US20220330656A1

US20220330656A1 - Article of footwear having a shoe upper assembly

Info

Publication number: US20220330656A1
Application number: US17/231,758
Authority: US
Inventors: Christopher Dunning; Arnaud Redon
Original assignee: Puma SE
Current assignee: Puma SE
Priority date: 2021-04-15
Filing date: 2021-04-15
Publication date: 2022-10-20
Also published as: EP4322793A1; WO2022219446A1

Abstract

A footwear upper and a top portion for an article of footwear are provided. The footwear upper can include an outward facing portion formed from a polyester yarn and an inward facing portion formed from a combination of polyester yarn and ultra-high-molecular weight polyethylene (UHMWPE) yarn. The inward facing portion can be directly coupled to the outward facing portion. Further, the top portion can include a weave of carbon polymer filler material plies. The plies can include weft plies and warp plies. The warp plies can follow a trajectory of a center of pressure of a foot within the article of footwear.

Description

CROSS REFERENCE TO RELATED APPLICATIONS

Not applicable

REFERENCE REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not applicable

SEQUENCE LISTING

Not applicable

BACKGROUND

Field of the Invention

The present disclosure relates generally to an article of footwear including a shoe upper assembly.

2. DESCRIPTION OF THE BACKGROUND

Many conventional shoes or other articles of footwear generally comprise an upper and a sole attached to a lower end of the upper. Conventional shoes further include an internal space, i.e., a void or cavity, which is created by interior surfaces of the upper and sole, that receives a foot of a user before securing the shoe to the foot. The sole is attached to a lower surface or boundary of the upper and is positioned between the upper and the ground. As a result, the sole typically provides stability and cushioning to the user when the shoe is being worn. In some instances, the sole may include multiple components, such as an outsole, a midsole, and a top portion. The outsole may provide traction to a bottom surface of the sole. The midsole may be attached to an inner surface of the outsole and may provide cushioning or added stability to the sole. For example, a sole may include a particular foam material that may increase stability at one or more desired locations along the sole, or a foam material that may reduce stress or impact energy on the foot or leg when a user is running, walking, or engaged in another activity. The sole may also include additional components, such as plates, embedded with the sole to increase the overall stiffness of the sole and reduce energy loss during use.
The upper generally extends upward from the sole and defines an interior cavity that completely or partially encases a foot. In most cases, the upper extends over the instep and toe regions of the foot, and across medial and lateral sides thereof. Many articles of footwear may also include a tongue that extends across the instep region to bridge a gap between edges of medial and lateral sides of the upper, which define an opening into the cavity. The tongue may also be disposed below a lacing system and between medial and lateral sides of the upper, to allow for adjustment of shoe tightness. The tongue may further be manipulable by a user to permit entry or exit of a foot from the internal space or cavity. In addition, the lacing system may allow a user to adjust certain dimensions of the upper or the sole, thereby allowing the upper to accommodate a wide variety of foot types having varying sizes and shapes.
The upper of many shoes may comprise a wide variety of materials, which may be utilized to form the upper and chosen for use based on one or more intended uses of the shoe. The upper may also include portions comprising varying materials specific to a particular area of the upper. For example, added stability may be desirable at a front of the upper or adjacent a heel region so as to provide a higher degree of resistance or rigidity. In contrast, other portions of a shoe may include a soft woven textile to provide an area with stretch-resistance, flexibility, air-permeability, or moisture-wicking properties.
However, in many cases, articles of footwear having uppers with an increased comfort and better fit are desired, along with soles having improved cushioning systems or structural characteristics such as a sole plate to add rigidity or spring-like properties.

SUMMARY

An article of footwear, as described herein, may have various configurations. The article of footwear may have an upper, and a top portion and a sole structure connected to the upper.
In some embodiments, the present disclosure provides a footwear upper. The footwear upper can include an outward facing portion formed from a polyester yarn and an inward facing portion formed from a combination of polyester yarn and ultra-high-molecular weight polyethylene (UHMWPE) yarn. The inward facing portion can be directly coupled to the outward facing portion. The inward facing portion can be directly coupled to the outward facing portion through the process of either knitting or weaving.
In some embodiments, the composition of the inward facing portion can be at least 70% UHMWPE yarn. In other embodiments, the composition of the inward facing portion can be at least 90% UHMWPE yarn.
In some embodiments, the inward facing portion can extend along the outward facing portion in forefoot, midfoot, and heel regions of the footwear upper. The inward facing portion can be exposed to an interior cavity defined by the footwear upper at least in the forefoot and midfoot regions.
In some embodiments, the present disclosure provides an article of footwear. The article of footwear can include an inward facing portion knitted together with an outward facing portion. The inward facing portion can be exposed to an interior cavity of the article of footwear and can be formed from a combination of polyester yarn and ultra-high-molecular-weight polyethylene yarn (UHMWPE). The article of footwear can also include a top portion coupled to the upper. The top portion can have weft plies and warp plies. The warp plies can follow a longitudinal path along the top portion defined by a trajectory of a center of pressure of a foot within the article of footwear and the weft plies can extend laterally across the top portion.
In some embodiments, the weft and warp plies can comprise carbon polymer filler material.
In some embodiments, a plurality of the weft plies in a metatarsal section of the top portion can be configured to extend in parallel with a virtual metatarsal line. The virtual metatarsal line can extend across the top portion from a point on a medial side of the top portion at about 0.73 times a length of the top portion measured from a heel end of the top portion and can extend across the top portion and back toward the heel end at an angle of about 20 degrees from a line extending across the top portion from the point on the medial side and perpendicular to the length.
In some embodiments, the weft plies in a heel strike section of the top portion can be orientated perpendicular with the warp plies. The heel strike section can be an area of the top portion extending between a first line extending tangentially along a medial side of the top portion and laterally outward at an angle of about 37 degrees from a line extending tangentially across a heel end of the top portion and a second line, parallel with the first line, spaced a distance from the first line. The distance can be about 35 mm. The weft plies in the heel strike section can be parallel with the first and second lines.
In some embodiments, the concentration of intersections of the warp and weft plies can be higher in at least one of a heel strike section, an arch section, or a metatarsal section.
In some embodiments, the composition of the inward facing portion can be at least 70% UHMWPE yarn. In other embodiments, the composition of the inward facing portion can be at least 90% UHMWPE yarn.
In some embodiments, a method of constructing an article of footwear is provided. The method can include knitting together an outward facing portion and an inward facing portion, wherein the inward facing portion is formed from a combination of polyester yarn and ultra-high-molecular-weight polyethylene (UHMWPE) yarn; forming an upper with the combination of the outward facing portion and the inward facing portion; and securing the upper to a sole structure. The method can also include weaving carbon polymer filler material plies to form a top portion to be secured to the upper.
Other aspects of the article of footwear, including features and advantages thereof, will become apparent to one of ordinary skill in the art upon examination of the figures and detailed description herein. Therefore, all such aspects of the article of footwear are intended to be included in the detailed description and this summary.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a lateral side view of an article of footwear configured as a right shoe that includes an upper and a sole structure, according to an embodiment of the disclosure;

FIG. 2 is a schematic view of an upper of the article of footwear of FIG. 1, according to an embodiment of the disclosure;

FIG. 3 is an isometric rear partial view of the article of foot wear of FIG. 1;

FIG. 4 is a top plan view of top portions of an article of footwear, according to an embodiment of the invention;

FIG. 5 is a map of force and pressure on a foot when the foot is in contact with the ground.

DETAILED DESCRIPTION OF THE DRAWINGS

The following discussion and accompanying figures disclose various embodiments or configurations of a shoe and a sole structure. Although embodiments of a shoe or sole structure are disclosed with reference to a sports shoe, such as a running shoe, tennis shoe, basketball shoe, etc., concepts associated with embodiments of the shoe or the sole structure may be applied to a wide range of footwear and footwear styles, including cross-training shoes, football shoes, golf shoes, hiking shoes, hiking boots, ski and snowboard boots, soccer shoes and cleats, walking shoes, and track cleats, for example. Concepts of the shoe or the sole structure may also be applied to articles of footwear that are considered non-athletic, including dress shoes, sandals, loafers, slippers, and heels. In addition to footwear, particular concepts described herein may also be applied and incorporated in other types of apparel or other athletic equipment, including helmets, padding or protective pads, shin guards, and gloves. Even further, particular concepts described herein may be incorporated in cushions, backpack straps, golf clubs, or other consumer or industrial products. Accordingly, concepts described herein may be utilized in a variety of products.
The term “about,” as used herein, refers to variation in the numerical quantity that may occur, for example, through typical measuring and manufacturing procedures used for articles of footwear or other articles of manufacture that may include embodiments of the disclosure herein; through inadvertent error in these procedures; through differences in the manufacture, source, or purity of the ingredients used to make the compositions or mixtures or carry out the methods; and the like. Throughout the disclosure, the terms “about” and “approximately” refer to a range of values ±5% of the numeric value that the term precedes.
As used herein in the context of geometric descriptions, unless otherwise limited or defined, “substantially” indicates correspondence to a particular shape or dimension within conventional manufacturing tolerances for components of a similar type or that are formed using similar processes. In this regard, for example, “substantially round” can indicate a profile that deviates from a circle to within acceptable manufacturing tolerances.
Further, as used herein, unless otherwise defined or limited, directional terms are used for convenience of reference for discussion of particular figures or examples. For example, references to “downward,” or other directions, or “lower” or other positions, may be used to discuss aspects of a particular example or figure, but do not necessarily require similar orientation or geometry in all installations or configurations.
The present disclosure is directed to an article of footwear and/or specific components of the article of footwear, for example, an upper, a top portion, and/or a sole or sole structure. The upper may comprise a knitted component, a woven textile, and/or a non-woven textile. The knitted component may be made by knitting of yarn, the woven textile by weaving of yarn, and the non-woven textile by manufacture of a unitary non-woven web. Knitted textiles include textiles formed by way of warp knitting, weft knitting, flat knitting, circular knitting, and/or other suitable knitting operations. The knit textile may have a plain knit structure, a mesh knit structure, and/or a rib knit structure, for example. Woven textiles include, but are not limited to, textiles formed by way of any of the numerous weave forms, such as plain weave, twill weave, satin weave, dobbin weave, jacquard weave, double weaves, and/or double cloth weaves, for example. Non-woven textiles include textiles made by air-laid and/or spun-laid methods, for example. The upper may comprise a variety of materials, such as a first yarn, a second yarn, and/or a third yarn, which may have varying properties or varying visual characteristics.
FIG. 1 depicts an embodiment of an article of footwear 100 including an upper 102, a top portion 120 (hidden; see FIG. 4), and a sole structure 104. The upper 102 is attached to the top portion 120 and together define an interior cavity 106 (also see FIG. 3) into which a foot may be inserted. For reference, the article of footwear 100 defines a forefoot region 108, a midfoot region 110, and a heel region 112. The forefoot region 108 generally corresponds with portions of the article of footwear 100 that encase portions of the foot that includes the toes, the ball of the foot, and joints connecting the metatarsals with the toes or phalanges. The midfoot region 110 is proximate and adjoining the forefoot region 108, and generally corresponds with portions of the article of footwear 100 that encase the arch of the foot, along with the bridge of the foot. The heel region 112 is proximate and adjoining the midfoot region 110 and generally corresponds with portions of the article of footwear 100 that encase rear portions of the foot, including the heel or calcaneus bone, the ankle, and/or the Achilles tendon.
The article of footwear 100 also includes a medial side 116 (e.g., see FIG. 2 as shown on the upper 102) and a lateral side 118 (e.g., see FIG. 1). In particular, the lateral side 118 corresponds to an outside portion of the article of footwear 100 and the medial side 116 corresponds to an inside portion of the article of footwear 100. As such, left and right articles of footwear have opposing lateral and medial sides (e.g., see FIG. 4), such that the medial sides 116 are closest to one another when a user is wearing the articles of footwear 100, while the lateral sides 118 are defined as the sides that are farthest from one another while being worn. The medial side 116 and the lateral side 118 adjoin one another at opposing, distal ends of the article of footwear 100.
Unless otherwise specified, the forefoot region 108, the midfoot region 110, the heel region 112, the medial side 116, and the lateral side 118 are intended to define boundaries or areas of the article of footwear 100. To that end, the forefoot region 108, the midfoot region 110, the heel region 112, the medial side 116, and the lateral side 118 generally characterize sections of the article of footwear 100. Further, the upper 102, the top portion 120, and the sole structure 104 may be characterized as having portions within the forefoot region 108, the midfoot region 110, the heel region 112, and on the medial side 116 and the lateral side 118. Therefore, the upper 102, the top portion 120, and the sole structure 104, and/or individual portions of the upper 102, the top portion 120, and the sole structure 104, may include portions thereof that are disposed within the forefoot region 108, the midfoot region 110, the heel region 112, and on the medial side 116 and the lateral side 118.
Many conventional footwear uppers are formed from multiple elements (e.g., textiles, polymer foam, polymer sheets, leather, and synthetic leather) that are joined through bonding or stitching at a seam. In some embodiments, an upper of an article of footwear according to an embodiment of the invention is formed from a knitted structure or knitted components. In various embodiments, a knitted component may incorporate various types of yarn that may provide different properties to an upper. For example, one area of an upper may be formed from a first type of yarn that imparts a first set of properties, and another area of the upper may be formed from a second type of yarn that imparts a second set of properties. Using this configuration, properties of an upper may vary throughout the upper by selecting specific yarns for different areas of the upper.
The upper 102 shown in FIGS. 1 through 3 incorporates various types of yarn. The upper 102 includes an outward facing portion 156 and an inward facing portion 158 of the upper 102. As shown, for example, the outward facing portion 156 can extend substantially across the entire upper 102. In some embodiments, the outward facing portion 156 can define the upper 102. The outward facing portion 156 can be formed from a polyester yarn.
Continuing with the embodiment shown in FIGS. 2 and 3, the inward facing portion 158 extends across a substantial area of the outward facing portion 156. In some embodiments, the inward facing portion 158 extends over at least some of the midfoot region 110 and/or some of the forefoot region 108. The inward facing portion 158 can also follow along the border of an eyestay 160. In some embodiments, the inward facing portion 158 is woven or knitted together with the outward facing portion 156. The inward facing portion 158 is exposed to the interior cavity 106 at least in the forefoot and midfoot regions, and thus will make contact with a user's foot.
The inward facing portion 158 is further configured to be made of a material that is both rigid and smooth. The rigidness of the inward facing portion 158 reduces stretching and therefore provides superior support of a user's foot. The smoothness of the inward facing portion 158 equates to lower friction with a user's foot and decreases the likelihood of blisters. In some embodiments, the inward facing portion 158 can be formed with at least one yarn having a tensile strength of about 17 MPa at yield and about 40 MPa at break. In some embodiments, the inward facing portion 158 can be formed with at least one yarn having an elongation of about 20% or more at yield and about 50% or more at break. In some embodiments, the inward facing portion 158 can be formed with at least one yarn having a tensile modulus of elasticity of about 600 MPa. In some embodiments, the inward facing portion 158 can be formed with at least one yarn having a flexural strength of about 27 MPa. In some embodiments, the inward facing portion 158 can be formed with at least one yarn having a Rockwell hardness of about 35 N/mm. In some embodiments, the inward facing portion 158 can be formed with at least one yarn having a coefficient of friction against hardened and ground steel of about 0.29 (normal pressure of 0.05 N/mm²and sliding speed of 0.6 m/s). In some embodiments, the inward facing portion 158 can be formed from a combination of polyester yarn and a second yarn having any or all of the properties described above. In some embodiments, a substantial majority of the inward facing portion 158 can be the second yarn (e.g., more than 70%). In some embodiments, the inward facing portion 158 can be almost solely the second yarn (e.g., more than 95%). In some embodiments, the inward facing portion 158 can be formed from a combination of polyester yarn and Ultra High Molecular Weight Polyethylene (UHMWPE) yarn. In some embodiments, a substantial majority of the inward facing portion 158 can be UHMWPE (e.g., more than 70% UHMWPE). In some embodiments, the inward facing portion 158 can be almost solely UHMWPE (e.g., more than 95% UHMWPE). In some embodiments, a shoe lining is not necessary, which reduces weight and improved fit due to the decrease in the number of glue lines. This also makes the footwear 100 less likely to experience failure due to wear because of the decrease in the number of materials and the decrease in the number of material joints.
Continuing, according to an aspect of the invention, the sole structure 104 is connected or secured to at least one of the top portion 120 or the upper 102 and extends between a foot of a user and the ground when the article of footwear 100 is worn by the user. The sole structure 104 may include one or more components, which may include an outsole, a midsole, and/or a heel that provide the sole structure 104 with preferable spring and damping properties. For example, in some embodiments, a sole structure may include an outsole that provides structural integrity to the sole structure, along with providing traction for a user and a midsole that provides a cushioning system.
The outsole 130 may be formed from one or more materials to impart durability, wear-resistance, abrasion resistance, or traction to the sole structure 104. In some embodiments, the outsole 130 may comprise a polyurethane (PU) plastic, such as a thermoplastic polyurethane (TPU) material, for example. Other thermoplastic elastomers consisting of block copolymers are also possible. In other embodiments, the outsole 130 can include carbon fiber or high-density wood, for example. In some embodiments, the outsole 130 has a uniform thickness.
Shown in FIG. 1, the outsole 130 has a front portion 132 and a rear portion 136. The outsole 130 extends front to rear through the forefoot region 108 and also through the heel region 112. However, other configurations are possible, for example, with at least some or none of the outsole 130 extending through any of the forefoot, midfoot, or heel regions 108, 110, 112. Further, the outsole 130 can extend across the entire forefoot region 108 and the heel region 112 from the medial side 116 to the lateral side 118. Again, it is contemplated that some or none of the outsole 130 can extend between the medial and lateral sides 116, 118 in any of the forefoot, midfoot, or heel regions 108, 110, 112. The front portion 132 of the outsole 130 is coupled to at least one the upper 102 or the top portion 120 (hidden; see FIG. 4) at the forefoot region 108 and the rear portion 136 of the outsole 130 is coupled to at least one of the upper 102 or the top portion 120 (hidden; see FIG. 4) at the heel region 112.
The outsole 130 may define a bottom end or bottom surface 138 of the sole structure 104 across the forefoot region 108, the midfoot region 110, and the heel region 112. Further, the outsole 130 may be a ground-engaging portion or include a ground-engaging surface of the sole structure 104 and may be opposite of the upper 102. For example, the outsole 130 can include any combination of ground engaging members (e.g., spikes 144, teeth, and/or barbs) that extend from the bottom surface 138 of the outsole 130 and which can be positioned throughout the front portion 132 and the rear portion 136.
As shown, the article of footwear 100 includes spikes 144 in the front portion 132 and the rear portions 136. The number and placement of the spikes 144 can affect traction with respect to linear movement. In some embodiments, the spikes 144 can vary in shape and size depending on user preference and environmental considerations such as the type of ground surface covering and weather conditions. It is contemplated that at least one of the spikes 144 can be removable.
FIG. 4 illustrates a top portion 120 according to an embodiment of the invention. The top portion 120 can be comprised of a weave of carbon polymer filler material plies with weft plies 122 and warp plies 124. It is contemplated, however, that other materials can be used for the top portion (e.g., carbon fiber). For a substantial portion of a length L of the top portion 120, the weft plies 122 extend between the medial side 116 and the lateral side 118 (i.e., in a lateral direction). The length L of the top portion 120 is defined as the longest straight-line distance between a heel end 142 and a toe end 152. The weft plies 122 increase the stiffness of the top portion 120 in the lateral direction to aid a user when executing “cutting” movements from side-to-side. The warp plies 124 extend from the heel region 112, through the midfoot region 110, and through the forefoot region 108 (i.e., in a longitudinal direction). The warp plies 124 also follow a path defined by a typical trajectory of a center of pressure 126 of a foot within the footwear 100 (see FIG. 5 showing a map of pressure on a foot and the center of pressure 126). Aligning the warp plies 124 along the typical trajectory of the center of pressure 126 stiffens the top portion 120 in the longitudinal direction and provides a lever arm along the length L for increased energy return. For example, when in use, a user's heel will strike the ground and the energy from the heel strike is stored in the top portion 120, which is then released when the user's toes push off the ground, thereby enhancing the user's “toe-off” energy. This can improve a user's running speed and/or reduce the load carried by the lower leg.
In some areas of the top portion 120, the spacing between adjacent weft plies 122 can be varied depending on the stiffening characteristic desired in a specific region of the footwear 100. For example, in a heel strike section 140 of the heel region 112, which will strike the ground during use, the concentration of weft plies 122 is greater. The heel strike section 140 can be defined as an area of the heel region 112 between a first line 146 extending tangentially across the heel region 112 and laterally outward at an angle of about 37 degrees from a line extending tangentially across the heel end 142 and a second line 148, parallel with the first line 146, spaced from the first line 146 a distance D. The distance D can be predetermined based on the size of the footwear 100. For example, in a size UK 8 (US 9), the distance D can be about 35 mm. In other footwear sizes, the distance D can be adjusted accordingly. The higher concentration of weft plies 122 in the heel strike section 140 increases the stiffness in the heel strike section 140 to absorb more energy created by a heel strike.
The concentration of weft plies 122 is also higher in an arch section 150 of the midfoot region 110, typically located under the arch of the user's foot, to aid in the transfer of the energy created from the heel strike in the heel strike section 140 to the forefoot region 108. The forefoot region 108 also has an area with an increased concentration of weft plies 122 in a metatarsal section 154. The metatarsal section 154 is positioned along a section of the forefoot region 108 that centers approximately on a virtual metatarsal line 128. The virtual metatarsal line 128 approximately aligns with the metatarsal line (a line extending along the metatarsal heads) of a user's foot when the user's foot is positioned inside the footwear 100. The virtual metatarsal line 128 can be defined as having a starting point on the medial side of the top portion 100 at about 0.73 times the length L and extending across the forefoot region 108 and back toward the midfoot region 110 at an angle of about 20 degrees from a line extending across the forefoot region 108 from the starting point perpendicular to the length L dimension. The higher concentration of weft plies 122 stiffens the area around the virtual metatarsal line 128. This increases the absorption of energy into forefoot region 108 of the top portion 120 as the user roles onto the toes and also increases the energy released from the top portion 120 when the user's toes push off the ground.
The stiffening characteristics of the combination of weft plies 122 and warp plies 124 can also be influenced by the angle at which they intersect. For example, as shown in FIG. 4, the weft and warp plies 122, 124 intersect approximately perpendicularly with each other in the heel region 112. The perpendicular arrangement provides a greater level of stiffness than other angles of intersection of the weft and warp plies 122, 124. The perpendicular arrangement can be provided in the heel region 112 to maximize the absorption of energy from a heel strike. The perpendicular arrangement of weft and warp plies 122, 124 can be seen in other areas, such as in the arch section 150 of the midfoot region 110 in which the weft plies 122 are more heavily concentrated. This adds extra support in the area of the foot arch and better facilitates the transfer of energy created by the heel strike through to the forefoot region 108. In the forefoot region 108, there is some deviation from a perpendicular arrangement to reduce the stiffness as the foot roles about the metatarsal line of a user's foot. The angular arrangement is substantially perpendicular again near the area in which the toes will be located, which, due to the increased stiffness, can increase the amount of energy released from the top portion 120 when the user's toes push off the ground.
Additionally, or alternatively, in some embodiments, at least one pattern-warp ply (not shown) can be incorporated into the weave of a top portion. For example, the pattern-warp ply can be at least one of a carbon fiber yarn or a glass fiber yarn and can be incorporated into the weave of carbon polymer filler material plies of the top portion. The pattern-warp ply can extend along the length of the top portion in the same direction as the warp plies and can also be laterally displaced relative to the warp plies during the weaving process to extend across the weave at an angle greater than 0 degrees from the direction of the warp plies.
In some embodiments, the pattern-warp ply can be woven into the weave of the top portion through a process known as open reed, or multi-axial, weaving. In open reed weaving, the pattern-warp ply is provided separately from the warp plies and can be independently controlled to dip into and out of the weaving shed and to laterally move relative to the warp plies. Laterally displacing the pattern-warp ply changes the angle of the direction of the pattern-warp ply with the warp and weft directions. This allows the pattern-warp ply to be woven into the top portion along the warp direction and also in a slanting direction across the top portion depending on the lateral displacement of the pattern-warp ply.
It is contemplated, that the pattern-warp plies can be woven into the weave of the top portion to provide localized patterns along the length of the top portion. In some embodiments, the pattern-warp plies can be included to provide additional performance characteristics to the weave of the top portion. For example, weaving at least one of a carbon fiber yarn or a glass fiber yarn into the weave of the top portion comprising carbon polymer filler material plies along the path defined by the typical trajectory of a center of pressure 126 of a foot within the footwear 100 (see FIG. 5) can provide added stiffness to a top portion in the longitudinal direction and can provide a lever arm along the length of the top portion for increased energy return.
In some embodiments, the pattern-warp ply can be at least one of a hotmelt yarn or a TPU yarn. The pattern-warp ply can be fused or melted together after the top portion is woven to provide rigidity to the top portion. In some embodiments, the top portion or at least some of the individual plies of the top portion can be soaked in a resin. In some embodiments, the top portion can be formed through a series of thermal activation, molding (e.g., conforming the top portion to a predetermined three-dimensional shape), pressing, and cooling to form and retain a three-dimensional shape of the top portion. It is contemplated that this can be performed for top portions formed from hotmelt yarn, TPU yarn, or top portions soaked in resin.
In other embodiments, other configurations are possible. For example, certain features and combinations of features that are presented with respect to particular embodiments in the discussion above can be utilized in other embodiments and in other combinations, as appropriate. Further, any of the embodiments described herein may be modified to include any of the structures or methodologies disclosed in connection with other embodiments. Additionally, the present disclosure is not limited to articles of footwear of the type specifically shown. Still further, aspects of the articles of footwear of any of the embodiments disclosed herein may be modified to work with any type of footwear, apparel, or other athletic equipment.
In some implementations, articles of footwear disclosed herein can be constructed using methods embodying aspects of the invention. Correspondingly, description herein of particular features or capabilities of a feature or combination of features is generally intended to inherently include disclosure of a method of using such features in the construction of an article of footwear. Similarly, express discussion of any method of constructing a particular article of footwear, unless otherwise indicated or limited, is intended to inherently include disclosure, as embodiments of the invention, of the utilized features and implemented capabilities of such features or combination of features.
For example, with reference to FIGS. 1-3, some embodiments can include a method of constructing an article of footwear by knitting together an outward facing portion and an inward facing portion, wherein the inward facing portion is formed from a combination of polyester yarn and ultra-high-molecular-weight polyethylene (UHMWPE) yarn; forming an upper with the combination of the outward facing portion and the inward facing portion; and securing the upper to a sole structure. Further, for example, the method can also include weaving carbon polymer filler material plies to form a top portion to be secured to the upper.
As noted previously, it will be appreciated by those skilled in the art that while the invention has been described above in connection with particular embodiments and examples, the invention is not necessarily so limited, and that numerous other embodiments, examples, uses, modifications and departures from the embodiments, examples and uses are intended to be encompassed by the claims attached hereto. The entire disclosure of each patent and publication cited herein is incorporated by reference, as if each such patent or publication were individually incorporated by reference herein. Various features and advantages of the invention are set forth in the following claims.

INDUSTRIAL APPLICABILITY

Numerous modifications to the present invention will be apparent to those skilled in the art in view of the foregoing description. Accordingly, this description is to be construed as illustrative only and is presented for the purpose of enabling those skilled in the art to make and use the invention. The exclusive rights to all modifications which come within the scope of the appended claims are reserved.

Claims

We claim:

1. A footwear upper, comprising:

an outward facing portion formed from a polyester yarn; and

an inward facing portion formed from a combination of polyester yarn and ultra-high-molecular weight polyethylene (UHMWPE) yarn,

wherein the inward facing portion is directly coupled to the outward facing portion.

2. The footwear upper of claim 1, wherein the inward facing portion is directly coupled to the outward facing portion through the process of at least one of knitting, braiding, or weaving.

3. The footwear upper of claim 1, wherein the composition of the inward facing portion is at least 70% UHMWPE yarn.

4. The footwear upper of claim 1, wherein the composition of the inward facing portion is at least 90% UHMWPE yarn.

5. The footwear upper of claim 1, wherein the inward facing portion extends along the outward facing portion in forefoot, midfoot, and heel regions of the footwear upper.

6. The footwear upper of claim 5, wherein the inward facing portion is exposed to an interior cavity defined by the footwear upper at least in the forefoot and midfoot regions.

7. An article of footwear, comprising:

an inward facing portion knitted together with an outward facing portion forming an upper;

wherein the inward facing portion is exposed to an interior cavity of the article of footwear and is formed from a combination of polyester yarn and ultra-high-molecular-weight polyethylene yarn (UHMWPE); and

a top portion coupled to the upper, the top portion having weft plies and warp plies.

8. The article of footwear of claim 7, wherein the warp plies follow a longitudinal path along the top portion defined by a trajectory of a center of pressure of a foot within the article of footwear and the weft plies extend laterally across the top portion.

9. The article of footwear of claim 7, wherein the weft and warp plies comprise carbon polymer filler material.

10. The article of footwear of claim 7, wherein a plurality of the weft plies in a metatarsal section of the top portion are configured to extend in parallel with a virtual metatarsal line.

11. The article of footwear of claim 10, wherein the virtual metatarsal line extends across the top portion from a point on a medial side of the top portion at about 0.73 times a length of the top portion measured from a heel end of the top portion and extending across the top portion and back toward the heel end at an angle of about 20 degrees from a line extending across the top portion from the point on the medial side and perpendicular to the length.

12. The article of footwear of claim 7, wherein the weft plies in a heel strike section of the top portion are orientated perpendicular with the warp plies.

13. The article of footwear of claim 12, wherein the heel strike section is an area of the top portion extending between a first line extending tangentially along a medial side of the top portion and laterally outward at an angle of about 37 degrees from a line extending tangentially across a heel end of the top portion and a second line, parallel with the first line, spaced a distance from the first line.

14. The article of footwear of claim 13, wherein the distance is about 35 mm.

15. The article of footwear of claim 13, wherein the weft plies in the heel strike section are parallel with the first and second lines.

16. The article of footwear of claim 7, wherein the concentration of intersections of the warp and weft plies are higher in at least one of a heel strike section, an arch section, or a metatarsal section.

17. The article of footwear of claim 7, wherein the composition of the inward facing portion is at least 70% UHMWPE yarn.

18. The article of footwear of claim 7, wherein the composition of the inward facing portion is at least 90% UHMWPE yarn.

19. A method of constructing an article of footwear, the method comprising:

knitting together an outward facing portion and an inward facing portion, wherein the inward facing portion is formed from a combination of polyester yarn and ultra-high-molecular-weight polyethylene (UHMWPE) yarn;

forming an upper with the combination of the outward facing portion and the inward facing portion; and

securing the upper to a sole structure.

20. The method of claim 19, further comprising weaving carbon polymer filler material plies to form a top portion to be secured to the upper.