U.S. patent application number 16/964911 was filed with the patent office on 2021-02-04 for shoe components having varying modulus zones.
This patent application is currently assigned to Quantum Materials, LLC. The applicant listed for this patent is Quantum Materials, LLC. Invention is credited to Jeffrey W. Bruner.
Application Number | 20210030116 16/964911 |
Document ID | / |
Family ID | 1000005180772 |
Filed Date | 2021-02-04 |
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United States Patent
Application |
20210030116 |
Kind Code |
A1 |
Bruner; Jeffrey W. |
February 4, 2021 |
SHOE COMPONENTS HAVING VARYING MODULUS ZONES
Abstract
In one aspect, a shoe component is described. The shoe component
comprises a body of continuous fabric having at least a first zone
and a second zone. The first zone of the fabric has a first modulus
of elasticity and the second zone of the fabric has a second
modulus of elasticity that is different than the first modulus of
elasticity. More than two zones can be provided per shoe component,
in some cases.
Inventors: |
Bruner; Jeffrey W.;
(Leasburg, NC) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Quantum Materials, LLC |
Colfax |
NC |
US |
|
|
Assignee: |
Quantum Materials, LLC
Colfax
NC
|
Family ID: |
1000005180772 |
Appl. No.: |
16/964911 |
Filed: |
January 25, 2019 |
PCT Filed: |
January 25, 2019 |
PCT NO: |
PCT/US2019/015195 |
371 Date: |
July 24, 2020 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
62622262 |
Jan 26, 2018 |
|
|
|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
A43B 17/00 20130101;
A43B 23/027 20130101 |
International
Class: |
A43B 23/02 20060101
A43B023/02; A43B 17/00 20060101 A43B017/00 |
Claims
1. A shoe component comprising: a body of continuous fabric having
at least a first zone and a second zone, wherein the first zone of
the fabric has a first modulus of elasticity and the second zone of
the fabric has a second modulus of elasticity that is different
than the first modulus of elasticity; wherein the first zone of the
fabric has a higher modulus of elasticity than the second zone of
the fabric; and wherein a ratio of the first modulus of elasticity
to the second modulus of elasticity is at least 2:1.
2. The shoe component of any of the preceding claims 1, wherein:
the body of continuous fabric further comprises a third zone; the
third zone of the fabric has a third modulus of elasticity; and the
third modulus of elasticity is different than the first modulus of
elasticity and/or the second modulus of elasticity.
3. The shoe component of claim 2, wherein: the body of continuous
fabric further comprises a fourth zone; the fourth zone of the
fabric has a fourth modulus of elasticity; and the fourth modulus
of elasticity is different than at least one of the first modulus
of elasticity, the second modulus of elasticity, and the third
modulus of activity.
4. The shoe component of claim 3, wherein: the body of continuous
fabric further comprises an nth zone having an nth modulus of
elasticity; the nth modulus of elasticity is different than at
least one of the first, second, third, and fourth moduli of
elasticity; and n is an integer greater than 4.
5. The shoe component of claim 1, wherein: the fabric is a woven
fabric; the first zone has a first weave construction; the second
zone has a second weave construction; and the first weave
construction and the second weave construction differ.
6. The shoe component of claim 5, wherein at least one of the first
and second weave constructions is a plain weave construction, a
basket weave construction, a twill construction, or a satin
construction.
7. The shoe component of claim 1, wherein: the first zone of the
fabric is formed from one or more first fibers; the second zone of
the fabric is formed from one or more second fibers; and the one or
more first fibers differ from the one or more second fibers.
8. The shoe component of claim 7, wherein the one or more first
fibers and the one or more second fibers have differing
elasticity.
9. The shoe component of claim 7, wherein the one or more first
fibers and the one or more second fibers have differing
tenacity.
10. The shoe component of claim 7, wherein the one or more first
fibers and the one or more second fibers have differing percent
elongation at break.
11. The shoe component of claim 7, wherein the one or more first
fibers and/or the one or more second fibers are formed from a shape
memory alloy configured to heat and/or massage a wearer's foot.
12. The shoe component of claim 7, wherein the one or more first
fibers and/or the one or more second fibers are formed from a shape
memory polymer configured to heat and/or massage a wearer's
foot.
13. The shoe component of claim 7, wherein the one or more first
fibers and/or the one or more second fibers are formed from a
combination of a shape memory alloy and a shape memory polymer
(SMAP) material configured to heat and/or massage a wearer's
foot.
14. The shoe component of claim 7, wherein the one or more first
fibers and/or the one or more second fibers are formed from a
rate-sensitive material configured to adjust a perceived stress
and/or strain in response to the speed or movement of a wearer.
15. The shoe component of claim 1, wherein the first zone of the
fabric has a higher density of filaments per area than the second
zone.
16. The shoe component of claim 1, wherein the first zone of the
fabric comprises one or more yarns having a tenacity that is
greater than about 9 grams per denier (gpd).
17. The shoe component of claim 1, wherein the second zone of the
fabric comprises one or more yarns having a tenacity that is less
than about 5 grams per denier (gpd).
18. The shoe component of claim 1, wherein the first zone of the
fabric comprises one or more yarns having a percent elongation at
break that is greater than about 50%.
19. The shoe component of claim 1, wherein the second zone of the
fabric comprises one or more yarns having a percent elongation at
break that is less than about 20%.
20. The shoe component of claim 1, wherein the shoe component is a
shoe upper.
21. The shoe component of claim 20, wherein one or more of the
fabric zones are disposed within a heel region, a toe region, or a
wing region of the shoe upper.
22. The shoe component of claim 20, wherein the first zone
comprises a higher modulus zone and the second zone comprises a
lower modulus zone, and wherein the higher modulus zone is disposed
proximate the wing region and the lower modulus zone is disposed
proximate the toe region.
23. The shoe component of claim 11, wherein the shoe component is a
shoe insole.
24. The shoe component of claim 11, wherein the shoe component is a
spacer fabric.
25. The shoe component of claim 24, wherein the first zone has a
higher modulus of elasticity than the second zone, and wherein the
first zone is disposed proximate a heel region or a ball region of
a wearer's foot.
26. The shoe component of claim 25, wherein the second zone is
disposed proximate an arch region or a toe region of the wearer's
foot.
27. The shoe component of claim 1, wherein the fabric is a
continuous, seamless woven fabric.
28. A method of making a shoe component, the method comprising:
forming at least a first zone and a second zone in a continuous
body of fabric, wherein the first zone has a first modulus of
elasticity and the second zone has a second modulus of elasticity
that is different than the first modulus of elasticity.
29. The method of claim 28, wherein forming the first and second
zones comprises weaving the first and second zones.
30. The method of claim 28, wherein the shoe component is a
seamless component.
31. The method of claim 29, wherein the shoe component formed by
the method is the shoe component of claim 1.
32. A shoe component comprising: a body of continuous fabric having
at least a first zone having a first modulus of elasticity and a
second zone having a second modulus of elasticity, wherein the
first modulus of elasticity is higher than the second modulus of
elasticity, wherein the first zone of the fabric is formed from one
or more first fibers; wherein the second zone of the fabric is
formed from one or more second fibers; wherein the one or more
first fibers differ from the one or more second fibers, and wherein
the one or more first fibers and/or the one or more second fibers
are formed from a shape memory alloy or a shape memory polymer
configured to heat and/or massage a wearer's foot.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority pursuant to 35 U.S.C.
.sctn. 119 to U.S. Provisional Patent Application Ser. No.
62/622,262, filed on Jan. 26, 2018, which is hereby incorporated by
reference in its entirety.
FIELD
[0002] The present subject matter relates to shoe components and,
in particular, to woven shoe components having one or more of zones
formed therein, such zones differing in elastic modulus, and
methods of making the same.
BACKGROUND
[0003] Textiles and fabrics are used to form various components or
portions of shoes and other footwear, including shoe uppers.
However, existing shoe components are formed via stitching together
a number of fabrics and/or materials, for example, to provide
comfortable footwear that adequately supports the foot and/or to
provide different areas in footwear that perform different
functions or have different properties. The need to stitch together
multiple fabrics and/or utilize different materials can
substantially reduce the efficiency at which shoe components are
manufactured while substantially increasing the cost.
[0004] Accordingly, a need exists for improved shoe components and
methods of making shoe components, particularly to provide shoe
components having multiple zones of differing properties or
functions.
SUMMARY
[0005] Shoe components and methods of making the same are
disclosed. The shoe components and related methods advantageously
reduce the amount of materials and/or processing steps needed to
manufacture shoe components and/or shoes. The components and
methods described herein utilize a fabric comprised of multiple
zones that differ in regards to elasticity, stiffness, modulus,
and/or any other physical or chemical attribute not inconsistent
with the objectives of the present invention.
[0006] In one aspect, a shoe component is described. The shoe
component comprises a body of continuous fabric having at least a
first zone and a second zone. The first zone of the fabric has a
first modulus of elasticity and the second zone of the fabric has a
second modulus of elasticity that is different than the first
modulus of elasticity. More than two zones can be provided per shoe
component, in some cases.
[0007] In some embodiments, the first zone of the fabric has a
higher modulus of elasticity than the second zone of the fabric.
For example, and in some cases, a ratio of the first modulus of
elasticity to the second modulus of elasticity is around 2:1. The
ratio of the first modulus of elasticity to the second modulus of
elasticity can be any value not inconsistent with the objectives of
the present invention. For example, the ratio of the first modulus
of elasticity to the second modulus of elasticity can be about
1.5:1, 2.5:1, 3:1, 4:1, 3:2, 4:3, 5:4, or any other value not
inconsistent with the instant disclosure. Alternatively, the first
zone of the fabric can have a lower modulus of elasticity than the
second zone of the fabric. In this regard, the ratio of the first
modulus of elasticity to the second modulus of elasticity may be
about 1:1.5, 1:2, 1:2.5, 1:3, 1:4, 2:3, 3:4, 4:5, or any other
value not inconsistent with the instant disclosure.
[0008] In further aspects, the shoe components described herein
comprise a fabric having more than two zones formed or disposed
therein. At least two of the zones have a different respective
modulus of elasticity. Two or more of the zones can, but do not
have to, have the same or about the same modulus of elasticity. In
some instances, the body of continuous fabric further comprises a
third zone having a third modulus of elasticity. The third modulus
of elasticity is different than the first modulus of elasticity
and/or the second modulus of elasticity. In further instances, the
body of continuous fabric can further comprise a fourth zone having
a fourth modulus of elasticity. The fourth modulus of elasticity is
different than at least one of the first modulus of elasticity, the
second modulus of elasticity, and the third modulus of activity. In
yet further instances, the body of continuous fabric further
comprises an nth zone having an nth modulus of elasticity, where
"n" is a whole number integer greater than 4. The nth modulus of
elasticity is different than at least one of the first, second,
third, and fourth moduli of elasticity.
[0009] Moreover, and in some aspects, the fabric forming the shoe
components described herein is a woven fabric. The first zone can
have a first weave construction and the second zone can have a
second weave construction that is different than the first weave
construction. The first zone can comprise a weave construction
selected from the group consisting of a plain weave construction,
one or more of a number of basket weave constructions, one or more
of a number of leno weave constructions, a jacquard weave
construction, one or more of a number of twill constructions, and
one or more of a number of satin constructions. The second zone can
differ from the weave construction selected for the first zone. Any
weave construction not inconsistent with the instant disclosure can
be used to form the fabric and/or first and second zones of the
fabric.
[0010] Moreover, in some cases, the first zone of the fabric is
formed from one or more first fibers and the second zone of the
fabric is formed from one or more second fibers. The one or more
first fibers differ from the one or more second fibers. For
example, the one or more first fibers and the one or more second
fibers can have differing elasticity, tenacity, and/or percent
elongation at break. In particular, in some preferred embodiments,
the one or more first fibers and the one or more second fibers can
have differing elongations at various set loads. Moreover, the
differing elongations can correspond to elastic portions of the
fibers.
[0011] Notably, providing one or more first fibers having differing
elasticity, tenacity, percent elongation characteristics, etc.,
than one or more second fibers advantageously allows formation of a
fabric having differing zones and/or regions for achieving a
desired performance outcome for a desired application. For example,
the first fibers may be woven together to form a first zone or
region of a shoe component and the second fibers may be woven
together to form a second zone or region of the shoe component that
is adjacent to and/or an extension of the first zone, wherein the
second zone has different properties than the first zone. A shoe
component constructed or formed from differing zones is configured
to achieve a desired and/or customized performance based upon the
end application, such as, for example, improved support or
compression resistance for athletic shoe components, improved
stretch or elasticity for dance shoe components, or improved
massaging capabilities for insole applications.
[0012] The one or more first fibers can also be formed from
different polymers or other materials than the one or more second
fibers. For example, the one or more first fibers can be formed
from a hard polymer and the one or more second fibers can be formed
from an elastomer. Any polymers and/or materials not inconsistent
with the instant disclosure can be used to form the one or more
first and second fibers and resultant fabric. The one or more first
and second fibers may be natural or synthetic fibers, and be
synthesized via any suitable method not inconsistent with the
instant disclosure.
[0013] Additionally, and in further cases, the first zone of the
fabric has a higher density and/or quantity of filaments per area
than the second zone. Moreover, the first zone of the fabric can
comprise a higher modulus zone formed from one or more yarns having
a tenacity that is greater than about 9 grams per denier (gpd). The
second zone of the fabric can optionally comprise a lower modulus
zone formed from one or more yarns having a tenacity that is less
than about 5 gpd. The fabric can be formed from any high and/or low
tenacity fiber(s) not inconsistent with the instant disclosure.
[0014] Furthermore, the first zone of the fabric can comprises one
or more yarns having a percent elongation at break that is greater
than about 50% whereas the second zone of the fabric optionally
comprises one or more yarns having a percent elongation at break
that is less than about 20%. The fabric can be formed from any
fibers having any differing physical, chemical, and/or or
mechanical properties or characteristics not inconsistent with the
instant disclosure.
[0015] The shoe components described herein can comprise shoe
uppers, in certain embodiments. One or more of the fabric zones can
be disposed within a heel region, a toe region, and/or a wing
region of the shoe upper. In certain embodiments, the first zone
comprises a higher modulus zone and the second zone comprises a
lower modulus zone. The higher modulus zone can be located or
disposed proximate to the wing region of the shoe upper, and the
lower modulus zone can be disposed proximate to the toe region of
the shoe upper. The first, second, and nth zones can be disposed at
any spatial location on or over the shoe upper not inconsistent
with the instant disclosure. The shoe components described herein
can also be insoles, in some embodiments.
[0016] Further, and in some embodiments, the shoe components
described herein can comprise spacer fabrics. For example, in some
instances, the spacer fabric includes at least a first zone of
fabric that has a higher modulus of elasticity than the second zone
of the fabric for forming a spacer fabric having areas of improved
stiffness, elasticity, and/or compression resistance. In certain
embodiments, the first zone of the fabric is disposed proximate to
a heel region or a ball region of a wearer's foot for improving the
stiffness and/or compression resistance proximate such regions of
the foot. The second zone of the fabric can be disposed proximate
an arch region or a toe region of the wearer's foot for providing
improved cushion, stretch, and/or elasticity proximate such regions
of the foot. The shoe components described herein can also be
insoles, in some embodiments.
[0017] In certain cases, the shoe components are seamless. The
fabric used to form the shoe components can be a continuous,
seamless woven fabric, in some embodiments.
[0018] Methods of making shoe components are also described. In one
aspect, a method of making a shoe component comprises forming at
least a first zone and a second zone in a continuous body of
fabric. The first zone has a first modulus of elasticity and the
second zone has a second modulus of elasticity that is different
than the first modulus of elasticity.
[0019] Forming the first and second zones can comprise weaving the
first and second zones. Shoe components formed using such a method
can comprise a shoe upper, spacer fabric, or insert. Additional
components, not limited to tongue or sole components, can be
attached to the shoe upper, spacer fabric, or insert, where
desired. Such additional components can be attached to the shoe
upper, spacer fabric, or insert by sewing, gluing, welding, bonding
or stitching, for example.
BRIEF DESCRIPTION OF THE FIGURES
[0020] FIG. 1 schematically illustrates a shoe component having a
plurality of zones of varying modulus according to one embodiment
described herein.
[0021] FIG. 2A schematically illustrates a shoe component having a
plurality of zones of varying modulus according to one embodiment
described herein.
[0022] FIG. 2B schematically illustrates a shoe component having a
plurality of zones of varying modulus according to one embodiment
described herein.
DETAILED DESCRIPTION
[0023] Embodiments described herein can be understood more readily
by reference to the following detailed description, examples, and
figures. Elements, apparatus, and methods described herein,
however, are not limited to the specific embodiments presented in
the detailed description, examples, and figures. It should be
recognized that these embodiments are merely illustrative of the
principles of the present invention. Numerous modifications and
adaptations will be readily apparent to those of skill in the art
without departing from the spirit and scope of the invention.
[0024] In addition, all ranges disclosed herein are to be
understood to encompass any and all subranges subsumed therein. For
example, a stated range of "1.0 to 10.0" should be considered to
include any and all subranges beginning with a minimum value of 1.0
or more and ending with a maximum value of 10.0 or less, e.g., 1.0
to 5.3, or 4.7 to 10.0, or 3.6 to 7.9.
[0025] All ranges disclosed herein are also to be considered to
include the end points of the range, unless expressly stated
otherwise. For example, a range of "between 5 and 10" should
generally be considered to include the end points 5 and 10.
[0026] The components and methods described herein can be formed or
carried out using a weaving machine. Any weaving machine not
inconsistent with the objectives of the present invention may be
used. In some cases, for example, a weaving loom is used. Methods
of making shoe components described herein, including seamless
continuous fabric comprised of at least two zones used to form shoe
components, can be carried out via weaving.
[0027] In certain embodiments, the weaving machines used to form
components via the methods described herein are automated. For
example, in some cases, an automated weaving machine may be used to
carry out a weaving process according to a computer executed
instructions or according to some other automated process, such as
a mechanically automated process. The computers associated with the
automated machines described herein can include at least one memory
element and processor configured to respectively store and execute
computer-readable program code portions that instruct the weaving
machines to weave in a desired sequence or manner.
[0028] As used herein, the term "fiber" refers to a fiber, a yarn,
or a filament. It is to be understood that the shoe components and
methods of making shoe components described herein can be carried
out using any fibers not inconsistent with the objectives of the
present invention, where "fibers" can refer collectively to fibers,
yarns, and filaments.
[0029] Additionally, a "toe region" of a shoe component, for
reference purposes herein, includes the toe box and the vamp of a
shoe upper. A "vamp," for reference purposes herein, refers to the
portion of a shoe upper that at least partially covers the top part
of the foot of a wearer between the toes and the ankle. A shoe
"upper," for reference purposes herein, refers to any portion of a
shoe that is higher than the sole. Similarly, a "wing portion," for
reference purposes herein, includes all or a portion of the medial
or lateral portion of a shoe upper. Finally, an "insole" portion,
for reference purposes herein, refers to a portion of fabric that
defines the interior bottom of a shoe or a shoe component and can
be positioned directly beneath the foot of a wearer of the shoe or
shoe component.
I. Shoe Components
[0030] In one aspect, shoe components are described herein. Such
components can comprise or be formed from a body of continuous
fabric. As described in more detail below, the fabric may be formed
via weaving. Notably, one or more "zones" are formed or disposed in
the fabric either during or after the weaving processes. Such zones
are regions or areas of the fabric that differ from other zones in
regards to stiffness, rigidity, elasticity, and/or other physical
or chemical attribute to provide, for example, increased or
decreased support, stretch, cushion, compression, or other
desirable feature, to a wearer's foot.
[0031] In some cases, for example, the shoe components set forth
herein comprise, consist, or consist essentially of fabric having
at least a first zone and a second zone formed therein. The first
zone of the fabric can have a first modulus of elasticity and the
second zone of the fabric can have a second modulus of elasticity
that is different than the first modulus of elasticity. The modulus
of elasticity is known as, and may be referred to as the "elastic
modulus" or "Young's modulus" or "initial modulus," in some
cases.
[0032] In some instances, the first zone of the fabric has a higher
modulus of elasticity than the second zone of the fabric. In some
cases, a ratio of the first modulus of elasticity to the second
modulus of elasticity is 2:1 or at least about 2:1. The ratio of
the first modulus of elasticity to the second modulus of elasticity
can be any value not inconsistent with the objectives of the
present invention. For example, the ratio of the first modulus of
elasticity to the second modulus of elasticity can be about 1.5:1,
2.5:1, 3:1, 4:1, 3:2, 4:3, 5:4, or any other value not inconsistent
with the instant disclosure.
[0033] Alternatively, in some embodiments, the first zone of the
fabric can have a lower modulus of elasticity than the second zone
of the fabric. In this regard, the ratio of the first modulus of
elasticity to the second modulus of elasticity may be about 1:1.5,
1:2, 1:2.5, 1:3, 1:4, 2:3, 3:4, 4:5, or any other value not
inconsistent with the instant disclosure.
[0034] It should be understood that a ratio of the first zone's
elastic modulus to the second zone's elastic modulus is calculated
by first determining the elastic modulus of each zone (such as in a
manner described further hereinbelow). The elastic modulus of a
particular zone can then be compared as a ratio to the elastic
modulus of a different zone.
[0035] It is further to be understood that the elastic modulus of a
particular zone described herein is not necessarily the same as the
total or overall elastic modulus of a shoe component having
multiple zones Similarly, the elastic modulus of a particular zone
described herein is not necessarily the same as the total or
overall elastic modulus of a seamless fabric described herein. For
example, in some cases, a particular zone can have an elastic
modulus that is higher or lower than the total or overall elastic
modulus of the shoe component or of a continuous fabric comprising
or containing the zone.
[0036] In general, a modulus of elasticity of a zone (or fabric)
described herein can be measured or determined in any manner not
inconsistent with the objectives of the present disclosure. For
example, in some cases, a zone's (or fabric's) elastic modulus can
be determined according to ASTM standard D4848-98. Of course, for
purposes of comparing the elastic modulus of one zone to the
elastic modulus of another zone (qualitatively or quantitatively,
as contemplated and described herein), it is to be understood that
the compared elastic moduli are to be determined or measured using
the same method or standard in a given instance.
[0037] The first and second zones, respectively, can differ in
regard to any chemical, physical, or mechanical attribute not
inconsistent with the objectives of the instant invention. For
example, and in some embodiments, the first zone of the fabric has
a higher quantity of fibers or filaments that the second zone
Similarly, in some embodiments, the first zone of the fabric has a
higher density of filaments per area than the second zone. The
first and second zones of the fabric can differ in fiber tenacity,
elongation, elongation at break, elastic modulus, stiffness, or any
other aspect not inconsistent with the instant disclosure.
[0038] In certain embodiments, at least one of the first and second
zones of the fabric comprise one or more high tenacity yarns,
fibers, or filaments having a tenacity that is greater than 4 grams
per denier (gpd), greater than 5 gpd, greater than about 9 gpd,
greater than about 10 gpd, greater than about 20 gpd, or greater
than about 30 gpd. Similarly, in some embodiments, at least one of
the first and second zones of the fabric comprise one or more low
tenacity yarns, fibers, or filaments having a tenacity that is less
than about 5 gpd, less than about 4 gpd, less than 3 gpd, less than
2 gpd, or less than 1 gpd. In some instances, the first zone of the
fabric has a tenacity of 3-4 gpd, and the second zone of the fabric
has a tenacity of 7-9 gpd or greater than 9 gpd. Such high and low
tenacity yarns, fibers, and/or filaments can be used together in a
single zone or provided in separate, spatially discrete zones.
[0039] Additionally, at least one of the first and second zones of
the fabric comprise one or more highly elastic yarns, fibers, or
filaments having a percent elongation at break that is greater than
about 50%, greater than about 100%, greater than about 200%, or
greater than about 300%. Similarly, at least one of the first and
second zones of the fabric comprise one or more non-elastic or
substantially non-elastic yarns having a percent elongation at
break that is less than about 20%, less than about 10%, less than
about 5%, or less than about 2%. Elastic and non-elastic yarns,
fibers, and/or filaments can be used together in a single zone or
provided in separate, spatially discrete zones.
[0040] The first and second zones can occupy any size, shape,
and/or spatial location over the fabric not inconsistent with the
objectives of the present invention. The first zone can be directly
adjacent to and optionally contact the second zone or be spaced
apart therefrom. In some aspects, the first and second zones can
partially overlap. Alternatively, in other embodiments, the first
and second zones do not overlap. The weave structures and/or fibers
defining the first and second zones can be customized depending on
the application or provided in a repetitive pattern over the
fabric. Some non-limiting examples of weave structure patterns are
shown in FIG. 1. The first and second zone can have the same or
different shapes and sizes. In certain embodiments, the size and/or
placement of the stiffer and/or more elastic zones can be
customized for athletic or orthotic shoes for providing adequate
support and stretch relative to the wearer's foot. Fabrics and shoe
components comprised of more than two zones are also
contemplated.
[0041] Moreover, a given "zone" of a fabric described herein can be
distinguished from another zone of the fabric in one or more
manners. For instance, as noted herein, differing zones can have
different moduli of elasticity. Moreover, differing zones can be
formed from different fibers and/or have different fiber
configurations or arrangements. Such configurations or arrangements
may include, without limitation, specific weave constructions that
are obtained via fiber placement and manipulation during weaving on
a weaving machine. Thus, the modulus of elasticity for a zone can
be determined, in some embodiments, by one or more characteristics
of the zone, including but not limited to fiber material, fiber
quantity, fiber density, weave structure, or woven construction,
such specific combinations of weave structures or specific patterns
having multiple weave structures, or any combination thereof.
[0042] Additionally, it is also possible for differing zones in a
single continuous fabric described herein to have the same modulus
of elasticity and/or share other structural features, such as fiber
and/or fiber configuration or arrangement. However, in such
instances, it is to be understood that the differing zones are not
immediately adjacent zones. Instead, such otherwise "identical" or
"repeating" zones may be separated from one another by one or more
other zones having different moduli of elasticity and/or different
constructions. The various zones can be spatially disposed in the
fabric.
[0043] It is to be understood that a single continuous fabric
described herein can have more than two differing modulus zones. In
some embodiments, for instance, the body of continuous fabric
further comprises a third zone having a third modulus of
elasticity. The third modulus of elasticity is different than the
first modulus of elasticity and/or the second modulus of
elasticity. Similarly, the body of continuous fabric can further
comprise a fourth zone. The fourth zone of the fabric has a fourth
modulus of elasticity, that is different than at least one of the
first modulus of elasticity, the second modulus of elasticity, and
the third modulus of activity.
[0044] More generally, in some cases, the body of continuous fabric
further comprises an nth zone having an nth modulus of elasticity.
The nth modulus of elasticity is different than at least one of the
first, second, third, and fourth moduli of elasticity. The value of
the integer "n" is greater than 4, but not particularly limited. In
some embodiments, "n" is an integer between 5 and 100, between 5
and 50, between 5 and 30, between 5 and 20, between 5 and 15, or
between 5 and 10. Moreover, it is further to be understood that any
two of the "n" zones of a continuous body of fabric described
herein can differ in any of the manners described herein for a
"first" and "second" zone.
[0045] Further, in some embodiments, the fabric is a woven fabric.
The first zone can have a first weave construction and the second
zone can have a second weave construction. The first weave
construction and the second weave construction differ. For example,
and in certain embodiments, the first zone can comprise a first
weave construction selected from the group consisting of a plain
weave construction, one or more of a number of basket weave
constructions, one or more of a number of leno weave constructions,
a jacquard weave construction, one or more of a number of twill
constructions, and one or more of a number of satin constructions.
The second zone can be formed from a second weave construction that
differs from the weave construction selected for the first zone.
Any weave construction(s) not inconsistent with the instant
disclosure can be used alone or in combination to form the fabric
and/or first and second zones of the fabric. Further, it is to be
understood that, in some cases, the first and second zones can have
weave constructions that differ in the weaving density or number of
yarn interlacings per unit area.
[0046] Moreover, and in certain embodiments the first zone of the
fabric is formed from one or more first fibers and the second zone
of the fabric is formed from one or more second fibers. The one or
more first fibers can differ from the one or more second fibers, in
terms of any physical, chemical, or mechanical attributes not
inconsistent with the objectives of the instant disclosure. For
example, the first fibers can be formed from a different polymer or
material than the second fibers. The first fibers can also differ
in regards to elastic modulus from the second fibers, and thus,
differ in elasticity, rigidity, and/or stiffness. The first and
second fibers can also have a differing tenacity or percent
elongation at break.
[0047] The shoe components constructed or formed from the fabric
described herein can comprise shoe uppers, spacer fabrics, or
insoles. Where the shoe component is a shoe upper, one or more of
the fabric zones can be disposed within a heel region, a toe
region, or a wing region of the shoe upper. In certain embodiments,
the first zone comprises a higher modulus zone and the second zone
comprises a lower modulus zone. The higher modulus zone can be
disposed proximate the wing region and the lower modulus zone can
be disposed proximate the toe and/or heel regions. The fabric
forming the shoe components described herein can comprise a
continuous, seamless woven fabric.
[0048] Further, and in certain embodiments, the shoe components
constructed or formed from the fabric described herein include
spacer fabrics. Such fabrics can be positioned or disposed
proximate a wearer's foot, in some instances. In some embodiments,
a spacer fabric described herein comprises a woven construction
formed from a fabric comprising or consisting of at least a first
zone and a second zone. The first zone can comprise a higher
modulus of elasticity than the second zone for increasing the
amount of support or stiffness provided to a given portion of the
foot. For example, and in some embodiments, the first zone of the
spacer fabric having the higher modulus of elasticity is disposed
proximate a heel region or a ball region of a wearer's foot. The
second zone of the fabric can be disposed proximate an arch region
or a toe region of the wearer's foot. More than two zones may be
formed, disposed, or otherwise provided per the spacer fabric. The
multiple zones of the spacer fabrics described herein can differ in
regards to any desired material property not inconsistent with the
objectives of the present subject matter, for example, and in some
aspects, such zones differ in regards to the modulus of elasticity,
weave construction, yarn material, tenacity, percent elongation at
break, and/or thickness.
[0049] As noted above, the shoe components set forth herein are
formed from one or more fibers, yarns, and/or filament. The type,
composition, quantity, density, weave construction, or any other
aspect of the fibers, yarns, and/or filaments can, but does not
have to, differ per zone. The shoe components can, in some
instances, comprise one or more zones formed from a single
component yarn, a multi-component yarn (such as a bi-component yarn
or a yarn having 3 or 4 or more components), or a combination of
single and multi-component yarns. A multi-component yarn can have a
sheath/core structure, a side-by-side structure, or an
islands-in-the-sea structure. Other multi-component yarn structures
can also be used. Further, in some embodiments, the shoe components
comprise one or more zones formed from a monofilament yarn, a
multifilament yarn, or a combination of monofilament and
multifilament yarns. The yarn forming the shoe components described
herein may also include separate filaments formed from different
materials, or a plurality of filaments that are each formed from
two or more different materials.
[0050] Additionally, in some instances, the shoe components
described herein comprise one or more zones that are at least
partially formed from an elastomeric yarn or a heat-fusible yarn.
For example, in some embodiments, stable and elastic single
component multifilament and/or monofilament yarns are used in one
or more zones. In some such cases, the yarns can be formed from low
melting point polymers, such as polymers having a melting point
below about 200.degree. C., 150.degree. C., below about 100.degree.
C., or below about 80.degree. C. In some embodiments, the yarns can
be formed from polymers having a melting point between about
80.degree. C. and about 150.degree. C. Such yarns can be heated,
with or without pressure, to cause the low melting components to
melt and flow, thereby modifying the physical properties of the
shoe component, including by serving as an adhesive. In other
cases, stable and elastic multi-component (e.g., bi-component)
multifilament and/or monofilament yarns are used. In some such
embodiments, the yarns in one or more zones can be formed from low
melting point polymers in combination with higher melting point
polymers (such as polyester or nylon), such that the low melting
point polymer components but not the higher melting point polymer
components of the yarns can be made to melt and flow by the
application of heat with or without pressure, thereby modifying the
physical properties of the shoe component in a desired manner,
including by providing an adhesive element and/or structural
support.
[0051] The fiber, yarn, or filament or one or more portions of the
fiber, yarn, or filament forming the shoe components and/or zones
thereof as described here can comprise or be formed from any
material not inconsistent with the objectives of the present
invention. In some embodiments, for example, the fiber, yarn, or
filament comprises or is formed from a synthetic material such as
nylon or another polyamide, polyester, polyethylene, polypropylene,
polybutylene, or another polyolefin, or polyacrylic. In other
cases, the fiber, yarn, or filament comprises or is formed from a
natural fiber material such as cotton, wool, or silk. Other fibers,
yarns, and filament materials may also be used, such as regenerated
cellulose or rayon.
[0052] In certain cases, the fiber, yarn, or filament comprises or
is formed from a rate-sensitive material, such as a rate-sensitive
thermoplastic elastomer. Such a "rate-sensitive" material can have
a first property whose value changes non-linearly with a second
property, the second property being a rate or frequency. In some
embodiments, for example, a rate-sensitive material includes or
comprises a rate-sensitive thermoplastic elastomer. Such materials
exhibit different stiffness values at different rates or
frequencies. For instance, rate-sensitive materials can be soft and
flexible at lower rates or frequencies, but stiffen or harden under
higher rates or frequencies. As described herein, such
rate-sensitivity can provide increasing stability and performance
under certain conditions of use of a fiber, yarn, filament, fabric,
and/or shoe component described herein. One non-limiting example of
a rate-sensitive material is D3O.RTM., a DuPont.TM. Hytrel.RTM.
thermoplastic elastomer.
[0053] The rate-sensitivity of a rate-sensitive material described
herein, in some cases, is further influenced by an operational
parameter. For example, in some embodiments, a rate-sensitive
material can be temperature-sensitive. A change in temperature, in
some cases, can affect the characteristics or properties of the
rate-sensitive material. Such rate-sensitive materials that are
temperature-sensitive can exhibit a significant shift in
rate-sensitivity upon a change in temperature, and in some cases,
upon a nominal change in temperature. For example, an increase or
decrease in temperature can change the melt viscosity at certain
shear rates. Thus, characteristics or properties of the
rate-sensitive material, including mechanical properties, thermal
properties, and electrical properties, in some cases, can vary at
different temperatures in rate-sensitive materials. Some examples
of such temperature sensitive materials include, but are not
limited to, Dupont Hytrel.RTM. thermoplastic elastomers, such as
Hytrel.RTM. G4074, Hytrel.RTM. 4056, Hytrel.RTM. 4069, Hytrel.RTM.
5526, Hytrel.RTM. 5556, Hyrel.RTM. 6356, and Hytrel.RTM. 7246. It
should be understood that other temperature-sensitive materials are
also contemplated.
[0054] In other embodiments, a rate-sensitive material can be
pressure-sensitive. For example, a change in pressure or load, in
some cases, can affect the characteristics or properties of the
rate-sensitive material. Such rate-sensitive materials that are
pressure-sensitive can exhibit a significant shift in
rate-sensitivity upon a change in pressure or load, and in some
cases, upon a nominal change in pressure or load. For example, an
increase or decrease in pressure or load can change the flow length
at certain melt flow rates. Thus, characteristics or properties,
including mechanical properties, thermal properties, and electrical
properties, in some cases, can vary at different values of pressure
or load in rate-sensitive materials. One such example of a pressure
sensitive material is Dupont Hytrel.RTM. 8833. It should be
understood that other pressure-sensitive materials are also
contemplated.
[0055] Rate-sensitive materials exhibit a variety of desirable
characteristics or properties at different rates or frequencies.
Non-limiting examples of desirable characteristics or properties
that can vary in rate-sensitive materials include adhesion, water
absorption, humidity absorption, hydrolysis resistance, tensile
strength, compression strength, impact strength, fatigue
resistance, heat absorption, light reflection, colorfastness,
abrasion-resistance, friction resistance, tear resistance,
flex-fatigue resistance, creep resistance, impact resistance,
chemical resistance, heat-aging resistance, wet-squeak resistance,
stress-cracking resistance, crack propagation resistance,
ultraviolet radiation resistance, nuclear radiation resistance,
breathability, gas permeability, ductility, elasticity,
brittleness, conduction, shrinkage, flammability, antimicrobial
properties, hardness, toughness, softness, flexibility, resilience,
porosity, rigidity, density, and others. It should be understood
that any rate-sensitive material, not inconsistent with the goals
of the present disclosure can be used. Moreover, selection of
certain characteristics or properties and/or profiles in
rate-sensitive materials can vary by region or zone of shoe
components described herein. Such rate-sensitive yarns and/or
materials, in some cases, can be configured to adjust the stress
and/or strain experienced by a wearer of a shoe component described
herein, based on acceleration, speed, or movement of the
wearer.
[0056] In still other cases, the fiber, yarn, or filament comprises
or is formed from a metallic material such as stainless steel,
copper, or a metal mixture or metal alloy. In some instances, the
metallic material is electrically conductive. Other electrically
conductive fibers, yarns, or filaments may also be used. Such
electrically conductive materials can be used, in some cases, for
the dissipation of static charge and/or for the formation of
"smart" or electrically integrated materials. It is also possible
for a fiber, yarn, or filament described herein to include or be
formed from a shape memory material such as a shape memory polymer
and/or a shape memory alloy such as Nitinol.
[0057] In certain embodiments, the shape memory polymer and/or the
shape memory alloy materials are configured to provide heating
and/or massaging of the wearer's foot. In further instances, the
fibers, yarns, or filaments described herein are formed from a
combination of shape memory alloys and shape memory polymers
(SMAP). The combined SMAP material may be configured to heat and/or
massage a wearer's foot when constructed or formed into a shoe
component.
[0058] In some cases, a shoe component configured to massage a
wearer's foot can comprise a shape memory alloy and/or shape memory
polymer material in a desired region of the shoe component, such as
near a toe, heel, arch, or ball region, such that the desired
region is massaged. For example, in some cases, such a massaging
configuration can be achieved via a textured surface of the shoe
component or a change in pressure applied to the wearer's foot
within the region. In some instances, a surface can be textured
according to the weave construction. Changes in pressure or
texture, in some cases, can occur from shape changes of the shape
memory material that are triggered by a specific stimulus, such as
a change in temperature. For example, as a shape memory material
changes in temperature, the shape of the material can change, which
consequently can modify a texture and/or increase or decrease a
pressure exerted upon the wearer from the shoe component at the
location of the changing shape memory material. Such a shape memory
material that responds to certain stimuli can elicit a massage
sensation or effect massaging of a wearer's foot.
[0059] In some cases, a shoe component configured to heat a
wearer's foot can comprise a shape memory alloy and/or shape memory
polymer material in a desired region of the shoe component, such as
near a toe, heel, arch, or ball region, such that the desired
region is heated. For example, in some cases, a heating
configuration can comprise insulation at a desired region of the
shoe component. In other cases, such a heating configuration can
include distributing, dispersing, or dissipating heat from a first
region to a second region. In some instances, such a heating
configuration can further complement or provoke massaging
configurations as described above.
[0060] In some embodiments, a shoe component comprises a shape
memory alloy and a shape memory polymer material in a desired
region of the shoe component, such as near a toe, heel, arch, or
ball region, such that the desired region is both heated and
massaged. In some instances, changes in temperature can result in
changes in shape. Wherein a region or zone of a shoe component can
be configured to heat, the same region can also be configured to
massage according to fluctuations in temperature within the
region.
[0061] Further, the fiber, yarn, or filament described herein may
be coated with one or more optional, additional materials for
providing a desired property. In some cases, for instance, the
fiber, yarn, or filaments forming the shoe components are coated
with a fluorocarbon such as polytetrafluoroethylene. The fiber,
yarn, or filament described herein can also optionally comprise one
or more additives, including polymer additives, which can provide
heat absorption and/or heat reflectivity properties. Additives
comprising thermochromic, photochromic, hydrochromic, or
pressure-chromic pigment and dye materials may also be used, in
some cases. Such pigment and dye materials are configured to change
color in response to exposure to heat, light, moisture, and/or
pressure. It is also possible to incorporate one or more
antimicrobial or antifungal materials into or onto the fiber, yarn,
or filament forming the shoe components described herein.
[0062] As described above, a shoe component can comprise or be
formed from various yarns and materials to define multiple zones.
Wherein certain materials, such as shape memory materials or an
additive as described above, can be uniquely responsive to a
stimulus or change in environment, such as a change in temperature,
a zone can also be uniquely responsive to a stimulus or a change in
environment. For example, a first zone comprising a first
responsive material can react according to properties of the first
responsive material, and a second zone comprising a second
responsive material can react according to properties of the second
responsive material, such that the first and second zones react or
respond according to their respective materials, which in some
cases are not the same responsive material. In some cases, the
stimulus eliciting the change can be the same for each zone, even
though the response of each material in the first and second zones
can differ.
[0063] Moreover, the fiber, yarn, or filaments forming the shoe
components described herein can have any size, shape, and/or denier
not inconsistent with the objectives of the present invention.
[0064] Further, the shoe components described herein can be
seamless. For example, in some cases, a three-dimensional shoe
upper has a continuous, repeating, and/or seamless construction
throughout the entire upper or a portion of the upper, such as a
heel portion.
II. Methods of Making Shoe Components
[0065] Methods of making shoe components are also disclosed. Such
methods are used to make or construct any of the shoe components
described in Section I above. Such methods obviate the need for
stitching seams and/or cutting and stitching different fabrics
together, in some aspects.
[0066] In one aspect, a method of making a shoe component comprises
forming at least a first zone and a second zone in a continuous
body of fabric. The first zone has a first modulus of elasticity
and the second zone has a second modulus of elasticity that is
different than the first modulus of elasticity, as described
above.
[0067] In some embodiments, the method of making the shoe component
comprises weaving the first and second zones. The shoe components
can optionally be a seamless component constructed from a seamless
woven fabric.
III. Shoes
[0068] In another aspect, shoes are described herein. A shoe
described herein can be, but does not have to be, an athletic shoe
or other athletic footwear, including a shoe or other footwear
specifically designed for baseball, basketball, boating or other
water sports, cross-training, football, hiking, hockey, running,
soccer, dancing, gymnastics, or walking activities.
[0069] A shoe can also be a non-athletic shoe or other footwear,
such as a deck shoe, dress boot, dress shoe, loafer, sandal, or
work boot. Further, a shoe described herein can be formed by a
method described hereinabove in Section II. Further, a shoe or
component of a shoe can have any structure or construction not
inconsistent with the objectives of the present invention,
including any structure or construction described hereinabove in
Section I.
[0070] In some embodiments, a shoe comprises a shoe component
described hereinabove in Section I and one or more additional shoe
components attached to the shoe component. Any additional shoe
components not inconsistent with the objectives of the present
invention may be used. In some cases, for instance, an additional
shoe component comprises a tongue component. In other cases, an
additional shoe component comprises a sole component, such as a
midsole or outsole.
[0071] Some embodiments described herein are further illustrated in
the following non-limiting examples. The following examples and the
foregoing description are directed to the fabrication of various
three-dimensional shoes and shoe components, including seamless
shoes and shoe components. However, it should be noted that methods
described herein, including methods of reducing the lateral
separation distance between fabric portions, can be expanded and
applied more generally to the weaving of other three-dimensional
fabrics that are not necessarily a shoe component.
EXAMPLE 1
Formation of Zones via Varying Weave Construction
[0072] Fabric comprising at least first and second zones that
differ in regards to the modulus and, thus, elasticity or stiffness
can be provided via varying the weave construction disposed in each
zone. For example, a tighter or more densely constructed weave
construction may be more rigid and stiff compared to other weave
structures. FIG. 1 is a schematic diagram of a shoe component
comprising one or more zones formed thereon. Each zone can comprise
a plurality of different weave constructions disposed in a desired
order or pattern. The zones can be disposed on or over the heel
region, toe region, or wing region of the shoe component. As FIG. 1
illustrates, a single zone can be constructed of a combination of
weave constructions. Alternatively, one zone can be constructed of
a single weave construction.
[0073] Further, in some embodiments, the first zone has a first
weave construction or a first combination of weave constructions
and the second zone has a second weave construction or a second
combination of weave constructions that differs from the first
zone. The first zone can comprise a weave construction selected
from the group consisting of a plain weave construction, a basket
weave construction, a leno weave construction, a jacquard weave
construction, a twill construction, and a satin construction. The
second zone can differ from the weave construction selected for the
first zone. Any weave construction not inconsistent with the
instant disclosure can be used to form the fabric and/or first and
second zones of the fabric.
[0074] Additionally, the filament size, shape, type, or density of
filaments in the different weave constructions can, but do not have
to differ. The denier, durometer ranges, shrink characteristics,
mechanical properties, or modulus of the filaments provided in each
weave construction can also differ. Alternatively, the denier,
durometer ranges, shrink characteristics, mechanical properties, or
modulus of the filaments provided in each weave construction can be
the same.
EXAMPLE 2
Formation of Zones via Yarn Selection
[0075] In some embodiments, a fabric having one or more zones
disposed therein is formed as a result of yarn selection. For
example, combining various types of yarns and/or polymers in
different patterns or locations of a fabric can result in a single
fabric having multiple zones, wherein at least two of the zones
have a different modulus of elasticity. Table 1 below includes
exemplary data associated with various materials.
TABLE-US-00001 TABLE 1 Exemplary Yarn Properties Tenacity
Elongation Tenacity at 0.5 % Elongation Material Type
(grams/denier, gpd) at Break (%) Elongation (gpd) at 5 gpd (%)
Dyneema .RTM. UHWPE 30-35 2.7-3 4.3-4.8 1.2-1.7 Spectra .RTM. UHWPE
30-35 2.7-3 4.3-4.8 1.2-1.7 Vectran .TM. LCP 26 3.1 3.3 0.8 Kevlar
.RTM. Aramid, para 18-20 2.5-3.5 2-3 0.5-1.0 Zylon .RTM. PBO 34 3.3
5.3 0.5 Hytrel .RTM. CoPE, 3 dpf 2.5 101 -- -- (values depend on
construction) HT PET Invista 840 den 9.5 14 0.5 10 HT PA Invista
T-715 8.6 21.6 0.22 11.1 PET, Textile Typical 4.5 50 -- -- PA,
Textile Typical 4 55 -- -- Industrial, Typical 3.5 60 -- -- PP HT
PP Innegra 9.3 9.8 0.7 3.9 Lycra .RTM. Spandex 1 >250 n/a --
Rubber yarn Typical <1 >350 -- --
[0076] In regards to Table 1 above, it should be noted that all of
the data is for reference purposes only, as some of the data can
differ depending on yarn construction and other data is only
average or typical data.
[0077] Notably, however, the material from which a given zone is
constructed can be selected or chosen according to performance
data, such as the data contained in Table 1. Any type of data not
inconsistent with the objectives of the present invention can be
used to select the yarns for various zones. In certain instances,
the continuous fabric is woven using multiple different yarns that
vary per zone. For example, a first zone can be formed from a
SPECTRA.RTM. yarn and a second zone can be formed from a PET yarn.
Alternatively, in some cases, a continuous fabric woven from a
single type of yarn, but having varied construction of the yarn, is
contemplated. For example, a CoPE yarn in a core-sheath
construction can be used to form a first zone and a CoPE yarn in a
side-by-side construction can be used to form a second zone. In
another example, a CoPE yarn in an 80:20 core-sheath construction
can be used to form a first zone and a CoPE yarn in an 50:50
core-sheath construction can be used to form a second zone. A
fabric constructed from any types and/or quantities of yarn types
not inconsistent with the objectives of the present invention can
be used to form a multi-zoned fabric.
[0078] Further, the yarn selected for use in a given zone can
depend on whether that zone is to provide more stiffness or more
elasticity to the wearer's foot. For example, a yarn having a
higher tenacity, a lower elongation, and/or a higher modulus can be
selected for a zone that requires more support and rigidity (e.g.,
a heel region, an arch region, etc.). Alternatively, yarn having
less tenacity, greater elongation, and lower modulus can be
selected for a zone that requires less support and more stretch
(e.g., a toe region, a wing region, etc.).
[0079] In some embodiments, the shoe components set forth herein
comprise one or more higher modulus, stiff zones being formed from
a single component yarn produced from a single polymer material.
Such zones can be constructed via weaving a stable filament or spun
yarn formed from hard polymers, such as, without limitation,
polyester, nylon, Kevlar.RTM., Spectra.RTM., Dyneema.RTM., etc. Any
other type of yarn, fiber, filament, polymer, and/or material not
inconsistent with the objectives of the present invention may also
be used to produce one or more stiff or substantially stiff zones
in the shoe components described herein. For instance, a single
type of multicomponent yarn (e.g., bicomponent), a covered yarn
(e.g., single-covered or double-covered), an auxetic yarn, an
intermingled yarn, or a twisted yarn can be used to form a
relatively high stiffness zone.
[0080] One or more softer, more elastic and lower modulus zones can
also be formed in the shoe components described herein. Such zones
can be constructed using a single component yarn produced from a
single polymer material. The lower modulus zones, in some cases,
comprise or are formed from elastic filament yarns having one or
more soft segments. Such materials include, without limitation,
rubber, elastomers, elastomeric melt polymers, extrudable polymers,
nylon, olefin, Lycra.RTM., Spandex.RTM., polyurethane, CoPolyester
(CoPE), Hytrel.RTM., etc. Any other type of yarn, fiber, filament,
polymer, and/or material not inconsistent with the objectives of
the present invention may also be used to produce one or more
elastic zones in the shoe components described herein. For example,
a single type of multicomponent yarn (e.g, bicomponent) can be used
to form a relatively low stiffness zone.
[0081] More generally, it is to be understood that the zones being
formed in the fabric for shoe components can comprise multi
component yarns produced from multiple polymers. Such yarns may be
core spun yarns, single covered yarns, double covered yarns,
auxetic yarns having auxetic structures or materials, wrapped
yarns, co-extruded yarns of two or more polymers, etc. Any yarn,
fiber, filament, polymer, and/or material not inconsistent with the
objectives of the present invention may be selected and used to
produce one or more zones in the shoe components described
herein.
[0082] Further, it is also possible to form zones having varying
modulus in a shoe component described herein using a feeder blend.
For example, a fabric or portion thereof can be formed from a first
feeder using a regular tenacity fiber or yarn (such as a regular
tenacity polyester yarn), a second feeder using a fusible fiber or
yarn, and a third feeder using a high modulus fiber or yarn (such
as a high modulus Kevlar.RTM., Spectra.RTM., or Dyneema.RTM. yarn).
Other combinations or feeder blends may also be used.
EXAMPLE 3
Formation of Zones via Yarn Modulus Engineering
[0083] In further embodiments, a shoe component is constructed or
formed from a fabric having differing modulus of elasticity zones
engineered therein. The various zones being engineered within a
shoe component can be expressed in terms of a relative modulus. For
example, one zone can have an elastic modulus that is about
2.0.times., 3.0.times., or more than 3.0.times. greater than
another zone Similarly, one zone can have an elastic modulus that
is about one-half, one-quarter or three-quarters the modulus of
another zone. Multiple zones having any combination of two or more
relative moduli including, without limitation, an elastic modulus
of 0.50.times., 0.75.times., 1.00.times., 2.00.times., 3.00.times.,
etc., can be formed and disposed in a fabric to provide varying
degrees of support and/or elasticity depending on the polymer blend
and processing conditions during yarn processing.
[0084] Table 2 below includes data obtained from tensile testing
various engineered yarns produced from 1600 denier DuPont.TM.
Hytrel.RTM. thermoplastic elastomers. Any other type of material
not inconsistent with the objectives of the present invention may
also be used to produce engineered yarns or textiles. For example
only, and without limitation, engineered yarns or textiles produced
from any elastomer, thermoplastic, nylon or other polyamide,
polyester, polyethylene, polypropylene, polybutylene or other
polyolefin, polyacrylic polyester, or para-aramid not inconsistent
with the instant application are contemplated.
[0085] Each yarn in Table 2 was engineered to exhibit a desired
relative modulus, however, moduli other than those shown may also
be obtained. For example, although not shown, yarns having a
relative modulus of 1.5.times., 2.5.times., 3.5.times., or other
ratio, can also be produced and incorporated into a shoe
component.
TABLE-US-00002 TABLE 2 Exemplary Yarn Properties Engineered Yarn
Tensile Properties Yarn Elastic Modulus 0.50x 0.75x 1.0x 2.0x 3.0x
Denier 1600 1600 1600 1600 1600 Load at 2% 47 61 93 175 366
Elongation, 4% 99 127 190 313 530 in grams (g) 6% 159 198 283 429
624 10% 287 348 470 642 824 Elongation 10 g 0.03% 0.04% 0.04% 0.03%
0.03% (%) at Load 20 g 0.71% 0.48% 0.35% 0.20% 0.09% 40 g 1.63%
1.29% 0.83% 0.39% 0.20% 60 g 2.56% 1.97% 1.27% 0.61% 0.28% 80 g
3.35% 2.61% 1.71% 0.85% 0.37% 100 g 4.07% 3.23% 2.14% 1.07% 0.45%
200 g 7.34% 6.04% 4.22% 2.33% 0.94% 400 g 13.00% 11.29% 8.53% 5.44%
2.29%
[0086] Table 3 below includes data obtained from tensile testing
800 denier monofilament yarn. Each yarn in Table 3 was engineered
to exhibit a desired relative modulus of elasticity, however,
moduli other than those shown may also be obtained.
TABLE-US-00003 TABLE 3 Exemplary Yarn Properties Engineered Yarn
Tensile Properties Yarn Elastic Modulus 0.50x 0.75x 1.0x 2.0x 3.0x
Denier 800 800 800 800 800 Load at 2% 24 31 47 88 183 Elongation,
4% 50 64 95 160 265 in grams (g) 6% 80 99 142 215 312 8% 111 136
188 268 355 10% 144 174 235 321 412 Elongation 10 g 0.83% 0.65%
0.43% 0.23% 0.11% (%) at Load 20 g 1.67% 1.29% 0.85% 0.45% 0.22% 40
g 3.20% 2.58% 1.70% 0.91% 0.44% 60 g 4.80% 3.75% 2.55% 1.36% 0.66%
80 g 6.00% 5.00% 3.37% 1.82% 0.87% 100 g 7.50% 6.06% 4.21% 2.50%
1.09% 200 g 13.89% 11.49% 8.50% 5.58% 3.02% 400 g 27.78% 22.99%
17.02% 12.46% 9.71%
[0087] The yarns in Tables 2 and/or 3 can be incorporated into a
single shoe component, for example, in regions or zones of a shoe
component. A shoe upper can have multiple zones formed from
different engineered yarns to provide more support and stability of
foot movement and also subtle and controlled support. Various
modulus yarns can be engineered into a shoe component to provide
maximum support and controlled movement of the foot in specific
regions of the shoe component.
[0088] Various embodiments of the present invention have been
described in fulfillment of the various objectives of the
invention. It should be recognized that these embodiments are
merely illustrative of the principles of the present invention.
Numerous modifications and adaptations thereof will be readily
apparent to those skilled in the art without departing from the
spirit and scope of the invention.
EXAMPLE 4
Zone Construction
[0089] Zones of a continuous fabric can be constructed according to
Examples 1-3. The present Example illustrates exemplary zone
constructions according to Examples 1-3, wherein a first zone
comprises an elastic modulus that is greater than an elastic
modulus of a second zone. Such exemplary zone constructions are
shown in FIG. 2A and FIG. 2B, wherein each zone substantially
corresponds to a specific region of the shoe component, such as a
toe region, vamp region, heel region or wing region. Referring to
FIG. 2A, a first zone in a shoe vamp region can comprise a first
modulus of 1.0.times., while a second zone in a shoe heel region
can comprise a second modulus of 3.0.times.. Furthermore, a third
zone in a shoe toe region can comprise a third modulus of
1.5.times.; a fourth zone in shoe wing region can comprise a fourth
modulus of 0.75.times.; a fifth zone in a shoe quarter region can
comprise a fifth modulus of 2.0.times.. Referring to FIG. 2B, a
first zone in a shoe vamp region can comprise a first modulus of
1.0.times., while a second zone in a shoe heel region can comprise
a second modulus of 2.0.times.. Furthermore, a third zone in a shoe
toe region can comprise a third modulus of 0.5.times.; a fourth
zone in shoe wing region can comprise a fourth modulus of
3.0.times.; a fifth zone in a shoe quarter region can comprise a
fifth modulus of 4.0.times.. Examples of weave construction
combinations that can form one or more zones having such a modulus,
as described above, are illustrated in FIG. 1.
[0090] Some additional, non-limiting, exemplary embodiments
according to the descriptions provided herein above are as
follows:
[0091] Embodiment 1. A shoe component comprising:
a body of continuous fabric having at least a first zone and a
second zone, wherein the first zone of the fabric has a first
modulus of elasticity and the second zone of the fabric has a
second modulus of elasticity that is different than the first
modulus of elasticity.
[0092] Embodiment 2. The shoe component of embodiment 1, wherein
the first zone of the fabric has a higher modulus of elasticity
than the second zone of the fabric.
[0093] Embodiment 3. The shoe component of embodiment 2, wherein a
ratio of the first modulus of elasticity to the second modulus of
elasticity is at least 2:1.
[0094] Embodiment 4. The shoe component of any of the preceding
embodiment, wherein:
the body of continuous fabric further comprises a third zone; the
third zone of the fabric has a third modulus of elasticity; and the
third modulus of elasticity is different than the first modulus of
elasticity and/or the second modulus of elasticity.
[0095] Embodiment 5. The shoe component of embodiment 4,
wherein:
the body of continuous fabric further comprises a fourth zone; the
fourth zone of the fabric has a fourth modulus of elasticity; and
the fourth modulus of elasticity is different than at least one of
the first modulus of elasticity, the second modulus of elasticity,
and the third modulus of activity.
[0096] Embodiment 6. The shoe component of embodiment 5,
wherein:
the body of continuous fabric further comprises an nth zone having
an nth modulus of elasticity; the nth modulus of elasticity is
different than at least one of the first, second, third, and fourth
moduli of elasticity; and n is an integer greater than 4.
[0097] Embodiment 7. The shoe component of any of embodiments 1-6,
wherein:
the fabric is a woven fabric; the first zone has a first weave
construction; the second zone has a second weave construction; and
the first weave construction and the second weave construction
differ.
[0098] Embodiment 8. The shoe component of embodiment 7, wherein at
least one of the first and second weave constructions is a plain
weave construction, a basket weave construction, a twill
construction, or a satin construction.
[0099] Embodiment 9. The shoe component of any of the preceding
embodiments, wherein:
the first zone of the fabric is formed from one or more first
fibers; the second zone of the fabric is formed from one or more
second fibers; and the one or more first fibers differ from the one
or more second fibers.
[0100] Embodiment 10. The shoe component of embodiment 9, wherein
the one or more first fibers and the one or more second fibers have
differing elasticity.
[0101] Embodiment 11. The shoe component of embodiment 9 or 10,
wherein the one or more first fibers and the one or more second
fibers have differing tenacity.
[0102] Embodiment 12. The shoe component of any of embodiments
9-11, wherein the one or more first fibers and the one or more
second fibers have differing percent elongation at break.
[0103] Embodiment 13. The shoe component of any of embodiments
9-12, wherein the one or more first fibers and/or the one or more
second fibers are formed from a shape memory alloy configured to
heat and/or massage a wearer's foot.
[0104] Embodiment 14. The shoe component of any of embodiments 9-12
wherein the one or more first fibers and/or the one or more second
fibers are formed from a shape memory polymer configured to heat
and/or massage a wearer's foot.
[0105] Embodiment 15. The shoe component of any one of embodiments
9-12, wherein the one or more first fibers and/or the one or more
second fibers are formed from a combination of a shape memory alloy
and a shape memory polymer (SMAP) material configured to heat
and/or massage a wearer's foot.
[0106] Embodiment 16. The shoe component of any one of embodiments
9-12, wherein the one or more first fibers and/or the one or more
second fibers are formed from a rate-sensitive material configured
to adjust a perceived stress and/or strain in response to the speed
or movement of a wearer.
[0107] Embodiment 17. The shoe component of any preceding
embodiment, wherein the first zone of the fabric has a higher
density of filaments per area than the second zone.
[0108] Embodiment 18. The shoe component of any preceding
embodiment, wherein the first zone of the fabric comprises one or
more yarns having a tenacity that is greater than about 9 grams per
denier (gpd).
[0109] Embodiment 19. The shoe component of any preceding
embodiment, wherein the second zone of the fabric comprises one or
more yarns having a tenacity that is less than about 5 grams per
denier (gpd).
[0110] Embodiment 20. The shoe component of any preceding
embodiment, wherein the first zone of the fabric comprises one or
more yarns having a percent elongation at break that is greater
than about 50%.
[0111] Embodiment 21. The shoe component of any preceding
embodiment, wherein the second zone of the fabric comprises one or
more yarns having a percent elongation at break that is less than
about 20%.
[0112] Embodiment 22. The shoe component of any of the preceding
embodiments, wherein the shoe component is a shoe upper.
[0113] Embodiment 23. The shoe component of embodiment 22, wherein
one or more of the fabric zones are disposed within a heel region,
a toe region, or a wing region of the shoe upper.
[0114] Embodiment 24.The shoe component of embodiment 22, wherein
the first zone comprises a higher modulus zone and the second zone
comprises a lower modulus zone, and wherein the higher modulus zone
is disposed proximate the wing region and the lower modulus zone is
disposed proximate the toe region.
[0115] Embodiment 25. The shoe component of any of embodiments
1-21, wherein the shoe component is a shoe insole.
[0116] Embodiment 26. The shoe component of any of embodiments
1-21, wherein the shoe component is a spacer fabric.
[0117] Embodiment 27. The shoe component of embodiment 26, wherein
the first zone has a higher modulus of elasticity than the second
zone, and wherein the first zone is disposed proximate a heel
region or a ball region of a wearer's foot.
[0118] Embodiment 28. The shoe component of embodiment 27, wherein
the second zone is disposed proximate an arch region or a toe
region of the wearer's foot.
[0119] Embodiment 29. The shoe component of any of the preceding
embodiments, wherein the fabric is a continuous, seamless woven
fabric.
[0120] Embodiment 30. A method of making a shoe component, the
method comprising: forming at least a first zone and a second zone
in a continuous body of fabric, wherein the first zone has a first
modulus of elasticity and the second zone has a second modulus of
elasticity that is different than the first modulus of
elasticity.
[0121] Embodiment 31. The method of embodiment 30, wherein forming
the first and second zones comprises weaving the first and second
zones.
[0122] Embodiment 32. The method of embodiment 30, wherein the shoe
component is a seamless component.
[0123] Embodiment 33. The method of embodiment 31 or 32, wherein
the shoe component formed by the method is the shoe component of
any of embodiments 1-29.
[0124] Embodiment 34. A shoe component comprising:
a body of continuous fabric having at least a first zone having a
first modulus of elasticity and a second zone having a second
modulus of elasticity, wherein the first modulus of elasticity is
higher than the second modulus of elasticity, wherein the first
zone of the fabric is formed from one or more first fibers; wherein
the second zone of the fabric is formed from one or more second
fibers; wherein the one or more first fibers differ from the one or
more second fibers, and wherein the one or more first fibers and/or
the one or more second fibers are formed from a shape memory alloy
or a shape memory polymer configured to heat and/or massage a
wearer's foot.
* * * * *