U.S. patent application number 15/149596 was filed with the patent office on 2017-01-26 for footwear including a textile upper.
The applicant listed for this patent is Under Armour, Inc.. Invention is credited to David Dombrow, Kevin P. Fallon, Thomas White.
Application Number | 20170020226 15/149596 |
Document ID | / |
Family ID | 57222254 |
Filed Date | 2017-01-26 |
United States Patent
Application |
20170020226 |
Kind Code |
A1 |
Dombrow; David ; et
al. |
January 26, 2017 |
FOOTWEAR INCLUDING A TEXTILE UPPER
Abstract
A textile upper for an article of footwear includes at least one
microclimate modulation structure located at one or more regions of
the upper. In an embodiment, a microclimate modulation structure
includes a plurality of knitted strands, the knitted strands
including a first strand type and a second strand type, the first
strand type having a greater thermal conductivity than the second
strand type. In another embodiment, the microclimate modulation
structure includes an uneven surface that includes a plurality of
knitted beams and a plurality of indentations defined between the
knitted beams.
Inventors: |
Dombrow; David; (Baltimore,
MD) ; Fallon; Kevin P.; (Portland, OR) ;
White; Thomas; (Baltimore, MD) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Under Armour, Inc. |
Baltimore |
MD |
US |
|
|
Family ID: |
57222254 |
Appl. No.: |
15/149596 |
Filed: |
May 9, 2016 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
62158709 |
May 8, 2015 |
|
|
|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
A43B 7/085 20130101;
A43B 23/028 20130101; A43B 23/0205 20130101; A43B 23/0245 20130101;
D10B 2501/043 20130101; A43B 23/0235 20130101; D04B 1/16 20130101;
D04B 1/22 20130101; A43B 23/086 20130101; D10B 2401/041 20130101;
A43B 5/06 20130101; A43B 23/088 20130101; D04B 1/123 20130101; A43B
23/0255 20130101; A43B 23/02 20130101; A43C 1/04 20130101; A43B
1/04 20130101; A43B 23/0275 20130101; A43C 5/00 20130101; D10B
2403/02 20130101; A43C 1/00 20130101 |
International
Class: |
A43B 7/08 20060101
A43B007/08; A43C 1/04 20060101 A43C001/04; A43B 23/04 20060101
A43B023/04; A43B 23/02 20060101 A43B023/02; A43B 5/06 20060101
A43B005/06 |
Claims
1. An article of footwear including a foot cavity, the article of
footwear comprising: a sole structure; an upper coupled to the sole
structure, the upper defining a forward section, a rearward
section, and a midfoot section disposed between the forward section
and the rearward section; and a microclimate moderation structure
disposed within the forward section of the upper, the microclimate
modulation structure comprising a knit structure with strands
oriented in courses and wales, the strands including a first strand
and a second strand, the first strand transferring heat at a higher
rate than the second strand.
2. The article of footwear according to claim 1, wherein the knit
structure is a flat knit structure including a technical face and a
technical back.
3. The article of footwear according to claim 2, wherein: the first
strand comprises a fiber defining a longitudinal axis; the second
strand comprises a fiber defining a longitudinal axis; and measured
thermal conductivity along the first fiber axis is greater than
measured thermal conductivity along the second fiber axis.
4. The article of footwear according to claim 3, wherein: the
measured thermal conductivity along the first fiber axis is at
least 5 W/m K; and the measured thermal conductivity along the
second fiber axis is less than 5 W/m K.
5. The article of footwear according to claim 1, wherein the
microclimate moderation structure further comprises an array of
indentions and beams oriented at selected locations within the
textile.
6. The article of footwear according to claim 5, wherein the beams
include longitudinal beams oriented along footwear longitudinal
axis.
7. The article of footwear according to claim 6 further including
transverse beams oriented along footwear transverse axis, the
longitudinal beams intersecting the transverse beams.
8. The article of footwear according to claim 6, wherein the
microclimate moderation structure further comprises exhaust
apertures oriented at selected locations along one or more of the
beams, the exhaust apertures permitting passage of air from the
foot cavity.
9. The article of footwear according to claim 8, wherein the
microclimate moderation structure further comprises a knitted web
layer spanning the array of beams and indentations, the web layer
comprising strands oriented in courses and wales.
10. The article of footwear according to claim 9, wherein: the web
layer further comprises apertures extending through the knitted web
layer; and each aperture is generally aligned with a corresponding
indention.
11. The article of footwear according to claim 9, wherein the heel
region includes a heel cup section and a planum section extending
from the heel region to the forefoot region, the heel cup section
and the planum section defining a seamless, unitary
construction.
12. The article of footwear according to claim 11, wherein the heel
region comprises a flat knit structure possessing an arcuate
profile.
13. An article of footwear including a foot cavity, the article of
footwear comprising: a sole structure; an upper coupled to the sole
structure, the upper defining a forefoot region, a midfoot region
and a hindfoot region; and a microclimate moderation structure
disposed within the forefoot region of the upper, the microclimate
moderation assembly comprising a flat knit textile including: a
first portion forming a toe cage of the upper, the first portion
including a strand operable to move heat along a predetermined
pathway from a first upper location to a second upper location, and
a second portion oriented rearward the first structure, the second
portion including an array of indentions and beams disposed at
selected locations within the textile.
14. The article of footwear according to claim 13, wherein the
microclimate moderation structure comprises a first strand and a
second strand, the first strand transferring heat at a first rate
and the second strand transferring heat at a second rate.
15. The article of footwear according to claim 14, wherein heat
transfer rate of the first strand is greater than the heat transfer
rate of the second strand.
16. The article of footwear according to claim 15, wherein: the
first strand is formed from material possesses a thermal
conductivity of greater than 0.40 W/m-K; and the second strand is
formed from material possessing a thermal conductivity of no more
than 0.40 W/mK.
17. The article of footwear according to claim 16, wherein the
first strand is an ultra-high molecular weight polyethylene fiber.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] The present application claims priority to Provisional
Application No. 62/158,709, filed 8 May 2015 and entitled "Footwear
Including a Textile Upper." The disclosure of the aforementioned
application is incorporated herein by reference in its
entirety.
FIELD OF THE INVENTION
[0002] The present invention relates to an article of footwear and,
in particular, footwear including an upper with a temperature
modulation structure.
BACKGROUND
[0003] Articles of footwear typically include an upper and a sole
structure attached to the upper that cooperate to define a foot
cavity. Controlling the microclimate of the foot cavity--the
temperature and humidity within the foot cavity, including the
position of air layers relative to the foot or sock--is important
for wearer comfort. High temperature and humidity inside the foot
cavity may cause discomfort and/or affect blood flow (straining on
the wearer's vascular system). Excessive humidity within the foot
cavity, moreover, may promote the growth of microorganisms (fungi
and bacteria).
[0004] Accordingly, it would be desirable to provide an upper for
footwear capable of affecting the microclimate within the foot
cavity.
SUMMARY OF THE INVENTION
[0005] An article of footwear includes a sole structure and an
upper attached to the sole structure. The upper is formed from a
textile including interlocked strands oriented in a predetermined
configuration. The upper further includes a microclimate modulation
structure operable to affect the microclimate of the foot cavity.
The microclimate modulation structure includes pockets configured
to capture heated and/or moist air away from the surface of the
foot. The microclimate modulation structure further includes
strands possessing high thermal conductivity that selectively
positioned within the textile structure. The high thermal
conductivity strands are capable of transferring heat at a higher
rate than surrounding strands.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] FIG. 1 is an exploded view of an article of footwear in
accordance with an embodiment of the invention (footwear configured
for a right foot).
[0007] FIG. 2A is side view in elevation of the article of footwear
shown in FIG. 1, showing the medial footwear side.
[0008] FIG. 2B is a side view in elevation of the article of
footwear shown in FIG. 1, showing the lateral footwear side.
[0009] FIG. 2C is a front perspective view of the article of
footwear of FIG. 1, showing the lateral footwear side.
[0010] FIG. 2D is a front perspective view of the article of
footwear shown in FIG. 1, showing the medial footwear side.
[0011] FIG. 2E is a rear perspective view of the article of
footwear shown in FIG. 1, showing the medial footwear side.
[0012] FIG. 3 is a side view in elevation of the article of
footwear shown in FIG. 1, showing the lateral footwear side and
further including a partial cut-out section.
[0013] FIG. 4 is a front perspective view of the article of
footwear in accordance with the invention, showing the lateral shoe
side.
[0014] FIG. 5A is a close-up view (medial shoe side) of the vamp
section of the article footwear shown in FIG. 4.
[0015] FIG. 5B is a close-up view (lateral shoe side) of the vamp
section of the article of footwear shown in FIG. 4.
[0016] FIG. 5C is cross sectional view of the vamp taken along
lines 5C-5C in FIG. 5A.
[0017] FIG. 5D is cross sectional view of the vamp taken along
lines 5D-5D in FIG. 5B.
[0018] FIG. 6A is a front perspective view of the article of
footwear of FIG. 4, showing the medial shoe side.
[0019] FIG. 6B is a top plan view of the article of footwear of
FIG. 4.
[0020] Like reference numerals have been used to identify like
elements throughout this disclosure.
DETAILED DESCRIPTION
[0021] As described herein with reference to the example embodiment
of FIGS. 1-6, an article of footwear 100 includes an upper 105
coupled to a sole structure 110 and further including a heel
counter 115 and a fastening element or fastener 120 (e.g., a lace
or cord, which is shown in phantom). In an embodiment, the upper
105 is a textile formed via knitting. Knitting is a process for
constructing fabric by interlocking a series of loops (bights) of
one or more strands organized in wales and courses. In general,
knitting includes warp knitting and weft knitting. In warp
knitting, a plurality of strands runs lengthwise in the fabric to
make all the loops.
[0022] In weft knitting, one continuous strand runs crosswise in
the fabric, making all of the loops in one course. Weft knitting
includes fabrics formed on both circular knitting and flat knitting
machines. With circular knitting machines, the fabric is produced
in the form of a tube, with the strands running continuously around
the fabric. With a flat knitting machine, the fabric is produced in
flat form, the threads alternating back and forth across the
fabric. In an embodiment, the upper 105 is formed via flat knitting
utilizing stitches including, but not limited to, a plain stitch; a
rib stitch, a purl stitch; a missed or float stitch (to produce a
float of yarn on the fabric's wrong side); and a tuck stitch (to
create an open space in the fabric). The resulting textile includes
an interior side (the technical back) and an exterior side (the
technical face), each layer being formed of the same or varying
strands and/or stitches. By way of example, the knit structure may
be a single knit/jersey fabric, a double knit/jersey fabric, and/or
a plated fabric (with yarns of different properties are disposed on
the face and back). In a specific embodiment, the textile is a
double knit fabric formed via a flat knitting process.
[0023] The strands forming the textile (and thus the upper 105) may
be any natural or synthetic strands suitable for their described
purpose (to form a knit upper). The term "strand" includes one or
more filaments organized into a fiber and/or an ordered assemblage
of textile fibers having a high ratio of length to diameter and
normally used as a unit (e.g., slivers, roving, single yarns, plies
yarns, cords, braids, ropes, etc.). In a preferred embodiment, a
strand is a yarn, i.e., a continuous strand of textile fibers,
filaments, or material in a form suitable for knitting, weaving, or
otherwise intertwining to form a textile fabric. A yarn may include
a number of fibers twisted together (spun yarn); a number of
filaments laid together without twist (a zero-twist yarn); a number
of filaments laid together with a degree of twist; and a single
filament with or without twist (a monofilament).
[0024] The strands include elastic strands or inelastic strands. An
elastic strand is formed of elastomeric material; consequently, by
virtue of its composition, the strand possesses the ability to
stretch. Accordingly, an elastic strand possesses elasticity and/or
recovery, i.e., the ability to stretch/deform under load and
recover to immediately after removal of the load. The degree to
which fibers, yarn, or cord returns to its original size and shape
after deformation indicates how well a fabric recovers. Some
specific examples of elastomers are elastic polymers such as
elastomeric polyester-polyurethane copolymers. By way of specific
example, elastane, a manufactured fiber in which the fiber-forming
substance is a long chain synthetic polymer composed of at least
85% of segmented polyurethane, may be utilized.
[0025] In contrast, inelastic strands are not formed of elastomeric
material; consequently, by virtue of their composition alone,
inelastic strands possess substantially no inherent stretch and
recover properties. Hard yarns are a type of inelastic strand. Hard
yarns include natural and/or synthetic spun staple yarns, natural
and/or synthetic continuous filament yarns, and/or combinations
thereof. By way of specific example, natural fibers include
cellulosic fibers (e.g., cotton, bamboo) and protein fibers (e.g.,
wool, silk, and soybean). Synthetic fibers include polyester fibers
(poly(ethylene terephthalate) fibers and poly(trimethylene
terephthalate) fibers), polycaprolactam fibers, poly(hexamethylene
adipamide) fibers, acrylic fibers, acetate fibers, rayon fibers,
nylon fibers and combinations thereof.
[0026] The strands suitable for forming the upper 105 further
include heat sensitive strands. Heat sensitive strands include
flowable (fusible) strands and softening. Flowable strands are
include polymers that possess a melting and/or glass transition
point at which the solid polymer liquefies, generating viscous flow
(i.e., becomes molten). In an embodiment, the melting and/or glass
transition point of the flowable polymer may be approximately
80.degree. C. to about 150.degree. C. (e.g., 85.degree. C.).
Examples of flowable strands include thermoplastic materials such
as polyurethanes (i.e., thermoplastic polyurethane or TPU),
ethylene vinyl acetates, polyamides (e.g., low melt nylons), and
polyesters (e.g., low melt polyester). Preferred examples of
melting strands include TPU and polyester. As a strand becomes
flowable, it surrounds adjacent strands. Upon cooling, the strands
form a rigid interconnected structure that strengthens the textile
and/or limits the movement of adjacent strands.
[0027] Softening strands are polymeric strands that possess a
softening point (the temperature at which a material softens beyond
some arbitrary softness). Many thermoplastic polymers do not have a
defined point that marks the transition from solid to fluid.
Instead, they become softer as temperature increases. The softening
point is measured via the Vicat method (ISO 306 and ASTM D 1525),
or via heat deflection test (HDT) (ISO 75 and ASTM D 648). In an
embodiment, the softening point of the strand is from approximately
60.degree. C. to approximately 90.degree. C. When softened, the
strands become tacky, adhering to adjacent stands. Once cooled,
movement of the textile strands is restricted (i.e., the textile at
that location stiffens).
[0028] One additional type of heat sensitive strand which may be
utilized is a thermosetting strand. Thermosetting strands are
generally flexible under ambient conditions, but become
irreversibly inflexible upon heating.
[0029] The strands may also include heat insensitive strands. Heat
insensitive strands are not sensitive to the processing
temperatures experienced by the upper (e.g., during formation
and/or use). Accordingly, heat insensitive strands possess a
softening, glass transition, or melting point value greater than
that of any softening or melting strands present in the textile
structure and/or greater than the temperature ranges specified
above.
[0030] It should be understood that a strand may be categorized in
a combination of the above categories. For example, a polyester
yarn may be both a heat insensitive and an inelastic strand, as
defined above.
[0031] Referring to FIGS. 2A-2D, the article of footwear 100 is an
athletic shoe (e.g., a running shoe) defining a forefoot region
200A, a midfoot region 200B, and a hindfoot region 200C, as well as
a medial side 205A and a lateral side 205B. The forefoot region
200A generally aligns with the ball and toes of the foot, the
midfoot region 200B generally aligns with the arch and instep areas
of the foot, and the hindfoot region 200C generally aligns with the
heel and ankle areas of the foot. Additionally, the medial side
205A is oriented along the medial (big toe) side of the foot, while
the lateral side 205B is oriented along the lateral (little toe)
side of the foot.
[0032] The upper 105 includes a plurality of sections that
cooperate to define the foot cavity. A heel section 210 includes
heel cup configured to align with and cover the calcaneus area of a
human foot. A lateral quarter section 215, disposed forward the
heel section 210, is oriented on the lateral shoe side 205B.
Similarly, a medial quarter section 220, disposed forward the heel
section 210, is oriented on the medial shoe side 205A. A vamp
section 225 is disposed forward the quarter sections 215, 225,
while a toe cage section 230 is disposed forward the vamp section.
The upper 105 may further includes an instep cover section 240
configured to align and span the instep area of the foot and a
planum section or footbed 300 (FIG. 3) that engages the planum
(bottom) of the foot.
[0033] With this configuration, the heel 210, lateral quarter 215,
medial quarter 220, vamp 225, toe cage 230 and planum 300 sections
cooperate to form a foot cavity 332 (FIG. 3) into which a human
foot is inserted by way of an access opening 235 formed
cooperatively by the heel 210, the lateral 215 and medial 220
quarters, and the instep cover 240.
[0034] The upper 105 may possess a unitary structure (also called a
unibody construction) to minimize the number of seams utilized to
form the shape of the upper. That is, the upper 105 may be formed
as a one-piece template, each template portion being integral with
adjacent template portions. Stated yet another way, each section
210, 215, 220, 225, 230, 240, 300 of the upper 105 may include a
common strand interconnecting that section with adjacent sections
(i.e., the common strand spans both sections). In addition, the
connection between adjacent sections may be stitchless and
seamless. By stitchless and/or seamless, it is meant that adjacent
sections are continuous or integral with each other, including no
edges that require joining by stitches, tape, adhesive, welding
(fusing), etc.
[0035] Referring to FIG. 2C, the lateral quarter section 215
extends from the heel section 210 to the vamp section 225,
traveling upward from the planum section 300 such that the lateral
quarter section spans the lateral side of the foot, proximate the
hindfoot 200C and midfoot regions 200B. As explained above, the
lateral quarter section 215 may be formed integrally (continuous
with) with the heel section 210, the vamp section 225, and the
planum section 300.
[0036] The lateral quarter section 215 is adapted to receive a
fastener such as a shoe lace. In an embodiment, the lateral quarter
215 includes a plurality of looped sections 245A, 245B, 245C, 245D
disposed at the lateral quarter distal edge (upper edge). As
illustrated, the looped sections 245A-245D are linearly spaced,
being generally aligned in an array extending longitudinally along
the shoe 100. In this manner, each looped section 245A-245D is
configured to receive the fastener 120 (the shoe lace), movably
capturing the fastener therein. The looped sections 245A-245D,
moreover, cooperate with one or more elements disposed on the
instep cover 240 to engage the fastener 120 and secure the shoe 100
to the foot of the wearer (described in greater detail, below).
[0037] Referring to FIGS. 2D & 2E, the medial quarter section
220 extends from the heel 210 to the vamp 225, traveling upward
from the planum 300 such that the medial quarter spans the medial
side of the foot, proximate the hindfoot 200C and midfoot 200B
regions. As explained above, the medial quarter 220 may be
seamlessly and/or stitchlessly integrated with each of the heel
210, the vamp, and planum 300 sections of the upper.
[0038] The instep cover 240 is configured to span the dorsum
portion of the midfoot (i.e., the instep). The instep cover 240 may
be formed integrally (stitchlessly and/or seamlessly) with the
medial quarter section 220. As best seen in FIG. 3, the instep
cover 240 defines a forward edge 305 (oriented toward the vamp 225)
and a rearward edge 310 oriented generally parallel to the forward
edge. The instep cover 240 further defines distal edge 315 oriented
generally orthogonal to the forward and rearward edges. The instep
cover 240 generally spans the instep of the foot, extending from
the medial shoe side 205A to the lateral shoe side 205B, and
extending from the throat line 250 of the vamp 225 at its forward
edge 305 to the access opening 235 at its rearward edge 310. As
noted above, the access opening 235 is partially defined by the
rearward edge 310.
[0039] The instep cover 240 may include one or more narrow,
elongated openings or slots 260 operable to permit passage of the
fastener 120 therethrough. The instep cover 240 may also include
additional openings or windows 285 operable to improve airflow
into/out of the upper.
[0040] The forefoot region 200A of the upper 105 includes the vamp
section 225, which extends forward from the lateral quarter 215 and
medial quarter 220 sections, being formed integrally therewith
(e.g., stitchlessly and seamlessly). The vamp section 225 defines
the throat line 250 within its proximal region and toe cage 230
within its distal region, the toe cage being configured to span the
toes of the foot.
[0041] The vamp 225, moreover, includes a microclimate modulation
structure (also called microclimate moderation structure) operable
to affect movement of heat, air, and/or moisture (e.g., vapor)
within the foot cavity 332. Thermal comfort is an important factor
considered in footwear design. The microclimate of footwear, which
contributes to thermal comfort, is influenced by heat and moisture
within the foot cavity. Accordingly, moving heat and/or moisture
away from the surface of the foot and/or exhausting heat from the
foot cavity 332 optimizes the microclimate which, in turn,
optimizes the thermal comfort experienced by the user.
[0042] The temperature modulation structure includes strands
selected to possess predetermined thermal conductivity values
positioned at selected locations within the knit construction of
the textile. Specifically, the temperature modulation structure 400
includes first, high thermal conductivity strands and second, low
thermal conductivity strands. High conductivity strands are strands
that transfer heat along its length (axis) and/or width (transverse
dimension) at a higher rate than low thermal conductivity strands.
In an embodiment, high thermal conductivity strands are strands
formed (e.g., entirely formed) of material possessing a thermal
conductivity value greater than 0.40 W/m K. By way of example, the
strands may be formed of high density polyethylene (HDPE, 0.45-0.52
@23 C) and/or ultra-high molecular weight polyethylene (UWMW-PE,
0.42-0.51 W/m K @23 C).
[0043] In a further embodiment, high thermal conductivity strand is
a strand that possessing an axial thermal conductivity of at least
5 W/m K (e.g., at least 10 W/m K or at least 20 W/m K). The high
thermal conductivity strand may be a multifilament fiber such as a
gel-spun fiber. By way of specific example, the high conductivity
strand is a gel-spun, multifilament fiber produced from ultra-high
molecular weight polyethylene (UHMW-PE), which possesses a thermal
conductivity value in the axial direction of 20 W/m K.
[0044] The low thermal conductivity strand, in contrast, transfers
heat along its length (axis) and/or width (transverse dimension) at
a lower rate than that of the high thermal conductivity strand. In
an embodiment, the low thermal conductivity strand is formed (e.g.,
entirely formed) of material possessing a thermal conductivity of
no more than 0.40 W/m K. By way of example, the low conductivity
strand may be formed of low density polyethylene (LDPE, 0.33 W/m K
@23 C), nylon (e.g., nylon 6; nylon 6,6; or nylon 12) (0.23-0.28
W/m K @23.degree. C.), polyester (0.15-0.24 W/m K @23.degree. C.),
and/or polypropylene (0.1-0.22 W/m K @23 C).
[0045] In another embodiment, the low thermal conductivity strand
possesses an axial thermal conductivity (as measured along its
axis) that is less than the axial conductivity of the high
conductivity strands. By way of example, the low thermal
conductivity strands possess an axial thermal conductivity value of
less than 5 W/m K when high thermal conductivity strand possesses a
thermal conductivity of greater than 5 W/m K; of less than 10 W/m K
when high conductivity strand possesses a thermal conductivity of
at least 10 W/m K; and/or less than 20 W/m K when high conductivity
strand possesses a thermal conductivity of greater than 20 W/m K.
Exemplary low thermal conductivity strands include strands formed
of polyester staple fibers (axial thermal conductivity: 1.18 W/m
K); polyester filament strands (axial thermal conductivity: 1.26
W/m K); nylon fiber strands (axial thermal conductivity: 1.43 W/m
K); polypropylene fiber strands (axial thermal conductivity: 1.24
W/m K); cotton strands (axial thermal conductivity: 2.88 W/m K);
wool strands (axial thermal conductivity: 0.48 W/m K); silk strands
(axial thermal conductivity: 1.49 W/m K); rayon strands (axial
thermal conductivity: 1.41-1.89 W/m K); and aramid strands (axial
thermal conductivity: 3.05-4.74 W/m K), as well as combinations
thereof.
[0046] The microclimate modulation structure 400 may further
possess a knit construction or structure configured to affect the
microclimate of the foot cavity 332 (either independently or in
cooperation with the high thermal conductivity strands). Referring
to FIGS. 4A, 4B, and 4C, the microclimate modulation structure 400
includes a first construction or portion 405 possessing a first
knit construction and a second construction or portion 410
possessing a second knit construction. The first portion 405 forms
the central area of the vamp 225, being oriented forward the throat
line 250, with its lateral boundaries generally coextensive
therewith, and its forward boundary located proximate the toe cage
230. The second portion 410 partially surrounds the first portion
405, being oriented along the forward, medial, and lateral sides of
the first portion. Stated another way, the second portion 410 forms
the toe cage 230, the lateral side 415 of the vamp 225, and the
medial side 420 of the vamp. As illustrated, the first portion 405
is integral with the second portion 410 with a seamless and/or
stitchless transition therebetween.
[0047] Each portion 405, 410 of the microclimate modulation
structure 400 is independently capable of affecting the movement of
heat, air, and/or moisture within the cavity and/or exhausting it
from the foot cavity 332. It should be understood, however, that
the portions 405, 410 cooperate with each other, working in concert
to affect the foot cavity microclimate (i.e., the portions operate
independently of each other and cooperatively with each other).
[0048] Referring to FIGS. 5A, 5B, 5C, and 5D, the first portion 405
of the microclimate modulation structure 400 includes an exterior
layer 505 (technical face) plated with an interior layer 510
(technical back). The exterior layer 505 includes a plurality of
chambers or pockets operable to position heated and/or moist air
away from the area immediately surrounding the foot (or sock
exterior surface). The pockets are formed via indentations 515
disposed between the intersection of a plurality of elongated,
longitudinal beams or sections 520 extending in a longitudinal or
lengthwise direction of the upper 105 (e.g., extending between the
throat line 250 and the toe cage 230) with a plurality of
elongated, transverse beams or sections 525 extending transversely
to the lengthwise direction of the upper (i.e., between lateral 415
and medial 420 sides).
[0049] The longitudinal 520 and transverse 525 beams define areas
of increased height relative to the indentations 515. In an
embodiment, the height of the beams 520, 525 and/or the depths of
the indentations 515 is approximately two millimeters or more to
provide appropriate spacing of the indentation from the interior
layer 510 and/or foot/sock surface (discussed in greater detail
below). By way of specific example, a combination of jersey and
float stitches may be utilized to form the indentations 515 and
beams 520, 525.
[0050] The knit construction may be configured such that each
indentation 515 formed into the outer side 535 of the exterior
layer 505 forms a corresponding beam 520, 525 protruding from the
inner side 540 of the exterior layer. Similarly, each indentation
515 formed into the inner side 540 of the exterior layer 505 forms
a corresponding beam 520, 525 protruding the outer side 535 of the
exterior layer (i.e., the topography on the inner side is the
negative of the outer side topography). Accordingly, as seen in
FIG. 5C, the transverse beams 525 of the outer side 535 define
cavities 515 along the inner side 540. Alternatively, the pattern
disposed on the inner side 540 may include only the transverse
beams 525, defining an indentation 515 between adjacent rows of
beams 520 (i.e., omitting longitudinal beams 520).
[0051] Each indentation 515 forms a pocket or chamber (e.g., a
polygonal or rectangular shaped pocket) within the exterior layer
505 along its inner, foot-cavity-facing side 540. Each pocket is
oriented in spaced relation from the immediate foot surface (or
sock surface) and/or the interior layer 510. That is, the
longitudinal 520 and/or transverse beams 525 on the inner side 540
act as spacers to maintain a gap between the indentations 515 and
the foot (and/or the interior layer 510). With this configuration,
the resulting pockets are capable of collecting/capturing heated
and/or moist air from the foot cavity 332 (e.g., heat generated by
the forefoot portion of the foot) and storing it away from the
foot/sock surface, thereby increasing wearer comfort. In operation,
heated and/or moist air along the surface of the foot travels
upward, away from the foot surface and into the pockets, where it
is collected. The moist air may travel through apertures 555 formed
into the interior layer 510 and aligned with indentations 515. The
depth of the indentation 515 and height of the beams 525 may
cooperate to create a pocket spaced approximately two millimeters
to five millimeters from the foot or sock surface. Moving heated
air two millimeters or more from the foot surface improves the
microclimate experienced by the wearer.
[0052] The first portion 405 of the microclimate modulation
structure 400 may further include exhaust ports 545 (i.e., openings
defined in the knit construction) in fluid communication with the
foot cavity 332. Referring to FIG. 5D, the outer side 535 of the
exterior layer 505 may include exhaust ports 545 positioned along
the longitudinal beam 520, proximate an indentation 515. In an
embodiment, a pair of exhaust ports 545 is aligned across the
longitudinal beam 520 transverse dimension. Stated another way,
each longitudinal beam 520 extends over the transverse beams 525 so
as to form a bridge-like structure or bridging portion 550 between
pairs of neighboring or consecutively aligned beams, with a
transverse channel 547 defined beneath the bridging portion of the
beam that communicates with neighboring indentations 515
consecutively aligned on each side of the bridging portion of the
beam. Each longitudinal beam 520 bridges (via bridging portion 550)
the peaks (defined by transverse beams) and valleys (defined by
indentations) of the first portion 405, with transverse channels
547 extending transversely through/under each longitudinal beam at
the indentation.
[0053] In addition, the exterior layer 505 may include vertical
channels or passages 552 in communication with the apertures 555 of
the interior layer 510.
[0054] With this configuration, movement of fluid (air/vapor) is
permitted into and out of the foot cavity 332. For example, heated
and/or moist air collected/captured within the cavity 332 (i.e.,
within each indentation 515) travels into the passages 542, through
vertical channel 552, and along transverse channel 547, escaping
via the exhaust ports 545, thereby improving the foot cavity
microclimate.
[0055] The interior layer 510, which is exposed to the foot cavity
332, is a generally planar layer that spans the array of
indentations 515 and beams 520, 525 of the vamp 225 (i.e., the
waffle pattern). In an embodiment, the layer 510 is generally
continuous, and may possess a lower stitch density than that of the
exterior layer 505 (e.g., to assist fluid movement therethrough).
As noted above, the interior layer 510 may further include
apertures 555 disposed at selected locations that permit passage of
fluid (air/vapor). By way of example, each aperture 555 may be
generally aligned with a corresponding pocket or indentation 515
along the interior side 540 of the exterior layer 505. With this
configuration, moist or heated air from the foot cavity 332 passes
through the apertures 555 and is directed into the pockets 515 of
the exterior layer 505 where it is stored away from the user.
[0056] As noted above, the portions 405, 410 of the modulation
structure 400 are formed of low thermal conductivity strands and
high thermal conductivity strands placed at selected locations
within the construction. In an embodiment, the interior layer 510
is formed primarily (e.g., >50%), substantially (e.g., >90%),
or completely (100%) of high thermal conductivity strands (with any
remainder being low conductivity strands). The exterior layer 505,
in contrast, is formed primarily, substantially, or completely of
low thermal conductivity strands. Accordingly, the interior layer
510 is a thermal conduction layer, being operable to transfer heat
at a higher rate than the exterior layer 505. In an embodiment, the
interior layer 510 is formed completely of high thermal
conductivity strands and the exterior layer 505 is formed
completely of low conductivity strands.
[0057] It is believed the above described configuration modulates
the comfort of the shoe 100 by affecting the movement of moisture,
airflow, and/or heat within the foot cavity 332. In operation, heat
and water vapor generated by the foot are released into the foot
cavity 332, traveling upward, toward the first portion 405 of the
microclimate modulation structure 400. The heat and/or water vapor
contacts the interior layer 510, which, being formed of high
thermal conductivity strands, conducts heat along its volume (its
surface area), spreading the heat over a wide surface area to
prevent the formation of hot spots and to disperse the heat. In
addition, the interior layer 510 draws water vapor away from the
foot via the capillary action of the knit structure. Heat and/or
water vapor, furthermore, pass through the apertures 555 of the
interior layer 510. Once past the interior layer 110, heat and/or
vapor are either received by the indentations 515 of the exterior
layer 505, being temporarily stored away from the surface of the
foot/sock. Additionally, the heat and/or vapor may be exhausted
from the foot cavity 332 via exhaust ports 545.
[0058] As noted above, the second portion 410 of the microclimate
modulation structure 400 surrounds the first portion 405, extending
along the lateral 415 and medial 420 sides of the vamp section 225,
terminating proximate the throat line 250 at its rear, and
extending forward to the toe cage 230. In an embodiment, the second
portion 410 includes a plurality of ribs and channels spaced along
the technical face (exterior side) and/or the technical back
(interior side) of the upper 105. Specifically, referring to FIGS.
4, 6A and 6B, the second portion possesses a double knit
construction including by rib (e.g., 2.times.1 rib) and float
(e.g., float single jacquard) stitches. To define integrated
interior 610 and exterior 615 layers. The stitches are located to
create a series of raised ribs or bands 625 separated by surface
channels 630. By way of example, the rib stitches and float
stitches are disposed at selected locations to form alternating
bands 625 and channels 630 within each layer, the bands being
oriented longitudinally along the upper (i.e., the bands extend
lengthwise, from throat line 250 to toe cage 230). Specifically,
the bands 625 are formed via rib stitches, while the channels 630
are formed via float stitches (where connected loops of the same
course are not in adjacent wales).
[0059] As with the first portion 405, the second portion 410
includes strands possessing relatively higher and lower thermal
conductivity values disposed at selected positions within the
construction. For example, the high thermal conductivity strands
may be located within the inner layer 610 of the knit structure, or
may be located in one or both of the exterior 615 and interior 610
layers of the structure. In an embodiment, the knit construction is
configured such that the exterior layer 615 is formed primarily,
substantially, or completely of low thermal conductivity strands
and the interior layer 610 is formed primarily, substantially, or
completely formed of high thermal conductivity strands.
[0060] It should be understood, however, that the amount of high
thermal conductivity strands present within the second portion 410
of the microclimate modulation structure 410 may be any suitable
for its described purpose. In an embodiment, the high thermal
conductivity strand 615 forms at least 25% (e.g., at least 30%, at
least 40%, at least 50%, etc.) of the second portion 410 (e.g., at
least 25% of the strands forming the second portion are high
thermal conductivity strands; or at least 25% of the overall strand
weight of the second portion is due to the high thermal
conductivity strands). In a further embodiment, the high thermal
conductivity strands represent no more than 60% of the strands
forming the second portion 410 (e.g., the high thermal conductivity
strands form 25%-60% of the second portion).
[0061] In addition, the knit construction selectively exposes
strands forming the interior layer 615 through the exterior layer
610 and, accordingly, the ambient environment. As noted above, each
of the exterior 610 and interior 615 layers includes continuous
strands forming courses along the crosswise textile direction. The
stitches may be selected such that a continuous strand forming the
interior layer 615 is exposed at selected locations along the
strand length, and vice versa. By way of specific example,
selectively placing float stitches within the exterior layer 610
further including ribbing selectively exposes the strand forming
the interior layer 610 (technical back, also called the inside
loop). With this configuration, the strand possessing high thermal
conductivity forming the inner layer (technical back) is
selectively exposed, appearing as a transverse bridge between the
longitudinal bands of ribbing. Stated another way, and as best seen
in FIG. 4, each surface channel 630 includes windows 635 exposing
interior layer 610. Each window is defined by adjacent knitted bars
640 extending transversely across the channel 630.
[0062] In operation, it is believed multiple independent and/or
cooperating mechanisms occur to affect the foot cavity
microclimate. Specifically, heat and/or water vapor generated by
the foot travels toward the second portion 410. The heat and/or
water are either directed along the channels 630, or contact the
high thermal conductivity strands. The channels 630 encourage the
movement of air, aiding in creating a cooling sensation. In
addition, the high thermal conductivity strands transfer heat,
spreading it along their lengths such that heat is spread over a
wide surface area. The strands of the first portion 405,
furthermore, are in communication with the strands of the second
portion 410. Accordingly, heat from the first portion is spread
across the second portion, and vice versa. Finally, the portions of
the high thermal conductivity strand exposed along the exterior
layer 610 permits escape of heat absorbed by the high thermal
conductivity strand to the ambient environment.
[0063] With specific regard to water vapor, hydrophobic, high
thermal conductivity strands such as strands formed of UHMW-PE do
not absorb water. Accordingly, it is believed that any water vapor
present in the cavity contacts the strand, where it is drawn away
from the foot cavity 332 via capillary action within the knit
structure.
[0064] The sole structure 110 comprises a durable, wear-resistant
component configured to provide cushioning as the shoe 100 impacts
the ground. In certain embodiments, the sole structure 110 may
include a midsole and an outsole. In additional embodiments, the
sole structure 110 can further include an insole that is disposed
between the midsole and the upper 105 when the shoe 100 is
assembled. In other embodiments, the sole structure 110 may be a
unitary and/or one-piece structure. As can be seen, e.g., in the
exploded view of FIG. 1, the sole structure 110 includes an upper
facing side 125 and an opposing, ground-facing side 130. The upper
facing side 125 may include a generally planar surface and a curved
rim or wall that defines the sole perimeter for contacting the
bottom surface 135 of the upper 105. The ground-facing side 130 of
the sole structure 110 can also define a generally planar surface
and can further be textured and/or include ground-engaging or
traction elements (e.g., as part of the outsole of the sole
structure) to enhance traction of the shoe 100 on different types
of terrains and depending upon a particular purpose in which the
shoe is to be implemented. The ground-facing side 130 of the sole
structure 110 can also include one or more recesses formed therein,
such as indentations or grooves extending in a lengthwise direction
of the sole structure 110 and/or transverse the lengthwise
direction of the sole structure, where the recesses can provide a
number of enhanced properties for the sole structure (e.g.,
flexure/pivotal bending along grooves to enhance flexibility of the
sole structure during use).
[0065] The sole structure 110 may be formed of a single material or
may be formed of a plurality of materials. In example embodiments
in which the sole structure includes a midsole and an outsole, the
midsole may be formed of one or more materials including, without
limitation, ethylene vinyl acetate (EVA), an EVA blended with one
or more of an EVA modifier, a polyolefin block copolymer, and a
triblock copolymer, and a polyether block amide. The outsole may be
formed of one or more materials including, without limitation,
elastomers (e.g., thermoplastic polyurethane), siloxanes, natural
rubber, and synthetic rubber.
[0066] 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, while most of the example embodiments
depicted in the figures show an article of footwear (shoe)
configured for a right foot, it is noted that the same or similar
features can also be provided for an article of footwear (shoe)
configured for a left foot (where such features of the left footed
shoe are reflection or "mirror image" symmetrical in relation to
the right footed shoe).
[0067] While the figures depict the first microclimate modulation
structure 400 as being located in the vamp 225 region of the shoe
100 proximate the instep of the upper 105, it should be understood
that the first structure may be located at any location suitable
for its described purpose.
[0068] Within the knit structure, various stitches may be used to
provide different sections 210, 215, 220, 225, 230, 240, 300 of the
upper 105 with different properties. For example, a first area may
be formed of a first stitch configuration, and a second area may be
formed of a second stitch configuration that is different from the
first stitch configuration to impart varying textures, structures,
patterning, and/or other characteristics to the upper member.
[0069] The dimensions (e.g., length, width, and depth), spacing,
geometric shape and pattern of the indentations 515, the
longitudinal beams 520, and/or the transverse beams 525 can vary
for different embodiments to provide different aesthetic and/or
heat transfer effects for the upper 105.
[0070] Stitching may be utilized to connect sections of the upper
together. In addition, a thermoplastic film may be utilized to
reinforce seams, replace stitching, and/or prevent fraying. For
example, seam tape available from Bemis Associates, Inc. (Shirley,
Mass.) may be utilized.
[0071] Instead of an instep cover 240, the upper 105 may include a
conventional tongue including a longitudinally extending member
free on its lateral and medial sides.
[0072] It is to be understood that terms such as "top", "bottom",
"front", "rear", "side", "height", "length", "width", "upper",
"lower", "interior", "exterior", "inner", "outer", 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.
[0073] 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.
* * * * *