U.S. patent application number 13/779084 was filed with the patent office on 2014-08-28 for 3 dimensionally woven footwear.
This patent application is currently assigned to UNDER ARMOUR, INC.. The applicant listed for this patent is UNDER ARMOUR, INC.. Invention is credited to Kevin Patrick FALLON.
Application Number | 20140237854 13/779084 |
Document ID | / |
Family ID | 51386670 |
Filed Date | 2014-08-28 |
United States Patent
Application |
20140237854 |
Kind Code |
A1 |
FALLON; Kevin Patrick |
August 28, 2014 |
3 DIMENSIONALLY WOVEN FOOTWEAR
Abstract
A shoe component, wherein the shoe component is formed by
3-dimensional weaving such that the shoe component has one or more
woven layers, each having a warp direction and a fill direction,
wherein the shoe component has one direction of stretch; a shoe
containing at least one of the shoe components in an upper; and a
shoe in which the entire upper, and optionally the midsole and/or
outsole, are entirely formed by 3-dimensional weaving.
Inventors: |
FALLON; Kevin Patrick;
(Baltimore, MD) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
UNDER ARMOUR, INC. |
Baltimore |
MD |
US |
|
|
Assignee: |
UNDER ARMOUR, INC.
Baltimore
MD
|
Family ID: |
51386670 |
Appl. No.: |
13/779084 |
Filed: |
February 27, 2013 |
Current U.S.
Class: |
36/84 |
Current CPC
Class: |
A43B 1/04 20130101; A43B
1/00 20130101; A43B 23/042 20130101; A43B 23/0205 20130101; A43B
23/0245 20130101 |
Class at
Publication: |
36/84 |
International
Class: |
A43B 1/00 20060101
A43B001/00 |
Claims
1. A shoe comprising: an upper; and a sole, wherein at least one
portion of the upper is formed by 3-dimensional weaving, wherein
said at least one portion has one or more woven layers, each having
a warp direction and a fill direction, such that said at least one
portion has one direction of stretch.
2. The shoe of claim 1, wherein said at least one portion of the
upper is at least one member selected from the group consisting of
tongue, quarters, vamps, heel seat, and toe box.
3. The shoe of claim 1, wherein the at least one portion of the
upper formed by 3-dimensional weaving is the entire upper.
4. The shoe of claim 1, wherein the sole comprises a midsole and an
outsole, and the upper and the midsole form a unitary structure
wherein the entire unitary structure is formed by 3-dimensional
weaving.
5. The shoe of any one of claims 1-4, wherein the one direction of
stretch is in a heel-toe direction.
6. The shoe of any one of claims 1-4, wherein the one direction of
stretch is in a medial-lateral direction.
7. The shoe of claim 3, wherein the upper comprises a lace
closure.
8. The shoe of claim 7, wherein the upper is woven from top
down.
9. The shoe of claim 7, wherein the upper is woven laterally.
10. The shoe of claim 3, wherein the shoe is a slip-on
construction.
11. The shoe of claim 10, wherein the upper is woven from top
down.
12. The shoe of claim 10, wherein the upper is woven laterally.
13. The shoe of claim 4, wherein the unitary structure comprises a
lace closure.
14. The shoe of claim 13, wherein the unitary structure is woven
from top down.
15. The shoe of claim 13, wherein the unitary structure is woven
laterally.
16. The shoe of claim 4, wherein the unitary structure is a slip-on
construction.
17. The shoe of claim 16, wherein the unitary structure is woven
from top down.
18. The shoe of claim 16, wherein the unitary structure is woven
laterally.
19. The shoe of claim 4, wherein the unitary structure comprises at
least one 3-dimensionally woven flange externally projecting
laterally from a vicinity of the midsole portion.
20. The shoe of claim 19, wherein the at least one 3-dimensionally
woven flange is a pair of 3-dimensionally woven flanges each
externally projecting laterally from opposite sides of the midsole
portion and having holes arranged therein such that the pair of
flanges can be externally wrapped over a vamp portion and form
lacing structures.
21. The shoe of claim 19, wherein the at least one 3-dimensionally
woven flange is a pair of 3-dimensionally woven flanges each
externally projecting laterally from opposite sides of the midsole
portion and wherein the pair of flanges contain a mechanism by
which the flanges can be detachably connected to one another when
externally wrapped over a vamp portion.
22. The shoe of claim 4, wherein the outsole is a solid piece
formed of a member selected form the group consisting of
thermoplastic rubbers, natural and synthetic rubbers, crepe rubber,
and composite materials; and is affixed to an underside of the
midsole portion of the unitary structure.
23. The shoe of claim 4, wherein the outsole comprises a plurality
of woven portions on an underside of the midsole portion of the
unitary structure, wherein the plurality of woven portions are
formed from at least one member selected from the group consisting
of fuseable yarns, abrasion resistant yarns, cushioning yarns, and
high tenacity yarns.
24. The shoe of claim 23, wherein the plurality of woven portions
forming the outsole are woven into the underside of the midsole
portion of the unitary structure during the 3-dimensional weaving
process of forming the unitary structure.
25. The shoe of claim 4, wherein the midsole portion of the unitary
structure comprises a plurality of 3-dimensionally woven layers
forming a pocket having an opening proximal to one end thereof,
wherein said pocket runs substantially an entire length from toe to
heel and substantially across an entire width of the midsole
portion.
26. The shoe of claim 25, wherein the opening for the pocket is in
an external layer of the plurality of 3-dimensionally woven
layers.
27. The shoe of claim 26, further comprising a support member
inserted in the pocket, such that a wearer of the shoe is provided
with arch support.
28. The shoe of claim 27, wherein the support member is formed so
as to provide cushioning to a wearer's foot.
29. The shoe of claim 25, wherein the opening for the pocket is in
an internal layer of the plurality of 3-dimensionally woven
layers.
30. The shoe of claim 29, further comprising a support member
inserted in the pocket, such that a wearer of the shoe is provided
with arch support.
31. The shoe of claim 29, further comprising an insert member
inserted in the pocket, and providing odor and/or bacteria control
to a wearer of the shoe.
32. The shoe of claim 4, wherein the unitary structure comprises a
plurality of 3-dimensionally woven layers, wherein an internal
layer of the unitary structure comprises one or more yarns selected
from the group consisting of cushioning yarns, antimicrobial yarns,
and wicking yarns.
33. In a conventional shoe construction formed of an upper portion
and a sole portion, the improvement wherein the upper portion is a
one piece upper formed by 3-dimensional weaving, wherein said one
piece upper has one or more woven layers, each having a warp
direction and a fill direction, such that said one piece upper has
one direction of stretch.
34. In the conventional shoe construction of claim 33, wherein the
one direction of stretch is in a heel to toe direction.
35. In the conventional shoe construction of claim 33, wherein the
one direction of stretch is in a medial-lateral direction.
36. A shoe component, wherein the shoe component is formed by
3-dimensional weaving such that the shoe component has one or more
woven layers, each having a warp direction and a fill direction,
wherein the shoe component has one direction of stretch.
37. The shoe component of claim 36, wherein the shoe component is a
member selected from the group consisting of tongue, quarters,
vamps, heel seat, and toe box.
38. The shoe component of claim 36, wherein the shoe component is a
midsole component.
39. The shoe component of claim 38, wherein the midsole component
comprises a plurality of 3-dimensionally woven layers forming a
pocket having an opening proximal to one end thereof, wherein said
pocket runs substantially an entire length from toe to heel and
substantially across an entire width of the midsole component.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is an application filed under 35 U.S.C.
.sctn.111(a) claiming the benefit pursuant to 35 U.S.C.
.sctn.119(e) (1) of the filing date of U.S. Provisional Application
No. 61/616,235 filed on Mar. 27, 2012 pursuant to 35 U.S.C.
.sctn.111(b), which is incorporated herein by reference in its
entirety.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to footwear. In particular,
the invention relates to footwear formed with the use of 3
dimensional weaving methods to form at least a portion of the
footwear, and potentially forming the entire footwear as a unitary
structure.
[0004] 2. Description of the Background
[0005] Shoes are conventionally prepared by a multistep process.
Shoes are typically assembled as they travel through a series of
rooms or departments, each doing a particular segment of the
assembly process. Even with the use of modern machines it can still
take a large number of separate operations to make a pair of
shoes.
[0006] From the material to be used in a shoe, leather, man made,
etc. all the pieces for the upper of the shoe are cut out in the
cutting room. The cutting is done by machines fitted with cutting
dies. This part of the process can generate significant amounts of
waste.
[0007] In the stitching room, the upper parts coming from the
cutting room are sewn together. Most of the refinements to the
upper are finished in the stitching room, finishing edges, applying
perforations, fancy stitching and inserting eyelets to name a few.
The upper must be a finished unit before going to the stock fitting
room.
[0008] In the stock fitting room, the other parts are assembled,
including outsoles, insoles, counters, toe boxes, shanks, heels,
etc. These pieces are attached to the last to form a semi-completed
unit. In the bottoming room, the outsole is attached to the
semi-finished shoe. The shoe is also given finishing touches here,
such as sole edging, trimming, etc. Depending on the type of
construction being used the bottoms are attached by stitching,
cementing or heat-molding.
[0009] In the lasting room, the upper and lining are drawn tightly
over the last and attached to the insole. This is done in separate
operations such as toe lasting, heel seat lasting, etc. This is
done by machines that grip the upper and stretch it over the last.
Proper lasting is critical to proper fit and appearance of the
shoe.
[0010] In the finishing room, the last is pulled from the shoe.
[0011] The outsole is the most basic part of a shoe. The outsole is
a protective layer of material between the foot and the ground.
Outsoles have a wide variety of functional properties such as wear,
flexibility, traction, insulation to mention a few. These
properties vary in accord with the type of footwear. Most shoes use
a "unit sole" which means the sole and heel are combined into one
unit. The unit sole is applied in one operation and reduces the
cost of production. There is no one type of outsole that is
regarded "best" for all footwear.
[0012] A typical bottom unit contains a cushioning element, a
midsole, often made of ethylene-vinyl alcohol (EVA) or polyurethane
(PU) forms, along with structural elements from thermoplastic
polyurethane (TPU), and traction elements most often made from
rubber, PU or TPU. Thermoplastic Rubber (TPR) is the most dominant
type of sole material used today. TPR soles are light-weight,
durable, flexible and slip resistant. TPR soles have very good
esthetics and can be made to look like leather, if desired. TPR
soles are used on casual shoes for men and women, kid's shoes and
light-weight work oxfords. PVC (polyvinylchloride) was, at one
time, a popular sole material, but it has limited esthetics.
Because it is very durable, it is used mainly today in work boot
construction. Rubber compounds, such as neoprene, nitrile and
hypalon are all rubber compounds are used mainly in the
construction of athletic footwear or "sneakers". Again, because of
their durability, these materials can also sometimes be found on
work boots. Crepe is a member of the rubber family and can be
either natural or man made. It is heavy, loses color and can be hot
in warm weather. Its use is limited to some sport and casual shoes.
Composite materials are also used for shoe soles. Composite
materials can be any mix of materials used to create slab soles
that are inexpensive but long wearing. They are used mainly on
inexpensive footwear. Sometimes they can be made to resemble
leather in appearance.
[0013] There are many ways to attach the sole to the upper but only
a few methods are typically used in mass production. Remarkable as
it may seem the manufacture of shoes remains fairly labor
intensive. No matter the type of construction the first stage in
construction is to attach the insole to the under surface of the
last. Two main operations follow: Lasting describes when the upper
sections are shaped to the last and insole. Followed by Bottoming,
where the sole is attached to the upper. The process of bottoming
will determine price, quality and performance of the shoe.
[0014] In molded methods, the lasted upper is placed in a mold and
the sole is directly molded to the bottom of a lasted upper instead
of being glued.
[0015] Force Lasting (also known as Strobel-stitched method or sew
in sock) has evolved from sport shoes but is increasingly used in
other footwear. The Strobel-stitched method (or sew in sock)
describes one of many force lasting techniques. The upper is sewn
directly to a sock by means of an overlooking machine (Strobel
stitcher). The upper is then pulled (force lasted) onto a last or
molding foot. Unit soles with raised walls or moulded soles are
attached to completely cover the seam. This technique is sometimes
known as the Californian process or slip lasting.
[0016] With regard to athletic footwear in particular,
state-of-the-art in athletic footwear making currently consists of
an upper that is cemented to a midsole and outsole to create a
finished product. Uppers are typically cut from multiple flat goods
(such as leather, mesh and synthetic materials) which are then
stitched or otherwise bonded together. There can be anywhere from 5
to 30 different materials used in a single upper, all of which are
required to somehow be attached to one another using multi-step
processes. Once the completed upper is assembled, it is somehow
formed into a 3-D shape, typically by a board or strobel lasting
process which pulls the material around a foot-form. After lasting,
the uppers then have a midsole cushioning element(s) cemented to
the bottom. Midsoles sometimes have structural elements molded or
cemented to them, including injection molded plastic or composite
structures. Rubber is the typical material bonded to the bottom of
a midsole to give the product abrasion and traction properties.
[0017] The main problem with this state of the art process is there
are still 50 to 70 pairs of hands that touch each shoe on its way
down the assembly line. Many of these are handling the processes of
stitching the upper, since each individual piece (even hidden
pieces like foams, linings and reinforcers) requires one person to
cut it out, another to treat it (skiving the edges, for instance),
and another to stitch it. So this requires huge coordination with
supply chain to have all materials in correct quantities and colors
at the factory at the correct time. It also means that through all
those hand-processes, there is opportunity for error and
inconsistencies. There is also a large amount of waste when it
comes to die-cutting out so many different materials. And finally,
the process of forming multiple layers of flat materials into a 3-D
shape is not always effective. The resulting uppers can be stiff,
not breathable and not stretchy or otherwise conforming to the
foot.
[0018] Accordingly, a shoe construction is needed in which the
components of the shoe, and ideally the entire upper or even a
unitary structure containing the upper and a midsole/outsole, can
be produced in a single process step, thus reducing costs of
production. Additionally, with athletic shoes in particular, it is
desirable to have a shoe that will stretch and recover, while
maintaining light weight and flexibility. Finally, a shoe design in
which the function of the shoe can be adjusted by the changing of
yarns, creating layers, and adjusting weave techniques in a single
process is desired.
SUMMARY OF THE INVENTION
[0019] Accordingly, one object of the present invention is to
provide a shoe component having built in stretch and recovery
properties.
[0020] A further object of the present invention is to provide a
shoe construction in which at least the upper is prepared in a
single process, and has one direction stretch and recovery
properties, while maintaining support and integrity of the
upper.
[0021] Another object of the present invention is to provide a shoe
in which the upper and at least the midsole form a unitary
structure which is made in a single process, and has stretch and
recovery properties while maintaining support and integrity of the
upper.
[0022] These and other objects of the present invention, either
individually or in combinations, have been satisfied by the
discovery of a shoe comprising:
[0023] an upper; and
[0024] a sole,
[0025] wherein at least one portion of the upper is formed by
3-dimensional weaving, wherein said at least one portion has one or
more woven layers, each having a warp direction and a fill
direction, such that said at least one portion has one direction of
stretch.
BRIEF DESCRIPTION OF THE DRAWINGS
[0026] A more complete appreciation of the invention and many of
the attendant advantages thereof will be readily obtained as the
same becomes better understood by reference to the following
detailed description when considered in connection with the
accompanying drawings, wherein:
[0027] FIG. 1 is a side view of one embodiment of a lace-up
configuration shoe of the present invention formed with the warp
yarns in the 3-dimensional weaving running in a medial-lateral
direction.
[0028] FIG. 2 is a side view of one embodiment of a lace-up
configuration shoe of the present invention formed with the warp
yarns in the 3-dimensional weaving running in a heel-to-toe
direction.
[0029] FIG. 3 is a further view of an embodiment of the lace-up
configuration shoe of FIG. 1 from a different perspective.
[0030] FIG. 4 is an exploded view of a lace-up shoe construction of
the present invention showing the upper 20, midsole 30, joining
with the outsole 40, and having inserted therein a cushioning or
support insert 50.
[0031] FIG. 5 is an exploded view of a lace-up shoe construction of
the present invention showing the upper 20, midsole 30, and outsole
40, wherein the midsole 30 is a separate structure from the upper
20.
[0032] FIG. 6 is a side view of one embodiment of a slip-on
configuration shoe of the present invention formed with the warp
yarns in the 3-dimensional weaving running in the medial-lateral
direction.
[0033] FIG. 7 is a side view of one embodiment of a slip-on
configuration shoe of the present invention formed with the warp
yarns in the 3-dimensional weaving running in a heel-to-toe
direction.
[0034] FIG. 8 is a further view of an embodiment of the slip-on
configuration shoe of FIG. 6 from a different perspective.
[0035] FIG. 9 is a side view of another embodiment of a slip-on
configuration shoe of the present invention formed with the warp
yarns in the 3-dimensional weaving running in a third
direction.
[0036] FIG. 10 is an exploded view of a slip-on shoe construction
of the present invention showing the upper 20, midsole 30, joining
with the outsole 40, and having inserted therein a cushioning or
support insert 50.
[0037] FIG. 11 is an exploded view of a slip-on shoe construction
of the present invention showing the upper 20, midsole 30, and
outsole 40, wherein the midsole 30 is a separate structure from the
upper 20.
[0038] FIG. 12 is a top view of one embodiment of a slip-on
configuration shoe of the present invention formed with the warp
yarns in the 3-dimensional weaving running in the medial-lateral
direction.
[0039] FIG. 13 is a top view of one embodiment of a slip-on
configuration shoe of the present invention formed with the warp
yarns in the 3-dimensional weaving running in a heel-to-toe
direction.
[0040] FIG. 14 shows one embodiment of a slip-on configuration shoe
of the present invention in which the midsole portion 30 of the
unitary structure 10 has a pocket built therein, having an opening
32 into which a support element 50 or other element can be
placed.
[0041] FIG. 15 is a top view of one embodiment of a lace-up
configuration shoe of the present invention formed with the warp
yarns in the 3-dimensional weaving running in the medial-lateral
direction.
[0042] FIG. 16 is a top view of one embodiment of a lace-up
configuration shoe of the present invention formed with the warp
yarns in the 3-dimensional weaving running in a heel-to-toe
direction.
[0043] FIG. 17 shows one embodiment of a lace-up configuration shoe
of the present invention in which the midsole portion 30 of the
unitary structure 10 has a pocket built therein, having an opening
32 into which a support element 50 or other element can be
placed.
[0044] FIG. 18 shows various shoe components of the present
invention formed by 3-dimensional weaving having the warp yarns
running in the direction shown.
[0045] FIG. 19 is a top view of one embodiment of a slip-on
configuration shoe of the present invention formed with the warp
yarns in the 3-dimensional weaving running in the medial lateral
direction, and showing a functional flange member 22 extending from
one side.
[0046] FIG. 20 shows an embodiment of a shoe of the present
invention wherein a functional flange 22 having lace holes 24
extends from the side of the shoe construction, and can be moved
into place as indicated by the arrow to provide a lace-up
configuration in conjunction with a similarly placed flange (not
shown) on the other side of the shoe.
[0047] FIG. 21 shows an embodiment of a lace-up configuration shoe
of the present invention having a functional (or decorative) flange
22 that can be moved into place as indicated by the arrow, and
affixed to either the upper of the shoe or to a second functional
(or decorative) flange (not shown) on the other side of the
shoe.
[0048] FIG. 22 is an exploded view of a tongue-less lace-up shoe
construction of the present invention showing the upper 20, midsole
30, and outsole 40, wherein the midsole 30 is a separate structure
from the upper 20.
[0049] FIG. 23 shows another view of a tongue-less lace-up shoe
construction of the present invention.
[0050] FIG. 24 shows a further embodiment of a slip-on shoe
construction of the present invention.
[0051] FIG. 25 is a cross-section view of a shoe construction of
the present invention wherein the unitary structure 10 has an upper
portion 20 and a midsole portion 30, and has a pair of functional
flanges 22 on the sides which can be moved into place over the
upper as indicated by the arrows.
[0052] FIG. 26 is a cross-section view of a shoe construction of
the invention shown in FIG. 25 wherein the functional flanges 22
are rotated towards an upper portion of the shoe; and
[0053] FIG. 27 is a cross-section view of a shoe construction of
the present invention including functional flanges 22 rotated
towards an upper portion of the shoe and additional flanges 26
located between functional flanges 22 and the midsole portion
30.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0054] The present invention relates to a shoe component formed by
3-dimensional weaving, a shoe incorporating at least one
3-dimensionally woven shoe component, a shoe upper formed entirely
from 3-dimensional weaving, a unitary structure comprising an upper
and a midsole where the entire unitary structure is formed by
3-dimensional weaving, and a shoe comprising the unitary structure,
as well as a shoe formed entirely by 3-dimensional weaving,
including upper and entire sole.
[0055] Central to the present invention is the technique of
3-dimensional weaving. 3-dimensional weaving is a technique for
creating a textile product by utilizing a three dimensional
Cartesian coordinate system as the infrastructure for weaving
simultaneous independent fabric layers in conjunction with weaving
connectors between and among the layers. The 3-dimensional weaving
technique is described in detail in U.S. Pat. Nos. 7,836,917 and
7,836,918, the entire contents of each of which are hereby
incorporated by reference. This technique is used to form fabrics
having a plurality of woven layers, into which can be directly
woven various openings, pockets, and textures. The 3-dimensional
weaving technique also provides a process for imparting a variety
of properties to the resulting fabric, including different modulus,
stretch and recovery characteristics.
[0056] The term "fiber" as used herein refers to a fundamental
component used in the assembly of yarns and fabrics. Generally, a
fiber is a component which has a length dimension which is much
greater than its diameter or width. This term includes ribbon,
strip, staple, and other forms of chopped, cut or discontinuous
fiber and the like having a regular or irregular cross section.
"Fiber" also includes a plurality of any one of the above or a
combination of the above.
[0057] As used herein, the term "high tenacity fiber" means that
class of synthetic or natural non-glass fibers having high values
of tenacity greater than 10 g/denier, such that they lend
themselves for applications where high abrasion resistance is
important. Typically, high performance fibers have a very high
degree of molecular orientation and crystallinity in the final
fiber structure.
[0058] The term "filament" as used herein refers to a fiber of
indefinite or extreme length such as found naturally in silk. This
term also refers to manufactured fibers produced by, among other
things, extrusion processes. Individual filaments making up a fiber
may have any one of a variety of cross sections to include round,
serrated or crenular, bean-shaped or others.
[0059] The term "yarn" as used herein refers to a continuous strand
of textile fibers, filaments or material in a form suitable for
weaving, or otherwise intertwining to form a textile fabric. Yarn
can occur in a variety of forms to include a spun yarn containing
staple fibers usually bound together by twist; a multi filament
yarn containing many continuous filaments or strands; or a mono
filament yarn which consists of a single strand.
[0060] The term "composite yarn" refers to a yarn prepared from two
or more yarns (or "ends"), which can be the same or different.
Composite yarn can occur in a variety of forms wherein the two or
more ends are in differing orientations relative to one another, so
long as the final composite yarn containing the two or more ends is
stably assembled (i.e. will remain intact unless forcibly separated
or disassembled). The two or more ends can, for example, be
parallel, wrapped one around the other(s), twisted together, or
combinations of any or all of these, as well as other orientations,
depending on the properties of the composite yarn desired.
[0061] In using the 3-dimensional weaving technique in the present
invention, the warp yarns can be any desired yarn having low levels
of stretch, preferably less than 5% stretch, more preferably less
than 3% stretch. The yarn can be a natural or synthetic yarn, and
can be of any desired denier based upon the desired overall weight
of the shoe component being made. Preferred deniers are from 10 to
400 denier, more preferably from 50 to 200 denier. The warp yarn
can also be a composite yarn if desired, such as a core-sheath
construction wherein a sheath yarn is wrapped around a core yarn.
Again, the core and sheath of such constructions can be any natural
or synthetic yarn, so long as the composite has the overall low
levels of stretch desired.
[0062] The warp yarns are preferably a high tenacity fiber.
Preferably the high tenacity fiber comprises a high molecular
weight polyolefin, preferably high molecular weight polyethylene or
high molecular weight polypropylene, an aramid, a high molecular
weight polyvinyl alcohol, a high molecular weight
polyacrylonitrile, liquid crystal polyesters or mixtures or
copolymers thereof.
[0063] The fill yarns can likewise be made from any natural or
synthetic yarns, and similarly have any desired denier based upon
the desired overall weight of the shoe component being made. Such
natural or synthetic fibers include, but are not limited to,
cotton, wool, nylon, polyester, rayon, cellulose acetate, etc. The
fill yarns preferably have deniers in the 10 to 400 denier range,
more preferably from 50 to 200 denier. The fill yarn preferably has
a higher level of stretch than the warp yarns, and more preferably
is an elastomeric yarn having high stretch and recovery
properties.
[0064] As the elastomeric yarn component, any elastomeric fiber may
be used, as monofilament or multifilament yarn. Additionally, two
or more elastomeric fibers can be combined in the core of a
composite yarn, or used as a blend, twisted, in parallel, or
air-tacked, etc. An elastomer is a natural or synthetic polymer
that, at room temperature, can be stretched and expanded to
typically twice its original length. After removal of the tensile
load it will immediately return to its original length. Along with
spandex, rubber and anidex (no longer produced in the United
States) are considered elastomeric fibers. Spun from a block
copolymer, spandex fibers exploit the high crystallinity and
hardness of polyurethane segments, yet remain "rubbery" due to
alternating segments of polyethylene glycol. Suitable elastomeric
fibers include, but are not limited to, fibers made from copolymers
having both rigid and flexible segments in the polymer chains, such
as, for example, block copolymers of polyurethane and polyethylene
glycol. Particularly suitable elastomeric fibers include, but are
not limited to, Spandex, such as LYCRA (produced by United Yarn
Products), ELASPAN (produced by Invista), DORLASTAN (produced by
Bayer), CLEAR SPAN (produced by Radici) and LINEL (produced by
Fillattice).
[0065] Elastomeric yarns typically have one or more of the
following materials properties: can be stretched over 500% without
breaking; able to be stretched repetitively and still recover
original length; lightweight; abrasion resistant; poor strength,
but stronger and more durable than rubber; soft, smooth, and
supple; resistant to body oils, perspiration, lotions, and
detergents; no static or pilling problem; very comfortable; and
easily dyed.
[0066] The elastomeric yarn can be any desired denier, preferably
from 10 to 400, more preferably from 15 to 350, most preferably
from 50 to 200. The elastomeric yarn can be used alone or combined
with one or more other yarns of any desired type, natural or
synthetic, so long as the combination retains its elastomeric
properties. If combined with one or more other yarns, the
elastomeric yarn and other yarns are preferably blended, or the one
or more other yarns are wrapped around the elastomeric yarn to
provide an elastomeric core composite yarn, thus retaining the
stretch property.
[0067] Elastomeric yarn containing composite yarns are further
described in U.S. Pat. Nos. 5,568,657 and 5,442,815, the contents
of which are incorporated herein by reference. Elastomeric yarn
containing composite yarns having wicking properties are described
in U.S. Provisional Application Ser. No. 61/020,790, filed Jan. 14,
2008, the contents of which are hereby incorporated by
reference.
[0068] The present invention uses this 3-dimensional weaving
process to generate shoe components, and in a preferred embodiment
to generate an entire shoe upper/midsole unitary structure, which
can be affixed to an outsole for providing a traction element or
cushioning element, or can have a plurality of traction elements
and/or cushioning elements affixed thereto on the exterior layer of
the midsole portion. In a particularly preferred embodiment, the
traction elements and/or cushioning elements are directly formed
during the 3-dimensional weaving process by the use of yarns that
provide traction properties to form at least a portion of the
exterior layer of the midsole portion of the unitary structure.
Such yarns for providing traction or cushioning properties include
fuseable yarns, abrasion yarns, cushioning yarns, and high tenacity
yarns.
[0069] In providing a cushioning effect to the lower midsole
portion of the unitary structure of a preferred embodiment of the
present invention, it is also preferred to weave in during the
3-dimensional weaving process various types of yarns and
structures, such as pile yarns, air mesh constructions, hollow
fibers, etc.
[0070] In the products of the present invention, the 3-dimensional
weaving process is preferably performed using a rigid warp yarn
with an elastomeric fill yarn. By using a plurality of successive
fabric forming operations, resulting in incremental stretch
capacity from each successive operation, the resulting multilayer
3-dimensionally woven fabric is provided with unidirectional
stretch. The multilayer 3-dimensionally woven fabric exhibits high
stretch/recovery properties in the fill direction (due to the
elastomeric yarns used therein) and rigid or extremely low stretch
properties in the warp direction.
[0071] This unidirectional stretch property can be used quite
effectively in the construction of shoes. Various components of the
shoe can be individually formed using the 3-dimensional weaving
technique in order to provide varied levels and directions of
stretch as needed. The unidirectional nature of the stretch in each
component can provide a unique combination of stretch and rigidity
that is highly beneficial in providing comfort and support in a
shoe construction. The components of the shoe can be any portion of
the shoe construction as desired, and are preferably selected from
the group consisting of the tongue, quarters, vamp, heel seat, and
toe box.
[0072] In a preferred embodiment of the present invention, a
unitary structure in the general shape of a foot covering is formed
by 3-dimensional weaving, such that the unitary structure contains
a top portion that is a shoe upper, and a bottom portion
corresponding to a shoe midsole (or even a full sole in some
alternative embodiments). In the preparation of such a unitary
structure, a flange can be preferably formed at the intersection of
the upper and midsole portions. This flange is typically formed on
an exterior surface of the unitary structure. The unitary structure
can be turned inside-out to result in the flange being present on
an interior surface if desired. Alternatively, the flange can be
formed in such a manner as to externally protrude laterally and can
be formed as a pair of flanges, one on each side of the unitary
structure in a shape and size sufficient to externally wrap over
the vamp portion of the shoe and connect one to another. In a
preferred embodiment, the pair of flanges can be configured to have
lacing holes and thus provide the capability to lace up the shoe on
the foot, or can be configured to have another form of attachment,
such as hook-and-loop (or "VELCRO") type closures.
[0073] The unitary structure of a preferred embodiment of the
present invention can be formed by weaving from top down or
laterally. Additionally, in either top down or lateral weaving of
the unitary structure, the warp direction can run in a heel to toe
direction or in a medial-lateral direction. When the warp direction
runs in a heel to toe direction, the resulting 3-dimensionally
woven fabric has stretch in a medial-lateral direction. When the
warp direction runs in a medial-lateral direction, the resulting
3-dimensionally woven fabric has stretch in a heel-to-toe
direction.
[0074] The above noted cushioning elements can also be provided by
insertion of a cushioning insert into a pocket formed in the
midsole portion of the structure of the present invention. The
pocket can have an opening to either the interior of the structure
or to the exterior of the structure. In a further embodiment, this
pocket can be used to house a support element which provides arch
support for the wearer.
[0075] The shoe construction of the present can take on any typical
shoe form, and is preferably a slip-on construction or lace-up
construction. For a slip on construction, it is preferred to have
at least a portion around the opening into which the wearer's foot
enters the shoe to be made of the 3-dimensionally woven fabric in
order to provide a more form fitting shoe. For the lace-up
construction, the upper further preferably comprises a tongue
portion. In the lace-up construction the tongue can be separately
formed, or can be formed as a portion of the upper during the
3-dimensional weaving process.
[0076] One feature provided by the 3-dimensional weaving process is
the ability to form pockets or compartments within and between the
plurality of layers of the 3-dimensionally woven fabric. These
pockets or compartments can be used as locations for inserts to
provide various functions, such as antimicrobial inserts, charcoal
or other odor reducing inserts, structural inserts, or as noted
above support inserts.
[0077] In a particularly preferred embodiment of the present
invention, the shoe of the present invention comprises an upper and
midsole unitary structure formed by 3-dimensional weaving using
yarns for both warp and fill of sufficiently low denier to provide
a total shoe weight of from 5-10 ounces, most preferably from 6-8
ounces, including the weight of the lightweight outsole.
[0078] In a further preferred embodiment, the exterior layer of the
midsole portion of the unitary structure of the present invention
is formed from low melting (fuseable) yarns which permit the
midsole portion to be affixed to the outsole upon application of
sufficient heat to melt/fuse the low melting yarns, thus adhering
the unitary structure to the outsole.
[0079] Referring now to the drawings, wherein like reference
numerals designate identical or corresponding parts throughout the
several views.
[0080] FIG. 1 depicts a side view of an embodiment of the present
invention. In the embodiment shown in FIG. 1, the warp direction of
the weaving of footwear structure 10 is shown by lines 12. In this
regard, footwear structure 10 is formed with the warp yarns in the
3-dimensional weaving running in the medial-lateral direction.
Footwear structure 10 includes upper 20, midsole 30, and outsole
40. Upper 20 includes tongue 28 woven integrally with upper 20.
Upper 20 also includes apertures 27 for receiving shoelaces for
securing the footwear structure to the foot of a person.
[0081] FIG. 2 depicts a side view of another embodiment of the
present invention. Footwear structure 10 of FIG. 2 includes the
same components as footwear structure of FIG. 1, however the warp
direction 12 in FIG. 2 is orthogonal to the warp direction 12 in
FIG. 1. In particular, footwear structure 10 in FIG. 2 is formed
with the warp yarns in the 3-dimensional weaving running in the
heel-to-toe direction.
[0082] FIG. 3 shows a perspective view of footwear structure 10.
This footwear structure could have a warp direction as shown in
either of FIG. 1 or 2. FIG. 3 also shows the flexibility of tongue
28. As indicated by the arrow in FIG. 3, tongue 28 can be moved in
a medial-lateral direction with respect to footwear structure
10.
[0083] FIG. 4 shows a cushioning or support insert 50 being
inserted into footwear structure 10. In addition, FIG. 4 also shows
outsole 40 being connected to midsole 30 of footwear structure 10.
In this embodiment, outsole 40 is separately formed from the
integrally woven upper 20 and midsole 30. The separately formed
outsole 40 is then attached to midsole 30.
[0084] FIG. 5 shows an additional embodiment in which both midsole
30 and outsole 40 are separately formed from integrally woven upper
20. Both midsole 30 and outsole 40 are then later attached to upper
20.
[0085] FIG. 6 illustrates a side view of one embodiment of a
slip-on configuration shoe of the present invention. This
embodiment is similar to that shown in FIG. 1, but does not include
the apertures 27 and tongue 28 shown in FIG. 1. In a similar manner
as FIG. 1, footwear structure 10 is formed with the warp yarns in
the 3-dimensional weaving running in the medial-lateral
direction.
[0086] FIG. 7 illustrates a side view of one embodiment of a
slip-on configuration shoe of the present invention. This
embodiment is similar to that shown in FIG. 2, but does not include
the apertures 27 and tongue 28 shown in FIG. 2. In a similar manner
as FIG. 2, footwear structure 10 is formed with the warp yarns in
the 3-dimensional weaving running in the heel-to-toe direction.
[0087] FIG. 8 illustrates a side view of another embodiment of a
slip-on configuration shoe of the present invention. This
embodiment is similar to that shown in FIG. 1, but this footwear
structure 10 is formed with the warp yarns in the 3-dimensional
weaving running in a direction oblique to both the medial-lateral
direction and the heel-to-toe direction. In this regard, the
present invention includes footwear structures with the orientation
of the upper in any possible angle relative to the warp.
[0088] FIG. 9 shows a perspective view of a slip on footwear
structure 10. This footwear structure could have a warp direction
as shown in either of FIG. 6 or 7.
[0089] FIG. 10 shows a cushioning or support insert 50 being
inserted into the slip on footwear structure 10. In addition, FIG.
9 also shows outsole 40 being connected to midsole 30 of slip on
footwear structure 10. In this embodiment, outsole 40 is separately
formed from the integrally woven upper 20 and midsole 30. The
separately formed outsole 40 is then attached to midsole 30.
[0090] FIG. 11 shows an additional embodiment in which both midsole
30 and outsole 40 are separately formed from integrally woven upper
20. Both midsole 30 and outsole 40 are then later attached to upper
20.
[0091] FIG. 12 illustrates a top view of one embodiment of a
slip-on footwear structure 10 formed with the warp yarns in the
3-dimensional weaving running in the medial-lateral direction.
[0092] FIG. 13 illustrates a top view of one embodiment of a
slip-on footwear structure 10 formed with the warp yarns in the
3-dimensional weaving running in the heel-to-toe direction.
[0093] FIG. 14 illustrates an embodiment of a slip on footwear
structure 10 which includes an opening 32 in midsole 30. Opening 32
allows support insert 50 to be inserted inside of footwear
structure 10. Outsole 40 can then be attached to midsole 30, which
seals opening 32.
[0094] FIG. 15 is a top view of embodiment of a least a
configuration of footwear structure 10 in which the warp yarns in
the 3-dimensional weaving running in the medial-lateral direction.
One example of such an embodiment is shown in FIG. 1.
[0095] FIG. 16 is a top view of embodiment of a lace up
configuration of footwear structure 10 in which the warp yarns in
the 3-dimensional weaving running in the heel-to-toe direction. One
example of such an embodiment is shown in FIG. 2.
[0096] FIG. 17 illustrates an embodiment of a lace up configuration
of footwear structure 10 which includes an opening 32 in midsole
30. Opening 32 allows support insert 50 to be inserted inside of
footwear structure 10. Outsole 40 can then be attached to midsole
30, which seals opening 32.
[0097] FIG. 18 shows various shoe components of the present
invention formed by 3-dimensional weaving having the warp yarns
running in direction 12.
[0098] FIG. 19 illustrates a top view of one embodiment of a
slip-on configuration of footwear structure 10 formed with the warp
yarns in the 3-dimensional weaving running in the medial-lateral
direction and including a functional flange member 22 extending
from one side.
[0099] FIG. 20 illustrates a perspective view of a lace up
configuration of footwear structure 10 including a functional
flange member 22 extending from one side. Functional flange member
22 includes apertures 27 for receiving shoelaces.
[0100] FIG. 21 depicts an embodiment of a lace-up configuration
shoe of the present invention having a functional (or decorative)
flange 22 that can be moved into place as indicated by the arrow.
Functional flange 22 can then be affixed to either the upper 20 or
to a second functional (or decorative) flange (not shown) on the
other side of the shoe. As noted above, the flanges 22 of the
present invention may be functional or decorative flanges. In
particular, functional flanges may be part of the lacing system
and/or may be used in securing the sole.
[0101] FIG. 22 is an exploded view of a tongue-less lace-up shoe
construction of footwear structure 10 showing the upper 20, midsole
30, and outsole 40. The midsole 30 is a separate structure from the
upper 20, as is the outsole 40. Midsole 30 and outsole 40 are
affixed to upper 20 after integrally weaving upper 20.
[0102] FIG. 23 shows another view of a tongue-less lace-up shoe
construction of the present invention.
[0103] FIG. 24 shows a further embodiment of a slip-on shoe
construction of the present invention.
[0104] FIG. 25 is a cross-section view of footwear structure 10
having an upper portion 20 and a midsole portion 30. Footwear
structure 10 also includes a pair of functional flanges 22 on the
sides which can be moved into place over the upper as indicated by
the arrows.
[0105] FIG. 26 shows the functional flanges 22 after they are
rotated towards an upper portion of the shoe.
[0106] FIG. 27 is a cross-section view of footwear structure 10
including functional flanges 22 rotated towards an upper portion of
the shoe and additional flanges 26 located between functional
flanges 22 and the midsole portion 30. The present invention allows
weaving of specific characteristics of the shoe (such as stretch,
non-stretch, sweat-wicking, etc) where desired in a single unified
upper. No (or very few) sewing or bonding processes are needed to
create the upper. The programming of the type of weave, along with
the choice of yarns, allows for simple changes to characteristics
within the upper for different types of shoes, sizes and colors.
Finally, there is no waste from cutting out dozens of materials,
rather only the waste from cutting out the entire upper. Thus, the
present invention provides both a process and performance
enhancement.
[0107] The present invention also allows for a certain amount of
shaping of the upper even before lasting, meaning the overall shape
of a woven upper should be a 3-D shape rather than a flat one. This
allows the upper to conform to the foot much better, and require
less (perhaps none) forcing of 2-D materials around a 3-D last.
This enhances the fit and performance of the end product, not only
by shaping it in 3-D and minimizing layers, but also because the
precision and consistency of the upper (with no human hands
touching it as it goes down a stitching line) will be vastly
improved.
[0108] Additional embodiments include weaving in the cushioning and
traction elements that are currently cemented to the upper, thereby
eliminating even more waste and processes.
[0109] Obviously, numerous modifications and variations of the
present invention are possible in light of the above teachings. It
is therefore to be understood that within the scope of the appended
claims, the invention may be practiced otherwise than as
specifically described herein.
* * * * *