U.S. patent application number 14/139245 was filed with the patent office on 2014-06-26 for woven footwear upper with lockout.
This patent application is currently assigned to Nike, Inc.. The applicant listed for this patent is Nike, Inc.. Invention is credited to Thomas G. Bell.
Application Number | 20140173932 14/139245 |
Document ID | / |
Family ID | 50973038 |
Filed Date | 2014-06-26 |
United States Patent
Application |
20140173932 |
Kind Code |
A1 |
Bell; Thomas G. |
June 26, 2014 |
Woven Footwear Upper With Lockout
Abstract
Aspects of the present invention relate to a shoe upper that is
formed as a substantially planar woven article with varied
functional zones and lockout strands integrated therein. The
lockout strands may be integrally incorporated with the woven shoe
upper to provide functional characteristics that differ from those
characteristics provided by the woven upper. The lockout strands
may be effective for transferring a load of a securing mechanism
through the woven upper while allowing the woven upper to have a
desired degree of elasticity, supper, and/or comfort.
Inventors: |
Bell; Thomas G.; (Portland,
OR) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Nike, Inc. |
Beaverton |
OR |
US |
|
|
Assignee: |
Nike, Inc.
Beaverton
OR
|
Family ID: |
50973038 |
Appl. No.: |
14/139245 |
Filed: |
December 23, 2013 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61745269 |
Dec 21, 2012 |
|
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|
Current U.S.
Class: |
36/84 ;
36/45 |
Current CPC
Class: |
A43B 13/02 20130101;
D03D 13/002 20130101; A43B 23/0275 20130101; A43C 11/002 20130101;
A43B 23/042 20130101; A43B 23/02 20130101; A43B 23/027 20130101;
D03D 15/08 20130101; A43B 23/0225 20130101; A43B 23/0265 20130101;
A43B 1/04 20130101; D10B 2501/043 20130101 |
Class at
Publication: |
36/84 ;
36/45 |
International
Class: |
A43B 23/02 20060101
A43B023/02; A43B 1/04 20060101 A43B001/04 |
Claims
1. A woven shoe upper comprising: a plurality of wefts having a
first modulus of elasticity; a plurality of warps having a second
modulus of elasticity; a lockout strand having a third modulus of
elasticity, the third modulus of elasticity is less than the first
modulus of elasticity and less than the second modulus of
elasticity, wherein the lockout strand is interwoven with the
plurality of warps and the plurality of wefts in the woven upper
portion.
2. The woven shoe upper of claim 1, wherein the lockout strand
extends from a forefoot opening to a sole coupling portion of the
woven shoe upper.
3. The woven shoe upper of claim 1, wherein the lockout strand
forms a loop proximate the forefoot opening, the loop is a lacing
mechanism.
4. The woven shoe upper of claim 1, wherein the lockout strand is
substantially parallel with the plurality of wefts.
5. The woven shoe upper of claim 1, wherein the lockout strand is
substantially parallel with the plurality of warps.
6. The woven shoe upper of claim 1, wherein the lockout strand
traverses both the plurality of wefts and the plurality warps in a
non-orthogonal manner.
7. The woven shoe upper portion of claim 1, wherein the lockout
strand traverses in a first direction relative to the plurality of
warps at a first portion of the woven shoe upper and traverses in a
second direction that is different from the first direction
relative to the plurality warps at a second portion of the woven
shoe upper.
8. The woven shoe upper of claim 1, wherein the lockout strand is
interwoven with the plurality of the warps.
9. The woven shoe upper of claim 1, wherein the lockout strand has
a diameter ranging from 0.5 millimeters to 2.0 millimeters.
10. The woven shoe upper of claim 1, wherein the lockout strand
forms a non-stretch region of the woven shoe upper.
11. The woven shoe upper of claim 1, wherein the lockout strand
extends through a first functional region and a second functional
region of the woven shoe upper.
12. A woven shoe upper comprising: a lateral side portion having a
forefoot edge and a lower edge; a medial side portion having a
forefoot edge and a lower edge; a forefoot opening extending
between the lateral side portion forefoot edge and the medial side
portion forefoot edge; a first lacing mechanism proximate the
lateral side portion forefoot edge; a second lacing mechanism
proximate the medial side portion forefoot edge; a first lockout
strand extending from the first lacing mechanism toward the lateral
side portion lower edge, the first lockout strand interwoven with
the lateral side portion; and a second lockout strand extending
from the second lacing mechanism toward the medial side portion
lower edge, the second lockout strand interwoven with the medial
side portion.
13. The woven shoe upper of claim 12, wherein the first lacing
mechanism is an aperture.
14. The woven shoe upper of claim 12, wherein the first lacing
mechanism is an eyelet.
15. The woven shoe upper of claim 12, wherein the first lockout
strand forming a non-stretch region of the lateral side
portion.
16. The woven shoe upper of claim 12, wherein the lateral side
portion is comprised of warps and wefts having a greater modulus of
elasticity than the first lockout strand.
17. The woven shoe upper of claim 12, wherein the lateral side
portion is comprised of warps and wefts having a smaller diameter
than the first lockout strand.
18. The woven shoe upper of claim 12, wherein the first lockout
strand forms a loop proximate the first lacing mechanism, such that
the first lacing mechanism is positioned within an interior of the
loop.
19. The woven shoe upper of claim 12, wherein the first lockout
strand forms a portion of the first lacing mechanism.
20. The woven shoe upper of claim 12, wherein the first lockout
strand is coupled with a midsole.
21. A shoe construction comprising: a sole; and an upper, the upper
comprising: (1) a medial side portion, the medial side portion
comprised of: a) a first region extending from a forefoot opening
toward the sole, the first region comprised of a lockout strand
extending from proximate the forefoot opening toward the sole, the
first region having a first modulus of elasticity in a direction of
the forefoot opening toward the sole direction; b) a second region
extending from the forefoot opening toward the sole, the second
region having a greater modulus of elasticity than the first region
in the direction of the forefoot opening toward the sole direction;
and c) a first aperture extending through the medial side portion
proximate the forefoot opening within the first region; and d)
wherein the first region and the second region are integrally
coupled sharing a common warp.
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of U.S. Provisional
Application No. 61/745,269, filed Dec. 21, 2012, and entitled
"Woven Footwear Upper."
BACKGROUND
[0002] The manufacturing of a shoe upper may involve sewing and
adhering a number of physically discrete pieces to result in a
three-dimensional volume able to receive a wearer's foot. The
manufacturing resources utilized to cut and secure the individual
portions can be costly and detrimental to the resulting quality of
the shoe upper. Even though the incorporation of multiple
physically discrete pieces may increase the burden on resource, the
various discrete pieces may be utilized in the shoe upper to impart
desired physical characteristics to the shoe upper.
SUMMARY
[0003] Aspects of the present invention relate to a shoe upper that
is formed as a substantially planar article with varied functional
zones integrally formed therein. The varied functional zones may be
strategically positioned zones having varied degrees of stretch.
Additionally, it is contemplated that the functional zones may
provide dimensional variation (e.g., thickness) and/or permeability
(e.g., breathability) characteristics. The substantially planar
upper may then be formed into a three-dimensional upper having a
volume that may be occupied by a wearer's foot. The upper having
integrally formed functional zones may be formed in a single
weaving operation that integrates the various functional zones in a
common manufacturing process without utilizing post-processing
coupling techniques to integrate the functional zones.
[0004] Aspects of the present invention relate to a shoe upper that
is formed as a substantially planar woven article with varied
functional zones and lockout strands integrated therein. The
lockout strands may be integrally incorporated with the woven shoe
upper to provide functional characteristics that differ from those
characteristics provided by the woven upper. The lockout strands
may be effective for transferring a load of a securing mechanism
through the woven upper while allowing the woven upper to have a
desired degree of elasticity, supper, and/or comfort.
[0005] 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 as an aid in determining the scope of
the claimed subject matter.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0006] Illustrative embodiments of the present invention are
described in detail below with reference to the attached drawing
figures, which are incorporated by reference herein and
wherein:
[0007] FIG. 1 depicts a shoe comprised of a multi-zoned
substantially-planar unitary upper in an as-worn position, in
accordance with aspects of the present invention;
[0008] FIG. 2 depicts the upper in a substantially planar
orientation, in accordance with aspects of the present
invention;
[0009] FIG. 3 depicts a lateral-side view of the upper formed in a
three-dimensional state from the manufactured substantially planar
state, in accordance with aspects of the present invention;
[0010] FIG. 4 depicts a medial-side view of the upper formed in a
three-dimensional state from the manufactured substantially planar
state, in accordance with aspects of the present invention;
[0011] FIG. 5 depicts a heel-end view of the upper formed in a
three-dimensional state from the manufactured substantially planar
state, in accordance with aspects of the present invention;
[0012] FIG. 6 depicts toe-end view of the upper formed in a
three-dimensional state from the manufactured substantially planar
state, in accordance with aspects of the present invention;
[0013] FIG. 7 depicts a top-down view of the upper formed in a
three-dimensional state from the manufactured substantially planar
state, in accordance with aspects of the present invention;
[0014] FIG. 8 depicts a bottom-up view of the upper formed in a
three-dimensional state from the manufactured substantially planar
state, in accordance with aspects of the present invention;
[0015] FIG. 9 depicts an exemplary portion of an upper having
integrally woven lockout strands, in accordance with aspects of the
present invention;
[0016] FIG. 10 depicts an exemplary woven portion comprised of
warps and wefts with non-orthogonally oriented lockout strands, in
accordance with aspects of the present invention;
[0017] FIG. 11 depicts another exemplary woven portion comprised of
warps and wefts with non-orthogonally oriented lockout strands, in
accordance with aspects of the present invention;
[0018] FIG. 12 depicts a portion of an exemplary shoe having a
lockout assembly, in accordance with aspects of the present
invention;
[0019] FIG. 13 depicts a cut-away, multi-layer, woven portion of an
upper, in accordance with aspects of the present invention;
[0020] FIG. 14 depicts an additional aspect of a substantially
planar woven shoe upper in both a front and a related back
perspective, in accordance with aspects of the present
invention;
[0021] FIG. 15 depicts a spectrum of weaving techniques to achieve
a varied modulus of elasticity, in accordance with aspects of the
present invention;
[0022] FIG. 16 depicts and exemplary heel region having a
dimensional zone and a heel counter zone within a woven upper
portion, in accordance with exemplary aspects of the present
invention;
[0023] FIG. 17 depicts a cut profile of an ankle collar region, in
accordance with aspects of the present invention;
[0024] FIG. 18 depicts a multi-region woven portion, in accordance
with aspects of the present invention;
[0025] FIG. 19 depicts an exemplary woven article that utilizes a
jacquard mechanism in combination with a leno weaving technique, in
accordance with aspects of the present invention;
[0026] FIG. 20 depicts an exemplary woven article having leno
twisted wefts running in the vertical direction and pulled warps
running in the horizontal direction, in accordance with aspects of
the present invention; and
[0027] FIG. 21 depicts an exemplary woven article having a
monofilament warp running in the horizontal direction and wefts
running in the vertical direction, in accordance with aspects of
the present invention.
DETAILED DESCRIPTION
[0028] The subject matter of embodiments of the present invention
is described with specificity herein 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 elements or combinations of
elements similar to the ones described in this document, in
conjunction with other present or future technologies.
[0029] Aspects of the present invention relate to a shoe upper that
is formed as a flat article with varied functional zones integrated
therein. For example, it is contemplated that a substantially
planar shoe upper is produced on a loom with strategically
positioned zones having varied degrees of stretch. Additionally, it
is contemplated that the functional zones may provide dimensional
variation (e.g., thickness) and/or permeability (e.g.,
breathability) characteristics. The substantially planar upper may
then be formed into a three-dimensional upper having a volume that
may be occupied by a wearer's foot. The upper having integrally
formed functional zone may be formed in a single weaving operation
that integrates the various functional zones in a common
manufacturing process without utilizing post-processing coupling
techniques to integrate the functional zones.
[0030] Further, Aspects of the present invention relate to a shoe
upper that is formed as a substantially planar woven article with
varied functional zones and lockout strands integrated therein. The
lockout strands may be integrally incorporated with the woven shoe
upper to provide functional characteristics that differ from those
characteristics provided by the woven upper. The lockout strands
may be effective for transferring a load of a securing mechanism
through the woven upper while allowing the woven upper to have a
desired degree of elasticity, supper, and/or comfort.
[0031] For example, it is contemplated that aspect provide a woven
shoe upper comprising a plurality of wefts having a first modulus
of elasticity, a plurality of warps having a second modulus of
elasticity, and a lockout strand having a third modulus of
elasticity. The third modulus of elasticity is less than the first
modulus of elasticity and less than the second modulus of
elasticity in an exemplary aspect. The lockout strand is interwoven
with the plurality of warps and the plurality of wefts in the woven
upper portion.
[0032] Further yet, it is contemplated that aspects provided herein
include a woven shoe upper comprising a lateral side portion having
a forefoot edge and a lower edge, a medial side portion having a
forefoot edge and a lower edge, a forefoot opening extending
between the lateral side portion forefoot edge and the medial side
portion forefoot edge, a first lacing mechanism proximate the
lateral side portion forefoot edge, and a second lacing mechanism
proximate the medial side portion forefoot edge. Further, it is
contemplated that the woven shoe upper may also include a first
lockout strand extending from the first lacing mechanism toward the
lateral side portion lower edge, the first lockout strand
interwoven with the lateral side portion. The woven shoe upper may
further include a second lockout strand extending from the second
lacing mechanism toward the medial side portion lower edge, the
second lockout strand interwoven with the medial side portion.
[0033] Additionally, it is contemplated aspect provide a shoe
construction comprising a sole and an upper. The upper comprising a
medial side portion, the medial side portion having a first region
extending from a forefoot opening toward the sole, the first region
comprised of a lockout strand extending from proximate the forefoot
opening toward the sole, the first region having a first modulus of
elasticity in a direction of the forefoot opening toward the sole
direction. The medial side portion also having a second region
extending from the forefoot opening toward the sole, the second
region having a greater modulus of elasticity than the first region
in the direction of the forefoot opening toward the sole direction.
The medial side portion also having a first aperture extending
through the medial side portion proximate the forefoot opening
within the first region, wherein the first region and the second
region are integrally coupled sharing a common warp.
[0034] FIG. 1 depicts a shoe 100 comprised of a multi-zoned
substantially-planar unitary upper 202 in an as-worn position, in
accordance with aspects of the present invention. The construction
of the shoe 100 of the present invention has the basic construction
of an athletic-type shoe. However, it should be understood that the
novel concept of the invention could be employed on other types of
footwear. Therefore, while the term "shoe" will be used herein, any
type of footwear is contemplated for any purpose such that the term
"shoe" should be interpreted herein as "footwear." Because much of
the construction of the shoe 100 is the same as that of a
conventional athletic shoe, the conventional features of the
constructions will be described only generally herein.
Additionally, relative location terminology will be utilized
herein. For example, the term "proximate" is intended to mean on,
about, near, by, next to, at, and the like. Therefore, when a
feature is proximate another feature, it is close in proximity but
not necessarily exactly at the describe location, in some
aspects.
[0035] The shoe 100 has a shoe sole 102 that is constructed of
resilient materials that are typically employed in the construction
of soles of athletic shoes. The sole 102 can be constructed with an
outsole, a midsole, and an insert, as is conventional. The shoe
sole 102 has a bottom surface that functions as the traction
surface of the shoe, and an opposite top. The size of the shoe 100
has a length that extends from a rear sole heel end 106 to a front
toe end 104 of the sole 102. The sole 102 has a width that extends
between a medial side 110 and a lateral side 108 of the sole
102.
[0036] The shoe 100 also is constructed with an upper 202. The
upper 202 is secured to the sole 102 and extends upwardly from the
shoe sole, such as the sole top surface. The upper 202 is
constructed of a flexible material, such as a woven or knit
material. The woven or knit material may be formed with a
combination of materials. For example, synthetic materials, such as
nylon, polyester, acrylic, carbon fibers, aramids, and other
synthetic materials may be utilized in the forming of at least a
portion of the upper 202. Similarly, it is contemplated that
natural materials, such as cotton, wool, bamboo, soy-based,
corn-based, and other natural materials may be utilized in the
forming of at least a portion of the upper 202. Further, it is
contemplated that multi-component materials may be utilized in the
construction of a portion of the upper 202. As will be discussed
hereinafter, it is contemplated that combinations of materials may
be utilized in various regions of the upper 202 to form functional
regions/zones in a substantially planar upper being formed through
weaving or knitting techniques. As also will be discussed, varied
manufacturing techniques may be implemented in specific zones of
the upper 202 to achieve strategic variations in functional
qualities at particular locations of the upper 202.
[0037] The upper 202 is constructed with a heel portion 206 that
extends around the sole 102 at the sole heel end 106. The upper
heel portion 206 extends upwardly from the shoe sole 102 to an
ankle edge 261 defining, in part, an ankle opening 216. The ankle
opening 216 provides access to the shoe interior.
[0038] From the heel portion 206, the upper 202 has a medial side
portion 210 and a lateral side portion 208 that extend along the
respective sole medial side 110 and the sole lateral side 108. The
upper medial side portion 210 extends upwardly from the sole medial
side 110 to an upper medial side edge 212. The upper lateral side
portion 208 extends upwardly from the sole lateral side 108 to an
upper lateral side edge 214. As illustrated in the figures, the
upper medial side edge 212 and the upper lateral side edge 214
extend rearwardly from opposite sides of a toe box 204 forming, in
combination, an upper edge 263, as seen in FIG. 2 hereinafter. As
best seen in FIG. 1, the length of the upper medial side edge 212
and the upper lateral side edge 214 define a forefoot opening 217
in the upper 202 that opens to the shoe interior 103.
[0039] The upper 202 is also constructed with the toe box 204 that
extends around and across the sole top surface at the sole toe end
104. The toe box 204 is connected between the upper medial side
portion 210 and the upper lateral side portion 208 and encloses a
portion of the shoe interior 103 adjacent the sole toe end 104. The
upper medial side edge 212 and the upper lateral side edge 214
extend rearwardly from the toe box 204.
[0040] A plurality of lacing mechanisms 230 are provided on the
upper medial side portion 210 and on the upper lateral side portion
208. The lacing mechanisms may be an aperture through which a
string or lace is intended to pass. Additional lacing mechanisms
are also contemplated such as hooks, loops, integrated
fibers/strings, and the like. For example, the lacing mechanism 230
may be a lacing opening that is typically occupied by a portion of
a fastener, such as lacing that close the shoe upper over the
forefoot opening 217 of the shoe. However, in an exemplary
embodiment, the lacing mechanisms 230 are an eyelet or grommet
style aperture. The lacing mechanisms 230 are arranged in lines
along the upper medial side portion 210 and the upper lateral side
portion 208, as is conventional. As illustrated in the figures, the
lacing mechanisms 230, in an exemplary embodiment, extend
substantially the entire length of the upper medial side edge 212
and the upper lateral side edge 214.
[0041] The shoe upper 202 includes a vamp 218 or a throat
positioned rearwardly of the toe box 204, and a tongue 220 that
extends rearwardly from the vamp 218 through the forefoot opening
217. The tongue 220 extends along the lengths of the upper medial
side portion 210 and the upper lateral side portion 208 to a distal
end of the tongue near an ankle opening 216. The length and width
of the tongue position the tongue side edges beneath the upper
medial side portion 210 and the upper lateral side portion 208, and
extend the tongue over the forefoot opening 217 of the shoe.
[0042] FIG. 2 illustrates the upper 202 in a substantially planar
orientation, in accordance with aspects of the present invention.
The term "substantially planar" means the upper is not formed into
a foot-receiving form having an interior volume into which a foot
may be inserted. "Substantially planar" does not imply a lack in
thickness or depth variation. To the contrary, a substantially
planar upper 202 is contemplated to have a heel dimensional region
274 (to be discussed hereinafter in greater detail) that
intentionally forms a varied thickness region from other portions
of the upper 202. A typical knit or woven article as it comes off
of a manufacturing machine (e.g., loom, knitting machine) may be in
a sheet-like form, with the exception of three-dimensional knitting
and weaving techniques. While these articles are in a sheet-like
state, they may have variations to thickness based on differences
in material utilized and/or techniques implemented. Therefore, a
substantially planar article may include a sheet-like article
having dimensional thickness variations, in an exemplary
aspect.
[0043] As depicted in FIG. 2, the upper 202 is substantially planar
and comprised of a plurality of functionally varied regions. It is
contemplated that the upper 202 is formed, as depicted in FIG. 2,
as an integrally manufactured article. Stated differently, the
upper 202 is formed in a unitary fashion from a common machine that
utilizes varying techniques to impart the functional regions and
dimensional characteristics. This is in contrast to a typical shoe
construction that requires a plurality of subsequent manufacturing
processes to couple one or more components to an underlying
substrate to achieve varied functional zones. For example, a cut
and sew (or bond) approach may be utilized in a typical upper
construction where multiple discrete cut pieces are mechanically
connected with sewing and/or adhesives in a series of discrete
events. Advantages of a unitarily formed substantially planar upper
over traditional shoe manufacturing may include reduced labor,
reduced time, and greater quality control, in an exemplary
aspect.
[0044] While the terms "medial" and "lateral" will be used herein
for purposes of convenience, it is intended and understood that
each term could be substituted for the other term. Or, in the
alternative, it is understood that generic terms, such as "first"
and "second" could be substituted for either medial or lateral.
This substitution is, in part, to allow for a right shoe
construction and a left shoe construction. Similarly, it is
contemplated that some portions of the upper 202 may alternatively
be coupled (either integrally or mechanically) to an opposite side
(e.g., the heel portion 206 may be integrally coupled with the
medial side portion 210 as opposed to the illustrated lateral side
portion 208, in an exemplary aspect).
[0045] Starting at the bottom leftmost portion of FIG. 2, the upper
202 is comprised of a lateral heel edge 240. The lateral heel edge
240 is formed to be mechanically coupled with a medial heel edge
241 to form a three-dimensional upper. The lateral heel edge 240 is
a portion of the upper 202 perimeter. The perimeter may be
constructed having different characteristics than other
portions/regions of the upper 202. For example, it is contemplated
that the perimeter, which is referenced as a perimeter region 260,
may be formed as a multi-layer density weave region. The perimeter
region 260 may have a relatively low modulus of elasticity compared
to other regions of the upper 202. Additionally, the perimeter
region 260 may have multiple layers for reinforcement against
ripping, tearing, unraveling, and other potentially destructive
characteristics. In an exemplary aspect, the perimeter region 260
may be formed with a high density weaving technique that may
incorporate varied materials (e.g., low stretch synthetic fibers).
Additionally, it is contemplated that the perimeter may be formed
with a multi-layer weaving technique. Because the perimeter region
260 may be a region in which mechanical fastening (e.g., sewing,
bonding, tacking, and the like) may be implemented to transform a
substantially planar upper to a three dimensional upper, the
enhanced resistance to deformation may be implemented.
[0046] The lateral heel edge 240 extends downwardly from the top of
the perimeter region 260, which is referred to as an ankle edge
261. The lateral heel edge 240 extends down to a medial lower heel
edge 255, which is also part of the perimeter region 260, in an
exemplary aspect. The medial lower heel edge 255 continues around
the heel portion 206 as it becomes a lateral lower heel edge 257.
The combination of the medial lower heel edge 255 and the lateral
lower heel edge 257 form a lower edge of the heel portion 206.
[0047] Continuing on from the lateral lower heel edge 257, the
perimeter extends to a lateral heel flap edge 256. The lateral heel
flap edge 256 merges into a lateral flap edge 242 in the toewardly
direction. The lateral flap edge 242 forms into the lateral toe
flap edge 244. In combination the lateral heel flap edge 256, the
lateral flap edge 242, and the lateral toe flap edge 244, in part,
define a lateral sole flap 252. The lateral sole flap 252, in an
exemplary aspect, may be coupled with an opposite medial sole flap
250 along the lateral flap edge 242 to form a bottom portion of the
interior 103 of the shoe 100. Stated differently, the lateral sole
flap 252 and the medial sole flap 250 may be mechanically coupled
to form, in part, a bottom surface of a three dimensional volume,
as will be illustrated in FIG. 8 hereinafter.
[0048] Similarly, it is contemplated that the lateral heel flap
edge 256 may be coupled with the lateral lower heel edge 257 to
also form, in part, a three-dimensional volume, the interior 103.
Further, it is contemplated that the lateral toe flap edge 244 and
a lateral toe edge 245 may be coupled to also form, in part, a
three-dimensional volume, the interior 103.
[0049] Alignment of a first edge with a second edge may be
accomplished, in an exemplary aspect utilizing one or more
registers. For example, FIG. 2 depicts a plurality of triangular
registers extending from the perimeter portion 260. In a
post-processing step in which a first edge is mechanically coupled
(e.g., sewn, sealed, bonded, adhered) with a second edge to form a
three-dimensional volume, a first register from the first edge may
be aligned with a second register from the second edge.
[0050] The lateral toe edge 245 extends toewardly from the lateral
toe flap edge 244 intersection around the toe box 204 as part of
the perimeter region 260. The lateral toe edge 245 merges into a
medial toe edge 248. Together, the medial toe edge 248 and the
lateral toe edge 245 form a toe edge defining a perimeter of the
toe box 204.
[0051] The medial toe edge 248 intersects a medial toe flap edge
246. The medial toe flap edge 246 intersects with the medial flap
edge 243, which extends heelwardly to a medial heel flap edge 254.
The medial flap edge 243 was previously discussed as a coupling
edge in connection with the lateral flap edge 242. The medial heel
flap edge 254 merges into the medial heel edge 241, which was
previously discussed as being formed in complement to the lateral
heel edge 240. Together the medial toe flap edge 246, the medial
sole flap 250, and the medial heel flap edge 254 define, at least
in part, a perimeter of the medial sole flap 250. The medial toe
flap edge 246 and the medial toe edge 248 are contemplated as being
coupled, in part, to form the three-dimensional volume of the upper
202. Similarly, it is contemplated that the medial heel flap edge
254 and the medial lower heel edge 255 are contemplated as being
coupled, in part, to form the three-dimensional volume of the upper
202. As previously discussed, the medial sole flap 250 and the
lateral sole flap 252 may be coupled to form a lower portion (e.g.,
sole-like surface) of the upper 202 when in a three-dimensional
configuration, as illustrated in FIG. 8 hereinafter.
[0052] In an exemplary aspect, it is contemplated that the medial
sole flap 250 and the lateral sole flap 252 are mechanically
coupled with the sole 102 of FIG. 1. For example, it is
contemplated that the upper 202 is coupled with the sole 102, at
least in part by way of the medial sole flap 250 and the lateral
sole flap 252. It is also contemplated that the medial sole flap
250 and the lateral sole flap 252 may be positioned between an
insole inserted into the interior 103 of the shoe 100 and the top
surface of the outsole 102. Further, yet, it is contemplated that
medial sole flap 250 and the lateral sole flap 252 may be
positioned between a bottom surface of a midsole portion and a top
surface of an outsole portion of the sole 102. It is further
contemplated that alternative and/or additional mechanism for
coupling the upper 202 to the sole 102 may be implemented.
[0053] The medial heel edge 241 extends along the medial side
portion 210 to the forefoot opening 217 as defined by the
previously discussed medial side edge 212 and the lateral side edge
214. The lateral side edge 214 extends heelwardly to intersect with
the ankle edge 261, which, as previously discussed, intersects the
lateral heel edge 240.
[0054] Together, the perimeter edges discussed define a
substantially planar upper 202 that may be manufactured in a
sheet-like manner having varied materials (e.g., organic,
synthetic), varied manufacturing technique (e.g., differing weaving
techniques), varied physical properties (e.g., modulus of
elasticity, impact attenuation), and varied geometric properties
(e.g., shape, dimension, thickness). It is further contemplated
that the upper 202 may be formed in a multiple-unit operation that
results in a number of similar or different uppers to be formed
during a common manufacturing operation. The uppers, such as upper
220, may then be removed from the multi-unit collection by cutting,
trimming, sheering, etching, burning, melting, and other known
techniques.
[0055] The upper 202 is also comprised of functionally-varied
regions. Functionally-varied regions are portions of the upper 202
that have varied physical characteristics from other portions of
the upper 202. The varied physical characteristics may include a
different modulus of elasticity. As used herein, a modulus of
elasticity is a measure of ability to stretch in one or more
directions. For example, the upper 202 may be comprised of a
"non-stretch" portion, a "standard stretch" portion, and a
"stretch" portion. The terms are not intended to be literally
interpreted, but instead intended to provide a relative measure of
elasticity. Therefore, a stretch portion has a greater modulus of
elasticity than a non-stretch portion. This does not imply that a
non-stretch portion is without stretch; instead, it means the
non-stretch portion is more limited in stretch than a standard or
stretch portion of the upper 202.
[0056] The upper 202 may have strategically placed functional
regions, such as stretch regions. For example, the upper 202 is
illustrated in this exemplary aspect as having a medial flap
stretch region 270. The medial flap stretch region 270 is located
on the medial side of the upper 202 at the convergence of the
medial sole flap 250 and the medial side portion 210 approximate an
arch location of a foot when received in the interior 103. A
corresponding lateral flap stretch region 272 is located on the
lateral side of the upper 202 at the convergences of the lateral
sole flap 252 and the lateral side portion 208. It is contemplated
that the medial flap stretch region 270 and the lateral flap
stretch region 272 are functional to adapt the shape of the upper
202 as it is formed into a three dimensional form having a sole,
such as the sole 102. The ability to stretch in the strategic
position and geometry provided, in an exemplary aspect, increases
the ease of manufacturing a three dimensional object from a
substantially planar form.
[0057] Another functional region contemplated is a toe stretch
region 266. The toe stretch region 266 is integrated into a portion
of the toe box 204 of the upper 202. The toe stretch region 266 is
functional to provide a more comfortable toe box 204 for a wearer.
The toe stretch region 266 may also improve the manufacturability
of the shoe from the substantially planar form to a three
dimensional form by providing adjustability and the ability to
compensate when manipulated from a planar to multi-dimensional
state. It is also contemplated that a more durable material may be
integrated into the toe stretch region 266 to protect the toe box
204 from damage.
[0058] The heel portion 206 is comprised of a heel stretch region
268. The heel stretch region 268 is functional to increase
manufacturability and wearability of the resulting shoe. For
example, the heel stretch region 268 may allow for a more
form-fitting upper 202 to a wearer's inserted heel region.
[0059] The forefoot region of the upper 202 is comprised of a
combination of a forefoot non-stretch region 262 and a forefoot
stretch region 264. In combination, the two functional regions
provide increased stability, wearability, and utility to the shoe.
For example, the forefoot non-stretch region 262 is effective to
transfer a lacing load applied by one or more lacing mechanisms.
The load may be effectively transferred through the upper 202
downwardly towards a sole or merely around a user's inserted foot.
The reduction of stretch in the forefoot non-stretch region 262
relative to surrounding areas allows for a uniform distribution of
load and tension to the upper 202 and a connected sole. However,
while the forefoot non-stretch region 262 may be effective to
distribute lacing mechanism forces, it may also reduce the
wearability of the upper 202 by limiting stretch in the toe to heel
direction for a user during movements. Therefore, it is
contemplated that the forefoot stretch region 264 is placed between
portions of the forefoot non-stretch region 262, as illustrated.
The forefoot stretch region 264 inserts a degree of flexibility
into the upper 202 that increases the wearability and ability to
form to a user's inserted foot.
[0060] Stated differently, the forefoot non-stretch region 262 is
formed in a wave-like pattern extending from a crest-like position
at the upper edge 263 downwardly towards a flap or side edge. Each
crest of the wave-like form corresponds to a lacing mechanism, such
as a second eyelet 234. Between two crests, the forefoot stretch
region 264 is located. The forefoot stretch region 264 may allow
for a toe-to-heel direction separation between two consecutive
crests. Further, as illustrated, it is contemplated that the
forefoot non-stretch region 262 follows the toe end of the forefoot
opening across to the opposite side of the forefoot opening. This
uninterrupted continuation, in an exemplary aspect, provides
structural integrity proximate the forefoot opening and further
aids in effectively transferring loads asserted by a lacing
mechanism. Additionally, it is contemplated that the forefoot
non-stretch region 262 extends toewardly proximate the toe box 204
to also provide structural integrity and effective transferring of
lacing mechanism loads within the upper 202.
[0061] Another functional region contemplated is the heel
dimensional region 274, which is located in the heel portion 206
proximate a portion of the ankle edge 261. The heel dimensional
region 274 is a region that has a greater thickness from an
interior surface to an exterior surface, sometimes referred to as a
collar. Such a change in thickness/dimensionality may be
accomplished by varying the material utilized in producing the
region. The variation may also be accomplished by varying the
manufacturing technique utilized in that region (e.g., change from
a plain weave to a dual-layer weave, allowing for floating yarns,
insertion of filler yarns). Additionally, it is contemplated that a
multi-layer weave may be implemented that creates a pocket into
which a filler material may be inserted (e.g., injectable foam,
injectable yarns). In an exemplary aspect, the injection of a
material prevents disturbing the structural integrity of the
article by cutting an opening to insert a filler or other material.
By injecting the material, the integrity of the woven member may be
maintained. The heel dimensional region 274 increases the
wearability for a user of the shoe by providing a dissipation of
force exerted by the heel portion 206 on the Achilles region of a
wearer. Further, the heel dimensional region 274 may provide a
better fit for the wearer as it has a greater volume to conform to
the contours of an inserted wearer's ankle.
[0062] The creation of a functional region may be accomplished in a
number of manners. One technique contemplates utilizing different
weaving techniques to achieve a variation in functionality. For
example, a non-stretch region may be formed utilizing a twill-like
weaving technique. A stretch region may be accomplished by
utilizing a satin weaving technique. A breathability region may be
accomplished by utilizing a leno weaving technique, a hatching
weaving, a slit weaving, and/or a plain-loose weaving technique
(see e.g., FIG. 15). Additionally, it is contemplated that multiple
layers may be incorporated to achieve the functional regions (e.g.,
additional layers for reinforcement functionality).
[0063] It is contemplated that a first functional region may be
surrounded by a second functional region, in an exemplary aspect
(see. e.g., FIG. 18). For example, it is contemplated that the heel
stretch region 268 is surrounded by a transitional zone in which
the material transitions from the stretch functionality to the
standard functionality, which may be accomplished by altering a
manufacturing technique employed at the heel stretch region 268.
Similarly, it is contemplated that the toe stretch region 266 may
be surrounded, in part, by another transitional region. The
utilization of a transitional region in both examples may also be
used to provide a reinforcement region to enhance the structural
integrity of the upper 202. Similarly, it is contemplated that the
heel dimensional region 274 is also surrounded, at least in part,
by a transitional region. The transition region may provide a
reinforcement border to prevent creep of the dimensional volume
with wear and use, in an exemplary aspect.
[0064] Another exemplary region of the upper 202 includes a
breathability region 275 in the toe box 204 of the upper 202. The
breathability region 275 may be formed from an open weave or
otherwise looser material configuration to allow for the
permeability of air into an interior (or the escape of air to the
exterior).
[0065] While specific combinations and locations of functional
regions are depicted and discussed herein, it is contemplated that
any combination of functional regions may be implemented in any
location and at any size/shape. Therefore, the examples provided
are not limiting, but instead exemplary in nature. Additional
functional zones may be implemented in different location and in
different combinations utilizing different materials and different
manufacturing techniques than those explicitly recited herein.
[0066] The ankle edge 261 is also comprised of a first eyelet 232.
When the lateral heel edge 240 is coupled with the medial heel edge
241, the first eyelet 232 and the second eyelet 234 serve as the
consecutive eyelets in the three-dimensional upper form, as will be
illustrated in FIG. 4 hereinafter.
[0067] FIG. 2 also depicts a relative modulus of elasticity in both
the approximate toe-to-heel direction and in the approximate
medial-to-lateral direction. In an exemplary aspect, it is
contemplated that there is a greater degree of elasticity in the
latter direction than in the former direction. For example, the toe
stretch region 266 would have a greater modulus of elasticity in
the medial/lateral direction compared to the toe/heel direction, in
an exemplary aspect. However, based on the exemplary configuration
of the upper 202, because the heel portion is oriented
perpendicular to the general toe-to-heel direction, the greater
degree of elasticity is in the ankle edge 261-to-the lateral lower
heel edge 257/medial lower heel edge 255 direction as opposed to
the lateral heel edge 240-to-the lateral side portion 208
direction. This directional difference in elasticity may be
accomplished, in an exemplary aspect, utilizing a weaving technique
wherein the warps or the wefts are of a greater degree of
elasticity than the other of the warps/wefts, for example. It is
contemplated that the degree of relative elasticity may be opposite
than that which is depicted in FIG. 2. Further, it is contemplated
that the relative elasticity may be similar in two or more
directions, in an exemplary aspect.
[0068] FIG. 3 depicts a lateral side view 300 of the upper 202
formed in a three-dimensional state from the manufactured
substantially planar state, in accordance with aspects of the
present invention. The lateral side 108, the heel end 106, and the
toe end 104 of the sole are depicted. Similarly, the lateral side
portion 208, the toe box 204 and the heel portion 206 are depicted
having a variety of functional zones. For example, the heel stretch
region 268, the heel dimensional region 274, the forefoot
non-stretch region 262, the forefoot stretch region 264, and the
toe stretch region 266 are depicted. Additionally depicted in FIG.
3, is the ankle opening 216.
[0069] FIG. 4 depicts a medial side view 400 of the upper 202
formed in a three-dimensional state from the manufactured
substantially planar state, in accordance with aspects of the
present invention. The medial side 110, the heel end 106, and the
toe end 104 of the sole are depicted. Similarly, the medial side
portion 210, the toe box 204 and the heel portion 206 are depicted
having a variety of functional zones. For example, the heel stretch
region 268, the heel dimensional region 274, the forefoot
non-stretch region 262, the forefoot stretch region 264, and the
toe stretch region 266 are depicted.
[0070] FIG. 4 also depicts the mechanical coupling of the lateral
heel edge 240 with the medial heel edge 241 to form an upper seam
402. The upper seam 402 may be formed using any type of joining
technique. For example, sewing, adhesives, laminating, mechanical
fasteners, and the like are contemplated. For example, it is
contemplated that a combination of sewing and adhesives, such as a
thermal activated adhesive may be utilized. Further yet, it is
contemplated that the upper seam 402 may be at any location and at
any orientation. Therefore, it is contemplated that the upper seam
402 may be formed along an Achilles region of the heel portion such
that there is a medial heel portion and a lateral heel portion of
the substantially planar upper that when joined, form a seem
proximate the Achilles region of a wearer. The first eyelet 232 and
the second eyelet 234 are also depicted on each side of the upper
seam 402 in this exemplary aspect.
[0071] FIG. 5 depicts a heel end perspective 500 of the upper 202
formed in a three-dimensional state from the manufactured
substantially planar state, in accordance with aspects of the
present invention. The heel end 106, the medial side 110, and the
lateral side 108 of the sole are depicted. The heel portion 206 is
depicted along with functional regions, such as the forefoot
non-stretch region 262, the heel dimensional region 274, and the
heel stretch region 268. Additional indicated is the ankle edge
261.
[0072] FIG. 6 depicts a toe end perspective 600 of the upper 202
formed in a three-dimensional state from the manufactured
substantially planar state, in accordance with aspects of the
present invention. The toe end 104, the medial side 110, and the
lateral side 108 of the sole are depicted. Additionally, the
functional regions of the toe stretch region 266 and the forefoot
non-stretch region 262 are depicted. The first eyelet 232 and the
second eyelet 234 on either side of the upper seam 402 are also
depicted.
[0073] FIG. 7 depicts a top perspective 700 of the upper 202 formed
in a three-dimensional state from the manufactured substantially
planar state, in accordance with aspects of the present invention.
The toe end 104, the heel end 106, the medial side 110, and the
lateral side 108 of the sole are depicted. Additionally, the
functional regions of the toe stretch region 266, the breathability
region 275, the forefoot non-stretch region 262, the forefoot
stretch region 264, the heel stretch region 268, and the heel
dimensional region 274 are depicted. Also depicted is the upper
seam 402 on the medial side of the upper 202.
[0074] FIG. 8 depicts a bottom perspective 800 of the upper 202
formed in a three-dimensional state from the manufactured
substantially planar state, in accordance with aspects of the
present invention. The depicted perspective is without a sole
attached allowing a view of the various edges mechanically coupled
to form the three-dimensional form of an upper. In particular, the
lateral sole flap 252 and the medial sole flap 250 are depicted
such that the lateral flap edge 242 is couple with the medial flap
edge 243 are coupled joining the two sole flaps. Similarly, the
lateral heel flap edge 256 and the medial heel flap edge 254 are
illustrated and while not explicitly depicted, coupled to the
lateral lower heel edge 257 and the medial lower heel edge 255
respectively. Further, the lateral toe flap edge 244 and the medial
toe flap edge 246 are illustrated and while not explicitly
depicted, coupled to the lateral toe edge 245 and the medial toe
edge 248 respectively.
[0075] As will be discussed hereinafter, it is contemplated that
one or more lockout strands or lockout strand assemblies may
leverage the mechanical joining of the lateral flap edge 242 and
the medial flap edge 243 to secure and anchor one or more portions
of a lockout strand. For example, a lockout strand that extends
from a forefoot opening (e.g., as part of a securing/lacing
mechanism) may be secured within the seam formed between the
lateral flap edge 242 and the medial flap edge 243. Further, it is
contemplated that one or more portions of a lockout strand may
extend through the seam between the lateral flap edge 242 and the
medial flap edge 243 such that when the formed upper is secured to
a bottom unit (e.g., sole assembly), the one or more portions of
the lockout strand are also secured to the bottom unit and/or the
upper. For example, if an adhesive or other bonding agent is
applied to a surface portion of the upper for securing to a surface
of a bottom unit, the adhesive or bonding agent may also interact
with the portions of the lockout strand(s) to secure those elements
as well. Therefore, it is contemplated that the sewing and or
adhering that may be used to form the upper and/or secure the upper
to the sole may further aid in anchoring or securing one or more
portions of a lockout strand, in exemplary aspects.
[0076] While a slip last type of construction is depicted, it is
contemplated that any type of lasting construction may be
implemented in exemplary aspects. For example it is contemplated
that a strobel last (e.g., a material is coupled with the upper
along a perimeter portion roughly matching a midsole perimeter) may
be utilized in aspects. Further, it is contemplated that a hybrid
last may be utilized that incorporates two or more lasting
techniques. An example of a hybrid lasting may include utilizing a
strobel last in a heel region and a slip last in a metatarsal
region of the foot.
Integrated Lockout Strand
[0077] It is contemplated that the following features may be
implemented in a substantially planar shoe upper. Additionally it
is contemplated that the following features may be implemented in a
three-dimensional article, such as a formed shoe upper. Therefore,
the following is not limited to substantially planar shoe upper
implementations.
[0078] FIG. 9 depicts an exemplary portion of an upper 900 having
integrally woven lockout strands, in an exemplary aspect. Lockout
strands are a material having a relatively low modulus of
elasticity (e.g., substantially no stretch under normal usage
scenarios). Examples of lockout strands include, but are not
limited to, synthetic materials, organic materials, and
multi-component structures. Further, it is contemplated that a
lockout strand may be a cable, thread, yarn, filament, cord, or any
other structure suitable for providing an integrated and/or
inserted flexible member for use as a lockout strand. Specific
example of a lockout strand include a nylon, a polyester, a
metallic, a carbon fiber, and/or another material cable having a
diameter between 0.5 millimeters and 2.0 millimeters. However,
smaller and larger diameters are contemplated herein.
[0079] It is contemplated that a lockout strand forms, at least in
part, a non-stretch functional region in a woven upper. As
previously discussed, a non-stretch region may be formed utilizing
a variety of weaving techniques and/or materials. In an exemplary
aspect, the utilization of a lockout strand reduces the modulus of
elasticity of a region of a woven shoe upper in at least one
direction (e.g., in a direction parallel with the lockout strand,
in a direction in which the lockout strand resists tension).
[0080] In an exemplary aspect, the lockout strands are functional
to transfer a tension load from a lacing apparatus (e.g., shoe
lace) from the forefoot region around the medial and lateral side
of a user's foot towards the sole. The lockout strands provide a
zone of minimal stretch that is effective for securing a shoe to
the user's foot. In an additional exemplary aspect, the utilization
of lockout strands are integrated and/or inserted into a woven
upper to provide zonal control of a modulus of elasticity.
Therefore, it is contemplated that a region of a shoe upper that is
desired to have a first attribute (e.g., breathability from a
plurality of woven apertures) that may introduce a greater degree
of stretch than desired to that region, the lockout strands may
also be utilized to achieve the desired modulus of elasticity while
still achieving the first attribute (as will be seen in FIG. 12
hereinafter).
[0081] Returning to FIG. 9, the upper 900 is woven with wefts and
warps generally in the direction of a first direction 902 and a
second direction 904. As will be discussed with respect to FIGS. 10
and 11 hereinafter, the lockout strands may extend in the first
direction 902, the second direction 904, and/or a direction
non-orthogonal to the first direction 902 and the second direction
904. Similar to the lockout strands, it is contemplated that the
warps/wefts may be oriented in exemplary aspects in either the
first direction 902 or the second direction 904. In an exemplary
aspect, the lockout strands are depicted in an orientation
substantially parallel with the wefts.
[0082] The upper 900 is comprised of a first region 906 and a
second region 908, in this exemplary aspect. The first region 906
may be a first functional region and the second region 908 may be a
second, different, functional region in an exemplary aspect. For
example, it is contemplated that the first region 906 may be a
ventilation region allowing for a greater degree of air/moisture
movement through the upper 900 that the second region 908, which
may be a reinforcement region, for example. As depicted, a first
group 910 of lockout strands and a second group 912 of lockout
strands extend in from the first region 906 into the second region
908 in a direction substantially parallel to the first direction
902.
[0083] The first group 910 is comprised of a first lockout strand
914, a second lockout strand 916, and a third lockout strand 918.
While three lockout strands are depicted, it is contemplated that
any number may be used in any orientation. The lockout strands 914
and 196 are offset as to which elements in the second direction 904
they are interwoven. This offsetting may be utilized to achieve a
stronger integration of the lockout strands with a region of the
woven upper 900.
[0084] In an exemplary aspect, the first group 910 may extend from
a lacing mechanism proximate a forefoot opening (or any location)
of the upper 900. For example, it is contemplated that an eyelet is
formed into the upper 900 through the creation of an aperture
during the weaving process. The first group 910 may be interwoven
with the upper 900 proximate (and even potentially around) the
aperture. Therefore, the first group 910 is effective to transfer a
force applied to the lacing mechanism (e.g., eyelet) by a lacing
structure downwardly towards a sole (e.g., a midsole portion). In
tan exemplary aspect, the second region 908 may be an integrally
woven reinforcement zone that terminates, securely, within the
second region 908 by way of the weaving technique implemented in
the second region 908, in this example.
[0085] FIG. 10 depicts an exemplary woven portion 1000 comprised of
warps and wefts with non-orthogonally oriented lockout strands, in
accordance with aspects of the present invention. An exemplary
non-orthogonally oriented lockout strand 1006 is integrated with
members in a substantially first direction 1002 while floating over
members oriented in a second direction 1004. The members in the
first direction 1002 are the warps, in an exemplary aspect.
[0086] The lockout strand 1006 has a first portion 1008 and a
second portion 1010 with an apex 1014. At the apex 1014, an
exemplary angle 1012 is formed. It is understood that the angle
1012 may be any angle. In the depicted aspect, the angle 1012 may
be a right angle, which results in a substantially 45 degree
traverse of the first direction 1002 and the second direction 1004,
in this example. However, it is contemplated that any angle of
traverse of any members is contemplated to achieve non-orthogonally
oriented lockout strand integration.
[0087] The apex 1014 represent a point in which the lockout strand
1006 changes from a first primary direction to a second primary
direction. While the apex 1014 is depicted as occurring on the
underlying warp/weft substrate, it is also contemplated that the
apex 1014 may be beyond the substrate (e.g., past an edge). The
apex extending past an edge may provide a lacing mechanism portion,
such as a loop through which a lacing structure may be
inserted.
[0088] FIG. 11 depicts an exemplary woven portion 1100 comprised of
warps and wefts with non-orthogonally oriented lockout strands, in
accordance with aspects of the present invention. An exemplary
non-orthogonally oriented lockout strand 1106 is integrated with
members in a substantially first direction 1102 while floating over
members oriented in a second direction 1104. The members in the
first direction 1102 are the wefts, in an exemplary aspect.
[0089] The lockout strand 1106 has a first portion 1108 and a
second portion 1110 with an apex 1114. At the apex 1114, an
exemplary loop 1112 is formed. As with FIG. 10, it is contemplated
that the lockout strand 1106 may traverse at any angle relative of
any members is to achieve non-orthogonally oriented lockout strand
integration.
[0090] The loop 1112 may be utilized as part of a lacing mechanism,
as previous discussed. Additionally, it is contemplated that the
loop 1112 may be coupled with one or more portions of a shoe. For
example, upon lasting an upper having the loop 112, the loop 112
may be sewn (or otherwise coupled) with the last. For example, the
loop 1112 may be integrated into a strobel stitch or a slip last
stitch to securely anchor the lockout strand to a portion of the
resulting shoe, such as the midsole. While the apex 1114 is
depicted as extending beyond a warp/weft substrate, it is
contemplated that the apex 1114 may occur within the warp/weft
substrate at any location.
[0091] As depicted, it is contemplated that a lockout strand mat be
interwoven with the warps and/or wefts of an underlying substrate.
For example, during the weaving process utilizing traditional warps
and wefts, the lockout strand may be integrated during the movement
of heddles, prior to packing the shed, and/or following the packing
of the shed, but prior to removing the woven article from the loop.
It is contemplated that a jacquard-type loom may be utilized to
form the substrate and an attachment may be positioned proximate
the shed of the substrate coming off the loom that is responsible
for interweaving the lockout strand. Additionally, it is
contemplated that a traditionally weft may be replaced or augmented
with a lockout strand during the weaving process to achieve an
interwoven lockout strand. Further, it is contemplated that a warp
may be replaced or augmented with a lockout strand to also achieve
an integrally formed interwoven lockout strand in the warp
direction.
Lockout Assembly
[0092] It is contemplated that the following features may be
implemented in a substantially planar shoe upper. Additionally it
is contemplated that the following features may be implemented in a
three-dimensional article, such as a formed shoe upper. Therefore,
the following is not limited to substantially planar shoe upper
implementations.
[0093] FIG. 12 depicts a portion of an exemplary shoe 1200, in
accordance with aspects of the present invention. The shoe 1200 is
comprised of an upper 1202 that forms a cavity between an exterior
layer 1206 and an interior layer 1207 utilizing a multi-layer
weaving technique. The cavity provides a volume of space in which a
lockout strand may be inserted to serve as a functional member of
the upper 1202.
[0094] For example, it is contemplated that a lockout strand 1214
may pass through the cavity along the lateral side portion 1208.
The lockout strand may then go through the exterior layer 1206 at
an aperture 1212. The aperture, as previously discussed, may be
formed with aperture reinforcement 1210, such as a non-stretch
region integrally formed with the exterior layer 1206. The lockout
strand may form a loop 1216 that is serves as a lacing mechanism
through which a lace 1218 (or any other lacing structure) may
pass.
[0095] Within the cavity between the exterior layer 1206 and the
interior layer 1207, the lockout strand may extend downwardly
towards a sole of the shoe 1200. It is contemplated that the cavity
may have a perimeter where the multiple layers are integrally
formed as a single layer, such as with a jacquard loom. At the
cavity perimeter, the lockout strand 1214 may be coupled with the
upper, such as with a lasting stitch (e.g., strobel stitch).
Additionally, it is contemplated that the lockout strand may pass
through another aperture to be coupled with one or more other
portions of the shoe 1200.
[0096] As depicted in FIG. 12, a plurality of the lockout strands
pass through the internal cavity of the lateral side portion 1208.
While each lockout strand is depicted as exiting the cavity through
a unique aperture, it is contemplated that one or more lockout
strands may share a common aperture. Further, it is contemplate
that a lockout strand may exit the cavity through a first aperture
and may loop back to re-enter the cavity at a second aperture, in
an exemplary aspect. Further, it is contemplated that the lockout
strand is incorporated into a lacing mechanism, such as an eyelet
within the upper 1202 proximate a forefoot opening.
[0097] Also depicted in FIG. 12 is a zonal reinforcement 1211. The
zonal reinforcement 1211 is positioned along the forefoot opening
and is also integrated into the aperture reinforcement 1210, in an
exemplary aspect. The zonal reinforcement 1211 may be an integrally
woven zone or an applied zone (e.g., laminate). The zonal
reinforcement 1211 may provide a non-stretch or reinforcement
function aiding in the securing of the foot to a user's foot.
[0098] FIG. 13 depicts a cut-away, multi-layer, woven portion 1300
of an upper 1302, in accordance with aspects of the present
invention. As previously discussed, it is contemplated that an
internal cavity may be formed during a common weaving process using
a weaving technique, such as that performed by a jacquard loom. The
multi-layer woven article can take a single layer and diverge into
two or more layers during the weaving process. Consequently, if a
cavity is desired, an interior layer 1307 and an exterior layer
1306 may be formed to define an internal cavity 1308.
[0099] As previously discussed, the internal cavity formed in a
woven shoe upper may provide a volume through which a lockout
strand may be inserted. For example, a lockout strand 1310 is
depicted as passing through the cavity 1308 and out of the cavity,
through the exterior layer 1306, at an aperture 1316. In this
depicted example, the lockout strand forms a loop 1312 after
exiting the cavity 1308. As contemplated herein, the loop 1312 may
be utilized as a lacing mechanism.
[0100] In an exemplary aspect, it is contemplated that the cavity
1308 forms a functional zone, such as a filled pocket. The cavity
1308 may be filled with floating yarns, padding, fibers, injectable
foam, foam, and other fillers 1314 (e.g., spacer mesh--a knit or
woven dimensional material having a first surface and a second
parallel surface spaced apart and maintained by elements extending
between said surfaces) and impact attenuators.
[0101] In an exemplary aspect, the fillers 1314 may be inserted to
separate the interior layer 1307 from the exterior layer 1306 to
facilitate the insertion or incorporation of the lockout strand
1310, in an exemplary aspect. For example, it is contemplated that
a spacer mesh material (or any filler material) may be inserted
into a cavity formed between two layers of a woven article. The
spacer mesh, in this example, may provide several functional
advantages.
[0102] First, it is contemplated that when weaving a multi-layer
portion of a woven article, a number of threads (or fibers) forming
each surface is reduced by the number of layers being formed. For
example, in a two-layer pocket as contemplated herein, the number
of warps may be half that of a single layer construction.
Therefore, it is contemplated that the spacer mesh material may
provide structural support and/or structural integrity to
compensate for the reduced density of woven fibers caused by the
formation of multiple layers. Further, it is contemplated that the
lockout strands may be inserted into the pocket/cavity after
formation of the substantially planar woven upper.
[0103] The insertion may be aided by the dimensional
characteristics of a spacer mesh that ensures the interior layer
1307 and the exterior layer 1306 are maintained separate to provide
a convenient path for insertion of the lockout strand without
unintentionally breaching either of the layers. Further to this
point, the spacer mesh material (or any filler) may allow for a
dispersion of forces applied by the lockout strand as experienced
by a wearer's foot when in an as-worn configuration. For example,
to limit the sensation of tension along the side of a foot, the
filler material may aid in dispersing the energy across a greater
portion of the wearer's foot, in an exemplary aspect.
[0104] In a further aspect, the use of spacer mesh or any filler
material may allow for the absence of specifically engineered
channels through which the lockout strands may extend. For example,
a more general pocket may be formed that is not sized and
positioned specifically for a lockout strand, but instead, the
pocket may be formed for receiving the filler material that may be
used for multiple lockout strands that extend there through in
varied and shoe-specific path. Stated differently, the
implementation of a filler or spacer mesh adds adaptability to the
manufacturing process as specific channels or features do not need
to be formed for individual lockout strands. Instead, a general
pocket may be formed having greater tolerances that is adapted to
receive the filler/spacer mesh. The received spacer mesh/filler may
not be formed having a specific channel through which the lockout
strand extends, but instead the lockout strand may pass through any
portion of a volume of the filler/spacer mesh.
Manufacturing Techniques
[0105] It is contemplated that any type and combination of
manufacturing techniques may be implemented in exemplary aspects.
For example, it is contemplated that a substantially planar upper
may be formed in a loom that is functional to alter the materials
and weaving techniques utilized in one or more regions. Similarly,
it is contemplated that a knitting machine may be implemented to
form a substantially planar upper, as provided herein.
[0106] Traditionally, weaving utilizes two distinct directional
sets of yarns/threads/fibers/filaments that are interlaced
orthogonally to one another to form the resulting cloth or fabric.
For example, a first directional set running in a first direction
of the resulting fabric may be referred to as a warp set, or
"warps" for short. Interlaced at a right angle to the warps are a
second directional set, referred to as a weft set, or "wefts" for
short. Stated differently, longitudinal elements (e.g., threads,
yarn, fibers, and filaments) of a woven article are the warp and
the lateral elements are the weft.
[0107] Depending on a number of factors, characteristics of the
resulting fabric may be affected. Those characteristics may
include, but are not limited to, the fabric's size, shape, feel,
look, texture, impact absorption/attenuation/response, moisture
repellency/wicking, thermal energy insulation/dissipation, and the
like. Factors that are contemplated as affecting the
characteristics include, but are not limited to how the warp and
weft are interwoven. Additionally, depending on the size of the
elements utilized in the warp and/or the weft relative to other
warp and/or weft affect the resulting fabric characteristics. The
type of material from which individual (or sets) of elements are
formed (e.g., twisted fibers, synthetic filaments, multi-material
filaments, and the like) also may affect the characteristics.
Reactions and other in-line and post-processing activities (e.g.,
introduction of stimulus to a reactive material or portion of
material) may affect the resulting characteristics of the fabric.
Other variables that are manipulated during the weaving process may
also affect the resulting characteristics (e.g., tension, loom
type, loom characteristics, temperature, and the like). Other
variables are considered. Exemplary techniques and mechanisms for
manufacturing one or more articles utilizing one or more techniques
are also contemplated and described in co-pending, commonly
assigned, U.S. Provisional No. 61,590,177, filed Jan. 24, 2012,
entitled "Intermittent Weaving Splicer," U.S. Provisional No.
61/590,179, filed Jan. 24, 2012, entitled "Weaving Finishing
Device," U.S. Provisional No. 61/590,183, filed Jan. 24, 2012,
entitled "Multi-Functional Weaving System," and U.S. application
Ser. No. 13/599,531, filed Aug. 30, 2012, entitled "Woven Textile
Bag," which claims priority to U.S. Publication No. 61/529,049,
filed Aug. 30, 2011, entitled "Woven Textile Apparel And
Accessories," all of which are incorporated by reference in their
entirety herein.
[0108] The formation of a woven product, such as a shoe upper, may
occur on a loom-like device. In an exemplary aspect, the loom holds
the warp threads in place as weft threads are interlaced in a
repeating or non-repeating manner. It is also contemplated that
other devices may be implemented other than a traditional loom to
form a woven article. For example, tablet weaving, back-strapping,
and other techniques are contemplated.
[0109] As will be discussed and described in more detail
hereinafter, it is possible to implement any number of weaving
techniques. In a plain weave (see e.g., FIG. 15) the warp and weft
are aligned so they form a simple criss-cross pattern, which may be
balanced so that there are the same number of ends per inch (i.e.,
warps) and picks per inch (i.e., wefts). Another example weaving
pattern that is contemplated herein is a twill weave (see e.g.,
FIG. 15). In a twill weave, a pattern of diagonal parallel ribs
(also referred to as a wale) may be visible. The ribs are formed by
passing the weft over one or more warps and then under two or more
warps. The following row of wefts then are offset by one or more
warps from the previous row providing a stepping pattern.
Additionally, a satin weave is contemplated (e.g., See FIG. 15). A
satin weave may have four or more wefts floating over a single warp
or vice versa. The type of woven process employed is not limited to
plain, twill, or satin, but instead they are merely exemplary in
nature and may form a building block from which the ultimate
weaving process is selected. As will be discussed with respect to
FIG. 15 hereinafter, it is contemplated that a modulus of
elasticity (e.g., stretachability) may fall on a spectrum from
stretchy to non-stretchy. In an exemplary aspect, that spectrum of
stretchy to non-stretchy may include the satin weave on a
stretchier end from a twill weave on a less stretchy end. The plain
weave may be placed on the spectrum of modulus of elasticity
between a satin and a twill weave.
[0110] In addition to traditional weaving techniques, it is also
contemplated that a dobby, jacquard, or other mechanism may be
implemented for manipulating heddles or harness (es) controlling
the position of one or more warps to form the resulting woven
article. Therefore, any combination of weaving techniques may be
implemented.
[0111] In the alternative of weaving, it is also contemplated that
a substantially planar upper may be formed utilizing a knitting
technique. A knit article, such as a shoe upper, is an article
formed, in an exemplary aspect, through a method of integrating
consecutive rows of loops (e.g., stitches) with a subsequent row of
loops. A new loop in a subsequent row is pulled through an existing
loop of a previous row, in an example. In knitting a
yarn/fiber/thread/filament follows a course forming the symmetric
loops (i.e., bights) symmetrically above and below the mean path of
the yarn. A variety of stitches (e.g., knit or purl, slip-stitch
fair-isle, drop-stitch) may be implemented to provide various
functionality (e.g., elasticity), dimensional effects (e.g.,
ribbing, welting, basket weaving) and aesthetic results. Any
combination of materials and stitching techniques may be
implemented in one or more aspects of the present invention.
[0112] A single spun yarn may be knitted as is, or it may be
braided or plied with another yarn. In plying, two or more yarns
are spun together. When spun together, a direction of spinning may
be opposite from which the yarns were originally spun (if at all);
for example, two Z-twist yarns may be plied with an S-twist. The
opposing twist may relieve some of the yarns' tendency to curl up
and produces a thicker, balanced yarn. Plied yarns may themselves
be plied together, producing cabled yarns or multi-stranded yarns.
Sometimes, the yarns being plied are fed at different rates, so
that one yarn loops around the other, as in boucle.
Exemplary Aspects--Substantially Planar
[0113] The following exemplary aspects make reference to features
previously discussed with respect to FIG. 2 hereinabove. While
specific features are identified from FIG. 2, they are not limiting
but instead provided for convenience. Stated differently, it is
intended for the additional aspects that are enabled herein, but
that are not specifically identified below, are also contemplated
within the scope of the present invention. Therefore, the exemplary
part numbering provided hereinafter is not intended to limit the
scope of the present invention. For example, FIG. 14 demonstrates a
similar, but different, exemplary substantially planar upper, in
accordance with aspects of the present invention.
[0114] An exemplary aspect is a woven substantially planar shoe
upper that is comprised of a woven first side portion (e.g., medial
side portion 210, lateral side portion 208) extending from a first
coupling edge (e.g., medial heel edge 241, lateral heel edge 240)
at a heel end towards a toe end and also extending from an upper
edge (e.g., upper edge 263) towards a first side edge (e.g., medial
flap edge 243, lateral flap edge 242), the upper edge defining, in
part, a forefoot opening (e.g., forefoot opening 217) and an ankle
opening (e.g., ankle opening 216) into an interior (e.g., interior
103) of the shoe upper portion when the shoe upper portion is
formed as a non-planar shoe upper.
[0115] The upper is also comprised of a woven second side portion
(e.g., medial side portion 210, lateral side portion 208) extending
from the heel end towards the toe end and also extending from the
upper edge towards a second side edge (e.g., medial flap edge 243,
lateral flap edge 242), the second side portion and the first side
portion form, in part, a medial side and a lateral side of the shoe
upper portion when the shoe upper portion is formed as a non-planar
shoe upper.
[0116] The upper is further comprised of a woven toe region
extending between the first side portion at the toe end and the
second side portion at the toe end, the toe region also extending
towards the upper edge forming a toe end of the forefoot opening.
The upper is also comprised of a woven heel region extending from
an ankle edge (e.g., ankle edge 261) to a heel sole edge (e.g.,
medial lower heel edge 255, lateral lower heel edge 257) and also
extending between the heel end of the second side portion and a
second coupling edge (e.g., lateral heel edge 240, medial heel edge
241). The first side portion is seamlessly (e.g., woven during a
common weaving operation, knit during a common knitting operation)
coupled with the toe region. The toe region is also seamlessly
coupled with the second side portion. Further, the second side
portion is seamlessly coupled with the heel region. The first side
portion, the second side portion, the toe portion, and the heel
portion are substantially planar. For example, it is contemplated
that all portions provided in this exemplary upper were formed
during a common weaving operation that also may have incorporated
various functional regions.
[0117] In an additional exemplary aspect, it is contemplated that a
woven shoe upper is comprised of a woven heel portion having an
ankle edge and an opposite heel sole edge. The heel portion is
comprised of a dimensional portion, a stretch portion, and a
non-stretch portion, in this exemplary aspect. The dimensional
portion has a thickness greater than the stretch portion and the
non-stretch portion. The dimensional portion, the stretch portion,
and the non-stretch portion are integrally formed, such as in a
common weaving operation.
[0118] The upper is further comprised of a woven toe portion having
a forefoot edge and an opposite toe sole edge (e.g., medial toe
edge 248, lateral toe edge 245). The toe portion comprised of a
stretch portion (e.g., toe stretch region 266) and a non-stretch
portion (e.g., a transitional region, perimeter region 260). The
stretch portion and the non-stretch portion integrally formed, such
as during a common manufacturing technique (e.g., a weaving
operation).
[0119] The upper is also comprised of a woven medial side portion
extending between the heel portion and the toe portion on a medial
side of the shoe upper, the medial side portion having a first
upper edge (e.g., medial side edge 212) and an opposite medial sole
edge (e.g., medial flap edge 243, medial toe edge 248). The upper
is comprised of a woven lateral side portion extending between the
heel portion and the toe portion on a lateral side of the shoe
upper, the lateral side portion having a first upper edge and an
opposite lateral sole edge (e.g., lateral flap edge 242, lateral
toe edge 245).
[0120] Another exemplary aspect of the present invention is a shoe
construction comprised of a sole and an upper. The upper is
comprised of a medial side portion and a lateral side portion. The
medial side portion is comprised of a) a first region extending
from a forefoot opening towards the sole; b) a second region
extending from the forefoot opening toward the first region, the
second region having a greater modulus of elasticity than the first
region; and c) a first aperture extending through the medial side
portion proximate the forefoot opening within the first region. The
lateral side portion is comprised of a) a third region extending
from a forefoot opening towards the sole; b) a fourth region
extending from the forefoot opening toward the third region, the
fourth region having a greater modulus of elasticity than the third
region; and c) a second aperture extending through the lateral side
portion proximate the forefoot opening within the third region. The
first region and the second region are integrally coupled sharing a
common warp. For example when two regions are formed during a
common weaving operation, they share a common warp. This is in
contrast to two previously cut portions that are then coupled
(e.g., sewn or adhered), which do not share a common weaving warp
thread. The third region and the fourth region are integrally
coupled sharing a common warp. In an exemplary aspect, it is
contemplated that the first, second, third, and fourth regions are
formed as part of a substantially planar shoe upper during a single
weaving operation.
Exemplary Aspects--Integrally Woven Lockout Strands
[0121] The following exemplary aspects make reference to features
previously discussed with respect to FIGS. 9-11 hereinabove. While
specific features are identified from FIGS. 9-11, they are not
limiting but instead provided for convenience. Stated differently,
it is intended for the additional aspects that are enabled herein,
but that are not specifically identified below, are also
contemplated within the scope of the present invention. Therefore,
the exemplary part numbering provided hereinafter is not intended
to limit the scope of the present invention.
[0122] In an exemplary aspect, it is contemplated that a shoe is
constructed with a woven upper (or at least a portion of an upper
that is woven). The formation of the woven upper may incorporate
wefts having a first amount of stretch (i.e., a modulus of
elasticity). Similarly the warps may also have a degree of stretch,
such as a second modulus of elasticity. The warps and wefts in this
example are contemplated has having an amount of stretch that is
conducive to forming a function shoe upper that is comfortable to
don and wear. However, to achieve desired performance results, a
lower modulus of elasticity may be utilized in strategic region,
such as a non-stretch region extending from a forefoot opening to a
sole coupling portion (i.e., a portion of the upper to which a sole
portion is coupled). The non-stretch region may be achieved by
interweaving lockout strands with the warps and/or wefts of the
upper. In this example, the non-stretch region is achieved by
incorporating a lockout strand having a modulus of elasticity hat
is less than the proximate warp(s) and/or weft(s).
[0123] With respect to the orientation of the lockout strands
relative to the underlying warps and/or wefts, it is contemplated
that the lockout strands may be orthogonally oriented to the warps
or wefts, they may be non-orthogonally oriented to the warps/wefts,
and/or they may change from a first orientation to a second
orientation as they traverse the warps/wefts.
[0124] In another exemplary aspect, it is contemplated that a woven
shoe upper may be formed with a lateral side portion and a medial
side portion. Each of the side portions form, at least in part, a
forefoot opening through which a user may insert a foot. The
forefoot opening may be defined, at least in part, by a forefoot
edge. As is typical with an athletic-type shoe, it is contemplated
that a plurality of lacing mechanisms, such as eyelets, are
positioned proximate the forefoot edge of both the lateral and the
medial side portions. However, in this example, a lockout strand
extends downwardly from the forefoot edge of the medial side
towards the lower portion of the medial side proximate the midsole.
Similarly, a second lockout strand extends downwardly from the
forefoot edge of the lateral side towards the lower portion of the
lateral side proximate the midsole. In both lockout strands, they
are interwoven with the upper proximate the lacing mechanism to
effectively transfer a load applied to the lacing mechanism through
the upper towards the midsole. Therefore, the woven upper may be
formed to achieve a desired aesthetic or functional purpose and the
lockout strands may accomplish the desired functional trait of
transferring the applied load around a user's foot.
[0125] As previously discussed, the interweaving of the lockout
strand may include incorporating the lockout strand between a warp
and a weft such that the lockout strand is in a common plane as the
warp/weft combination. This is in contrast to sewing a secondary
material into a woven article, in that example, the secondary
material in not integrally woven, but instead alternatives from a
firs side to a second side of a woven article as it is inserted,
this side changing may cause deformations in the woven structure as
a load is applied along the length of the secondary material.
[0126] Another exemplary aspect contemplates a shoe construction
having a sole and an upper. The upper is again comprised of a
medial side portion and a lateral side portion. The medial side
portion (and an exemplary lateral side portion) is comprised of a
first region. The first region, in this example, extends from a
forefoot opening toward the sole, such as a sole coupling region of
the medial side portion. The first region incorporates a lockout
strand, which is a material different from the other warps and
wefts within that region of the medial side portion. The
interweaving of the lockout strand provides this first region with
a modulus of elasticity in the direction of the lockout strand that
is less than a second region of the medial side portion.
[0127] The second region, in this example, extends from the
forefoot opening also towards the sole. However, the second region
does not have an interwoven lockout strand. Therefore, the second
region has a great modulus of elasticity when measured in the
direction of the lockout strands of the first region than the first
region.
[0128] It is contemplated that the first region may coincide with
an eyelet and the second region may coincide with a region between
two eyelets along the forefoot opening. Therefore, the first region
is functional to transfer a load applied to the eyelet downwardly
through the upper while the second region is functional to provide
stretch and comfort to a user. The first region and the second
region, in this example, are integrally formed from a common
weaving operation and therefore share at least a common warp and/or
weft.
Exemplary Aspects--Multi-Layered Upper with a Lockout Strand
Assembly
[0129] The following exemplary aspects make reference to features
previously discussed with respect to FIGS. 12-13 hereinabove. While
specific features are identified from FIGS. 12-19, they are not
limiting but instead provided for convenience. Stated differently,
it is intended for the additional aspects that are enabled herein,
but that are not specifically identified below, are also
contemplated within the scope of the present invention. Therefore,
the exemplary part numbering provided hereinafter is not intended
to limit the scope of the present invention.
[0130] In an exemplary aspect, a shoe construction is comprised of
a sole and a woven upper. The woven upper is comprised of a
multi-layer portion having a first layer and a second layer. The
two layers form a cavity, such as a pocket, a tunnel, or other
volume of space between the layers. The upper is also comprised of
a reinforcement portion that forms an aperture through the first
layer. The reinforcement portion may be an integrally formed
portion or it may be a post-weaving portion. For example, it is
contemplated hat a heat activated laminate (or any laminate) may be
affixed to the upper to form the reinforcement portion.
Additionally, it is contemplated that a mechanical reinforcement,
such as a metallic eyelet may also be added as a reinforcement
portion, in an exemplary aspect.
[0131] The upper may also be comprised of a lockout strand. The
lockout strand extending through the internal cavity of the
multi-layer portion of the upper. The lockout strand may then
extend out of the cavity through the reinforced aperture of the
first layer. For example, it is contemplated that a looped portion
of the lockout strand may pass through the internal cavity and
extend out of the cavity through an aperture formed proximate a
forefoot opening. The looped portion may then serve as a lacing
mechanism in an exemplary aspect. The remainder of the lockout
strand may continue down the upper towards the sole as an effective
mechanism for transferring an applied load toward a midsole of the
sole, in this example.
[0132] In an exemplary aspect, it is contemplated that a plurality
of apertures are formed in the first layer (e.g., the exterior
layer or the interior layer). The apertures may be formed during
the weaving process to provide a functional zone. As previously
discussed, the functional zones may be a stretch zone caused by the
apertures or a ventilation zone caused by the apertures.
[0133] Another exemplary aspect is directed to a shoe construction
comprised of a woven shoe upper having both a medial side portion
and a lateral side portion. The medial side portion is comprised of
an integrally woven multi-layer portion forming a medial side
internal cavity. The integrally woven aspect may be achieved using
a jacquard loom that is capable of forming at least two sheds from
a common grouping of warps. Additional loom configurations (e.g., a
dobby loom) may also be implemented to achieve an integrally woven
multi-layer article.
[0134] In this example, it is contemplated that a number of
apertures extend through an exterior later of the medial
multi-layer portion near the forefoot opening. Additionally, it is
contemplated that another of other apertures extend through an
exterior layer of the lateral multi-layer portion. These apertures
may serve as an aperture through which a lockout strand may exit
from an internal volume of the upper to an exterior location of the
upper, such as near the forefoot opening. Unlike a typical eyelet
that passes through the upper to allow threading of a lace, the
apertures discussed in this example do not pass through all layers
of an upper. Instead, the apertures, in this example, merely
provide a means of egress and ingress to the cavity in the
multi-layer woven upper.
[0135] As with other exemplary multi-layer woven article provided
herein, it is contemplated that both a first layer and a second
layer of a multi-layer woven article diverge from a common woven
layer. For example, two or more layers may share a common weft,
such as along a single layer portion. Similarly, it is contemplated
that two or more layers may share a common warp, such as along a
common layer portion. Therefore, unlike when two independently
created articles are coupled in a post-processing fashion (e.g.,
sewing, bonding), an integrally formed multi-layer woven article is
formed from a common weaving operation.
Additional Aspects
[0136] FIG. 14 depicts an additional aspect of a substantially
planar woven shoe upper in both a front and a related back
perspective, in accordance with aspects of the present invention.
Various functional regions are depicted, such as stretch,
non-stretch, dimensional, breathability, and the like. Additionally
depicted is a region in which a heel counter may be inserted. In an
exemplary aspect, it is contemplated that a multi-layer weaving
technique may be implemented to form a pocket or cavity into which
a heel counter may be inserted. In an exemplary aspect, an enclosed
cavity is formed during a weaving operation; however, upon cutting
the heel portion from a larger woven article (e.g., beam width
portion), the enclosed cavity becomes accessible for the insertion
of a supplemental material, such as a structural heel counter
piece. A pocket for receiving the heel counter piece is depicted in
FIG. 14 proximate the heel portion 206.
[0137] While aspects of FIG. 14 a similar to that of FIG. 2
discussed previously, the lateral heel edge 240, when coupled with
the medial heel edge 241, is located more toewardly in FIG. 14 than
in FIG. 2. Stated differently, the exemplary substantially planar
woven upper depicted in FIG. 14 has a more forwardly positioned
coupling seem than that of FIG. 2. An additional difference between
FIG. 2 and FIG. 14 uppers is the location and position of the
medial flap. In FIG. 14, a portion of the medial flap is formed
heelwardly from the lateral heel edge 240. As a result, a first
portion of the medial flap is located toewardly of the medial heel
edge 241 and a second portion of the medial flap is located
heelwardly of the lateral heel edge 240. Further, FIG. 14
contemplated a multi-layer weave that creates a first layer forming
a back surface a d a second layer forming the front surface. The
multi-layer aspects may be utilized to provide a varied functional
zones by the varied layers. For example, the back layer (i.e.,
closest to the skin) may be woven to form a comfort layer, such as
a terry cloth-type weave. Similarly, the exterior layer may be
formed to provide a functional characteristic, such as
breathability through a leno weave type technique. As previously
discussed, it is contemplated that a variety of weaving techniques
may be implemented at various location of the article and at
different layers. Stated differently, it is contemplated that a
first layer at a first location may be formed with a first weaving
technique and a second layer at the first location is formed with a
second weaving technique, in an exemplary aspect.
[0138] While the number of FIG. 14 is provided, it is provided to
identify comparable portions to that which was discussed in FIG. 2
hereinabove. Therefore, it is contemplated that additional features
and alternative features are found in FIG. 14 than explicitly
described with respect to FIG. 2.
[0139] FIG. 15 depicts a spectrum of weaving techniques to achieve
a varied modulus of elasticity, in accordance with aspects of the
present invention. The spectrum of stretch is laid out along a
continuum 1502 that extend between a stretch end 1504 and a
non-stretch end 1506. A functional zone may utilize one or more
weaving techniques associated with a varied degree of elasticity
based on the continuum 1502. For example, near the end 1504 when a
stretch functional zone is desired, a satin weave technique may be
implemented. Exemplary satin weave techniques are illustrated in
region 1508 of the continuum 1502. Similarly, when desiring a
medium level of elasticity, weaving techniques (e.g., interlock,
hatching, slit, and leno) may be implemented, as illustrated in a
region 1510. Further, at a lower degree of modulus of elasticity a
plain weave may be implemented, as illustrated in a region 1512.
Finally, nearest the end 150 demonstrating a non-stretch region of
the continuum 1502, a twill weave may be implemented, as depicted
at region 1514. Therefore, a resultant amount of stretch may be
determined based on the continuum 1502, in an exemplary aspect.
[0140] FIG. 16 depicts and exemplary heel region 1600 having a
dimensional zone and a heel counter zone within a woven upper
portion, in accordance with exemplary aspects of the present
invention. In particular, the heel region 1600 is cut in half
forming an un-finished portion 1602 and a finished portion 1604
that are separated by a cutline 1606, The un-finished portion 1602
include a portion 1603 that is to be removed to form the shoe
upper. The portion 1603 has been removed and a finished edge is
formed on the finished portion 1604, as will be discussed in
greater detail hereinafter at FIG. 17.
[0141] The dimensional zone is constructed having a pocket 1610 in
to which dimensional material is inserted. The dimensional material
may be a foam material 1608 that is injected. Similarly depicted is
a heel counter pocket 1614 into which a heel counter material 1612,
such as a polymer-based material, is inserted. As previously
discussed and will be discussed in more detail with respect to FIG.
18, multiple weaving techniques may be implemented for the various
zones, in an exemplary aspect.
[0142] FIG. 17 depicts a cut profile of an ankle collar region
1700, in accordance with aspects of the present invention. The
ankle collar may be formed from a multi-layer woven structure into
which a dimensional material 1705 is inserted. The multi-layer
material may be formed from a first layer 1702 and a second layer
1704. The apex (e.g., top portion) of the ankle collar may be
defined at a position 1710. In an exemplary aspect, an upper is
formed from a larger portion of material such that a portion of the
larger material is removed by cutting, melting, or other
techniques. As a result of the removal of excess material, an edge
may be formed. In an effort to provide a well fitting and good
feeling article of footwear, the edge that is formed may not be
desired to be proximate a skin-contacting region of the shoe.
Therefore, in an exemplary aspect, the edge is positioned away from
a user's potential contact regions. However, in a multi-layer woven
article, when the article is cut, the edge will typically be formed
at the apex 1710, which may be in a skin-contacting region.
Therefore, it is contemplated that a variation in modulus of
elasticity between an outer layer 1704 and an interior layer 1708
may be utilized to shift the edge from the apex 1710 to a position
1706 that is more towards an exterior of the ankle collar than the
apex 1710. This shift in location may be accomplished by utilizing
a weaving technique (or material selection) at the interior layer
1708 that has a greater modulus of elasticity than the outer layer
1704. Consequently, when tension is applied across the interior
layer 1708 and the outer layer 1704, the interior layer 1708
stretches a greater degree than the outer layer 1704. Therefore,
the edge formed when the ankle collar is cut from the greater
portion of material is positioned at 1706 rather than the apex
1710. The insertion of a dimensional material may further
exaggerate the movement of the edge away from the apex 1710 as a
greater load is applied across the outer layer 1704 and the
interior layer 1708.
[0143] In an exemplary aspect, it is contemplated that a portion of
a woven article is treated with a material in a location prior to
cutting at the location to provide a finished edge or an edge that
is more easily finished. For example, it is contemplated that a
silicone or a urethane (or any material that may bond) is applied
to the woven article along a portion that is intended to be an edge
(e.g., where a cut may be made). After curing, the applied material
may be effective for substantially maintaining the wefts and warps
in a desired relative location to one another. Stated differently,
it is contemplated that prior to cutting a portion of a woven
article from the woven article, that a material is applied
proximate the cut location. The applied material helps to keep the
edge from fraying (unraveling). However, as discussed above, this
applied material may form an edge that is not desirable to be in
contact with a wearer's skin. Therefore, as discussed above,
manipulating the location at which the edge ultimately is
positioned (e.g., outwardly from the apex location) using a
variable modulus of elasticity weave between the top layer and the
bottom layer may be desired, in an exemplary aspect.
[0144] FIG. 18 depicts a multi-region woven portion 1800, in
accordance with aspects of the present invention. In a common
weaving operation performed by a jacquard-enabled loom, four unique
regions are formed. For example, a first region 1802, a second
region 1804, a third region 1806, and a fourth region 1808 are
formed. In an exemplary aspect, the woven portion 1800 may be a toe
box region of a substantially planar woven shoe upper. The first
region 1802 may be formed as a reinforcement functional zone that
is resistant to abrasion, such as the leading edge of a toe region.
It is contemplated that the first region 1802 may be formed with a
twill weaving technique that implements a durable filament/fiber.
Consequently, it is contemplated that the first region 1802 has a
relatively low modulus of elasticity.
[0145] The second region 1802 may also be formed with a twill
weaving technique. However, it is contemplated that a variation in
the weaving may be formed between the first region 1802 and the
second region 1804. For example, an alternative twill weaving
technique may be utilized and/or alternative materials may be
utilized between the regions to accomplish varied functional
characteristics. The third region 1806 may utilize a satin weaving
technique to provide a greater degree of elasticity than found in
the first region 1802 or the second region 1804. The third region
1806 is effective to absorb tension forces exerted across the woven
article to allow a breathability region (e.g., region 1808) to
continue to provide an effective transfer of air and moisture
through the woven article. The fourth region 1808 may be formed
utilizing an open-plain weaving technique that is effective to form
a breathability region within the woven article.
[0146] As depicted in FIG. 18, a variety of weaving techniques in a
variety of region formations may be implemented in exemplary
aspects of the present invention. As such, FIG. 18 depicts a
variety of weaving techniques formed in a common/integrated weaving
process that are effective to achieve functional zones/regions
within a woven article of footwear.
[0147] FIG. 19 depicts an exemplary woven article 1900 that
utilizes a jacquard mechanism in combination with a leno weaving
technique, in accordance with aspects of the present invention. As
a result, functional characteristics may be formed in a region,
such as reinforcement and/or dimensional portions 1902 based on a
jacquard mechanism while also implementing breathability regions
1904 based on a leno weaving technique during a common weaving
operation.
[0148] FIG. 20 depicts an exemplary woven article 2000 having leno
twisted wefts 2004 running in the vertical direction and pulled
(spaced in a wave-like formation) warps 2002 running in the
horizontal direction, in accordance with aspects of the present
invention. The combination of a leno twisting technique on the
wefts 2004 in combination with the physical manipulation of the
warps 2002 result in the creation of openings 2006. The opening
2006 may provide a breathability functional zone within a woven
shoe portion.
[0149] FIG. 21 depicts an exemplary woven article 2100 having a
monofilament warp running in the horizontal direction and wefts
running in the vertical direction, in accordance with aspects of
the present invention. The wefts may float in formation over the
warps forming the openings 2102. It is contemplated that the
openings 2102 may be formed in an location at any size and at any
relative position to one another. Further, it is contemplated that
the monofilament may be removed or displaced from the openings
(e.g., melted). For example, a laser or other heat generating
device may selectively terminate the monofilament (or any filament)
within the openings to provide a clear opening through which heat,
moisture, light, and the like may pass.
[0150] While embodiments provided herein refer to a substantially
planar upper, it is understood that features described herein may
be incorporated into articles formed in a non-substantially planar
manner. For example, aspects directed to and including lockout
strands may be implemented in any type of footwear or article,
regardless substantial planarness.
[0151] Although the shoe construction is described above by
referring to particular aspects, it should be understood that the
modifications and variations could be made to the shoe construction
described without departing from the intended scope of protection
provided by the following claims.
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