U.S. patent application number 15/940234 was filed with the patent office on 2018-08-02 for article of footwear with braided upper.
The applicant listed for this patent is NIKE, Inc.. Invention is credited to Robert M. Bruce.
Application Number | 20180213878 15/940234 |
Document ID | / |
Family ID | 52109756 |
Filed Date | 2018-08-02 |
United States Patent
Application |
20180213878 |
Kind Code |
A1 |
Bruce; Robert M. |
August 2, 2018 |
ARTICLE OF FOOTWEAR WITH BRAIDED UPPER
Abstract
An article of footwear includes a braided upper comprised of a
unitary braided structure. The unitary braided structure of the
braided upper may be engineered with specific features tailored to
particular activities. Different regions of the upper may have
different braided configurations. For example, higher braid
densities may be used in specific areas of the footwear to provide
additional structural support or compression. Also, strands of a
different material may be incorporated in different regions of the
braided upper to provide specific properties to the footwear in
those areas.
Inventors: |
Bruce; Robert M.; (Portland,
OR) |
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Applicant: |
Name |
City |
State |
Country |
Type |
NIKE, Inc. |
Beaverton |
OR |
US |
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|
Family ID: |
52109756 |
Appl. No.: |
15/940234 |
Filed: |
March 29, 2018 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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14495252 |
Sep 24, 2014 |
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15940234 |
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14163392 |
Jan 24, 2014 |
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14495252 |
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61839097 |
Jun 25, 2013 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
A43B 1/04 20130101; A43B
23/0215 20130101; D10B 2501/043 20130101; A43B 23/04 20130101; A43B
23/0295 20130101; A43B 23/0245 20130101; A43B 23/042 20130101; D04C
1/06 20130101 |
International
Class: |
A43B 1/04 20060101
A43B001/04; D04C 1/06 20060101 D04C001/06; A43B 23/04 20060101
A43B023/04; A43B 23/02 20060101 A43B023/02 |
Claims
1. An article of footwear comprising: a sole; and an upper attached
to the sole, wherein said upper comprises a unitary braided
structure formed form a plurality of interlaced yarns; the unitary
braided structure having a first region with a first braid
configuration and at least a second region with a second braid
configuration different from said first braid configuration, the
second region framing the first region, wherein the first braid
configuration has a density of braids that is lower than a density
of braids of the second braid configuration.
2. The article of footwear of claim 1, wherein the first region and
the second region are braided from yarns having material
properties, and wherein the first region is braided with at least
one yarn that is different from the yarns of the second region.
3. The article of footwear of claim 2, wherein the first braid
configuration has different stretch properties than stretch
properties of the second braid configuration.
4. The article of footwear of claim 3, wherein the first braid
configuration is more elastic than the second braid
configuration.
5. The article of footwear of claim 1, wherein the first braid
configuration has a different braid angle than the second braid
configuration.
6. The article of footwear of claim 1, wherein the first braid
configuration has a different braid pitch than the second braid
configuration.
7. The article of footwear of claim 1, wherein the second braid
configuration is made of a material having greater tensile strength
than a material of the first braid configuration.
8. An upper for an article of footwear comprising: a unitary
braided structure formed form a plurality of interlaced yarns; the
unitary braided structure having a first region with a first braid
configuration and at least a second region with a second braid
configuration different from said first braid configuration, the
second region framing the first region, wherein the first braid
configuration has a density of braids that is lower than a density
of braids of the second braid configuration.
9. The upper for footwear of claim 8, wherein the first region and
the second region are braided from yarns having material
properties, and wherein the first region is braided with at least
one yarn that is different from the yarns of the second region.
10. The upper for footwear of claim 9, wherein the first braid
configuration has different stretch properties than stretch
properties of the second braid configuration.
11. The upper for footwear of claim 10, wherein the first braid
configuration is more elastic than the second braid
configuration.
12. The upper for footwear of claim 8, wherein the first braid
configuration has a different braid angle than the second braid
configuration.
13. The upper for footwear of claim 8, wherein the first braid
configuration has a different braid pitch than the second braid
configuration.
14. The upper for footwear of claim 8, wherein the second braid
configuration is made of a material having greater tensile strength
than a material of the first braid configuration.
15. The upper for footwear of claim 8, wherein the second braid
configuration with the second braid density provides at least one
of greater abrasion resistance, greater durability, greater tensile
strength and greater stability compared to the abrasion resistance,
durability, tensile strength and stability of the first braid
configuration with the first braid density.
16. An article of footwear comprising: a sole; and an upper
comprising a unitary braided structure attached to the sole, the
unitary braided structure formed form a plurality of interlaced
yarns; said upper having a toe region, a forefoot region, a midfoot
region, a heel region, and an ankle region; said upper also having
a perimeter around a throat and around an ankle opening; wherein
the unitary braided structure has a first braid density forming at
least a portion of the forefoot region, the midfoot region and the
heel region and a second braid density at the perimeter around the
throat and the ankle opening and forming a band at a front of the
throat; wherein the upper has at least one region where the first
braid density is surrounded by a band of the second braid density;
and wherein the second braid density is higher than the first braid
density.
17. The article of footwear of claim 16, further comprising
ground-engaging components attached to the sole.
18. The article of footwear of claim 17, wherein the braided
structure has an inward side and an outward side, and further
comprising an outer covering over an outer surface of the unitary
braided structure.
19. The article of footwear of claim 16, wherein the braided
structure has an inward side and an outward side, the braided
structure further comprising an inner covering disposed on the
inward side of the unitary braided structure.
20. The article of footwear of claim 16, wherein the article of
footwear has a throat and wherein the article of footwear also has
eyelets disposed on a medial side of the throat and on a lateral
side of the throat, further comprising floating cables laced
through the braided structure and attached to at least one eyelet
on the medial side of the throat and at least one eyelet on the
lateral side of the throat.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent
application Ser. No. 14/495,252, filed Sep. 24, 2014, and titled
"Article Of Footwear With Braided Upper" which is a continuation of
U.S. patent application Ser. No. 14/163,392, filed Jan. 24, 2014,
and titled "Article of Footwear with Braided Upper" which
application claims priority to U.S. Provisional Patent Application
61/839,097, filed Jun. 25, 2013, and titled "Article of Footwear
with Braided Upper" referred to throughout the detailed description
as the "Braided Upper" application, the entireties of the three
afore-mentioned applications are herein incorporated by reference.
This application is also related to co-pending U.S. patent
application Ser. No. 14/163,438, filed Jan. 24, 2014, and titled
"Braided Upper With Overlays For Article Of Footwear" the entirety
of which is herein incorporated by reference.
BACKGROUND
[0002] The present embodiments relate generally to articles of
footwear, and in particular to articles of footwear with a braided
upper.
[0003] Typical athletic shoes have two major components, an upper
that provides the enclosure for receiving the foot, and a sole
secured to the upper. The upper may be adjustable using laces,
hook-and-loop fasteners or other devices to secure the shoe
properly to the foot. The sole has the primary contact with the
playing surface. The sole may be designed to absorb the shock as
the shoe contacts the ground or other surfaces. The upper may be
designed to provide the appropriate type of protection to the foot
and to maximize the wearer's comfort.
BRIEF SUMMARY
[0004] In one aspect, embodiments of the article of footwear have a
sole and an upper attached to the sole. The upper has a braided
structure that has a first region with a first density of braids
and at least a second region with a different density of braids.
The first density of braids is lower than the second density of
braids. The high density braids may be used in regions of the
footwear that require more stability, more durability and/or more
strength.
[0005] In another aspect, an embodiment is an article of footwear
with a sole and an upper. The upper has a braided structure and is
attached to the sole. The upper has a higher braid density around
the perimeter of its throat and around the perimeter of its ankle
opening.
[0006] In yet another aspect, embodiments of the article of
footwear have an upper formed from a braided structure attached to
the sole. The braided structure has a first high density band
attached at the lateral side of the footwear to the sole at the
forefoot region and attached at the medial side of the footwear to
the sole at the midfoot region. The braided structure has a second
high density band attached at the lateral side to the sole at the
midfoot region and at the medial side to the sole at the forefoot
region. The two bands intersect at the apex of the midfoot
region.
[0007] In yet another aspect, embodiments of the article of
footwear is made of a braided structure forming an upper for the
footwear and a sole attached to the upper. Floating cables are
laced through a portion of the braided structure of the upper in
different regions of the upper. The floating cables may be attached
at one end to eyelets of the upper, and at their other end to the
sole.
[0008] In yet another aspect, embodiments of the article of
footwear include a sole bearing ground-engaging components and an
upper attached to the sole. The upper has a throat, a heel region,
a midfoot region and a forefoot region. It has a low density braid
at the midfoot region and a high density braid at the heel region.
It also has a high density braid around the throat and another band
of high density braid in front of the throat of the upper. The
upper has an integrated lateral side lace laced through the band of
high density braid on a lateral side of the article of footwear to
a lateral side eyelet, and an integrated medial side lace laced
through the band of high density braid on the medial side of the
article of footwear to a medial side eyelet.
[0009] In yet another aspect, an upper for an article of footwear
has a heel region, a midfoot region, and a forefoot region. The
upper has eyelets disposed on either side of a throat. The upper
has a braided structure with bands of high density braids at the
heel region and at the midfoot region, and bands of low density
braids at the forefoot region and in the toe region. It also has a
lateral side lace attached at the lateral side of the upper to a
bottom of the lateral side of the upper; and a medial side lace
attached at a medial side of the upper to a bottom of the medial
side of the upper. The laces are then laced through the braided
structure and through at least one eyelet on the lateral side of
the upper and at least one eyelet on the medial side of the
upper.
[0010] In yet another aspect, a method of manufacture of braided
uppers uses overlast braiding to manufacture the braided uppers. A
last with pins demarcating various bands having higher or lower
braiding densities may be fed through a braiding apparatus one,
twice or several times to produce the desired braided
structure.
[0011] Other systems, methods, features and advantages of the
embodiments will be, or will become, apparent to one of ordinary
skill in the art upon examination of the following figures and
detailed description. It is intended that all such additional
systems, methods, features and advantages be included within this
description and this summary, be within the scope of the
embodiments, and be protected by the following claims.
BRIEF DESCRIPTION OF SEVERAL VIEWS OF THE DRAWINGS
[0012] The embodiments can be better understood with reference to
the following drawings and description. The components in the
figures are not necessarily to scale, emphasis instead being placed
upon illustrating the principles of the embodiments. Moreover, in
the figures, like reference numerals designate corresponding parts
throughout the different views.
[0013] FIG. 1 is a schematic representation of a two-dimensional
braided fabric;
[0014] FIG. 2 is a schematic representation of a three-dimensional
braided structure;
[0015] FIG. 3 is a schematic representation of a perspective side
view of an embodiment of an article of footwear having a braided
upper;
[0016] FIG. 4 is a schematic representation of a lateral side view
of an embodiment of an article of footwear having a braided
upper;
[0017] FIG. 5 is a schematic representation of a medial side view
of the embodiment of the article of footwear shown in FIG. 4;
[0018] FIG. 6 is a schematic representation of a perspective top
front view of the article of footwear shown in FIG. 4;
[0019] FIG. 7 is a medial side view of an embodiment of an article
of footwear;
[0020] FIG. 8 is a schematic representation of a top view of the
embodiment shown in FIG. 7;
[0021] FIG. 9 is schematic representation of an article of footwear
using floating strands;
[0022] FIG. 10 is a schematic representation of an embodiment of an
article of footwear using integrated laces;
[0023] FIG. 11 is a schematic representation of another embodiment
of an article of footwear using integrated laces;
[0024] FIG. 12 is a schematic representation of an embodiment of an
article of footwear using integrated cables;
[0025] FIG. 13 is a bottom view of the upper of the embodiment of
FIG. 12, before the upper is attached to a sole;
[0026] FIG. 14 is a schematic representation of an article of
footwear having floating cables and a tensioning device;
[0027] FIG. 15 is a schematic representation of a side view of an
embodiment that uses different braiding strands;
[0028] FIG. 16 is a rear perspective view of the embodiment of FIG.
15;
[0029] FIG. 17 is a side perspective view of another embodiment of
an article of footwear that uses different braiding strands;
[0030] FIG. 18 is a top perspective view of another embodiment of
an article of footwear with an outer covering and an inner
covering; and
[0031] FIG. 19 is a top view of an embodiment with an outer
covering and an inner covering.
[0032] FIG. 20 is a schematic diagram illustrating overlast
braiding.
[0033] FIG. 21 is a schematic diagram illustrating the use of pins
for overlast braiding.
[0034] FIG. 22 is a schematic diagram illustrating the positioning
of pins on a last prior to braiding.
[0035] FIG. 23 is a schematic diagram illustrating braiding over a
footwear last.
[0036] FIG. 24 is a schematic diagram illustrating an embodiment of
a braided upper for an article of footwear and a last that could be
used to manufacture that embodiment.
[0037] FIG. 25 is a schematic diagram illustrating another
embodiment of a braided upper for an article of footwear and a last
that could be used to manufacture that embodiment.
[0038] FIG. 26 FIG. is a schematic diagram illustrating yet another
embodiment of a braided upper for an article of footwear and a last
that could be used to manufacture that embodiment.
DETAILED DESCRIPTION
[0039] Embodiments of the article of footwear with a braided upper
include braided uppers that have engineered regions adapted to a
wearer's foot. The braided upper may be attached to a sole using
stitching, stapling, fusing, adhesives or any other attachment
method. Articles of footwear having different performance and/or
comfort characteristics may be engineered by varying, for example,
the braid angle, the braid pitch, the braid coverage and/or other
parameters. The braided upper may also have different materials
having different mechanical or other properties in different parts
of the upper to provide specific characteristics to specific
regions of the upper.
[0040] Braided fabrics can be formed by intertwining three or more
strands of yarn, filaments or other fibers to form the fabric. In
the example shown in FIG. 1, strands 11 are intertwined forming a
fabric 10 with an open structure.
[0041] Braiding can be used to form three-dimensional structures,
as in the example shown in FIG. 2, by braiding strands of yarn over
a form or a last. Strands 21 can be fabricated from fibers such as
nylon, carbon, polyurethane, polyester, cotton, aramid (e.g.,
Kevlar.RTM.), polyethylene or polypropylene. These strands can be
braided to form three-dimensional structures for a wide variety of
applications. For example, braided three-dimensional structures may
be used to manufacture products as varied as bicycle helmets,
aircraft fuselage components and rocket nozzles.
[0042] Braided structures may be fabricated manually, or may be
manufactured using automated braiding machinery, such as the
machinery disclosed in U.S. Pat. Nos. 7,252,028; 8,261,648;
5,361,674; 5,398,586; and 4,275,638, all of which are incorporated
by reference in their entirety herein. Such three-dimensional
braided structures may also be manufactured to a specific design
by, for example, TEF Braids, Warrensburg, N.Y or A&P
Technology, Cincinnati, Ohio.
[0043] In some embodiments, articles of apparel and/or footwear may
use one or more braided structures or configurations. In some
embodiments, an article of footwear may include one or more regions
that comprise a braided structure. For example, an upper may
include one or more layers of a braided material. In one exemplary
embodiment, a substantial majority of an upper can comprise a
braided construction. One exemplary configuration is shown in FIG.
3, which comprises article of footwear 100 with a braided upper
101. The details of this particular embodiment are discussed
below.
[0044] In some embodiments, uppers manufactured from braided
materials may be much lighter than uppers manufactured using other
materials. Such uppers can also be manufactured to be compliant
with a wearer's foot. The perimeters of the material--for example
at the ankle opening or at the throat of the upper--may be fixed
using stitching, adhesives, fusing or another method so that the
braid does not unravel. By controlling the density of the braid in
different regions of the upper, those regions can be, for example,
more soft and pliable for comfort, or stiffer for more stability
and support. Specific examples of footwear with different braiding
densities in different regions of the footwear are described
below.
[0045] The braided upper can also be manufactured using strands
made of different materials, as shown in certain of the embodiments
described below. This provides additional flexibility in the
manufacture of footwear for specific athletic or recreational
activities. For example, strands made of a material with a greater
tensile strength may be used in those sections of the footwear that
undergo higher stress during a specific activity. Softer and more
pliable strands may be used in sections of the footwear that are
not subject to high stress, to provide a more comfortable and
closely-fitting upper in those sections. Strands of an
abrasion-resistant material may be used in particular regions of
the footwear that may experience frequent contact against abrasive
surfaces such as concrete or sand. Strands of a more durable
material may be used in those regions of an upper that experience
frequent contact with other surfaces, such as the surface of a
football or soccer ball.
[0046] In some embodiments, strands with different material
properties could be braided together, or otherwise associated with
one another, to provide specific properties at one or more regions
of an upper. For example, an upper may be fabricated from fibers
that stretch to a certain degree, as the wearer's foot moves
through each stride he or she takes, thus increasing the wearer's
comfort. In that case, high tensile strength, non-stretch fibers
may be threaded through those specific regions of the footwear that
require additional structural support. As another example, an upper
may be fabricated with a more open braid in some areas, for example
to improve breathability or comfort. In that case, additional
fibers may be laced through the braid to provide additional support
in certain parts of those areas, or to provide increased durability
for high-impact regions of the footwear.
[0047] The upper may also have floating cables, i.e., cables that
are not braided into the fabric of the upper may be used to relieve
the stress on certain sections of the upper. The floating cables
may be made of a different material that is separate from and not
attached to the braided structure. The cables may also be used as
laces to secure the footwear to the foot, or to tighten up certain
parts of the footwear, as described below. For example, the cables
may be anchored at a first end at the sole of the footwear, and at
a second end at an eyelet, for example. Such floating cables may
also be used to add to the support and stability of certain parts
of the footwear, such as around the ankle opening.
[0048] By using braiding, uppers for articles of footwear may be
engineered with specific features tailored to a particular athletic
or recreational activity. Braided uppers can be very light while
conforming closely and comfortably to the wearer's feet. In some
embodiments, the fit of the upper may be adjusted to provide the
specific degree of tension or tightness the wearer may prefer.
Braided uppers are characterized by close containment over the
wearer's foot. In some embodiments, the braided fabric may wrap all
the way around the footwear, as shown in the figures below. Such a
structure has tensional integrity or "tensegrity," since the
wearer's foot is in compression, while the braided strands are in
tension around the wearer's foot.
[0049] The braided upper may be attached to a sole structure using
adhesives, welding, molding, fusing stitching, stapling or other
appropriate methods. The sole can include an insole made of a
relatively soft material to provide cushioning. The outsole is
generally made of a harder, more abrasion-resistant material such
as rubber or EVA. The outsole may have ground-engaging structures
such as cleats or spikes on its bottom surface, for providing
increased traction.
[0050] Some embodiments may include braided uppers that extend
beneath the foot, thereby providing 360 degree coverage at some
regions of the foot. However, other embodiments need not include
uppers that extend beneath the foot. In other embodiments, for
example, a braided upper could have a lower periphery joined with a
sole structure and/or sock liner.
[0051] FIG. 3 is a perspective side front view of an embodiment of
an article of footwear, for example a running shoe. As illustrated
in FIG. 3, the upper 101 of an article of footwear 100 can
generally be described as having an ankle region 102, a heel region
103, a midfoot or instep region 104, a forefoot region 105, and a
toe region 106. The article of footwear has an opening 109 at the
top of the ankle region 102 that allows the wearer to insert a foot
into the upper. Article of footwear 100 also has a medial side 107
and a lateral side 108. In the example shown in FIG. 3, the article
of footwear also has a sole 110, a throat 112, and a shoelace 113.
The sole of article of footwear 100 may be attached to the upper
101 by any of several well-known means such as by fusing, molding,
welding, stitching, stapling or adhesives.
[0052] In some embodiments, upper 101 may comprise one or more
layers of braided materials, as well as an optional outer covering,
which is not shown in FIG. 3, but is discussed in further detail
below with reference to FIG. 6. In particular, in some embodiments,
upper 101 comprises a plurality of strands 111 that are braided
together into a single braided construction having the overall
geometry of a shoe last or foot. As previously discussed, the
braided construction formed by plurality of strands 111 may not be
uniform, so that the braided configuration and/or the materials of
the braided strands could vary over different regions of upper
101.
[0053] In some embodiments, upper 101 may formed from a braided
structure 199. Braided structure 199 may be a structure forming at
least some portions of upper 101, including, for example, ankle
region 102, heel region 103, midfoot or instep region 104, forefoot
region 105, and toe region 106, as well as lateral side 108 and
medial side 107. Braided structure 199 is formed as a unitary
braided structure. As utilized herein, a braided structure (e.g.,
braided structure 199) is defined as being a "unitary braided
structure" when formed as a one-piece element through a braiding
process. That is, the braiding process substantially forms the
various features and structures of the braided component without
the need for significant additional manufacturing steps or
processes. Further, as used herein, a unitary braided structure has
structures or elements that share at least one common yarn, strand,
filament or other braiding elements. Thus, it may be understood
that whenever two or more portions or regions of a braided
structure comprise part of the same unitary braided structure,
these portions will share at least one common braiding element,
such as a yarn, strand, filament or other element used to form
braids.
[0054] As one example of a property of the braided construction
that can vary across different regions of braided structure 199,
and therefore upper 101 which is comprised of braided structure
199, the density of the braid can be varied. For example, in one
embodiment, the plurality of strands 111 can be configured in a
relatively open braid, as shown in the forefoot region 105 of
article of footwear 100, or in a higher density braid, as shown by
band 121 at the rear of forefoot region 105, band 122 around
opening 109 and band 123 around throat 112. Bands with lower
density braids may be lighter, more comfortable and more easily
ventilated, while bands with higher density braids may provide
additional stability, shape and strength. Also, different bands may
be fabricated from strands having different physical or other
properties, such as tensile strength, elasticity, diameter, shape
or color.
[0055] In some embodiments, forefoot region 105, band 121, band 122
and band 123 all comprise portions of a common braided structure
199, which is a unitary braided structure. Therefore, though some
properties may vary between forefoot region 105, band 121, band 122
and band 123, such as density, strength, etc., these portions may
share at least one common yarn, thread, strand, filament or other
braiding element.
[0056] It will be understood that each of the embodiments described
in this detailed description and in the figures, of a braided
upper, may be at least partially comprised of a unitary braided
construction. Thus, two or more different portions of the uppers
may always share at least one common yarn, thread, strand, filament
or other braided element in common.
[0057] As previously discussed, some embodiments of upper 101
include an outer covering (not shown in FIG. 3). Outer coverings
for braided uppers are described below in connection with FIG. 6,
FIG. 18 and FIG. 19. For clarity, they are not shown in the other
figures, since they would obscure the features being described.
Other embodiments may use an inner covering or backing layer (see
FIG. 6) between the braided structure and the wearer's foot, in
addition to or instead of an outer covering.
[0058] Braided structures can vary in different embodiments. For
example, braided structures can vary in structural properties such
as the number of strands in the braid, the diameter of one or more
strands of the braid, the density of the strands and the material
properties of the strands such as elasticity, rigidity, tensile
strength, compressibility as well as possibly other material
properties.
[0059] The term "braided configuration" is used to refer to the
relative disposition of different components, including braiding
elements, braid density, strands, laces and floating cables. The
configuration of a braided upper could vary over different regions
of the structure. By incorporating regions with different braided
configurations into an upper, the different regions can be
configured with a variety of different properties, to improve the
performance of the article of footwear and increase the comfort to
the wearer. As an example, using a different braiding pattern at
different portions of a braided structure within an upper may
create different braid densities at these different portions, which
may result in different ventilation properties for the
portions.
[0060] The embodiments depict articles of footwear including uppers
with portions having different braided configurations and/or
different material properties. However, as previously discussed,
these uppers may be formed of unitary braided structures, such that
two different portions having different braided configurations may
nonetheless share one or more common yarns, threads, strands,
filaments or other braiding elements. Moreover, in at least some
embodiments, different braided configurations may be achieved on
different portions of an upper by varying the braiding pattern in
some manner. In other words, in at least some embodiments,
different portions of an upper having different braided
configurations may share a substantially identical set of yarns,
threads, strands, etc. Of course, in other embodiments, different
portions of an upper may have some yarns of different material
properties, though these different portions may still share at
least one common yarn, thread or other braiding element.
[0061] FIG. 3 described above and FIGS. 4-19 described below
illustrate different embodiments of uppers that are configured with
various regions having substantially different braided
configurations. The configuration of a braided upper can be
engineered by using different densities of braids in different
parts of the upper, by using different braid patterns, by using
floating cables to produce additional tension in specific regions,
or by using different braiding materials in different regions of
the upper. For example, different portions of an upper could have
different braid densities and/or could be comprised of strands
having different stretch or compressibility characteristics.
Varying the stretch and/or compressibility characteristics of one
or more portions of an upper may help to control comfort and feel
at different locations. For example, increased stretch or
compressibility in some locations may reduce sag and change the
feel of the upper. In some cases, using highly stretchable and
compressible strands in at least some portions of an upper may give
those portions a sock-like feel.
[0062] For example, the running shoe example shown in FIG. 3 has
been engineered to provide the appropriate level of structural
stability, support, durability and comfort, as follows. A band 121
of higher density braiding across the forefoot provides structural
integrity across the forefoot as the runner pushes off against the
ground. Higher density band 122 around opening 109 provides
additional durability, padding and support for the region of the
foot below the ankle. Higher density band 123 around throat 112
strengthens the region around the shoe lace, such that the wearer
can pull on the laces to close the throat of the shoe around the
wearer's foot. High density band 123 also provides greater
durability to the region around the shoe lace. The lower density
regions in the greater regions of the footwear result in a lighter
footwear, more breathability and more comfort. In particular, for
example, the forward part of forefoot region 105 as well as a
majority of mid foot region 104 and heel region 103 are configured
with a substantially lower density braid than the braid in band
121, band 122 and/or band 123.
[0063] The use of braided materials with different braid densities
shown in the example of FIG. 3 may be applied to a wide variety of
footwear. For example, FIG. 4 and FIG. 5 are a lateral side view
and a medial side view, respectively, of an example of an article
of footwear with a braided upper 200 that may be used as a soccer
shoe, for example. Braided upper 200 is shown without its outer
covering in FIG. 4 and FIG. 5. FIG. 6 is a top front view of the
footwear, showing the outer covering 250 of braided upper 200. The
example shown in FIGS. 4-6 has a toe region 206, a forefoot region
204, a midfoot region 203, a heel region 202 and an ankle region
201. In some cases, sole 220 may have cleats 240 for improved
traction. Upper 200 may be attached to sole 220 using stitching,
stapling, overmolding, fusing, adhesives or other attachment
methods.
[0064] The embodiment shown in FIG. 4 uses a high density braid 205
at toe region 206 to provide added protection at the toe of
footwear 200. This embodiment may be used, for example, as a soccer
shoe. In that case, a higher density braid at toe region 205
(especially at the medial side, which is shown in FIG. 5) of the
forefoot protects the wearer's toes and forefoot as the wearer
kicks the ball. The footwear has a lower density braid at heel
region 202 and midfoot region 203, compared to the density of the
braid in forefoot region 204 and toe region 205.
[0065] In some embodiments, upper 200 includes several bands or
extended regions having braided configurations that differ from
surrounding regions of upper 200. For example, a band 210 of higher
density braid at the forefoot region 204 of the upper extends
laterally from the lateral side 213 of the footwear to its medial
side. Another band 211 extends from the same location diagonally
over the instep to a location below the front of the ankle on the
medial side. A similar band 212 extends from the lateral side at a
location below the front of the ankle to the location on the medial
side that is the endpoint for band 210. Thus band 211 and band 212
cross at the apex of midfoot region 203 of the upper 200. These
high density bands provide compression and stability in selected
regions of the midfoot region 203.
[0066] As can be seen in FIGS. 4-6, the upper 200 has a more open
structure at midfoot 203, allowing for greater comfort and
flexibility. It has a somewhat less open structure at the heel,
ankle and forefoot regions, providing greater stability and
compression around the ankle and the forefoot. Band 210, band 211
and band 212 provide compression at midfoot region 203, to restrain
a wearer's foot from sliding within the footwear. The more open
structure elsewhere at the midfoot provides a lighter upper with
greater comfort to the wearer.
[0067] FIG. 5 and FIG. 6 are a medial side view and a top front
perspective view, respectively, of the example of a braided upper
200 shown in FIG. 4. These figures show the high density braid 205
at the toe region 206, and in a band at the rear of forefoot 205.
Band 210 has a higher density braid at the forefoot region 205 of
the upper extending laterally from the lateral side 213 of the
footwear to medial side 214. Band 211 and band 212 are higher
density bands that extend diagonally over the instep and cross over
each other at their apex. FIG. 5 also shows a high density region
260 at the portion of the forefoot adjoining the sole on the medial
side of the footwear, which is a part of the footwear that would
have frequent contact with, for example, a soccer ball. As noted
above, high density region 260 at the forefoot and high density
region 205 at the toe protect the wearer's toes and forefoot as the
wearer kicks the ball, and provides for increased durability in
those high-impact regions. These high density regions may
optionally be fabricated from strands that have increased
durability, abrasion resistance and wear resistance compared to the
strands used for the other parts of the footwear.
[0068] FIG. 6 is a perspective view of the upper of FIGS. 4 and 5.
Upper 200 is shown in FIG. 6 with an outer covering 250. The
braided structure is shown in phantom. In the call-out shown in
FIG. 6, outer covering 250 is shown covering fibers 251 that form
the braided structure of braided upper 200. The footwear may
optionally also have an inner covering 252, on the interior side of
the braided structure. The formation of an outer and/or an inner
covering is discussed below with reference to FIGS. 18 and 19.
[0069] As previously mentioned, in some embodiments, different
portions of a braided upper may comprise strands having different
material characteristics, such as stretch and/or compressibility.
For example, in some embodiments, band 210, band 211 and/or band
212 seen in FIGS. 5 and 6, could be made of strands that stretch
less than the strands forming the adjacent portions of forefoot
region 204 and midfoot region 203. In such embodiments, band 210,
band 211 and band 212 may therefore undergo less stretching
relative to adjacent strands, which may help band 210, band 211
and/or band 212 to function as integrated straps that keep upper
200 in place on a foot.
[0070] FIGS. 7 and 8 are a medial side view and a top front
perspective view, respectively, of another embodiment. This
embodiment could be adapted for use as a track shoe, for example.
In this embodiment, the article of footwear 300 has a heel region
303, a midfoot region 304, a forefoot region 305 and a toe region
306. Opening 309 allows a wearer to insert his or her foot into the
footwear. It also has a thin outsole 320, which provides traction
and cushioning. If used as a track shoe, outsole 320 could have
spikes 321.
[0071] This embodiment may or may not have an outer covering or an
inner covering such as the ones shown in FIG. 6. For convenience,
this embodiment is shown in FIGS. 7 and 8 without an outer covering
or an inner covering. This embodiment has a high density braided
region 310 to the rear of forefoot region 305, and high density
braided region 311 extending from the heel up to the front of the
wearer's ankle. It also has a low density braided region 313 at
midfoot region 304 of the footwear. This low density open-braided
midfoot region allows the footwear to expand and fit comfortably
around the wearer's foot. Unlike the embodiment of FIGS. 4-6, this
embodiment has an open throat 315, as best seen in FIG. 8. It also
has eyelets 312 formed on either side of open throat 315. Eyelets
312 can be formed in any manner. In some embodiments, eyelets 312
can be formed from open loops of the braiding material. In other
embodiments, eyelets 312 can be formed by leaving openings in the
braided structure as shown in FIGS. 7 and 8. In still other
embodiments, eyelets 312 can be separate components attached to the
edge on either side of the open throat using stitching, stapling,
fusing or other attachment means.
[0072] Referring to FIGS. 7 and 8, some embodiments include strands
made of different materials having different material
characteristics. For example, in some embodiments, high density
braided region 310, heel region 303 and strands surrounding eyelets
312 may be made of a first material that is substantially different
than a second material comprising low density braided region 313.
In some embodiments, the second material may have more stretch
and/or compressibility than the first material. This configuration
may increase stretch in low density braided region 313 to better
fit the sides of a foot while reducing stretch in heel region 303,
around eyelets 312 and across the rear of forefoot region 305. Such
variations in material properties can help create necessary
supporting structures within article of footwear 300 that frame or
support the more flexible regions.
[0073] Embodiments of the upper may include mechanisms for
adjusting the tension on the wearer's foot. In the embodiment shown
in FIG. 9, an article of footwear 400 has a relatively lower
density braid in the midfoot region 413, in the forefoot region 414
and in the toe region 406, providing improved comfort and
breathability in those areas. In addition, article 400 has higher
density band 410 across the footwear at the front of throat 415,
high density band 422 around throat 415 and high density band 411
around opening 409, to provide added strength and stability in
those regions. This embodiment uses a conventional shoe lace 421 to
fasten article of footwear 400 around the wearer's foot.
[0074] In this embodiment, article of footwear 400 includes a
plurality of strands 451 on either side of midfoot region 413 and a
plurality of strands 452 on either side of the front of throat 415
that may be used to adjust tension around a wearer's foot.
Plurality of strands 451 and plurality of strands 452 extend from
the sole of the footwear up to eyelets on either side of throat
415. Plurality of strands 451 and plurality of strands 452 are
floating with respect to the braid, i.e., they are not attached to
the braid, except possibly at the sole end and at the eyelet end.
They may be attached to the sole and to the eyelets, such that when
shoelace 421 is tightened, the stress is experienced by plurality
of strands 451 and plurality of strands 452, thus relieving the
stress on the braided structure itself.
[0075] Other embodiments may use integrated laces to allow a wearer
to adjust the tension on the sides of the footwear to his or her
best preference. For example, the embodiment shown in FIG. 10 uses
two different integrated laces, a medial side lace 421 and a
lateral side lace 420, that are integrated into the sides of upper
400. Each lace is attached to the bottom of the footwear at the
outsole, on its respective medial or lateral side. The medial side
lace 421 is interlaced through the open braided midfoot region 404
on the medial side of the footwear to, for example, the top (or
first) eyelet on the medial side of the throat opening. It is then
laced through the second eyelet on the lateral side of the throat
opening, the third eyelet on the medial side, the fourth eyelet on
the lateral side, etc. The lateral side lace 420 is attached to the
outsole of the footwear, and then laced through the open braided
midfoot region 404 on the lateral side of the footwear, to the top
(or first) eyelet on the lateral side of the throat opening. It is
then laced through the second eyelet on the medial side of the
throat opening, the third eyelet on the lateral side, the fourth
eyelet on the medial side, etc. After being laced through the
bottom eyelets on the medial and lateral sides, lace 420 and lace
421 can be tightened around the wearer's foot. The two laces can
then be tied to each other using a bow knot 423 or any other
suitable knot. Upper 400 has a high density region 410 providing
increased tensile strength in the part of the upper that comes
under tension when the laces are tied in bow 423. This version
allows the wearer to create maximum tension between the top of his
or her foot in front of the ankle and the front of the heel,
without putting the braided structure itself under stress.
[0076] In an alternative version of this embodiment, shown in FIG.
11, the laces may start from the forefoot region of the footwear at
the outsole. In that case, lateral side lace 430 and medial side
lace 431 are first laced through high density braid 410 to bottom
eyelets 440, and the bow 433 knotting the laces together would be
made after the laces have been laced through the top eyelets. Lace
430 and lace 431 can thus be used to tighten the upper around the
wearer's foot at throat 415. High density braid 411 provides
increased stability around the ankle opening and increased tensile
strength when the laces are tied to form bow 433. This version
creates the maximum tension between the top of the footwear and the
eyelets in the forefoot, and results in a bow at the top of the
foot near the ankle.
[0077] It will of course be understood that the embodiments shown
in FIGS. 9-11 can also utilize different materials for strands in
different regions of upper 400. In particular, in some embodiments,
regions associated with high density braids could utilize strands
with less stretch and/or compressibility than the strands
associated with lower density regions. Moreover, in alternative
embodiments, two different regions could have similar densities but
different material characteristics.
[0078] Embodiments can alternatively include integrated cables that
provide specific properties to the braided upper. In some
embodiments, the upper may have one or more integrated cables or
other tensioning elements, to modify the tension control in a
braided upper. The cables may be strands of the same material as
the material used to fabricate the braided upper, but are more
typically strands of a material having different properties, such
as greater tensile strength, greater resistance to abrasion, or a
different modulus of elasticity compared to the materials used to
fabricate the fabric of the upper.
[0079] FIG. 12 and FIG. 13 are a side view and a bottom view,
respectively, of an article of footwear 500 that includes
integrated cables. FIG. 12 is an illustration of the footwear
without an outer covering or an inner covering, which are optional.
Outer and/or inner coverings such as those described in connection
with FIG. 6, FIG. 18 and FIG. 19 may be used, for example. In this
embodiment, floating cables 520 are laced through the braided
structure 540 of the upper in the ankle region 501, the heel region
502, the midfoot region 503, the forefoot region 504 and the toe
region 506, such that they can slide with respect to the braided
structure. In the heel region, floating cables 520 may be attached
at a lateral end to a lateral side eyelet and at a medial end to a
medial side eyelet.
[0080] FIG. 12 shows that the article of footwear may include a
sole 550. FIG. 13 illustrates the bottom of the footwear before a
sole is attached. Floating cables 520 in the ankle region 501, heel
region 502, midfoot region 503 and forefoot region 504, experience
tension as shoelace 521 is tightened around throat 510 of footwear
500, thus relieving the stress on the braided structure in those
regions of footwear 500, while maintaining compression over the
wearer's foot. In addition, floating cables 525 extend from the
front of throat 510 to toe region 506, and relieve the tension on
the braided structure in the toe region.
[0081] Floating cables 520 and floating cables 525 provide an
adjustable structure to the footwear. When shoelace 521 is
tightened around a wearer's foot, floating cables 520 and floating
cables 525 provide tensional integrity (or "tensegrity") to the
structure of the footwear, because they keep the braided structure
around the wearer's foot in compression, while experiencing tension
as the wearer runs, jumps, turns or engages in other activities.
Because the floating cables are not fixed except at their endpoints
around throat 510, the tension on each of the floating cables is
fairly evenly distributed around the wearer's foot.
[0082] In one alternative version of the embodiment shown in FIG.
12, the sole may have channels at its upper surface such that
floating cables 520 and/or floating cables 525 are routed through
the channels. In another version of this embodiment, floating
cables 520 and/or floating cables 525 are routed under the sole. In
yet another version, the floating cables are anchored at the sole
at both the medial side of the sole and the lateral side of the
sole. Each of these versions may optionally have an outer
covering.
[0083] FIG. 14 shows another embodiment of an article of footwear,
shown without its outer covering, which is optional. This article
of footwear 600 has a heel region 602, a midfoot region 603, a
forefoot region 604, a toe region 606 and an outsole 610. Outsole
610 may be made of rubber or EVA. It may be fused to the upper,
overmolded over the upper, or attached to the upper using
stitching, stapling or adhesives. Article of footwear 600 also has
floating cables 620 that are attached at one end to outsole 610,
then are laced through the braids at heel region 602 and attached
to eyelets 622 at the throat of the footwear. Cables 620 are placed
under tension when shoelace 621 is tightened around the wearer's
foot. Article of footwear 600 also has floating cables 651 that are
laced through the braids from the front of the heel at the outsole
in the heel region of footwear on the medial and lateral sides of
footwear 600. Floating cables 651 are then gathered in tension
control device 650, positioned in the back of the heel, as shown in
FIG. 14. In some embodiments, a wearer can adjust the tension by
manually twisting tension control device 650 to tighten or loosen
cables 651. In other embodiments, tension control device 650 can be
operated by a servo motor, such that a wearer can adjust the
tension on cables 651 remotely. For example, a wearer could adjust
the tension remotely while engaging in an athletic activity.
[0084] Tension control device 650 may be any device used to control
the tension of the tensioning element. Examples of different
tension control devices include, but are not limited to: reel
devices with a ratcheting mechanism, reel devices with a cam
mechanism, manual tensioning devices, automatic tensioning devices,
as well as possibly other kinds of tensioning devices. Examples of
a tensioning device comprising a reel and ratcheting mechanism that
could be used with the embodiments described herein are disclosed
in Soderberg et al., U.S. patent application Ser. No. 12/623,362
(published as U.S. Patent Application Publication Number
2010/0139057), filed Nov. 20, 2009 and entitled "Reel Based Lacing
System", the entirety of which is hereby incorporated by
reference.
[0085] In some embodiments, the tensioning device may be motorized,
as described in U.S. Provisional Patent Application No. 61/695953,
entitled "Motorized Tensioning Device," which is incorporated by
reference herein in its entirety.
[0086] Embodiments may also be engineered by using different
braiding strands. In the embodiments described below, two or more
different kinds of braiding strands are used to control the
performance of the footwear. The strands used for the braid in
certain regions of the footwear have different material properties,
to produce increased or decreased tension, for example, in those
certain regions of the footwear. The different braiding materials
may also have greater abrasion resistance, greater flexibility or
greater durability compared to the material used for the majority
of the upper. In some embodiments, the different braiding materials
could have different stretch. In some embodiments, the different
braiding materials could have different compressibility.
[0087] FIG. 15 and FIG. 16 are a side view and a rear perspective
view, respectively, of such an embodiment, shown without an outer
covering. In the example shown in FIG. 15 and FIG. 16, footwear 700
has a heel region 702, a midfoot region 703, a forefoot region 704
and a toe region 706. In this embodiment, the footwear is primarily
formed using a first material for the strands 710 used to fabricate
braided footwear 700. In addition, strands of a second different
material having different characteristics may be used to form band
730 and band 731. Thus strands having different tensile strength,
Young's modulus, thickness, color, flexibility and/or abrasion
resistance may be used to form band 730 and/or band 731. For
example, the strands used for these bands may have greater tensile
strength to stabilize the footwear around the heel and from the top
of the footwear near the ankle to the side of the forefoot, as
shown in FIG. 15 and FIG. 16. As another example, the strands may
have greater abrasion resistance when used in footwear intended for
sports such as sand volleyball. Also, one or more of band 730 and
band 731 may be of a different color, to produce a decorative
effect, if the footwear does not have an outer covering or if the
outer covering is transparent or translucent.
[0088] In the example shown in FIGS. 15 and 16, strands of band 731
may have greater tensile strength. Tensioning device 750 can be
used to increase the tension from the back of the heel to the sole,
as shown in FIGS. 15 and 16. In this example, strands 730 may have
greater elasticity, and thus allow the upper to expand somewhat to
allow a wearer to insert his or her foot into footwear 700.
[0089] In some embodiments, strands of band 730 and/or band 731
could be made of materials that stretch less than strands in
regions adjacent to band 730 and/or band 731. In some embodiments,
strands of band 730 and/or band 731 could be made of materials that
compress less than strands in regions adjacent to band 730 and/or
band 731. In still further embodiments, band 730 could be
configured to undergo less stretching than band 731, while both
band 730 and band 731 undergo less stretching than strands in some
other portions of article 700. In such cases, band 730 and band 731
could be made of two different materials with significantly
different stretching properties, while the remainder of article 700
could be made of a third material with still different stretching
properties.
[0090] FIG. 17 shows another embodiment in which strands of a
different material are used to stabilize the footwear around the
wearer's foot or to provide a decorative effect. In this
embodiment, footwear 800 has two bands that use strands of the
different material. The strands for band 821 are laced through
braids in braided material 810 from the midfoot region 803 over the
apex of forefoot region 804. The strands used for band 821 may be
more flexible and resilient that the strands used for braided
material 810, to allow the forefoot part of the footwear to flex
more comfortably. Band 822 may have strands that have greater
tensile strength and less flexibility than the strands used for
braided material 810, to provide increased stability around the
ankle region of footwear 800. At the back of the heel, a tension
control device 823 may be used to tighten band 822 around the
ankle.
[0091] As noted above, any of the embodiments described herein may
have an outer covering, an inner covering, or both an outer
covering and an inner covering. An outer covering may be used to
provide further protection to the braids and to the wearer's foot.
The wearer's foot may optionally or alternatively be protected by
an inner covering.
[0092] For example, as shown the schematic diagram of FIG. 18, the
upper 900 of an article of footwear has an outer covering 950 and
an inner covering 952 on either side of braided fabric strands 951.
Upper 900 has a high-density braid at its toe region 906, a band of
high-density braid 921 in front of throat 908, and another
high-density band 912 in part of midfoot 904. Band 912 experiences
increased tension as shoelace 913 is tightened around a wearer's
foot. Upper 900 has somewhat lower density braids in forefoot
region 905, heel region 902, ankle region 901 and most of midfoot
region 904. Upper 900 is attached to sole 920 by conventional
means, such as by using adhesives, stitching, stapling, molding or
fusing. Sole 920 may optionally have a ground-engaging component
such as cleats 940 shown in FIG. 18 or spikes such as those shown
in FIG. 7.
[0093] FIG. 19 is a schematic diagram of another example of an
embodiment of an article of footwear with an outer covering shown.
In this embodiment, upper 1000 has a high density braid 1011 around
ankle opening 1009 to provide more stability. Upper 1000 also has a
band 1032 fabricated from higher tensile strength strands around
throat 1015 because the perimeter of the throat may experience
additional stress as the footwear is tightened around a wearer's
foot. Band 1031 at the transition from midfoot 1013 to forefoot
1014 may be fabricated from a softer more elastic material, to
allow the footwear to flex more comfortably. Upper 1000 has a
relatively lower braid density in the forefoot region 1014 and toe
region 1006, as well as part of midfoot region 1013.
[0094] Outer covering 950 and inner covering 952 (if used) shown in
FIGS. 18 and 19--as well as outer covering 250 and inner covering
252 shown in FIG. 6--may be formed, for example, by spraying a last
covered with the braided upper with thermoplastic polyurethane or
polyester, or by dipping a last with the braided upper into a
polymer solution and curing the solution in place. Outer covering
950 and/or inner covering 952 could be fabricated by laying a sheet
of thermoplastic polyurethane (or another polymer layer or film) on
one side or both sides the braided material, and then embedding the
braids into the sheet(s) by applying heat and/or pressure. The
inner covering may be used in addition to or instead of the outer
covering. Inner coverings such as the one shown in FIG. 6 could be
used with any of the embodiments disclosed herein.
[0095] Outer covering 950, as well as an inner covering or backing
layer 952, may be formed by bonding a thermoplastic polymer to the
braided structure, as disclosed in U.S. patent application Ser. No.
12/847,860, filed Jul. 30, 2010 and entitled "Article Of Footwear
Incorporating Floating Tensile Strands," which is incorporated by
reference herein in its entirety. Alternatively, outer covering 950
and/or inner covering 952 may be formed by molding, as disclosed in
U.S. patent application Ser. No. 12/419,985, filed Apr. 7, 2009,
entitled "Method for Molding Tensile Strength Elements," which is
incorporated by reference herein in its entirety. Outer covering
950 and/or inner covering 952 could also be attached to the braided
fabric by welding or fusing a polymer "skin" to the fabric.
[0096] The strands used to form the braided footwear may be made
from fibers such as nylon, carbon, polyurethane, polyester, cotton,
aramid such as Kevlar.RTM., polyethylene, polypropylene or other
materials. The soles and/or outsoles may be made of rubber, EVA or
any other combination of suitable materials. The outer covering
may, for example, be thermoplastic polyurethane or polyester. It
may be formed over the braided region of the upper on a last by
spraying or dipping, or it may be fabricated separately and
attached to the braided region of the upper by stitching or welding
or by using adhesives, for example.
[0097] In some embodiments, the strands forming the braided
footwear are coated with a thermoplastic material, such as
thermoplastic polyurethane, that softens at elevated temperatures.
After the footwear is braided, all of the footwear or only regions
of the footwear may be heated to a temperature such that the coated
thermoplastic on each strand softens and melds with the coated
thermoplastic on any strand that may be in contact with that
strand. After the footwear has cooled down, the thermoplastic
coatings become hard. Thus each coated strand is essentially fused
or welded at every point that it comes in contact with another
coated strand. This process further prevents the individual strands
of the braided material from moving relative to each other, and
thus further fixes and stabilizes the structure of the
footwear.
[0098] As previously discussed, two or more different portions of a
braided upper could be constructed of strands having different
material properties. In addition, it is contemplated that some
portions could comprise gradations in one or more material
characteristics. Specifically, a stretchable or compressible
material may be used in one or more locations. This stretchable
material can provide the feel of compressibility when the material
is stretched elastically. As an example, in one alternative
embodiment, instep region 104 of upper 101 (shown in FIG. 1) could
comprise strands that vary in stretch and/or compressibility from
sole 110 to band 123. Thus, for example, the stretch,
compressibility and/or other material characteristics of the
strands could vary in a continuous or near-continuous manner over
different portions. By varying the stretch and compressibility, for
example, the upper can be configured to reduce sag at different
locations and also to change the feel over different locations.
[0099] The principles discussed in connection with FIG. 1 could be
applied to each embodiment. In other words, in each embodiment with
one or more braided regions, the stretch or compressibility of the
regions could vary as described here.
[0100] Some embodiments may also incorporate materials whose
characteristics change in response to different conditions. As one
possible example, a braided upper could include a region with
braided strands that stretch up to a predetermined amount (e.g., a
predetermined percentage of their length) and then cease to
stretch. In one embodiment, region 310 of article 300 (shown in
FIG. 7) may be made of a material that stretches less than material
comprising low density braided region 313. In addition, the strands
of region 310 may undergo some stretching when tension is first
applied, so that the strands stretch up to a predetermined
percentage of their initial length, at which time the strands stop
stretching. Such a configuration would provide motion limiting
features for article 300. In particular, region 310 would initially
stretch as the foot flexes or otherwise applies tension to article
300 and region 310 would apply a restraining force to the foot
after the strands of region 310 stretched to a maximum length.
[0101] The principles discussed in connection with FIG. 7 could be
applied to each embodiment. In other words, in each embodiment with
one or more braided regions, one or more of the braided regions
could be arranged to provide motion limiting features as described
here.
[0102] The uppers for articles of footwear described herein may be
made manually by braiding yarn, filaments or other fibers to form
the patterns shown in the drawings. A last may be used to conform
the upper to the desired shape and size. Cables as shown in FIG. 14
may be manually laced through the braided material. Strands as
shown in FIGS. 15 and 16 may also be manually braided using
different materials.
[0103] Some embodiments may utilize an over braiding technique to
manufacture some or all of a braided upper. For example, in some
cases, an over braiding machine or apparatus may be used to form a
braided upper. Specifically, in some cases, a footwear last may be
inserted through a braiding point of a braiding apparatus, thereby
allowing one or more layers of a braided material to be formed over
the footwear last.
[0104] FIG. 20 is a schematic diagram illustrating an example of
the use of a footwear last 1100 with an over braiding apparatus
1120 for the manufacture of a braided upper for an article of
footwear. In some embodiments, last 1100 may be a conventional
footwear last with an ankle region 1101, a heel region 1102, an
instep or midfoot region 1103, a forefoot region 1104 and a toe
region 1105.
[0105] Generally, over braiding apparatus 1120 may be any machine,
system and/or device that is capable of applying one or more
braided layers over a footwear last or other form. For purposes of
clarity, over braiding apparatus 1120 is shown schematically in the
figures. In some embodiments, over braiding apparatus 1120 may
comprise an outer frame portion 1117. In some embodiments, outer
frame portion 1117 may house one or more spools (not shown) of yarn
1119. Yarn 1119 may then extend from outer frame portion 1117
towards a central braiding point 1115. As discussed below, a
braided upper may be formed by moving footwear last 1100 through
central braiding point 1115.
[0106] In some embodiments, an over braiding system can include
provisions to facilitate the creation of various different
structures in a braided upper. In some embodiments, for example, an
over braiding system can include provisions to facilitate the
creation of eyelets or other openings in a braided upper. In other
embodiments, an over braiding system can include provisions to
create regions of different braiding density.
[0107] Some embodiments may utilize pins or similar structures to
enhance an over braiding technique. As an example, FIGS. 21 and 22
illustrate the use of pins of different dimensions and
characteristics in different regions of the upper. In some
embodiments, rows of pins with small pinheads 1130 may be used to
delineate the eyelets around an upper's midfoot opening, i.e., to
form eyelets for the footwear's shoelaces. Additionally, in some
embodiments, a row of pins with no pinheads 1131 may be used to
demarcate a high-density braid in the toe region 1105 of the
upper.
[0108] Pins or similar structures may facilitate the creation of
various structural features (such as eyelets or other openings) or
of zones of different properties (such as densities) in a various
manners. For example, placing pins with larger pin heads at
locations of a last corresponding to eyelet holes may help prevent
the buildup of yarn in these locations during the over braiding
process, thereby helping to create openings and/or eyelets. As
another example, demarcating different regions of a last with rows
of pins can help provide visual cues to an operator of an over
braiding apparatus to modify the braiding type and/or density of
those regions as they pass through the central braiding point.
Alternatively, in some embodiments, pins may interact with yarns to
modify the tension of the braid at the pin location, which could
affect the density of the resulting braid.
[0109] FIG. 23 is a schematic illustration of a braided upper as it
is being manufactured in over braiding apparatus 1120. In this
illustration, toe region 1180 of an upper has already been formed,
and over braiding apparatus 1120 is forming the forefoot region of
the upper. The density of the braiding can be varied by, for
example, feeding the toe region 1105 of the last through braiding
apparatus 1120 more slowly while the toe region is being formed (to
produce a relatively higher density braid) than while the forefoot
region is being formed (to produce a relatively lower density
braid). The last may also be fed at an angle and/or twisted to form
braided regions such as the regions shown in FIGS. 4-6, for
example. The last may also be fed through the braiding apparatus
two or more times in order to form more complex structures, or may
alternatively be fed through two or more braiding apparatuses. In
some embodiments, once the over braiding process has been
completed, a braided upper may be removed from the footwear last.
In some cases, one or more openings (such as a throat opening) can
be cut out of the resulting over braided upper to form the final
upper for use in an article of footwear.
[0110] It should be understood that in other embodiments, over
braiding an upper on a footwear last can be accomplished without
the use of an over braiding apparatus such as over braiding
apparatus 1120 shown in the figures. In some embodiments, for
example, over braiding can be achieved by manually braiding yarns
around a footwear last. Still other embodiments could incorporate a
combination of automatic over braiding methods and manual over
braiding methods.
[0111] FIGS. 24-26 illustrate exemplary embodiments of a particular
arrangement of pins on a footwear last and a corresponding braided
upper that may be manufactured with that particular arrangement of
the pins. For example, FIG. 24 illustrates an upper 1200 with
eyelets 1201 formed using a last 1100 with pins 1130. In
particular, pins 1130 have been placed on last 1100 in a
configuration that corresponds with a typical eyelet pattern for
footwear. The resulting eyelets 1201 are then formed as the yarns
of upper 1200 are braided around pins 1130 during the over braiding
process. In another example, FIG. 25 illustrates an upper 1300
formed with different density bands. In particular, upper 1300
includes a high density band 1301 at the forefoot, which is formed
by two rows of pins 1140 at the forefoot of a last 1100. Upper 1300
may also include a high density band 1305 in a toe region, which is
formed by demarcating the toe region by one row of pins 1141 on
last 1100. As still another example, FIG. 26 illustrates an upper
1400 with band 1401, band 1402, band 1403 and band 1405. These
bands have been formed using the illustrated configuration of pins
1151, pins 1152, pins 1153 and pins 1155 on footwear last 1100,
respectively.
[0112] While various embodiments have been described, the
description is intended to be exemplary, rather than limiting and
it will be apparent to those of ordinary skill in the art that many
more embodiments and implementations are possible that are within
the scope of the embodiments. Accordingly, the embodiments are not
to be restricted except in light of the attached claims and their
equivalents. Also, various modifications and changes may be made
within the scope of the attached claims.
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