JP2016524941A - Braided upper having an overlay for footwear products and method of manufacturing the same - Google Patents

Abstract

The footwear product includes a braided upper having an overlay portion. The overlay portion may be applied to the edge of the braided upper. The overlay portion can include a lace hole for receiving a lace. The overlay portion can extend around the portion of the upper to reduce stretch and increase support. The overlay portion can facilitate attachment between the braided upper and the sole system. [Selection] Figure 8

Description

 The present embodiment relates to footwear products, and specifically to an upper for footwear products.

  Athletic shoes often have two main components: an upper that forms an enclosure for receiving a foot, and a sole secured to the upper. The upper may be adjustable using laces, hook-and-loop fasteners, or other devices for properly securing the shoe to the foot. The sole is in primary contact with the playing surface. The sole may be designed to absorb the impact of the shoe as it contacts the ground or other surface. The upper may be designed to provide the appropriate type of protection to the foot and to maximize the wearer's comfort.

US Pat. No. 7,252,028 US Pat. No. 8,261,648 US Pat. No. 5,361,674 US Pat. No. 5,398,586 U.S. Pat. No. 4,275,638

  In one aspect, an article of footwear includes an upper and a sole system, the upper being formed of a braided structure and an overlay portion. The overlay portion is joined to the braided structure, and the overlay portion is less stretch resistant than the braided structure.

  In another aspect, an article of footwear includes an upper and a sole system, the upper being further coupled to a lace member. The upper is formed of a braided structure and an overlay portion, the overlay portion including a plurality of lace holes for receiving the lace members.

  In another aspect, a method of forming an article of footwear includes forming a knitted structure having an internal cavity, cutting the knitted structure to create an opening, thereby providing an opening in the knitted structure; Forming an edge associated with the opening and joining an overlay portion to the edge, the overlay portion including a plurality of lace holes. The method also includes inserting a lace through the lace hole and combining the sole system and the braided structure to form an article of footwear.

  Other systems, methods, features and advantages of this embodiment will be, or will be apparent to those skilled in the art from consideration of the following drawings and detailed description. All such additional systems, methods, features and advantages are included in this specification and this summary, are within the scope of this embodiment, and are intended to be protected by the following claims.

  Embodiments can be better understood with reference to the following drawings and description. The components in the drawings are not necessarily to scale, but rather are emphasized to illustrate the principles of the embodiments. Moreover, in the drawings, like reference numerals designate like parts throughout the different drawings.

FIG. 2 shows a schematic isometric view of an embodiment of an article of footwear including a braided upper with an overlay. Fig. 2 shows an exploded isometric view of the footwear product of Fig. 1; FIG. 2 shows a schematic isometric view of the footwear product of FIG. 1 including an enlarged view of the strand provided in contact with the overlay. FIG. 4 shows a schematic isometric view of another embodiment of a configuration of strands joined to an overlay. FIG. 2 shows a schematic isometric view of the footwear product of FIG. 1 including an enlarged cross-sectional view of an overlay lace hole. FIG. 4 is a schematic isometric view of an embodiment of an overlay that includes lace holes, each lace hole being partially surrounded by a strand of braided upper. FIG. 6 is a schematic enlarged view of another embodiment of an overlay including lace holes, where the strands of the braided upper do not surround each lace hole. FIG. 2 shows a schematic rear isometric view of an embodiment of an article of footwear including a braided upper with an overlay. FIG. 2 shows a schematic exploded isometric view of an embodiment of an article of footwear including a braided upper having a plurality of separate overlays. Fig. 10 shows a schematic side view of the footwear product of Fig. 9; Fig. 10 shows a schematic top view of the footwear product of Fig. 9; FIG. 3 shows a schematic isometric view of an embodiment of an article of footwear having two different knitted areas and an overlay covering the knitted areas. FIG. 13 shows a schematic isometric view of the footwear product of FIG. 12 with a portion of the braided upper and the overlay shown in cross-section. FIG. 3 shows a schematic side view of an embodiment of a pre-cut braided structure shaped as an upper for footwear products. FIG. 15 shows a schematic diagram of the steps of cutting the braided structure of FIG. 14 to form an opening in the upper according to the process of the present invention. FIG. 16 shows an isometric view of joining the overlay to the upper of FIG. 15 in accordance with the process of the present invention. FIG. 17 shows an isometric view of a finished footwear product embodiment constructed using the process of the present invention of FIGS. FIG. 6 shows an isometric view of an embodiment of a braided upper with a bottom side overlay coupled to the sole member. FIG. 19 shows an isometric view of the braided upper of FIG. 18 joined with a sole member.

  FIG. 1 is an isometric view of an embodiment of an article of footwear 100, also referred to simply as product 100. The product 100 includes various types of shoes including, but not limited to, hiking boots, soccer shoes, football shoes, sneakers, running shoes, cross training shoes, rugby shoes, basketball shoes, baseball shoes and other types of shoes. It may be configured for use in footwear. Further, in some embodiments, the product 100 includes, but is not limited to, slippers, sandals, high heels, loafers and any other type of footwear, clothing and / or sports equipment (eg, gloves, helmets, etc.). May be configured for use with various types of non-sport related footwear.

  In some embodiments, the footwear product 100 may include an upper 102 and a sole system 110. The sole system 110 is secured to the upper 102 and extends between the foot and the ground when the product 100 is worn. In different embodiments, the sole system 110 may include different components. For example, the sole system 110 may include an outsole and a midsole and / or insole. In some cases, one or more of those components may be optional.

  The sole system 110 may provide one or more functions to the product 100. For example, in some embodiments, the sole system 110 may be configured to provide traction to the product 100. In addition to providing traction, the sole system 110 may counteract ground reaction forces when compressed between the foot and the ground during walking, running or other walking activities. The configuration of the sole system 110 may vary significantly to include various conventional or non-conventional structures in different embodiments. In some cases, the configuration of the sole system 110 may be selected according to one or more types of ground on which the sole system 110 may be used. Examples of the ground include, but are not limited to, natural grass, artificial grass, soil, and other surfaces.

  In general, the upper 102 may be any type of upper. Specifically, the upper 102 may have any design, shape, size and / or color. For example, in embodiments where the product 100 is a baseball shoe, the upper 102 could be a high top upper that is configured to provide high support for the ankle. In embodiments where the product 100 is a running shoe, the upper 102 could be a low top upper.

  With reference to FIG. 1, the components of the product 100, such as the upper 102, may be divided into a foot tip portion 10, a midfoot portion 12, and a heel portion 14 for reference purposes. The toe portion 10 may be generally related to the toes and joints connecting the metatarsals and the phalanges. The midfoot 12 may be generally related to the arch of the foot. Similarly, the heel portion 14 may be associated with the heel of the foot including the ribs. Further, the upper 102 may include an outer side portion 16 and an inner side portion 18. Specifically, the outer side portion 16 and the inner side portion 18 may be both side portions of the product 100. Further, both the outer side portion 16 and the inner side portion 18 may extend through the foot tip portion 10, the middle foot portion 12 and the heel portion 14.

  It will be appreciated that the toe portion 10, midfoot portion 12 and heel portion 14 are for illustrative purposes only and are not intended to delimit the exact region of the upper 102. Similarly, the outer side 16 and the inner side 18 are intended to schematically represent the two sides of the upper 102, rather than strictly defining the upper 102 boundary in two halves. .

  For the sake of consistency and convenience, adjectives representing directions are used throughout this detailed description, corresponding to the illustrated embodiments. The term “longitudinal” as used throughout this detailed description and in the claims refers to the direction in which the length of the component extends. For example, the longitudinal direction of the upper 102 may extend from the toe portion 10 to the heel portion 14 of the upper 102. Also, the term “lateral” as used throughout this detailed description and claims refers to the direction extending along the width of the component. For example, the lateral direction of the upper 102 may extend between the inner side portion 18 and the outer side portion 16 of the upper 102. Also, the term “vertical direction”, as used throughout this detailed description and in the claims, refers to a direction that is perpendicular to both the longitudinal and lateral directions.

  Further, the term “proximal” refers to the portion of the footwear component that is close to the foot portion when the footwear product is worn. Similarly, the term proximal direction refers to the direction toward the foot when the product is worn. The term “distal” refers to the portion of the footwear component that is away from the foot portion when the footwear product is worn. The distal direction refers to the direction that is directed away from the foot when the product is worn.

  In some embodiments, the upper 102 may comprise a knitted structure, such as a knitted fabric or other knitted structure. A braided structure can be formed by twisting three or more strands of yarns, filaments or other fibers to form the structure. As an example, the upper 102 is formed from a plurality of strands 130 that are knitted to form a shape that generally resembles the shape of a foot, as can be seen in FIG.

  Braiding can be used to form a three-dimensional structure by braiding a strand of yarn on a formwork or shoe mold (last). The braided strands, eg, the plurality of strands 130 of the embodiments of the present invention, are made from fibers such as nylon, carbon, polyurethane, polyester, cotton, aramid (eg, Kevlar®), polyethylene or polypropylene. Can do. The strands can be knitted to form a three-dimensional structure for a wide range of applications.

  The braided structures may be made by hand, or the machines disclosed in Patent Literature 1, Patent Literature 2, Patent Literature 3, Patent Literature 4 and Patent Literature 5, all of which are incorporated herein by reference in their entirety. You may manufacture using automatic braiding machines, such as. Such three-dimensional braided structures may be manufactured for specific designs, for example, by TEF Braids (Warrensburg, NY) or A & P Technology (Cincinnati, Ohio).

  By using braiding, an upper for a footwear product can be designed with specific functions tailored to a specific athletic or recreational activity. The braided upper fits snugly and comfortably on the wearer's foot and can be very light. In some embodiments, the fit of the upper may be adjusted to provide some degree of tension or tightening that the wearer may prefer. The braided upper is characterized by a close containment that covers the wearer's foot. In some embodiments, the knitted fabric may wrap around the footwear from end to end as shown in the following drawings. Such structures have tension integrity or “tensegrity” because when the braided strand is tensioned around the wearer's foot, the wearer's foot is compressed.

  Some embodiments may include a braided upper that extends under the foot, thereby forming a 360 degree covering in some areas of the foot. However, other embodiments need not include an upper that extends under the foot. In other embodiments, for example, the braided upper could have a lower perimeter joined to the sole structure and / or insole.

  FIG. 2 shows an exploded isometric view of an embodiment of the product 100 that includes an upper 102 configured with a braided structure. 1 and 2, it can be seen that the upper 102 has an opening 120 that can receive a foot. In addition, the upper 102 has a tightening region 124. The clamping region 124 may further include a clamping gap 125 that separates the outer clamping edge 126 and the inner clamping edge 127 (see FIG. 2).

  The clamping region 124 may further be associated with the clamping member 160. In the embodiment of the present invention, the fastening member 160 may be a lace. However, in other embodiments, the fastening member 160 may be any other type of fastener including, but not limited to, straps, snaps, buttons, zippers, hook-and-loop fasteners (eg, velcro) and other types of fasteners. Would be able to.

  Embodiments that utilize a braided upper can include equipment that helps to provide the upper with additional structure. In some embodiments, for example, the product may be joined to a particular portion of the braided upper or otherwise attached to enhance various characteristics of the upper. A dough portion may be included. For example, these fabric parts are to improve strength and durability, to give stretch resistance to some positions of the upper, and to facilitate joining with the braided structure of other components It may be used.

  Throughout the detailed description and in the claims, the term “overlay portion” or simply overlay refers to any portion of fabric that is attached to the surface of a braided structure, such as a braided upper. In some embodiments, the overlay portion is composed of a different material than the braided strand. Further, in some embodiments, the overlay portion may have material properties that are substantially different from the strands of the braided structure. In an embodiment of the present invention, the overlay portion can withstand expansion and contraction compared to the corresponding portion of the braided structure.

  In general, the overlay portion may be formed of any material. The materials of the present invention include, but are not limited to, fabrics (including woven and non-woven fabrics), leather (including natural and synthetic leather), polymeric materials, and other types of materials. In one embodiment, one or more overlay portions may be formed of thermoplastic polyurethane (TPU).

  In an embodiment of the present invention, product 100 may be associated with overlay component 140. Overlay component 140 may further comprise a number of different overlay portions including a first overlay portion 150, a second overlay portion 152, and a third overlay portion 154. Each overlay portion may be provided at a specific position on the upper. For example, the first overlay portion 150 may be coupled with the clamping region 124 of the upper 102. Similarly, the second overlay portion 152 may be coupled to the opening 120. The third overlay portion 154 may then be coupled to the heel portion 14 and a portion of both the outer side portion 16 and the inner side portion 18 of the upper 102.

  Referring now to FIG. 2, in some embodiments, the first overlay portion 150 extends along the edge of the clamping region 124. Specifically, the first overlay portion 150 includes a first section 181 associated with the outer clamping edge 126 of the clamping region 124. The first overlay portion 150 also includes a second compartment 182 associated with the inner clamping edge 127 of the clamping region 124. In some embodiments, the intermediate section 183 extends along the foremost edge 129 of the clamping region 124 and is joined to the first section 181 and the second section 182 of the first overlay portion 150. .

  In this configuration, the first overlay portion 150 may form the outer and inner eyestays for the upper 102 or may form the outer and inner eyestay portions for the upper 102. Specifically, the first overlay portion 150 may facilitate attachment of the upper 102 and the clamping member 160. As described in more detail below, the use of overlay portions along the edges of the clamping region 124 can help to more evenly distribute the tension applied to the upper 102 by the clamping member 160.

  In at least some embodiments, the first overlay portion 150 completes the braided structure of the upper 102 along the outer clamping edge 126, the inner clamping edge 127 and the foremost edge 129 of the clamping region 124. May be useful. Specifically, in embodiments where the braided strands may be opened at either the outer clamping edge 126, the inner clamping edge 127, or the foremost edge 129, the first overlay portion 150 includes: To prevent the strands from unraveling along their edges, it can be useful to join, fuse, or otherwise hold the ends of the strands in place.

  In some embodiments, the second overlay portion 152 extends along the edge of the opening 120. Specifically, the second overlay portion 152 is associated with the opening edge 195. Further, in some embodiments, the second overlay portion 152 may be such that all edges of the upper 102 associated with the opening 120 and / or the opening in the tightening region 124 are the first overlay portion 150 or the second overlay portion 152. Substantially continuous with the first overlay portion 150 so as to be covered by the overlay portion 152.

  This configuration helps to complete the open edge 195 by joining any open strand to the second overlay portion 152. In addition, the second overlay portion 152 may help to reinforce the opening 120 so that the braided structure near the opening 120 may not extend excessively. Such reinforcement is particularly effective in the opening 120 because the opening 120 may be subject to large tensile and other stresses when the user inserts and / or pulls out his or her foot. There is a possibility.

  In some embodiments, the third overlay portion 154 includes a first section 171 that extends along the outer side 16 and a second section 172 that extends along the inner side 18 of the upper 102. May be included. Further, the third section 173 of the third overlay portion 154 may extend below the upper 102 (eg, the lower surface) at the heel portion 14. In some embodiments, the third compartment 173 connects the first compartment 171 and the second compartment 172 such that the third overlay portion 154 continuously wraps around the sides and bottom of the upper 102. ing.

  In some embodiments, the first section 171 of the third overlay portion 154 extends from the first section 181 of the first overlay portion 150 and is continuous with the first section 181 of the first overlay portion 150. Is formed. Further, in some embodiments, the second section 172 of the third overlay portion 154 extends from the second section 182 of the first overlay portion 150 and the second section 182 of the first overlay portion 150. And continuously formed. Since the third overlay portion 154 can act to reduce the stretch along its length, this configuration can be achieved with the first overlay portion 150 (at the top of the foot) and the bottom of the heel portion 14. By resisting the extension of the upper to the side 199 (see FIG. 8), it may help to improve support under the heel.

  FIG. 3 shows an enlarged view of a portion of the product 100, where some strands may be joined to the second overlay portion 152. With reference to FIG. 3, several strands 304 may be disposed in contact with the inner surface 302 of the second overlay portion 152. In this embodiment, the strands 304 may form part of the closed woven edge 305 of the upper 102 that has few unbound or free ends of the strands. In this case, the strands 304 may be joined to the second overlay portion 152 to reinforce the continuously woven section of the braided structure.

  In the alternative embodiment shown in FIG. 4, some strands 470 may be composed of untied or free ends 472. In this configuration, the open end 472 can be secured to the overlay portion 452 to hold the strand 470 in place and to help prevent the strand 470 from loosening or unraveling. Good. Thus, it will be appreciated that in some embodiments, an overlay portion may be used to hold the untied or free end associated with the edge of the braided structure. Such a configuration can provide a means of finishing the edges of the braided structure, or any edges including untied or free ends that may unravel.

  The configuration described here can provide an overlay portion at the opening 120 that can act to reinforce the edge of the braided structure. This can help to reduce the elongation of the upper 102 in the opening 120 in order to maintain the structural integrity of the upper 102. In addition, the second overlay portion 152 may help to secure any untied or open ends of the braided structure to prevent edge breaks and / or unraveling of the braided structure. is there.

  In the following, various processes for joining the overlay portion to a braided structure such as a braided upper will be described in more detail. The materials of the present invention used to bond can include any known adhesive, lysate, resin or other binder.

  FIG. 5 is an isometric view of the product 100 including a portion of the first overlay portion 150 and a schematic enlarged cross-sectional view of the clamping member 160. Referring to FIG. 5, the first overlay portion 150 includes a plurality of lace holes 400. Specifically, the plurality of lacing holes 400 including the lacing holes 402 illustrated in the enlarged cross-sectional view are openings in the first overlay portion 150 configured to receive a portion of the clamping member 160. .

  In contrast to an alternative embodiment in which the strands of the upper 102 may be secured directly to a portion of the clamping member, this embodiment provides that the strands of the upper 102 are laced in the first overlay portion 150. It is comprised so that it may be indirectly fixed to the fastening member 160 via. Specifically, although the strand 410 is illustrated as being secured directly to the first overlay portion 150, the fastening member 160 is secured through the plurality of lace holes 400 in the first overlay portion 150. ing. In this configuration, the force transmitted to the entire knitting structure of the upper 102 can be dispersed by tightening the member 160 more uniformly. This may prevent the clamping member 160, for example, from excessively pulling a particular strand, thereby promoting better comfort and fit to the foot of the product 100.

  6 and 7 show two possible configurations for the strands near the lacing hole in the overlay portion. First, referring to FIG. 6, in some embodiments, one or more strands may extend around a lace hole, thereby acting to reinforce that lace hole. For example, in FIG. 6, a first strand 512 and a second strand 514 are wrapped around a first lace hole 502 and a second lace hole 504, respectively. This includes the effect of reinforcing the first lacing hole 502 and the second lacing hole 504 and the effect of realizing more direct transmission of tension between the fastening member 160 and the braided strand of the upper 102. There is.

  Referring to the alternative embodiment shown in FIG. 7, the first lace hole 502 and the second lace hole 504 are not surrounded by any strand of the upper. Specifically, it can be seen from the figure that the strand 610 is joined to the first overlay portion 150 without surrounding the first lace hole 502 and the second lace hole 504. Of course, in still other embodiments, some string holes may be surrounded or reinforced by strands, while other string holes are not surrounded or reinforced. It does not have to be.

  FIG. 8 shows a rear isometric view of the upper 102 with the strands 130 of the upper 102 shown in phantom. Referring to FIG. 7, it can be seen that the third overlay portion 156 wraps under the bottom side 199 of the upper 102 at the heel portion 14. In some cases, this configuration allows the third overlay portion 156 to hold the foot heel. Accordingly, this configuration may provide additional support for the heel of the foot when the product 100 is worn by reducing stretch through the heel portion 14.

  In some embodiments, multiple separate overlay components may be used. In some embodiments, the separate overlay components may be configured to intersect or overlap at predetermined portions of the upper. Such a construction of overlaying overlay components can provide a means to increase strength and stretch resistance over a large portion of the upper, potentially including the entire upper.

  9-11 illustrate an embodiment of an article of footwear 800 that includes an upper 802 and a sole structure 805 (shown only in FIG. 10). First, referring to FIG. 9, the upper 802 has a knitted structure in which a plurality of strands 830 are knitted. In addition, a plurality of overlay components are associated with the upper 802, including a first overlay component 810, a second overlay component 812, a third overlay component 814, and a fourth overlay component 816.

  In an embodiment of the invention, each overlay component is associated with a specific portion of upper 802. For example, the first overlay component 810 is associated with both edges 870 of the opening 860 and the clamping region 862. Accordingly, in some cases, the first overlay component 810 may be used to finish a plurality of strands 830 along both edges 870. In addition, the first overlay component 810 can provide stretch resistance in the vicinity of the opening 860.

  The second overlay component 812 is associated with the front toe 868 of the upper 802. In some embodiments, the second overlay component 812 can help improve stretch resistance at the front toe 868. In addition, in some embodiments, the second overlay component 812 can provide a covering for the front toe 868. In particular, the presence of the second overlay component 812 may help prevent debris from entering the upper 802 via the front toe 868.

  The third overlay component 814 may be associated with the toe portion 811 of the upper 802. In some embodiments, the third overlay component 814 may be positioned in front of the clamping area 862. Furthermore, as can be seen in FIG. 9, the third overlay component 814 can completely surround the upper 802 (and the foot within the upper 802). In an embodiment of the present invention, the third overlay component 814 is comprised of a first band 817 and a second band 819 that are joined together at the upper intersection region 815. Therefore, this structure can give the toe part 811 the target stretch resistance which improves the supportability of the active leg | foot which the step part 811 may step on the ground firmly.

  The fourth overlay component 816 may be associated with the heel portion 813 of the upper 802. In some embodiments, the fourth overlay component 816 may comprise a heel counter-like overlay portion 825 and a strap-like overlay portion 827. Combining the overlay portion 825 and the overlay portion 827 may help to limit the stretchability at the heel portion 813, so that the heel support within the upper 802 can be increased.

  As can be seen from FIGS. 10 and 11, when assembled with the upper 802, some of these overlay portions may overlap one another. For example, it can be clearly seen from the figure that the third overlay component 814 overlaps a portion of the first overlay component 810 in the overlap region 902. Further, it can be seen in the figure that the third overlay component 814 overlaps a portion of the second overlay component 812 in the overlap region 903. Similarly, it can be clearly seen from the figure that the fourth overlay component 816 overlaps a portion of the first overlay component 810 in the overlap region 904. This overlapping arrangement can help to increase the structural integrity of the upper 802 because some of the overlay components can reinforce the support of the overlapping overlay components. Furthermore, by overlaying and joining portions of different overlay components together, the overlay components may function as an integral frame for supporting the upper 802 braided structure.

  Embodiments using braided regions having different characteristics may include equipment that further reinforces some regions, but not other regions. In some embodiments, the product may include an overlay portion that is configured to cover a predetermined area of the product.

  FIGS. 12 and 13 show isometric views of a product 1100 configured with an overlay portion covering two specific areas of the upper 1102. Specifically, FIG. 12 shows an isometric exploded view of product 1100 and FIG. 13 shows an isometric view including an enlarged cross-sectional view. With reference to FIGS. 12 and 13, the product 1100 includes an upper 1102 and a sole system 1110. The upper 1102 further includes at least four different areas including a first area 1151, a second area 1152, a third area 1153, and a fourth area 1154. In the embodiment of the present invention, the first region 1151 is a toe region of the upper 1102. The second region 1152 is disposed directly adjacent to and behind the first region 1151. The third region 1153 is disposed adjacent to and behind the second region 1152. The fourth area 1154 extends to the rear of the third area 1153. Further, the fourth region 1154 is a region that is substantially larger than the remaining region, and includes the entire midfoot portion 1103 and the heel portion 1105 of the upper 1102. Thus, the first region 1151, the second region 1152, and the third region 1153 may be characterized as a band of the upper 1102 that extends laterally across the upper 1102.

  Each region of the upper 1102 may be associated with a specific material property such as a braid density. In the embodiment of the present invention, both the first region 1151 and the third region 1153 are associated with the first weaving density, and the second region 1152 and the fourth region 1154 are associated with the second weaving density. In some embodiments, the first braid density may be greater than the second braid density. Thus, the first region 1151 and the third region 1153 can be tightly knitted to provide a region with increased strength and, in some embodiments, can withstand elongation.

  Product 1100 may further be associated with a first overlay portion 1160 and a second overlay portion 1162. The first overlay portion 1160 may be formed in a shape that covers the first region 1151 of the upper 1102. The second overlay portion 1162 may be formed in a shape that covers the third region 1153 of the upper 1102. For example, the second overlay portion 1162 may be disposed on the strand 1170 of the third region 1153, as illustrated in the enlarged cross-sectional view of FIG. With this arrangement, the first overlay portion 1160 and the second overlay portion 1162 can further reinforce the first region 1151 and the second region 1152, thereby providing support and stretch resistance in those regions. Can be increased.

  Embodiments of the present invention only illustrate some possible configurations for the overlay portion to the upper. It should be understood that some other embodiments may include an overlay portion configured in a variety of different shapes, sizes and arrangements. Further, in alternative embodiments, any number of different overlay components may be used. The number, shape, size, and placement of overlay components or parts provide desired properties, including stretch resistance, high strength, support, comfort or any other desired properties at any location on the footwear product You can choose to do.

  As described in the braided upper application, the braided upper can be configured with a variety of different features and functions. It should be noted that the overlay portion described in this detailed description may be utilized with a variety of different embodiments of the braided upper that may or may not include some of the features described in the braided upper application. Should be understood. By way of example, in some embodiments, strands having different material properties may be knitted together or otherwise joined together to give specific properties to one or more regions of the upper. Will be able to. For example, the upper may be made from a fiber that stretches to some extent as the wearer's foot moves with each stride he or she takes, thereby increasing the wearer's comfort. In that case, high tensile strength, non-stretchable fibers may be inserted through those specific areas of the footwear that require additional structural support. As another example, the upper may be made with additional opening braids in some areas, for example to improve breathability or comfort. In that case, additional fibers may be passed through the braid to give additional support to some parts of those areas, or to give high durability to the high impact areas of the footwear. Good. The upper having any of these configurations further includes one or more overlay portions to further control the properties and functionality of the upper including support and / or stretch resistance in various regions of the upper. May be combined.

  The upper may also have floating cables, i.e., cables that are not woven into the fabric of the upper may be utilized to relieve stress on some sections of the upper. The floating cable may be formed 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 some parts of the footwear, as will be described below. For example, the cables may secure, for example, a first end to a footwear sole and a second end to a lace hole. Such floating cables may also be used to increase the support and stability of some parts of the footwear, such as around the ankle opening. In some embodiments, the overlay portion may be used with a braided upper that includes a floating cable, and in some cases, the overlay portion may be used to reinforce a portion with or without a cable. . In some embodiments, the overlay portion could also be used to help secure the end of the floating cable to the upper.

  The combination of these features, including any of the features described in the braided upper application, together with the overlay portion described above and illustrated in the drawings, forms the upper for a specific athletic or entertainment activity. May make it easier. A braided upper with a combination of these features can be very light while simultaneously fitting snugly and comfortably to the wearer's foot. In some embodiments, the fit of the upper may be adjusted to provide a certain degree of tension or tightening that the wearer may prefer.

  FIGS. 14-17 illustrate several steps in an exemplary process for forming a product composed of a braided upper and an overlay portion. First, as shown in FIG. 14, the braided upper 1402 can be formed using some braiding process. An exemplary process for forming a knitted product is disclosed in the knitted upper application already described and incorporated by reference. Next, as shown in FIG. 15, in some embodiments, an opening 1502 can be cut into the upper 1402. This can create a new edge 1504 adjacent to the opening 1502. Opening 1502 can be used for foot insertion and can form a region for fasteners such as laces.

  In embodiments of the present invention, overlay portion 1510 may then be joined along edge 1504 (see FIG. 15) of upper 1402, as shown in FIG. In some embodiments, the joining may be achieved using a welding process such as an ultrasonic welding process. Thereby, the exposed strands along the edge 1504 can be fused to the overlay portion 1510 to finish both ends and reinforce and support the edge 1504 when the product is tightened. can do. Then, as shown in FIG. 17, the strap 1602 can be inserted into the string hole 1610. Further, in some embodiments, a sole system 1620 can be added to the bottom of the upper 1402.

  Some embodiments can include equipment to facilitate joining the upper and the sole system. In some embodiments, an overlay portion may be provided between the upper and the sole system, thereby facilitating the joining of the upper and the sole system.

  18 and 19 show an isometric view of an embodiment in which the overlay portion can be used to assist in attaching the sole system to the upper. 18 and 19, upper 1702 can be coupled to overlay component 1720 and overlay component 1722. In some embodiments, the overlay component 1720 may be coupled to the opening 1716 of the upper 1702. Overlay component 1722 can be coupled to the bottom side 1703 of upper 1702. In some embodiments, the overlay component 1722 may extend across the bottom side 1703, while in other embodiments, the overlay component 1722 extends only over some portions of the bottom side 1703. It may be. Further, in some cases, overlay component 1722 may extend partially upward around a lower periphery 1705 of upper 1702.

  In some embodiments, the sole system 1730 can be coupled to the upper 1702. Further, in some embodiments, overlay component 1722 can facilitate joining or coupling of sole system 1730 to upper 1702. For example, as clearly shown in the enlarged cross-sectional view of FIG. 19, the overlay component 1722 may be coupled to the sole system 1730 and the bottom side of the upper 1702 to facilitate coupling of the sole system 1730 and the upper 1702. A portion 1703 can be provided.

  In some embodiments, the material properties of overlay component 1722 and sole system 1730 can be selected so that overlay component 1722 and sole system 1730 can be easily joined using an adhesive or other process. . For example, in some embodiments, the overlay component 1722 may be formed of a thermoplastic urethane (TPU) material and the sole system 1730 is of a similar material or a material that readily bonds to the TPU. It is contemplated that it may be formed. However, in still other embodiments, overlay component 1722 and sole system 1730 can be formed of any other material that can be bonded with or without separate adhesives.

  Although various embodiments have been described, the description is intended to be illustrative rather than limiting, and those skilled in the art will further be within the scope of those embodiments. It will be apparent that many embodiments and implementations are possible. Accordingly, the embodiments should not be limited except in terms of the appended claims and their equivalents. Various changes and modifications may be made within the scope of the appended claims.

This application is related to US Provisional Patent Application No. 61 / 839,097 entitled “Article of Footwear with Braided Upper” (Attorney No. 51-3210) filed June 25, 2013. Claimed priority, the entire specification of which is hereby incorporated by reference and shall be referred to as the “knitted upper” application throughout the detailed description. This application is also incorporated in co-pending US patent application Ser. No. 14 / 163,392 filed Jan. 24, 2014 under the title “Article of Footwear with Braided Upper” (Attorney No. 51-3642). All of which are hereby incorporated by reference in their entirety.

Claims (21)

A footwear product comprising an upper and a sole system,
The upper further comprises a braided structure and an overlay part,
The overlay portion is joined to the braided structure;
The overlay product is a footwear product that has less stretch resistance than the braided structure.   The article of footwear recited in claim 1, wherein the overlay portion is disposed on an edge of the upper that is coupled to an opening in the upper that receives a foot.   The article of footwear recited in claim 1, wherein the overlay portion includes a lace hole for receiving a fastener.   The footwear product of claim 1, wherein the overlay portion is disposed on a toe portion of the upper.   The article of footwear according to claim 1, wherein the overlay portion includes a section provided on a bottom side portion of the upper.   The footwear product of claim 1, wherein the overlay portion is formed of a polymeric material. An article of footwear comprising an upper and a sole system, wherein the upper is further coupled with a lace member;
The upper is composed of a braided structure and an overlay part,
The article of footwear, wherein the overlay portion includes a plurality of lacing holes for receiving the lace members.   The footwear product of claim 7, wherein the overlay portion forms an eyestay for the upper.   The article of footwear according to claim 7, wherein the overlay portion is disposed on an outer side of the fixing region of the upper, and the overlay portion is disposed on an inner edge of the fixing region.   The article of footwear according to claim 7, wherein the overlay portion extends to an outer side portion of the upper, an inner side portion of the upper, and a bottom side portion of the upper.   The footwear product of claim 7, wherein the overlay portion is a first overlay portion, and the footwear product includes a second overlay portion that is different from the first overlay portion.   The article of footwear according to claim 11, wherein the first overlay portion overlaps the second overlay portion in an overlap region.   8. An article of footwear according to claim 7, wherein the second overlay portion covers the bottom side of the upper.   13. An article of footwear according to claim 12, wherein the second overlay portion can be joined to the sole system to secure the sole system in place on the footwear product. A method of making a footwear product,
Forming a braided structure having an internal cavity;
Cutting the braided structure to form an opening, thereby forming an opening in the braided structure and an edge associated with the opening;
Joining an overlay portion to the edge, the overlay portion including a plurality of lace holes;
Inserting a string into the string hole;
Coupling a sole system to the braided structure to form an article of footwear;
Including methods.   The method of claim 15, wherein forming the braided structure includes creating the braided structure having a central cavity.   The method of claim 15, wherein forming the braid structure comprises overblading the braid structure into a shoe mold.   The method of claim 15, wherein joining the overlay portion comprises welding the overlay portion to the edge.   The method of claim 15, wherein joining the overlay portion comprises securing at least one open end of the braided strand to the overlay portion.   16. The overlay portion is a first overlay portion, a second overlay portion is joined to a bottom side of the braided structure, and the sole system is attached to the second overlay portion. the method of.   16. The method of claim 15, wherein the overlay portion is joined to the edge such that at least one strand of the braided structure extends around at least one lace hole in the overlay portion.

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