purpose of illustrating an exemplary beveled edge 73, in
accordance with embodiments of the invention. As shown in FIG. 2A,
the vertical band 72 includes an outside surface 74 (e.g., a
surface that faces toward the outside of the shaft 50) and an
opposed (and, at least approximately, parallel) inside surface 76
(e.g., a surface that faces toward the inside of the shaft 50). The
vertical band 72 includes a beveled edge 73 on each side that is
defined by an angled surface 78 extending from an edge of the
outside surface 74 to a corresponding edge of the inside surface
76. As FIG. 2A depicts, the overall cross section of the vertical
band 72 approximately defines a trapezoid, where the beveled edges
73 taper inward such that the outside surface 74 is wider than the
inside surface 76. In other embodiments, the angled surface 78 can
be curved such that the beveled edge 73 is concave.
[0037] FIG. 2B depicts the cross-section of the vertical band 72 in
an assembled position--that is, the vertical band 72 is depicted as
being disposed above to a horizontal band 70. As illustrated in
FIG. 2B, the horizontal band 70 also includes an outside surface 80
(e.g., a surface that faces toward the outside of the shaft 50) and
an opposed (and, at least approximately, parallel) inside surface
82 (e.g., a surface that faces toward the inside of the shaft 50).
As shown, the beveled edge 73 allows the vertical band 72 to lay
relatively flat against the horizontal band 70 by partially
accommodating the curved portion 84 of the outside surface 80 of
the horizontal band 70, which is curved due to the interaction
between the horizontal band 70 and an adjacent vertical band (not
shown).
[0038] FIG. 3A shows a perspective view of the outside of the woven
portion 52 of the shaft 50 of a boot 1, illustrating the
"anti-bulging" effect facilitated by the beveled edges 73 of the
vertical bands 72, as described above. Similarly, FIG. 3B is a
perspective view of the inside of the woven 52 portion of the shaft
50, which more clearly shows the angled surface 78 extending from
the outside surface 74 to the inside surface 76 of a vertical band
72, thereby defining the beveled edge 73, which accommodates the
curved portion 84 of the horizontal band 70.
[0039] FIG. 4 shows a flat 100 in accordance with embodiments of
the invention. As shown, the flat 100 includes a sole assembly 110
and an upper 112 disposed on top of the sole assembly 110. As shown
in FIG. 4, the upper 112 includes a first portion 114 and a second
portion 116. A woven portion 118 is disposed between the first
portion 114 and the second portion 116. In embodiments, the first
portion 114 and the second portion 116 have a smooth, continuous
surface, although, according to some embodiments, the continuous
surfaces of the first portion 114 and the second portion 116 are
textured, as desired. The woven portion 118 includes a number of
vertical bands 120 that are interwoven with a number of horizontal
bands 122. In embodiments, each horizontal band 122 is secured to
itself, or to a vertical band 120 or another part of the flat 100.
In an embodiment, for example, the horizontal bands 122 are secured
in a hidden region 123 in the heel area of the flat 100. As with
the boot 1, described above, the woven portion 118 of the flat 100
can include a diagonal weave and can be constructed from any number
of sets of bands and according to any number of different weave
configurations. According to various embodiments, each vertical
band 120 includes a beveled edge 125 similar to the beveled edge 73
described above with reference to FIGS. 2A, 2B, 3A, and 3B.
[0040] FIG. 4, the flat 100 further includes a trim portion 130
that is secured along a top edge (not shown) of the second portion
116 of the upper 112. In embodiments, the trim portion 130 is
secured using a series of stitches 131, although any other suitable
method of securing the trim portion 130 to the second portion 116
of the upper 112 can be used. As shown, the trim portion 130 forms
a perimeter around the top of the upper 112, defining an opening
132, into which a wearer (not shown) can place the wearer's foot
(not shown). As is further illustrated in FIG. 4, the flat 100
includes an insert 134. According to various embodiments, the
insert 134 can be constructed from any suitable type of fabric or
other material and can provide added comfort to the wearer. In
embodiments, the insert 134 is an insole that covers only the
inside surface of the sole assembly 110, while in other
embodiments, the insert 134 covers the entire inside surface of the
flat 100, or any portion thereof.
[0041] As shown in FIG. 4, the sole assembly 110 includes a sole
body 140 that is secured, at its upper edge 142, to the first
portion 114 of the upper 112. An outsole 144 is disposed along the
bottom of the sole body 140. The sole body 140 can be constructed
according to any desired shape. For example, as shown in FIG. 4,
the illustrated sole body 140 includes a heel portion 146 and a
forefoot portion 148, with a shank 150 disposed between them.
According to various embodiments of the invention, tread features
152 are included on one or more portions of the outsole 144. For
instance, in an embodiment, the outsole 144 includes recesses (not
shown), such as those described above with respect to the boot 1,
that are configured to receive tread inserts (not shown). In other
embodiments, tread features 152 are integrated into the
construction of the outsole 144.
[0042] FIGS. 5A-5E, 6A-6C, and 7A-7D show a process for
constructing a boot 201 (shown, fully constructed, in FIG. 7D) in
accordance with embodiments of the invention. With particular
reference to FIGS. 5A and 5B, the boot is constructed by first
creating a boot shell 200. According to various embodiments of the
invention, the boot shell 200 is a single, continuous piece, molded
from a material such as ethylene vinyl acetate (EVA) foam,
polyurethane foam, or a combination of materials. For instance, in
embodiments, to form the boot shell 200, liquid EVA is injected
into a clamshell-type mold, which are brought together with a third
mold piece inserted between them to create a cavity 205 in the boot
shell, shown in FIG. 5C. An example of such a molding process is
described in U.S. Pat. No. 6,439,536 to Piccolo, which is
incorporated herein by reference.
[0043] As shown in FIGS. 5A and 5B, the boot shell 200 includes a
sole portion 210 and an upper portion 212. The upper portion 212
includes a vamp 214 and a shaft portion 216. As is further
illustrated, the shaft portion 216 is molded with a number of
vertical grooves 218 disposed therein. The vertical grooves 218
define a number of adjacent vertical-band portions 220 that can be
separated from one another to create vertical bands 201B. In other
embodiments, the boot shell 200 is molded such that the shaft
portion 216 includes a number of (already separated) vertical bands
201B. In embodiments, a hole 221 is disposed at the lower end 222
of each vertical groove 218, as shown in FIG. 5D. As is further
shown in FIGS. 5A and 5B, the boot shell 200 further includes a
transverse groove 223 that indicates the location of the top of the
woven portion 201A of the fully-constructed article 201. FIG. 5E
shows the sole portion 210 of the boot shell 200, which includes a
sole body 210A, which is defined by an outsole 210B and a sole
periphery 210C. As illustrated, in embodiments, the outsole 201B
includes recesses 210D disposed in a heel portion 211A and a
forefoot portion 211B. A shank 210E is disposed between the
recesses 210D. According to embodiments, any number of different
portions of the sole portion 210 of the boot shell 200 can be
constructed to be thicker than other portions of the boot shell
200, thereby providing additional support and comfort for the
wearer.
[0044] According to various embodiments of the invention, the
vertical grooves 218 serve as guides for cutting the shaft portion
216 to separate the vertical-band portions 220 from one another,
thereby forming vertical bands 201B such as, for example, the
vertical bands 201B depicted in FIG. 7D. According to embodiments,
the hole 221 indicates the location of the beginning of the cut and
can facilitate the cutting process by allowing a cutting tool (not
shown) to be inserted therein and moved upwardly along the vertical
groove 218, thereby avoiding fraying or splitting the shaft portion
216, which may result from forcing a cutting tool into the vertical
groove 218.
[0045] Moreover, in embodiments, the design of the vertical grooves
218 can facilitate the creation of beveled edges 201C such as those
described above with reference to FIGS. 2A, 2B, 3A, and 3B. FIGS.
5C and 5D show a perspective view of the boot shell 200 in
accordance with embodiments of the invention and more clearly shows
the design of the vertical grooves 218. As shown, a vertical groove
218 includes a thin webbing 230 extending between an edge 232 of a
first vertical-band portion 234 and an edge 233 of a second,
adjacent, vertical-band portion 236. The thin webbing 230 runs from
the corresponding hole 221 to the top of the shaft portion 216 of
the boot shell 200.
[0046] In this manner, the edges 232 and 233 of the adjacent
vertical-band portions 234 and 236 are spaced apart, thereby
allowing for insertion of a cutting tool (not shown) at an angle.
Inserting the cutting tool at an angle facilitates cutting (along
the vertical groove 218) the adjacent vertical-band portions 234
and 236 apart such that an angled edge surface is created, as
described above with reference to FIGS. 2A, 2B, 3A and 3B, to form
the beveled edge 201C. For instance, in some embodiments, a cutting
tool having two opposed, angled cutting surfaces is used to cut
along the two edges 232 and 233 of the adjacent vertical-band
portions 234 and 236, thereby simultaneously forming a beveled edge
201C along both edges 232 and 233. In other embodiments, the edges
232 and 233 are molded to include the bevel, in which case the
adjacent vertical-band portions 234 and 236 are spaced apart by
cutting the thin webbing 230 (e.g., an angled cutting surface is
not necessary).
[0047] In addition to forming the boot shell 200, methods of
constructing the boot 201 according to embodiments of the invention
include forming a number of horizontal bands 201D. In embodiments,
as described above, the horizontal bands 201D are formed as
continuous, molded bands, using a foam material such as, for
example, EVA. In some embodiments, the horizontal bands 201D are
formed individually, while, in other embodiments, the horizontal
bands 201D are formed as a set of horizontal-band portions that can
be separated from one another to create horizontal bands 201D.
FIGS. 6A-6C depict the latter scenario, in which a set 300 of
horizontal-band portions 310 has been formed using a single molding
process. As with the formation of the boot shell 200 described
above, in an embodiment, the set 300 of horizontal-band portions
310 is formed by injecting liquid EVA into a clamshell-type mold
and bringing the two sides of the mold together, with a mold insert
disposed between them to provide a cavity 312, shown in FIG. 6B, in
the set 300.
[0048] As shown in FIGS. 6A and 6C, according to various
embodiments, the shape of the set 300 of horizontal-band portions
310 is configured to correspond to the shape of the shaft portion
216 of the boot shell 200. In this manner, when the horizontal
bands 201D are interwoven with the vertical bands 201B, the weave
meshes well and provides the desired shape of the resulting boot
201. For instance, as shown in FIGS. 6A and 6C, the overall shape
of the set 300 of horizontal-band portions 310 is constructed such
that a top section 314 of the set 300 is wider than a lower section
316. Additionally, as shown, a lower-most horizontal-band portion
317 is configured to taper outwardly from top to bottom to
accommodate the shape of the boot shell 200 where the vamp 214
meets the shaft portion 216.
[0049] As illustrated in FIGS. 6A-6C, the set 300 of
horizontal-band portions 310 includes a horizontal groove 320
between each pair of adjacent horizontal-band portions 310. To
construct the boot, the horizontal-band portions 310 are separated
from one another by cutting along each horizontal groove 320 using
a cutting tool, thereby forming horizontal bands 201D. Then, each
horizontal band 201D can be slid, from the top of the boot shell
200, downward, interweaving the horizontal band 201D with the
vertical bands 201B. According to embodiments, the top edge of the
upper-most horizontal band 201D is aligned with the transverse
groove 223 defined in the boot shell 200. As shown in FIG. 7A, a
trim portion 330 is secured to the top of the shaft portion 216. In
embodiments, the trim portion 330 can be any suitable material such
as, for example, EVA, leather, or other material and can be
attached using any number of attaching devices such as, for
example, a series of stitches 332.
[0050] According to various embodiments, as illustrated in FIGS. 7B
and 7C, the sole assembly 350 of the boot is completed by disposing
tread inserts 352 within the recesses 210D defined in the outsole
210B. The tread inserts 352 can be attached using any number of
different attachment mechanisms such as glue, stitches, or the
like. Additionally, a fabric insert 355, shown in FIG. 5D, is
disposed within the constructed boot 201 to add comfort for the
wearer. Other embodiments do not include a fabric insert. Any
number of additional features or combinations of features can be
included in the constructed boot 201, as well, without departing
from the scope of the invention.
[0051] FIG. 8 is a flowchart depicting a method 800 of constructing
a boot in accordance with embodiments of the invention. For
example, the method 800 can be used to construct the boot 1 shown
in FIG. 1. A boot shell having a sole portion and an upper is
molded (block 810). The upper includes a vamp and a shaft portion.
In embodiments, the shaft portion of the boot shell (e.g., the boot
shell 200 shown in FIGS. 5A and 5B) includes a number of vertical
grooves that define adjacent vertical-band portions, which can be
separated from one another to create vertical bands. In
embodiments, the boot shell is molded as a single continuous piece.
In some embodiments, the boot shell is molded such that a hole is
provided at the lower end of each vertical groove. In other
embodiments, the boot shell is molded such that the shaft portion
includes a number of separated vertical bands. Additionally, in
some embodiments, the vertical grooves include a webbing extending
between adjacent vertical-band portions to facilitate beveling of
the edges of the resulting vertical bands.
[0052] A set of continuous horizontal-band portions is molded
(block 812). In some embodiments, the horizontal bands are molded
individually. In other embodiments, the set of horizontal-band
portions is molded as a single, continuous piece (e.g., the set 300
of horizontal-band portions 310 shown in FIGS. 6A-6C) having
horizontal grooves disposed between adjacent horizontal-band
portions such that cutting along the horizontal grooves separates
the horizontal-band portions from one another, thereby creating
horizontal bands. According to various embodiments, the set of
horizontal-band portions is configured to correspond to the shape
of the shaft portion of the boot shell.
[0053] As indicated in FIG. 8, the vertical grooves of the boot
shell are separated to create vertical bands (block 814). According
to various embodiments, the vertical grooves are cut such that the
edges of each resulting vertical band are beveled. In other
embodiments, the beveled edges are formed during the molding of the
boot shell. The horizontal-band portions are separated from each
other to form horizontal bands (provided that the set of horizontal
bands was formed as a single piece with horizontal grooves) (block
816). It will be readily appreciated that, in embodiments in which
the horizontal bands are formed individually, the step of
separating the horizontal bands from one another should be
unnecessary.
[0054] A first, lower-most, horizontal band is interwoven with the
vertical bands (block 818). According to embodiments, the
interweaving is performed by sliding the first horizontal band
downwardly, from the top of the boot shell, in an interwoven
fashion with respect to the vertical bands. Similarly, as indicated
at block 820, the additional horizontal bands are interwoven with
the vertical bands. In the method 800, a trim portion is attached
to the top of the shaft of the boot (block 822). According to
various embodiments, the constructed boot is augmented with tread
features, lining inserts, and the like.
[0055] FIG. 9 is a flowchart depicting a method 900 of constructing
a flat shoe in accordance with embodiments of the invention. For
example, the method 900 can be used to create the flat 100 shown in
FIG. 4. A flat shell with vertical grooves is molded (block 910).
In embodiments, the flat shell is molded as a single continuous
piece. In some embodiments, the flat shell is molded such that a
hole is provided at the lower end of each vertical groove. In other
embodiments, the flat shell is molded to include separated vertical
bands. Additionally, in embodiments, the vertical grooves include a
thin webbing extending between adjacent vertical-band portions to
facilitate beveling of the edges of the vertical-band portions. In
some embodiments, the edges of the vertical-band portions are
molded to include the beveled edges. According to embodiments, the
flat shell includes a sole portion, while, in other embodiments, a
sole portion is constructed separately.
[0056] As indicated at block 912, a set of horizontal bands is
molded. In some embodiments, the set of horizontal bands is molded
as a single piece, while, in other embodiments, each horizontal
band is molded individually. The vertical grooves are cut to create
vertical bands (block 914) and, as shown at block 916, a first
horizontal band is interwoven with the vertical bands. The first
horizontal band is secured (block 918). Similarly, as indicated at
block 920, each additional horizontal band is interwoven with the
vertical bands and, each of the additional horizontal bands is
secured (block 922). According to embodiments, each horizontal band
can be secured by attaching it to itself, to a vertical band, or to
another part of the shoe. In some embodiments, for example, the
horizontal bands are secured at a hidden position in the heel-area
of the flat such as the hidden position 123 shown in FIG. 4. As
shown in FIG. 9, a trim portion is attached (block 924) and the
sole assembly (if constructed independently from the flat shell) is
attached (block 926). According to various embodiments, the
constructed flat can be augmented with tread features, lining
inserts, and the like.
[0057] The present invention has been described in relation to
particular embodiments, which are intended in all respects to be
illustrative rather than restrictive. Alternative embodiments will
become apparent to those of ordinary skill in the art to which the
present invention pertains without departing from its scope. It
will be understood that certain features and subcombinations are of
utility and may be employed without reference to other features and
subcombinations. This is contemplated by and is within the scope of
the claims.
* * * * *