U.S. patent application number 14/458712 was filed with the patent office on 2015-02-19 for performance footwear.
The applicant listed for this patent is Under Armour, Inc.. Invention is credited to David Dombrow, Kevin Fallon.
Application Number | 20150047227 14/458712 |
Document ID | / |
Family ID | 52465760 |
Filed Date | 2015-02-19 |
United States Patent
Application |
20150047227 |
Kind Code |
A1 |
Fallon; Kevin ; et
al. |
February 19, 2015 |
PERFORMANCE FOOTWEAR
Abstract
The present invention is directed toward footwear including an
upper connected to a sole structure. The upper includes two
portions formed via compression molding in which textile layers are
compressed to form a fabric laminate. One of the upper portions
generally defines a seamless heel cup. The other upper portion
generally defines a toe cage. The toe cage includes one or more
integrated toe guides operable to position a toe of a wearer in a
predetermined position within the cavity.
Inventors: |
Fallon; Kevin; (Portland,
OR) ; Dombrow; David; (Baltimore, MD) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Under Armour, Inc. |
Baltimore |
MD |
US |
|
|
Family ID: |
52465760 |
Appl. No.: |
14/458712 |
Filed: |
August 13, 2014 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61865384 |
Aug 13, 2013 |
|
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|
Current U.S.
Class: |
36/88 |
Current CPC
Class: |
A43B 23/17 20130101;
A43B 7/26 20130101; A43B 23/0295 20130101; A43B 23/0235 20130101;
A43B 23/026 20130101; A43B 23/087 20130101; A43B 23/0215
20130101 |
Class at
Publication: |
36/88 |
International
Class: |
A43B 7/26 20060101
A43B007/26; A43B 5/00 20060101 A43B005/00 |
Claims
1. An article of footwear comprising: a sole structure; and an
upper secured to the sole structure, wherein the article of
footwear includes a hindfoot section, a midfoot section, and a
forefoot section, the sections cooperating to define a cavity
operable to receive a foot of a wearer, and wherein the article of
footwear comprises a single compartment toe cage operable to house
all toes of the foot, the toe cage including a toe guide extending
into the cavity, the toe guide operable to orient a toe of the foot
in a predetermined position relative to at least one of the upper
and an adjacent toe.
2. The article of footwear of claim 1, wherein the upper comprises
a planum portion including a seamless heel cup and a dorsum portion
including a toe cap disposed above the toes of the foot.
3. The article of footwear of claim 2, wherein the toe cap includes
the toe guide operable to position the toe within the footwear.
4. The article of footwear of claim 3, wherein the toe guide
comprises a truncated wall extending downward from the toe cap.
5. The article of footwear of claim 1, wherein the upper comprises
a laminate comprising an interior layer facing the cavity, an
exterior layer forming an exterior of the shoe, and an intermediate
layer disposed between interior and exterior layers.
6. The article of footwear of claim 5, wherein at least one of the
interior layer and the exterior layer comprises fabric.
7. The article of footwear of claim 1, wherein the upper comprises
a planum portion including a seamless heel cup and a dorsum portion
including a seamless toe cap, the toe cap being disposed above the
toes of the foot.
8. The article of footwear of claim 7, wherein: the toe cap
comprises an undulating surface defined by a plurality of raised
areas and recesses; and the toes of the foot align with the raised
areas of the toe cap.
9. The article of footwear of claim 1, wherein the toe guide is
formed into the upper via compression molding.
10. The article of footwear of claim 1, wherein the toe guide is
effective to deflect and receives the hallux, thereby separating it
from the second toe.
11. An article of footwear comprising: a sole structure; and an
upper secured to the sole structure, the upper comprising: a planum
section including a seamless heel cup, and a dorsum section
including a toe cap, wherein the planum section is connected to the
dorsum section, the planum and dorsum sections cooperating to
define a cavity operable to receive a foot of a wearer.
12. The article of footwear of claim 11, wherein at least one of
the planum section and the dorsum section comprises a laminate
including an interior layer facing the cavity, an exterior layer
forming an exterior of the shoe, and an intermediate layer disposed
between interior and exterior layers.
13. The article of footwear of claim 12, wherein at least one of
the interior layer and the exterior layer comprises fabric.
14. The article of footwear of claim 12, wherein: the interior
layer comprises a synthetic fabric including an elastic fiber; the
intermediate layer comprises foam; and the exterior layer comprises
a synthetic fabric including an elastic fiber.
15. The article of footwear of claim 14, wherein the laminate is
capable of being formed into a three-dimensional shape via
compression molding.
16. The article of footwear of claim 11, wherein the toe cap is
seamless.
17. The article of footwear of claim 11, wherein: the sole
structure includes a first, upper-facing surface and a second,
ground-facing surface; and the second surface of the sole structure
further comprises a generally transverse groove, the groove
defining a flection line of the sole structure.
18. The article of footwear of claim 11, wherein: the toe cap
cooperates with the planum portion to form a toe cage; and the toe
cap is a molded structure including a generally horizontal toe
cover portion bordered by rim extending toward the sole
structure.
19. An article of footwear comprising: a sole structure; an upper
coupled to the sole structure; a toe cage operable to house a
plurality of toes; and a partition extending into the cavity, the
partition operable to orient a toe of the plurality of toes in a
predetermined position.
20. The article of footwear of claim 19, wherein: the toe cage
defines a ceiling; and the partition extends distally from the
ceiling toward the sole structure such that a gap exists between a
distal end of the partition and sole structure.
21. The article of footwear of claim 19, wherein: the upper defines
a toe cage having a ceiling and a floor; and the partition extends
distally from the ceiling toward the floor such that a gap exists
between a distal end of the partition and floor of the toe
cage.
22. The article of footwear of claim 21, wherein the upper further
includes a seamless heel cup.
23. The article of footwear of claim 19, wherein the article of
footwear includes a hindfoot section, a midfoot section, and a
forefoot section, the sections cooperating to define a cavity
operable to receive a foot of a wearer.
24. The article of footwear of claim 19, wherein the partition is
truncated.
25. The article of footwear of claim 19, wherein the partition is
defined by a curved recess molded into the toe cage.
26. The article of footwear of claim 19 further including a raised
area formed into the upper, the raised area being operable to
receive a single toe.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] The present application claims priority to provisional
application No. 61/865,384, filed 13 Aug. 2013 and entitled
"Performance Footwear," the disclosure of which is hereby
incorporated by reference in its entirety.
FIELD OF THE INVENTION
[0002] The present invention is directed toward an article of
footwear and, in particular, to a running shoe.
BACKGROUND OF THE INVENTION
[0003] Performance footwear such as running shoes is designed for
comfort and durability. To provide these features, performance
footwear is typically constructed from a material or a combination
of materials having insulative, moisture resistant, and/or abrasion
resistant characteristics. The processes for constructing
performance footwear can be labor intensive, often requiring
sophisticated and expensive stitching and/or injection molding
equipment. For example, conventional uppers may are constructed via
stitching, i.e., by cutting material according to a pattern to form
a series of individual pieces, and then stitching the individual
pieces of the pattern together to form the upper. The end result is
a shoe having a significant number of seams. Seams, which are
friction points, are located throughout the upper and, in
particular, in the heel and bottom areas. In light of this,
conventional footwear requires an insole or other covering to hide
the stitched seam along the bottom of the upper.
[0004] In another conventional method is formed via injection. This
type of footwear is designed for harsh weather conditions (e.g.
rubber boots). While generally seamless, this type of footwear is
water and vapor impermeable, resulting in footwear lacking
breathability. In the context of athletic footwear, this process
results in wearer discomfort because airflow into and out of the
shoe is prevented. Accordingly, heat and perspiration from the
wearer cannot be evacuated to the ambient environment, resulting in
wearer discomfort.
[0005] Thus, it would be desirable to provide performance footwear
that is lightweight, breathable, and durable, but avoids seams
and/or stitches in the heel and/or footpad areas.
BRIEF SUMMARY OF THE INVENTION
[0006] The present invention is directed toward footwear including
an upper connected to a sole structure. In an embodiment, the upper
includes a first upper portion secured to a second upper portion.
Each upper portion is formed via compression molding in which
textile layers are compressed to form a fabric laminate. With this
process, the macrostructure and microstructure of each portion
upper is controlled. Specifically, the first upper portion includes
a macrostructure that generally defines the insole and heel cup of
the upper. The heel cup, moreover, is seamless. The second upper
portion includes a macrostructure that generally defines the instep
and toe cage areas of the upper. The toe cage may further include
an engineered microstructure. In an embodiment, the toe cage
includes one or more integrated toe guides operable to position a
toe of a wearer in a predetermined position within the cavity.
[0007] In another embodiment, the upper is configured with a
microstructure formed of protrusions along the interior and/or
exterior upper surface.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0008] FIG. 1A is a side perspective view an article of footwear in
accordance with an embodiment of the invention, showing the medial
footwear side (footwear configured for a left foot).
[0009] FIG. 1B is a side view in elevation of an article of
footwear in accordance with an embodiment, showing the lateral side
footwear side (footwear configured for left foot).
[0010] FIG. 1C is a rear perspective view of the article of
footwear shown in FIG. 1B.
[0011] FIG. 2 is an exploded view of the article of footwear shown
in FIG. 1A.
[0012] FIG. 3 is a top perspective view of the planum portion of
the upper in accordance with an embodiment of the invention (upper
configured for the right foot).
[0013] FIG. 4 is a top perspective view of the dorsum portion of
the upper in accordance with an embodiment of the invention
(adapted for right foot).
[0014] FIG. 5A is a perspective, close-up view of a toe cage in
accordance with an embodiment of the invention.
[0015] FIG. 5B is top plan view of the toe cage of FIG. 5A.
[0016] FIG. 5C is a cross sectional view of the toe cage shown in
FIG. 5A.
[0017] FIG. 6 illustrates a cross sectional view of compression
molding apparatus, showing upper formation.
[0018] FIG. 7 is a top perspective view of a sole structure in
accordance with an embodiment of the invention, showing the medial
side of the sole structure (adapted for the right foot).
[0019] FIG. 8 is a bottom plan view of a sole structure in
accordance with an embodiment of the invention.
[0020] FIG. 9A is a perspective, close-up view of a toe cage in
accordance with an embodiment of the invention.
[0021] FIG. 9B is a top plan view of the toe cage of FIG. 9A.
[0022] FIG. 9C is a cross-section view of a toe cage in accordance
with an embodiment of the invention.
[0023] Like numerals identify like components throughout the
figures.
DETAILED DESCRIPTION OF THE INVENTION
[0024] Turning to FIGS. 1A, 1B, and 1C, an article of footwear 10
in accordance with an embodiment of the present invention includes
an upper 105 coupled to (e.g., mounted on) a sole structure 110.
The article of footwear 10 defines several regions corresponding
with various parts of a foot. Specifically, the footwear 10 defines
a rear footwear region 115 generally corresponding with the rear of
the foot (e.g., the hindfoot including the heel); an intermediate
footwear region 120 disposed forward the rear region and generally
corresponding to the midfoot (e.g., the arched, instep, and ball
areas of the foot); and a forward footwear region 125 disposed
forward of intermediate region and generally corresponding to the
forefoot (e.g., the toes of the foot). The article of footwear 10
may further include a fastener 127 (e.g., a shoe lace) and a heel
counter 129 (discussed in greater detail below).
[0025] The upper 105 includes a heel 130, a lateral side 135, a
medial side 140, an instep 145, and a toe cage or box 150. The heel
130 forms a rear portion of upper 105 and is generally configured
to extend along the heel of the foot. The lateral side 135 spans
through a longitudinal length of footwear 10, extending along the
lateral side of the foot. Similarly, the medial side 140 extends
along the longitudinal length of footwear 10 such that it extends
along the medial side 140 of the foot. The instep 145, positioned
between the lateral side and the medial side, extends over the
instep of the foot and generally includes tongue 147. Finally, the
toe cage 150 defines the forward area of the upper 105, being
configured to house the toes of the foot.
[0026] The upper 105 defines a cavity that receives the foot.
Specifically, the heel 130, lateral side 135, medial side 140,
instep 145, and toe cage 150 cooperate to define an interior cavity
into which a foot is inserted by way of an access opening or collar
155. The collar 155 may be finished with, e.g., fabric tape applied
via adhesive. In an embodiment, a strip of material is applied
around an inside edge of collar 155 to allow the edge of collar to
be finished without a binding to reduce fraying and/or to help
collar adhere to the skin of the user. The material may be an
elastomeric and/or tacky polymer such as, but not limited to,
polyurethane, silicone, nylon, and polyester.
[0027] In the embodiment shown in FIG. 2, the upper 105 is formed
of two portions, a first or planum portion 205 coupled (e.g.,
connected) to a second or dorsum portion 210 via a seamless
coupling member 215. Referring to FIG. 3, the planum portion 205,
which generally covers the heel and planum areas of the foot,
includes a heel cup 315A and a planum support 315B extending
forward from the heel cup. The heel cup 315A is a self-supporting
structure configured to surround the lateral side, medial side, and
bottom of the heel bone (calcaneus). As shown, the heel cup 315A is
defined by a wall 325 with a lateral portion 330A terminating in a
forward lateral edge 335A and a medial portion 330B terminating in
a forward medial edge 335B. The vertical wall 325 curves forward at
its lower end, transitioning to the planum support 315B, with the
vertical wall and planum support cooperating to define a curved
heel pocket or cup 340. In a further embodiment, the vertical wall
may curve inward (toward the foot) as it travels upward (in the
direction of the collar 155).
[0028] The planum support 315B extends forward from the curved heel
pocket 340 to define a midfoot support region 345A and a forefoot
support region 345B. The midfoot support region 345A may be a
generally U-shaped structure defining a bottom wall 350; a
generally vertical, lateral tab or wall 355A terminating in a
lateral forward edge 360A; and a generally vertical, medial tab or
wall 355B terminating in a medial forward edge 360B. The forefoot
support region 345B defines a generally planar member configured to
span the ball and toes of the foot.
[0029] The heel cup 340 of the planum portion 205 is seamless.
Conventional footwear typically includes a seam (e.g., a welded
seam or a stitched seam) within the heel cup. For example, a
conventional heel cup includes a vertical seam along the connection
between two heel halves (lateral and medial halves) and a
longitudinal seam along the connection between the two halves of
the footpad. The heel 130 of the article of footwear 10 discussed
herein, in contrast, does not include a seam. Instead, the heel 130
is a unitary structure shaped to define a seamless, unitary heel
cup 340. In a further embodiment, the entire planum portion 205 is
seamless, with the heel cup 315A and the planum support 315B
forming a unitary and/or one-piece structure.
[0030] Additionally, the upper 105 in accordance with an embodiment
of the invention is sockless, defining a shell that encloses the
foot. Conventional footwear typically includes an upper with an
opened bottom that is attached (e.g., stitched) to the sole. A
layer of material is then set inside the footwear to create a
cushioned layer between the sole and the foot that hides the joint
between the upper and the sole structure. In contrast, the "insole"
of the article of footwear 10 in accordance with an embodiment of
the invention is effectively integrated into the upper 105 such
that the heel and insole form a unitary structure (e.g., the
interior layer of the textile laminate forming the upper 105
functions as the sock). Thus, no further sock or insole is
required.
[0031] Referring to FIG. 4, the dorsum portion 210, which generally
covers the dorsum of the foot, includes a proximal section 405A and
a distal section 405B. The proximal section 405A generally defines
the lateral 135, medial 140, instep 145 areas of the upper 105. As
illustrated, the proximal section 405A of the dorsum portion 210
includes a lateral flap 410A and a medial flap 410B separated by a
central opening 415. The lateral flap 410A is a generally planar
member including a plurality of tabs or loops 420A-420D extending
laterally inward (toward the central opening 415). A loop includes
two fabric elements oriented parallel to each, being fixed
(connected) to each other at two longitudinally-spaced-apart
locations. With this configuration, each loop 420A-420D defines a
channel through which the fastener 127 may be passed, thereby
creating a connection point for the fastener (see FIG. 1B). It
should be understood, however, that other fastener connections such
as eyelets/grommets 422 may be utilized to secure the fastener
127.
[0032] The proximal section 405A further includes a tongue
connection 425 to which a tongue 147 may be attached (e.g., via
thermal tape). The tongue 147 may be formed of materials similar to
that of the upper, and may be formed utilizing the same method
(discussed in greater detail below). Specifically, the tongue 147
may include a three dimensional macrostructure where the tongue
curves in the transverse dimension (e.g., it curves along its
width) such that it follows the contour of the foot instep 145. The
tongue 147, moreover, may be configured such that it tapers along
its transverse and/or longitudinal edges, being thicker in the
tongue central region and gradually thinning toward its edges
(e.g., the edge may be 1/16 the thickness of the central region).
This may be achieved by compressing the fabric laminate of the
tongue to a greater degree along the edges, and/or by utilizing a
skived foam layer as the layer of the fabric laminate.
[0033] Alternatively, the tongue 147 may be formed of different
materials including, but not limited to, fabric, mesh, etc.
[0034] In an embodiment, one or more portions 205, 210 of the upper
105 may include perforations to permit the flow of fluid (e.g., air
and/or water) therethrough. In other embodiments, the upper 105
contains no perforations to lessen or prevent the flow of fluid
through the upper.
[0035] While not described in detail, it should be understood that
the medial flap 410B is a minor image of the lateral flap 410A,
including loops and/or perforations as explained above.
[0036] The distal section 405B of the dorsum portion 210 includes
the toe cage 150, which covers/houses the toes of the wearer. In
the illustrated embodiment, the toe cage 150 includes a generally
horizontal top cover 435A (configured to span over the toes of the
foot) and a rim or lip 435B extending downward from the top cover
(e.g., the rim may be oriented substantially orthogonal to the
cover 435A). The toe cage 150 is configured to cooperate with the
forefoot support region 345B of the planum support to define a
single cavity within the upper 105 that receives all of the toes of
the foot. As with the proximal section 405A, the distal section
405B may further include perforations 430 operable to permit fluid
flow therethrough.
[0037] In an embodiment, the dorsum portion 210 possesses a unitary
(one piece) construction. The toe cage 150, furthermore, may be a
stitchless, contoured (three-dimensional) structure. In a further
embodiment, the toe cage 150 is seamless.
[0038] Each of the planum portion 205 and the dorsum portion 210
may be formed/shaped via a compression molding process (discussed
in greater detail below). Compression molding permits formation of
a textile laminate having unique geometries (e.g., predetermined
macrostructures and microstructures). That is, in addition to the
seamless heel cup 340 of the planum portion 205 (macrosture), the
toe cage 150 may further include an undulating topography defining
one or more toe guides integrated into the dorsum portion 210
(microstructure). Referring to FIGS. 5A, 5B, and 5C, the toe cage
150 includes a plurality of toe guides 505A, 505B, 505C, 505D,
505E, each operable to position a toe in a predetermined position
within the toe cage cavity 507 (e.g., in a specified lateral
position within the upper) and/or in a predetermined position
relative to an adjacent toe. By way of example, the distal section
405B of the dorsum portion 210 includes one or more truncated walls
or partitions (also called a terminal digit baffle) extending into
the toe cage cavity 507. The partitions deflect or guide a toe into
a predetermined position relative to the upper 105 and/or adjacent
toes. In an embodiment, the partitions extend downward (toward the
sole structure 110) from the ceiling of the toe cage 150. In
another embodiment, the partitions extend upward from the planum
support 315B of the planum portion 205 (not illustrated).
[0039] In a preferred embodiment, the toe guides 505A-505E are
defined by a series of recessed areas and raised areas integrated
(e.g., molded) into the upper 105 and, in particular, the toe cage
150. Specifically, the top of the toe cage 150 undulates, defining
one or more raised areas 515A-515E (each having an apex 520A-520E),
as well as one or more recessed areas 525A-525D (each having a
nadir 530A-530D). With this configuration, each raised area
515A-515E defines an elongated, open channel or half cylinder
517A-517E operable to receive a portion of a toe (in a preferred
embodiment, a channel 517A-517E does not completely enclose the
toe). The recessed areas 525A-525D that border a raised area,
moreover, extend downward at a depth sufficient to direct a toe
into the channel 517A-517E of the raised area 515A-515E. Each
raised area 515A-515E generally aligns with a corresponding toe,
while each recess 525A-525D generally aligns with an associated
space between the toes. Accordingly, each channel 517A-517E
receives a toe of the wearer. Specifically, in the illustrated
embodiment, the first toe guide 505A (the channel 517A defined by
the raised area 515A) receives the hallux (the big toe), the second
toe guide 505B (the channel 517B defined by the raised area 515B)
receives the second toe (the long toe), the third toe guide 505C
(the channel 517C defined by the raised area 515C) receives the
third toe (the middle toe), the fourth toe guide 505D (the channel
517D defined by the raised area 515D) receives the fourth toe (the
ring toe), and the fifth toe guide 505E (the channel 517E defined
by the raised area 515E) receives the fifth toe (the pinky toe).
The outer walls 540, 545 of the cage, moreover, guide the medial
(big) toe and the lateral (pinky) toe into its corresponding toe
guide 505A and 505E, respectively.
[0040] The height of each raised 515A-515E and/or recessed
525A-525D area may similar among the toe guides; alternatively, the
height of the areas may differ. That is, the distance measured from
the top side of the sole structure 110 (and/or the planum support
315B) to the apex 520A-520E or nadir 530A-530D may equal or differ.
By way of example, the heights of the raised areas 515A-515E may
successively lessen in the lateral direction of the shoe, with the
first toe guide 505A possessing the greatest height and the fifth
toe guide 505E possessing the lowest height.
[0041] In an embodiment, the nadir 530A-530D extends into the toe
cage cavity 507 at a depth that enables the partition to interact
with (contact/deflect) a toe positioned within the cavity, but
still permits passage of a toe underneath the recess 525A-525D,
thereby permitting a user to manually reposition/move/flex toes as
desired. Stated another way, since the partitions defined by the
recessed areas 525A-525D do not extend completely through the toe
cage cavity 507, a space or gap exists between the distal end of
the partition (i.e., the nadir 530A-530D of the recessed area
525A-525D) and the planum support 315B to form a nadir or recess
gap 532. The recess gap 532 may possess any height h1 suitable for
its described purpose. By way of example, the height h1 of the
recess gap 532 is selected to permit a user to manually reposition
the toes within the toe cage 150 if desired. The height h1 of the
recess gap 532 may be consistent across each recessed area
525A-525D, or may differ between recessed areas.
[0042] Similarly, the apex height h2, i.e., the height h2 measured
from the planum support 315B to the apex 520A-520E of a raised area
515A (the apex gap), may be any suitable for its described purpose,
and may be the same or differ between toe guides 505A-505E. In the
illustrated embodiment, the apex height h2 is greater than the
recess height h1.
[0043] With this configuration, each toe guide 505A-505E--each
raised area--possesses a depth effective to receive a portion of a
toe (i.e., the upper portion/area of the toe). By way of example,
the depth of the toe guide 505A-505E may be configured to
receive/enclose from about 10% to about 50% of a toe, and
preferably about 15%-40% of the toe.
[0044] Each raised area 515A-515E and recessed area 525A-525D may
extend longitudinally along the toe cage 150, being laterally
spaced from each other in the transverse direction (i.e., across
width of shoe) such that the walls are generally parallel. The toe
guides 505A-505E may possess any length suitable for its described
purpose. By way of example, each raised area 515A-515E and recessed
area 525A-525D may extend from the front of the toe cage 150 and
terminate proximate the instep 145 (e.g., proximate the tongue
connection 425 of the article of footwear 10).
[0045] As shown, each raised area 515A-515E and recessed area
525A-525D define a gently curved surface, being contoured with the
outer surface of a toe. The width w1, w2, w3, w4, w5 of each toe
guide 505A-505E may be the same, or may differ to accommodate the
differing widths of the toe on the foot. By way of example, the
width w1 of the first toe guide 505A (configured to receive the big
toe) may be greater than the width w3 of the third toe guide 505C
(configured to receive the middle toe). The width w3 of the third
toe guide 505C, moreover, may be greater than the width w5 of the
fifth toe guide 505 E (configured to receive the pinky toe).
[0046] With the above described configuration, the toe guides
505A-505E maintain each toe in its natural position, guiding or
limiting the lateral movement of each toe. In operation, as a
wearer inserts a foot into the proper article of footwear, the
partitions formed by the recessed areas 525A-525D guide each toe
into its corresponding raised area channel. During use (i.e., with
the foot at rest or in motion), the partitions continuously guide
its associated toe to the raised area channel to maintain the toe
within its respective guide 505A-505E. Stated another way, the toe
guides 505A-505E may be configured to laterally flex each toe,
driving adjacent toes away from each other such that each toe may
be slightly spaced/separated from its adjacent toes. Additionally,
the toe guides 505A-505E maintain the position of each toe by
preventing the lateral movement of a toe during use (e.g., while
running). Accordingly, the toe guides 505A-505E stabilize each toe,
reducing the internal movement or slipping of the user's foot and
facilitating the ability of each individual toe to provide balance.
This, in turn, optimizes the performance and comfort of the
wearer.
[0047] The configuration of the upper 105 described above provides
a single, open cavity toe cage 150 that receives all the toes and,
while restricting their lateral movement, still permits a user to
manipulate the toes and reposition them within the toe cage cavity
507 as desired. This is in contrast to known upper configurations
that provide a series of individual cavities, one for each toe. In
these configurations, each toe is completely enclosed within its
own cavity, with each cavity being individually articulable. Thus,
conventional configurations do not provide a single, open
cavity.
[0048] With the above-described upper configuration, two levels of
motion are provided during use. First, the entire toe cage 150
moves as a single unit, pivoting about the ball of the foot (e.g.,
along the flex line of the sole structure 110, discussed in greater
detail below). Second, while the natural movement of the toes is
still permitted, the toes are spread within the toe cage by the toe
guides 505A-505E, which alleviates toe crowding. This, in turn,
increases wearer comfort during use and provides a more natural
(barefoot) feel to the wearer.
[0049] As noted above, the planum portion 205 may be connected to
the dorsum portion 210 in a seamless and/or stitchless manner. In
an embodiment, a coupling member 215 couples (e.g., connects) the
dorsum portion 210 to the planum portion 205. Specifically, the
upper 105 includes a lateral coupling member 215 disposed along the
lateral side of the upper and a medial coupling member disposed
along the medial side of the upper. By way of example, the portions
205, 210 of the upper 105 may be connected via a fabric tape such
as a thermal adhesive tape (e.g., BEMIS seam tape, available from
Bemis Associates, Inc., Shirley, Mass.). In a preferred embodiment,
the coupling member 215 comprises fabric similar to the fabric
forming the upper (e.g., polyester, spandex, etc.).
[0050] As noted above, the flaps of the dorsum portion 210 are
generally contoured to the edges 355A, 355B, 360A, 360B of the
planum portion 210. Accordingly, the planum portion 205 mates with
the dorsum portion 210. Specifically, the lateral 410A and medial
410B flaps of the dorsum portion 210, cut in a fashion
complementary to that of the planum portion 205, are each brought
into adjacent relationship with the lateral 330A, 355A and medial
330B, 355B walls of a heel cup 340 and the planum portion 205,
respectively. The corresponding edges 235A, 235B, 260A, 260B are
stitched together, and the coupling member 215 (e.g., fabric tape)
is applied such that the coupling member bridges the connection
between the portions 205, 210, covering the stitching. Preferably,
the coupling member 215 is disposed on both the interior and
exterior surfaces of the upper 105. Heat is then applied to the
coupling member 215 to seal the seam, fixing the member to the
upper 105.
[0051] With this configuration, the coupling member 215 provides a
seamless connection that minimizes and/or eliminates the friction
caused by conventional (exposed) seams. That is, a seamless
connection is provided because the coupling member 215 creates a
generally uninterrupted and/or continuous surface along the
interior surface and/or exterior surface of the upper 105.
[0052] Alternatively, the planum 205 and dorsum 210 portions may be
connected without stitching, instead utilizing a thermoplastic film
that traverses the seam between adjacent portions, bonding the
portions 205, 210 together (e.g., SEWFREE tape, available from
Bemis Associates, Inc., Shirley, Mass.).
[0053] In other embodiments, ultrasonic welding could be utilized.
In an embodiment, individual pieces are joined by ultrasonic
welding, and the weld is covered by a strip of heat sealable
film.
[0054] In either embodiment, the coupling member 215 may possess a
curved or undulating shape to track the contours of the connected
upper portions 205, 210.
[0055] Once formed, the resulting upper is coupled (e.g., mounted)
to the sole structure 110, e.g., via an adhesive, welding (e.g.,
ultrasonic welding), etc.
[0056] The upper 105 may comprise any materials suitable for its
described purpose. In particular, the upper 105 may be formed of
material capable of forming a three dimensional structure as
described above (e.g., a structure including a toe guide). By way
of example, the upper 105 may be formed of a fabric laminate. By
way of further example, the upper 105 may be formed of fabric
laminate that is capable of being shaped via compression molding.
By way of still further example, the upper 105 is formed of a
fabric lamination including a foam layer.
[0057] Compression molding is a method of molding in which the
molding material is first placed in an open, heated mold cavity.
The mold is closed with a top force or plug member, pressure is
applied to force the material into contact with all mold areas,
while heat and pressure are maintained until the molding material
has cured. An exemplary compression molding apparatus is
illustrated in FIG. 6. As shown, the compression molding apparatus
605 includes a first or female molding portion 610 configured to
receive a second or male molding portion 615 possessing a shape
complementary to the shape of the first molding portion. The
apparatus 605 may be utilized to shape a single layer, or may be
utilized to shape a multilayered structure. In the embodiment shown
in FIG. 6, the formed upper 105 includes three layers--an outer or
exterior layer 620, a middle or intermediate layer 625, and an
inner or interior layer 630. By way of example, the exterior layer
620 may be a breathable, synthetic fabric (e.g., a polyester
fabric), the intermediate layer 625 may be open-celled foam (e.g.,
ethylene vinylacetate), and the interior layer 630 may be a
breathable, synthetic fabric (e.g., a polyester fabric).
[0058] Additionally, the exterior layer 620 and/or the interior
layer 630 may further include an elastic fiber (e.g., spandex or
elastane) to provide the layers with elastic properties. In an
embodiment, the exterior layer 620 is fabric including 85%
polyester and 15% spandex (weight 215 g/m.sup.2), the intermediate
layer 625 is polyurethane foam, and the interior layer 630 is
fabric including 79% polyester and 21% spandex (weight 210
g/m.sup.2).
[0059] The exterior 620 and interior 630 fabric layers may possess
similar or different properties such as elongation properties. By
way of example, the exterior layer 620 may possess greater
elongation along its length than the interior layer 630, while the
interior layer 630 may possess greater elongation along its width
then the exterior layer 620.
[0060] In other embodiments, the outer 620 and/or inner 630 layers
may be formed of leather, GORETEX, etc.
[0061] Upon compression (and the application of heat), the layers
620, 625, 630 adhere, forming a fabric laminate. Additionally, the
fabric laminate conforms to the shape of the molding portions 610,
615, permanently holding its shape. In this manner, the planum
portion 205 and dorsum portion 210 of the upper 105 may be formed,
possessing the shape of the mold.
[0062] This formation process enables the creation of the
macrostructure of the upper 105 (the general shape of the planum
205 and dorsum 210 portions of the upper), but also the
microstructure of the upper (the toe guide structure). In an
embodiment, the microstructure may further include protrusions,
e.g., generally rounded nubs or bosses extending outward from
either the interior surface or the exterior surface of the upper.
When extending from the exterior surface of the upper, the
protrusions may provide abrasion resistance or impact protection in
specified areas of the upper. In addition, the protrusions may
define contact areas configured to improve contact with a ball
during game play (e.g., a soccer ball, kickball, etc.).
[0063] When disposed on the interior surface of the upper 105, the
protrusions act as spacers to create air gaps or channels between
the upper and the foot of the wearer, enabling airflow within the
channels. The protrusions are integrated into the upper 105, being
formed as the result of the shape of the mold portions 610, 615 (a
negative of the protrusion pattern is formed into the appropriate
mold portion 610, 615). The protrusions may be any size and shape
suitable for their described purpose, and may be disposed in any
predetermined pattern along a portion of the upper, or along the
entire upper 105.
[0064] In addition, a reinforcing element may be inserted between
the interior layer 630 and the foam layer 625 and/or the exterior
layer 620 and the foam layer. A reinforcing element is a component
possessing rigidity that is equal to or greater than that of the
interior layer/and/or exterior layer. By way of example, a
generally U-shaped reinforcing plate may be located within the heel
portion of the upper 105. The reinforcing plate, formed of, e.g.,
fabric or plastic, provides additional support to the ankle,
functioning as an internal heel counter. Additionally, the plate
may provide protection to the ankle that may occur during use
(e.g., contact with other shoes).
[0065] The sole structure 110 is a durable, wear-resistant
component configured to provide cushioning as the article footwear
10 impacts the ground. In an embodiment, the sole structure 110 may
include an insole, a midsole, and an outsole. In other embodiments,
the sole may be a unitary and/or one-piece structure. Turning to
the embodiment illustrated in FIG. 7, the sole structure 110
includes a first, upper-facing side 705 (also called a top side)
and a second, ground-facing side 710 (also called a bottom side).
The top side 705 may possess a generally planar surface having a
gently curved rim or wall 715 that defines the sole perimeter.
[0066] The sole structure 110 may further include a heel counter
129 adapted to surround the heel portion of the upper 105. The heel
counter 129 is an external strengthening device in the heel area of
the upper 105 configured to control and stabilize the wearer's heel
inside the shoe and to minimize excessive supination or pronation
of the foot. As shown, the heel counter 129 includes a generally
central leg 720 mounted on and extending distally (upward) from the
first side 705 of the sole structure 110. A pair of arms 725A, 725B
extends from the distal portion of the central leg. Specifically, a
first arm 725A extends laterally toward the lateral side of the
footwear and a second arm 725B extends laterally toward the medial
side of the footwear. As shown, each arm 725A, 725B is generally
horizontal, curving outward (radially from the longitudinal axis of
the sole structure) in the forward direction.
[0067] The first arm 725A terminates in a first lateral leg 730A.
Similarly, the second arm 725B terminates in a second lateral leg
730B. Each leg 730A, 730B extends downward (toward the sole
structure 110), being angled slightly forward (toward the toe cage
150). The proximal end of each lateral leg 730A, 730B, similar to
that of the central leg 720, is mounted on the top side 705 of the
sole structure. With this configuration, the heel counter 129
defines a cage structure having a first lateral window 735A on the
lateral side of the shoe and a second lateral window 735B on the
medial side of the shoe. As shown, the heel counter 129 may possess
a generally cupped shaped, with each leg initially curving outward,
beyond the rim of the sole structure, then curving inward.
[0068] The heel counter 129 may be formed of any material suitable
for its described purpose. By way of example, the heel counter 129
is formed of a thermoplastic elastomer such as ethylene vinyl
acetate or polyurethane. The heel counter 129, moreover, may be
flexible, semi-rigid, or rigid. With this configuration, the heel
counter 129 provides rearfoot stability, preventing injury and
prolonging the life of the article of footwear.
[0069] Referring to FIG. 8, the bottom side 710 of the sole
structure 110 may define a generally planar surface. The surface of
the bottom side 710, moreover, may be textured. In the illustrated
embodiment, the bottom side 710 of the sole structure 110 includes
a plurality of friction ridges 805 disposed along the sole in a
predetermined pattern. By way of example, the friction ridges 805
may be provided in a fingerprint pattern including one or more of
an arch pattern, a loop pattern (right or left), and/or a whorl
pattern.
[0070] Additionally, the bottom side 710 of the sole structure 110
may include one or more recesses formed therein. In the illustrated
embodiment, the bottom side 710 of the sole structure 110 includes
a first, generally-transverse recess or flex line 810 disposed
forward of the heel and a second, generally-transverse recess or
flex line 815 disposed rearward of the toe cage 150 (e.g., forward
of the ball of the foot). The first 810 and second 815 flex lines
are configured to provide flexure to the sole, enabling movement
(pivoting) along the lines. Additionally, the bottom side 710 of
the sole structure 110 may further include one or more of a
continuous (closed-loop) recess 820 disposed at an intermediate
location between the transverse recesses 810, 815 (e.g., proximate
the plantar fascia region of the foot) and a plurality of
longitudinal recesses 825 disposed at selected locations along the
sole structure 110.
[0071] The sole structure 110 may be formed of a single material or
may be formed of a plurality of materials. By way of example, the
sole structure may include a primary structure formed of a first
material (e.g., ethylene vinyl acetate) and a secondary structure
formed of a second material (e.g., thermoplastic polyurethane). In
an embodiment, the primary structure is a midsole and the secondary
structure is an outsole. In the illustrated embodiment, the outsole
structure 830 is provided as a series of individual pads disposed
at predetermined locations along the bottom side 710 of the
midsole. The material forming the outsole 830 differs from that of
the material forming the midsole by possessing different mechanical
properties. By way of example, the materials may possess different
relative wear ratios. By way of further example, the materials may
possess different Shore Hardness values. The outsole pads 830,
then, are a secondary structure formed of material possessing a
different wear rate than that of the material forming the primary
structure. Specifically, the sole structure 110 includes a first
toe pad disposed proximate the big toe of the wearer, one or more
ball pads disposed proximate the ball of the foot and spaced
laterally across the sole structure, and a heel pad disposed
proximate the heel of the foot.
[0072] While the invention has been described in detail and with
reference to specific embodiments thereof, it will be apparent to
one skilled in the art that various changes and modifications can
be made therein without departing from the spirit and scope
thereof. For example, portions 115, 120, 125 are not necessarily
intended to demarcate precise areas of footwear 10 and may simply
represent general areas of footwear to provide a frame of
reference.
[0073] The upper 105 may possess any dimensions or shapes suitable
for its described purpose. Additionally, the dorsum portion 210 of
the upper 105 may include any number of toe guides. By way of
example, referring to FIGS. 9A, 9B, and 9C, instead of including a
toe guide for each toe (all five toes), the toe cage 150 may
include a guide for a single toe. As shown, the toe cage includes a
single toe guide 905 is provided that receives the big toe. The toe
guide is defined by the raised area 910 bounded by a recessed area
or partition 915 on one side and the medial outer wall 920 of the
toe cage on the opposite side, thereby forming an open channel 925
that receives a portion of the toe (i.e. the channel does not
completely enclose the toe). With this configuration, the big toe
is directed into the toe guide 905, with the remaining toes (the
second through fifth toes) being positioned within the remaining
area 935 of the toe cage 150. Accordingly, the big toe is slightly
separated from its adjacent (second) toe and/or is the lateral
positioned of the toe is maintained during use. The second through
fifth toes are left unguided (save for the second toe being driven
away from the big toe by the partition). In the illustrated
embodiment, the height of the toe guide 905 is greater than the
height of the remaining cavity 930. The width w1 of the toe guide
905, moreover, is less than the width w2 of remaining upper portion
935.
[0074] The upper 105 may be stylized as any shoe type. For example,
the upper 105 may be stylized as a boot or high top athletic shoe
that rises above the ankle of the wearer, terminating in a collar
positioned above the inner ankle bone of the user, thereby
providing a gapless gasket seal above the user's ankle. In such an
embodiment, the upper includes a dorsum portion and a planum
portion as described above.
[0075] The materials forming the planum portion 205 of the upper
105 may be the same or different as that forming the dorsum portion
210 of the upper. For example, the planum portion 205 may be formed
of a different material than the dorsum portion 210. Specifically,
the dorsum portion may be formed of a breathable fabric similar to
that described above, which is compression molded to include a
plurality of toe guides operable to adjust the position of each toe
relative to the upper 105. The planum portion 205, however, is
composed of non-breathable fabric operable to prevent the passage
of fluid (e.g., water) therethrough.
[0076] Additionally, the interior layer 630 and the exterior layer
620 may be formed of the same textile or may be formed of different
textiles. For example, the interior layer 630 may be a breathable
fabric, while the exterior layer 620 may be formed of a natural or
synthetic rubber such as polychloroprene (neoprene). Additionally,
the rubber may be blended with other materials to provide desired
properties (e.g., spandex to improve elasticity).
[0077] The sole structure 110 may further include an extension
(operable to provide toe protection) overmolded onto the toe cage
150 of the upper 105.
[0078] Also, the planum portion 205 and the dorsum portion 210
portions may include different graphics thereon.
[0079] While the planum portion 205 of the upper 105 may be secured
to the sole structure 110 via welding or adhesive, all or a part of
the planum portion may be secured to the sole structure via
stitching. Additionally, while the illustrated embodiment does not
include an insole, an insole may be added, being secured to the
planum portion 205 of the upper 105 via adhesive, welding,
stitching, etc.
[0080] As noted above, the upper 105 or portions thereof may be
formed of any material suitable for its described purpose. By way
of example, the upper 105 maybe formed of flexible textile material
of a predetermined gauge or density. Specifically, the upper 105 or
portions thereof may be formed of, for example, knit, woven or
non-woven material made using fibers such as, but not limited to,
nylon, polyester, polyurethane and or spandex, with elastomeric
properties. The fabric may be breathable (permitting the passage of
fluid such as air or water therethrough), or may be non-breathable
(preventing passage of fluid therethrough).
[0081] A protective coating may also be applied to seams and/or
stitching on other portions of the article of footwear 10 for the
purpose of durability and to prevent the textile from fraying. For
example, stitching that secures the sole structure 110 to the upper
105 may have such a coating. Additionally, coatings may also be
applied to the textile upper 105, either internally or externally,
to provide enhanced textile durability in high wear areas such as,
but not limited to, the areas above and beneath the toes and the
instep.
[0082] Additionally, the upper 105 and sole structure 110 may have
external polyurethane or silicone coatings to provide regional
properties such as tacky grip for improved ball control.
[0083] In other embodiments, the sole structure 110 may include one
or more of an insole, a midsole, and an outsole. For example, the
midsole may be a polymer foam material such as ethylene
vinylacetate or polyurethane, while the outsole may be formed of
various rubber compounds (blown rubber, carbon reinforced rubber)
operable to provide a durable, wear-resistant surface for engaging
the ground. The insole, a relatively thin cushioning member located
within the upper 105 and adjacent to a plantar surface of the foot,
is provided to enhance the comfort of wearer.
[0084] Thus, it is intended that the present invention covers the
modifications and variations of this invention provided they come
within the scope of the appended claims and their equivalents. It
is to be understood that terms such as "top," "bottom," "front,"
"rear," "side," "height," "length," "width," "upper," "lower,"
"interior," "exterior," "medial," "lateral," and the like as may be
used herein, merely describe points of reference and do not limit
the present invention to any particular orientation or
configuration.
* * * * *