WO2013148244A1 - Chaussure tissée en 3 dimensions - Google Patents

Chaussure tissée en 3 dimensions Download PDF

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Publication number
WO2013148244A1
WO2013148244A1 PCT/US2013/031340 US2013031340W WO2013148244A1 WO 2013148244 A1 WO2013148244 A1 WO 2013148244A1 US 2013031340 W US2013031340 W US 2013031340W WO 2013148244 A1 WO2013148244 A1 WO 2013148244A1
Authority
WO
WIPO (PCT)
Prior art keywords
shoe
woven
midsole
unitary structure
yarns
Prior art date
Application number
PCT/US2013/031340
Other languages
English (en)
Inventor
Kevin P. Fallon
Original Assignee
Under Armour, Inc.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Under Armour, Inc. filed Critical Under Armour, Inc.
Publication of WO2013148244A1 publication Critical patent/WO2013148244A1/fr

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Classifications

    • A—HUMAN NECESSITIES
    • A43—FOOTWEAR
    • A43B—CHARACTERISTIC FEATURES OF FOOTWEAR; PARTS OF FOOTWEAR
    • A43B1/00—Footwear characterised by the material
    • A43B1/0045—Footwear characterised by the material made at least partially of deodorant means
    • A—HUMAN NECESSITIES
    • A43—FOOTWEAR
    • A43B—CHARACTERISTIC FEATURES OF FOOTWEAR; PARTS OF FOOTWEAR
    • A43B13/00—Soles; Sole-and-heel integral units
    • A43B13/02—Soles; Sole-and-heel integral units characterised by the material
    • A43B13/12—Soles with several layers of different materials
    • A43B13/125—Soles with several layers of different materials characterised by the midsole or middle layer
    • A—HUMAN NECESSITIES
    • A43—FOOTWEAR
    • A43B—CHARACTERISTIC FEATURES OF FOOTWEAR; PARTS OF FOOTWEAR
    • A43B13/00—Soles; Sole-and-heel integral units
    • A43B13/14—Soles; Sole-and-heel integral units characterised by the constructive form
    • A—HUMAN NECESSITIES
    • A43—FOOTWEAR
    • A43B—CHARACTERISTIC FEATURES OF FOOTWEAR; PARTS OF FOOTWEAR
    • A43B3/00—Footwear characterised by the shape or the use
    • A43B3/0031—Footwear characterised by the shape or the use provided with a pocket, e.g. for keys or a card
    • A—HUMAN NECESSITIES
    • A43—FOOTWEAR
    • A43B—CHARACTERISTIC FEATURES OF FOOTWEAR; PARTS OF FOOTWEAR
    • A43B3/00—Footwear characterised by the shape or the use
    • A43B3/0036—Footwear characterised by the shape or the use characterised by a special shape or design
    • A43B3/0078—Footwear characterised by the shape or the use characterised by a special shape or design provided with logos, letters, signatures or the like decoration
    • A—HUMAN NECESSITIES
    • A43—FOOTWEAR
    • A43B—CHARACTERISTIC FEATURES OF FOOTWEAR; PARTS OF FOOTWEAR
    • A43B9/00—Footwear characterised by the assembling of the individual parts
    • A—HUMAN NECESSITIES
    • A43—FOOTWEAR
    • A43D—MACHINES, TOOLS, EQUIPMENT OR METHODS FOR MANUFACTURING OR REPAIRING FOOTWEAR
    • A43D111/00—Shoe machines with conveyors for jacked shoes or for shoes or shoe parts

Definitions

  • the present invention relates to footwear.
  • the invention relates to footwear formed with the use of 3 dimensional weaving methods to form at least a portion of the footwear, and potentially forming the entire footwear as a unitary structure.
  • Shoes are conventionally prepared by a multistep process. Shoes are typically assembled as they travel through a series of rooms or departments, each doing a particular segment of the assembly process. Even with the use of modern machines it can still take a large number of separate operations to make a pair of shoes.
  • the upper parts coming from the cutting room are sewn together. Most of the refinements to the upper are finished in the stitching room, finishing edges, applying perforations, fancy stitching and inserting eyelets to name a few.
  • the upper must be a finished unit before going to the stock fitting room.
  • the other parts are assembled, including outsoles, insoles, counters, toe boxes, shanks, heels, etc. These pieces are attached to the last to form a semi- completed unit.
  • the outsole is attached to the semi-finished shoe.
  • the shoe is also given finishing touches here, such as sole edging, trimming, etc.
  • the bottoms are attached by stitching, cementing or heat- molding.
  • the upper and lining are drawn tightly over the last and attached to the insole. This is done in separate operations such as toe lasting, heel seat lasting, etc. This is done by machines that grip the upper and stretch it over the last. Proper lasting is critical to proper fit and appearance of the shoe.
  • the outsole is the most basic part of a shoe.
  • the outsole is a protective layer of material between the foot and the ground.
  • Outsoles have a wide variety of functional properties such as wear, flexibility, traction, insulation to mention a few. These properties vary in accord with the type of footwear.
  • Most shoes use a "unit sole” which means the sole and heel are combined into one unit. The unit sole is applied in one operation and reduces the cost of production. There is no one type of outsole that is regarded "best" for all footwear.
  • a typical bottom unit contains a cushioning element, a midsole, often made of ethylene-vinyl alcohol (EVA) or polyurethane (PU) forms, along with structural elements from thermoplastic polyurethane (TPU), and traction elements most often made from rubber, PU or TPU.
  • Thermoplastic Rubber (TPR) is the most dominant type of sole material used today. TPR soles are light-weight, durable, flexible and slip resistant. TPR soles have very good esthetics and can be made to look like leather, if desired. TPR soles are used on casual shoes for men and women, kid's shoes and light-weight work oxfords.
  • PVC polyurethane
  • polyvinylchloride was, at one time, a popular sole material, but it has limited esthetics. Because it is very durable, it is used mainly today in work boot construction. Rubber compounds, such as neoprene, nitrile and hypalon are all rubber compounds are used mainly in the construction of athletic footwear or "sneakers". Again, because of their durability, these materials can also sometimes be found on work boots. Crepe is a member of the rubber family and can be either natural or man made. It is heavy, loses color and can be hot in warm weather. Its use is limited to some sport and casual shoes. Composite materials are also used for shoe soles. Composite materials can be any mix of materials used to create slab soles that are inexpensive but long wearing. They are used mainly on inexpensive footwear. Sometimes they can be made to resemble leather in appearance.
  • Lasting describes when the upper sections are shaped to the last and insole.
  • Bottoming where the sole is attached to the upper. The process of bottoming will determine price, quality and performance of the shoe.
  • the lasted upper is placed in a mold and the sole is directly molded to the bottom of a lasted upper instead of being glued.
  • Force Lasting also known as Strobel-stitched method or sew in sock
  • Strobel-stitched method or sew in sock
  • the Strobel-stitched method describes one of many force lasting techniques.
  • the upper is sewn directly to a sock by means of an overlocking machine (Strobel stitcher).
  • the upper is then pulled (force lasted) onto a last or molding foot.
  • Unit soles with raised walls or moulded soles are attached to completely cover the seam. This technique is sometimes known as the Californian process or slip lasting.
  • the resulting uppers can be stiff, not breathable and not stretchy or otherwise conforming to the foot. [0016] Accordingly, a shoe construction is needed in which the components of the shoe, and ideally the entire upper or even a unitary structure containing the upper and a
  • midsole/outsole can be produced in a single process step, thus reducing costs of production. Additionally, with athletic shoes in particular, it is desirable to have a shoe that will stretch and recover, while maintaining light weight and flexibility. Finally, a shoe design in which the function of the shoe can be adjusted by the changing of yarns, creating layers, and adjusting weave techniques in a single process is desired.
  • one object of the present invention is to provide a shoe component having built in stretch and recovery properties.
  • a further object of the present invention is to provide a shoe construction in which at least the upper is prepared in a single process, and has one direction stretch and recovery properties, while maintaining support and integrity of the upper.
  • Another object of the present invention is to provide a shoe in which the upper and at least the midsole form a unitary structure which is made in a single process, and has stretch and recovery properties while maintaining support and integrity of the upper.
  • At least one portion of the upper is formed by 3 -dimensional weaving, wherein said at least one portion has one or more woven layers, each having a warp direction and a fill direction, such that said at least one portion has one direction of stretch.
  • Fig. 1 is a side view of one embodiment of a lace-up configuration shoe of the present invention formed with the warp yarns in the 3 -dimensional weaving running in a medial- lateral direction.
  • Fig. 2 is a side view of one embodiment of a lace-up configuration shoe of the present invention formed with the warp yarns in the 3-dimensional weaving running in a heel-to-toe direction.
  • FIG. 3 is a further view of an embodiment of the lace-up configuration shoe of Fig. 1 from a different perspective.
  • Fig. 4 is an exploded view of a lace-up shoe construction of the present invention showing the upper 20, midsole 30, joining with the outsole 40, and having inserted therein a cushioning or support insert 50.
  • Fig. 5 is an exploded view of a lace-up shoe construction of the present invention showing the upper 20, midsole 30, and outsole 40, wherein the midsole 30 is a separate structure from the upper 20.
  • Fig. 6 is a side view of one embodiment of a slip-on configuration shoe of the present invention formed with the warp yarns in the 3-dimensional weaving running in the medial- lateral direction.
  • Fig. 7 is a side view of one embodiment of a slip-on configuration shoe of the present invention formed with the warp yarns in the 3-dimensional weaving running in a heel-to-toe direction.
  • Fig. 8 is a further view of an embodiment of the slip-on configuration shoe of Fig. 6 from a different perspective.
  • Fig. 9 is a side view of another embodiment of a slip-on configuration shoe of the present invention formed with the warp yarns in the 3-dimensional weaving running in a third direction.
  • Fig. 10 is an exploded view of a slip-on shoe construction of the present invention showing the upper 20, midsole 30, joining with the outsole 40, and having inserted therein a cushioning or support insert 50.
  • Fig. 11 is an exploded view of a slip-on shoe construction of the present invention showing the upper 20, midsole 30, and outsole 40, wherein the midsole 30 is a separate structure from the upper 20.
  • Fig. 12 is a top view of one embodiment of a slip-on configuration shoe of the present invention formed with the warp yarns in the 3-dimensional weaving running in the medial- lateral direction.
  • Fig. 13 is a top view of one embodiment of a slip-on configuration shoe of the present invention formed with the warp yarns in the 3-dimensional weaving running in a heel-to-toe direction.
  • Fig. 14 shows one embodiment of a slip-on configuration shoe of the present invention in which the midsole portion 30 of the unitary structure 10 has a pocket built therein, having an opening 32 into which a support element 50 or other element can be placed.
  • Fig. 15 is a top view of one embodiment of a lace-up configuration shoe of the present invention formed with the warp yarns in the 3 -dimensional weaving running in the medial-lateral direction.
  • Fig. 16 is a top view of one embodiment of a lace-up configuration shoe of the present invention formed with the warp yarns in the 3 -dimensional weaving running in a heel-to-toe direction.
  • FIG. 17 shows one embodiment of a lace-up configuration shoe of the present invention in which the midsole portion 30 of the unitary structure 10 has a pocket built therein, having an opening 32 into which a support element 50 or other element can be placed.
  • Fig. 18 shows various shoe components of the present invention formed by 3- dimensional weaving having the warp yarns running in the direction shown.
  • Fig. 19 is a top view of one embodiment of a slip-on configuration shoe of the present invention formed with the warp yarns in the 3 -dimensional weaving running in the medial lateral direction, and showing a functional flange member 22 extending from one side.
  • Fig. 20 shows an embodiment of a shoe of the present invention wherein a functional flange 22 having lace holes 24 extends from the side of the shoe construction, and can be moved into place as indicated by the arrow to provide a lace-up configuration in conjunction with a similarly placed flange (not shown) on the other side of the shoe.
  • Fig. 21 shows an embodiment of a lace-up configuration shoe of the present invention having a functional (or decorative) flange 22 that can be moved into place as indicated by the arrow, and affixed to either the upper of the shoe or to a second functional (or decorative) flange (not shown) on the other side of the shoe.
  • Fig. 22 is an exploded view of a tongue-less lace-up shoe construction of the present invention showing the upper 20, midsole 30, and outsole 40, wherein the midsole 30 is a separate structure from the upper 20.
  • Fig. 23 shows another view of a tongue-less lace-up shoe construction of the present invention.
  • Fig. 24 shows a further embodiment of a slip-on shoe construction of the present invention.
  • Fig. 25 is a cross-section view of a shoe construction of the present invention wherein the unitary structure 10 has an upper portion 20 and a midsole portion 30, and has a pair of functional flanges 22 on the sides which can be moved into place over the upper as indicated by the arrows.
  • Fig. 26 is a cross-section view of a shoe construction of the invention shown in Fig. 25 wherein the functional flanges 22 are rotated towards an upper portion of the shoe;
  • Fig. 27 is a cross-section view of a shoe construction of the present invention including functional flanges 22 rotated towards an upper portion of the shoe and additional flanges 26 located between functional flanges 22 and the midsole portion 30.
  • the present invention relates to a shoe component formed by 3 -dimensional weaving, a shoe incorporating at least one 3-dimensionally woven shoe component, a shoe upper formed entirely from 3 -dimensional weaving, a unitary structure comprising an upper and a midsole where the entire unitary structure is formed by 3-dimensional weaving, and a shoe comprising the unitary structure, as well as a shoe formed entirely by 3-dimensional weaving, including upper and entire sole.
  • 3-dimensional weaving is a technique for creating a textile product by utilizing a three dimensional Cartesian coordinate system as the infrastructure for weaving simultaneous independent fabric layers in conjunction with weaving connectors between and among the layers.
  • the 3-dimensional weaving technique is described in detail in U.S. Patents 7,836,917 and 7,836,918, the entire contents of each of which are hereby incorporated by reference.
  • This technique is used to form fabrics having a plurality of woven layers, into which can be directly woven various openings, pockets, and textures.
  • the 3-dimensional weaving technique also provides a process for imparting a variety of properties to the resulting fabric, including different modulus, stretch and recovery characteristics.
  • fiber refers to a fundamental component used in the assembly of yarns and fabrics. Generally, a fiber is a component which has a length dimension which is much greater than its diameter or width. This term includes ribbon, strip, staple, and other forms of chopped, cut or discontinuous fiber and the like having a regular or irregular cross section. “Fiber” also includes a plurality of any one of the above or a combination of the above. [0052] As used herein, the term “high tenacity fiber” means that class of synthetic or natural non-glass fibers having high values of tenacity greater than 10 g/denier, such that they lend themselves for applications where high abrasion resistance is important. Typically, high performance fibers have a very high degree of molecular orientation and crystallinity in the final fiber structure.
  • filament refers to a fiber of indefinite or extreme length such as found naturally in silk. This term also refers to manufactured fibers produced by, among other things, extrusion processes. Individual filaments making up a fiber may have any one of a variety of cross sections to include round, serrated or crenular, bean-shaped or others.
  • Yarn refers to a continuous strand of textile fibers, filaments or material in a form suitable for weaving, or otherwise intertwining to form a textile fabric. Yarn can occur in a variety of forms to include a spun yarn containing staple fibers usually bound together by twist; a multi filament yarn containing many continuous filaments or strands; or a mono filament yarn which consists of a single strand.
  • composite yarn refers to a yarn prepared from two or more yarns (or “ends”), which can be the same or different.
  • Composite yarn can occur in a variety of forms wherein the two or more ends are in differing orientations relative to one another, so long as the final composite yarn containing the two or more ends is stably assembled (i.e. will remain intact unless forcibly separated or disassembled).
  • the two or more ends can, for example, be parallel, wrapped one around the other(s), twisted together, or combinations of any or all of these, as well as other orientations, depending on the properties of the composite yarn desired.
  • the warp yarns can be any desired yarn having low levels of stretch, preferably less than 5% stretch, more preferably less than 3% stretch.
  • the yarn can be a natural or synthetic yarn, and can be of any desired denier based upon the desired overall weight of the shoe component being made. Preferred deniers are from 10 to 400 denier, more preferably from 50 to 200 denier.
  • the warp yarn can also be a composite yarn if desired, such as a core-sheath construction wherein a sheath yarn is wrapped around a core yarn. Again, the core and sheath of such constructions can be any natural or synthetic yarn, so long as the composite has the overall low levels of stretch desired.
  • the warp yarns are preferably a high tenacity fiber.
  • the high tenacity fiber comprises a high molecular weight polyolefin, preferably high molecular weight polyethylene or high molecular weight polypropylene, an aramid, a high molecular weight polyvinyl alcohol, a high molecular weight polyacrylonitrile, liquid crystal polyesters or mixtures or copolymers thereof.
  • the fill yarns can likewise be made from any natural or synthetic yarns, and similarly have any desired denier based upon the desired overall weight of the shoe component being made.
  • Such natural or synthetic fibers include, but are not limited to, cotton, wool, nylon, polyester, rayon, cellulose acetate, etc.
  • the fill yarns preferably have deniers in the 10 to 400 denier range, more preferably from 50 to 200 denier.
  • the fill yarn preferably has a higher level of stretch than the warp yarns, and more preferably is an elastomeric yarn having high stretch and recovery properties.
  • any elastomeric fiber may be used, as monofilament or multifilament yarn. Additionally, two or more elastomeric fibers can be combined in the core of a composite yarn, or used as a blend, twisted, in parallel, or air- tacked, etc.
  • An elastomer is a natural or synthetic polymer that, at room temperature, can be stretched and expanded to typically twice its original length. After removal of the tensile load it will immediately return to its original length. Along with spandex, rubber and anidex (no longer produced in the United States) are considered elastomeric fibers.
  • Suitable elastomeric fibers include, but are not limited to, fibers made from copolymers having both rigid and flexible segments in the polymer chains, such as, for example, block copolymers of polyurethane and polyethylene glycol.
  • Particularly suitable elastomeric fibers include, but are not limited to, Spandex, such as LYCRA (produced by United Yarn Products),
  • ELASPAN produced by Invista
  • DORLASTAN produced by Bayer
  • CLEAR SPAN produced by Radici
  • LINEL produced by Fillattice
  • Elastomeric yarns typically have one or more of the following materials properties: can be stretched over 500% without breaking; able to be stretched repetitively and still recover original length; lightweight; abrasion resistant; poor strength, but stronger and more durable than rubber; soft, smooth, and supple; resistant to body oils, perspiration, lotions, and detergents; no static or pilling problem; very comfortable; and easily dyed.
  • the elastomeric yarn can be any desired denier, preferably from 10 to 400, more preferably from 15 to 350, most preferably from 50 to 200.
  • the elastomeric yarn can be used alone or combined with one or more other yarns of any desired type, natural or synthetic, so long as the combination retains its elastomeric properties. If combined with one or more other yarns, the elastomeric yarn and other yarns are preferably blended, or the one or more other yarns are wrapped around the elastomeric yarn to provide an elastomeric core composite yarn, thus retaining the stretch property.
  • Elastomeric yarn containing composite yarns are further described in U.S. Patents 5,568,657 and 5,442,815, the contents of which are incorporated herein by reference.
  • the present invention uses this 3-dimensional weaving process to generate shoe components, and in a preferred embodiment to generate an entire shoe upper/midsole unitary structure, which can be affixed to an outsole for providing a traction element or cushioning element, or can have a plurality of traction elements and/or cushioning elements affixed thereto on the exterior layer of the midsole portion.
  • the traction elements and/or cushioning elements are directly formed during the 3- dimensional weaving process by the use of yarns that provide traction properties to form at least a portion of the exterior layer of the midsole portion of the unitary structure.
  • Such yarns for providing traction or cushioning properties include fuseable yarns, abrasion yarns, cushioning yarns, and high tenacity yarns.
  • the 3-dimensional weaving process is preferably performed using a rigid warp yarn with an elastomeric fill yarn.
  • the resulting multilayer 3-dimensionally woven fabric is provided with unidirectional stretch.
  • the multilayer 3-dimensionally woven fabric exhibits high stretch/recovery properties in the fill direction (due to the elastomeric yarns used therein) and rigid or extremely low stretch properties in the warp direction.
  • This unidirectional stretch property can be used quite effectively in the construction of shoes.
  • Various components of the shoe can be individually formed using the 3- dimensional weaving technique in order to provide varied levels and directions of stretch as needed.
  • the unidirectional nature of the stretch in each component can provide a unique combination of stretch and rigidity that is highly beneficial in providing comfort and support in a shoe construction.
  • the components of the shoe can be any portion of the shoe construction as desired, and are preferably selected from the group consisting of the tongue, quarters, vamp, heel seat, and toe box.
  • a unitary structure in the general shape of a foot covering is formed by 3 -dimensional weaving, such that the unitary structure contains a top portion that is a shoe upper, and a bottom portion corresponding to a shoe midsole (or even a full sole in some alternative embodiments).
  • a flange can be preferably formed at the intersection of the upper and midsole portions. This flange is typically formed on an exterior surface of the unitary structure.
  • the unitary structure can be turned inside-out to result in the flange being present on an interior surface if desired.
  • the flange can be formed in such a manner as to externally protrude laterally and can be formed as a pair of flanges, one on each side of the unitary structure in a shape and size sufficient to externally wrap over the vamp portion of the shoe and connect one to another.
  • the pair of flanges can be configured to have lacing holes and thus provide the capability to lace up the shoe on the foot, or can be configured to have another form of attachment, such as hook-and-loop (or "VELCRO") type closures.
  • the unitary structure of a preferred embodiment of the present invention can be formed by weaving from top down or laterally. Additionally, in either top down or lateral weaving of the unitary structure, the warp direction can run in a heel to toe direction or in a medial-lateral direction. When the warp direction runs in a heel to toe direction, the resulting 3-dimensionally woven fabric has stretch in a medial-lateral direction. When the warp direction runs in a medial-lateral direction, the resulting 3-dimensionally woven fabric has stretch in a heel-to-toe direction.
  • the above noted cushioning elements can also be provided by insertion of a cushioning insert into a pocket formed in the midsole portion of the structure of the present invention.
  • the pocket can have an opening to either the interior of the structure or to the exterior of the structure.
  • this pocket can be used to house a support element which provides arch support for the wearer.
  • the shoe construction of the present can take on any typical shoe form, and is preferably a slip-on construction or lace-up construction.
  • a slip on construction it is preferred to have at least a portion around the opening into which the wearer's foot enters the shoe to be made of the 3-dimensionally woven fabric in order to provide a more form fitting shoe.
  • the upper further preferably comprises a tongue portion.
  • the tongue can be separately formed, or can be formed as a portion of the upper during the 3-dimensional weaving process.
  • One feature provided by the 3-dimensional weaving process is the ability to form pockets or compartments within and between the plurality of layers of the 3-dimensionally woven fabric. These pockets or compartments can be used as locations for inserts to provide various functions, such as antimicrobial inserts, charcoal or other odor reducing inserts, structural inserts, or as noted above support inserts.
  • the shoe of the present invention comprises an upper and midsole unitary structure formed by 3-dimensional weaving using yarns for both warp and fill of sufficiently low denier to provide a total shoe weight of from 5-10 ounces, most preferably from 6-8 ounces, including the weight of the lightweight outsole.
  • the exterior layer of the midsole portion of the unitary structure of the present invention is formed from low melting (fuseable) yarns which permit the midsole portion to be affixed to the outsole upon application of sufficient heat to melt/fuse the low melting yarns, thus adhering the unitary structure to the outsole.
  • Figure 1 depicts a side view of an embodiment of the present invention.
  • the warp direction of the weaving of footwear structure 10 is shown by lines 12.
  • footwear structure 10 is formed with the warp yarns in the 3-dimensional weaving running in the medial-lateral direction.
  • Footwear structure 10 includes upper 20, midsole 30, and outsole 40.
  • Upper 20 includes tongue 28 woven integrally with upper 20.
  • Upper 20 also includes apertures 27 for receiving shoelaces for securing the footwear structure to the foot of a person.
  • Figure 2 depicts a side view of another embodiment of the present invention.
  • Footwear structure 10 of Figure 2 includes the same components as footwear structure of Figure 1, however the warp direction 12 in Figure 2 is orthogonal to the warp direction 12 in Figure 1.
  • footwear structure 10 in Figure 2 is formed with the warp yarns in the 3-dimensional weaving running in the heel-to-toe direction.
  • Figure 3 shows a perspective view of footwear structure 10. This footwear structure could have a warp direction as shown in either of Figures 1 or 2. Figure 3 also shows the flexibility of tongue 28. As indicated by the arrow in Figure 3, tongue 28 can be moved in a medial-lateral direction with respect to footwear structure 10.
  • Figure 4 shows a cushioning or support insert 50 being inserted into footwear structure 10.
  • Figure 4 also shows outsole 40 being connected to midsole 30 of footwear structure 10.
  • outsole 40 is separately formed from the integrally woven upper 20 and midsole 30. The separately formed outsole 40 is then attached to midsole 30.
  • Figure 5 shows an additional embodiment in which both midsole 30 and outsole 40 are separately formed from integrally woven upper 20. Both midsole 30 and outsole 40 are then later attached to upper 20.
  • Figure 6 illustrates a side view of one embodiment of a slip-on configuration shoe of the present invention. This embodiment is similar to that shown in Figure 1, but does not include the apertures 27 and tongue 28 shown in Figure 1.
  • footwear structure 10 is formed with the warp yarns in the 3 -dimensional weaving running in the medial-lateral direction.
  • Figure 7 illustrates a side view of one embodiment of a slip-on configuration shoe of the present invention. This embodiment is similar to that shown in Figure 2, but does not include the apertures 27 and tongue 28 shown in Figure 2.
  • footwear structure 10 is formed with the warp yarns in the 3 -dimensional weaving running in the heel-to-toe direction.
  • Figure 8 illustrates a side view of another embodiment of a slip-on configuration shoe of the present invention.
  • This embodiment is similar to that shown in Figure 1 , but this footwear structure 10 is formed with the warp yarns in the 3 -dimensional weaving running in a direction oblique to both the medial-lateral direction and the heel-to-toe direction.
  • the present invention includes footwear structures with the orientation of the upper in any possible angle relative to the warp.
  • Figure 9 shows a perspective view of a slip on footwear structure 10. This footwear structure could have a warp direction as shown in either of Figures 6 or 7.
  • Figure 10 shows a cushioning or support insert 50 being inserted into the slip on footwear structure 10.
  • Figure 9 also shows outsole 40 being connected to midsole 30 of slip on footwear structure 10.
  • outsole 40 is separately formed from the integrally woven upper 20 and midsole 30. The separately formed outsole 40 is then attached to midsole 30.
  • Figure 11 shows an additional embodiment in which both midsole 30 and outsole 40 are separately formed from integrally woven upper 20. Both midsole 30 and outsole 40 are then later attached to upper 20.
  • Figure 12 illustrates a top view of one embodiment of a slip-on footwear structure 10 formed with the warp yarns in the 3 -dimensional weaving running in the medial-lateral direction.
  • Figure 13 illustrates a top view of one embodiment of a slip-on footwear structure 10 formed with the warp yarns in the 3 -dimensional weaving running in the heel-to-toe direction.
  • Figure 14 illustrates an embodiment of a slip on footwear structure 10 which includes an opening 32 in midsole 30. Opening 32 allows support insert 50 to be inserted inside of footwear structure 10. Outsole 40 can then be attached to midsole 30, which seals opening 32.
  • Figure 15 is a top view of embodiment of a least a configuration of footwear structure
  • Figure 16 is a top view of embodiment of a lace up configuration of footwear structure 10 in which the warp yarns in the 3 -dimensional weaving running in the heel-to-toe direction.
  • Figure 2 One example of such an embodiment is shown in Figure 2.
  • Figure 17 illustrates an embodiment of a lace up configuration of footwear structure
  • Opening 32 allows support insert 50 to be inserted inside of footwear structure 10.
  • Outsole 40 can then be attached to midsole 30, which seals opening 32.
  • Figure 18 shows various shoe components of the present invention formed by 3- dimensional weaving having the warp yarns running in direction 12.
  • Figure 19 illustrates a top view of one embodiment of a slip-on configuration of footwear structure 10 formed with the warp yarns in the 3 -dimensional weaving running in the medial-lateral direction and including a functional flange member 22 extending from one side.
  • Figure 20 illustrates a perspective view of a lace up configuration of footwear structure 10 including a functional flange member 22 extending from one side.
  • Functional flange member 22 includes apertures 27 for receiving shoelaces.
  • Figure 21 depicts an embodiment of a lace-up configuration shoe of the present invention having a functional (or decorative) flange 22 that can be moved into place as indicated by the arrow.
  • Functional flange 22 can then be affixed to either the upper 20 or to a second functional (or decorative) flange (not shown) on the other side of the shoe.
  • the flanges 22 of the present invention may be functional or decorative flanges.
  • functional flanges may be part of the lacing system and/or may be used in securing the sole.
  • Figure 22 is an exploded view of a tongue-less lace-up shoe construction of footwear structure 10 showing the upper 20, midsole 30, and outsole 40.
  • the midsole 30 is a separate structure from the upper 20, as is the outsole 40.
  • Midsole 30 and outsole 40 are affixed to upper 20 after integrally weaving upper 20.
  • Figure 23 shows another view of a tongue-less lace-up shoe construction of the present invention.
  • Figure 24 shows a further embodiment of a slip-on shoe construction of the present invention.
  • Figure 25 is a cross-section view of footwear structure 10 having an upper portion 20 and a midsole portion 30. Footwear structure 10 also includes a pair of functional flanges 22 on the sides which can be moved into place over the upper as indicated by the arrows.
  • Figure 26 shows the functional flanges 22 after they are rotated towards an upper portion of the shoe.
  • Figure 27 is a cross-section view of footwear structure 10 including functional flanges 22 rotated towards an upper portion of the shoe and additional flanges 26 located between functional flanges 22 and the midsole portion 30.
  • the present invention allows weaving of specific characteristics of the shoe (such as stretch, non-stretch, sweat-wicking, etc) where desired in a single unified upper. No (or very few) sewing or bonding processes are needed to create the upper.
  • the programming of the type of weave, along with the choice of yarns allows for simple changes to characteristics within the upper for different types of shoes, sizes and colors. Finally, there is no waste from cutting out dozens of materials, rather only the waste from cutting out the entire upper. Thus, the present invention provides both a process and performance enhancement.
  • the present invention also allows for a certain amount of shaping of the upper even before lasting, meaning the overall shape of a woven upper should be a 3-D shape rather than a flat one. This allows the upper to conform to the foot much better, and require less (perhaps none) forcing of 2-D materials around a 3-D last. This enhances the fit and performance of the end product, not only by shaping it in 3-D and minimizing layers, but also because the precision and consistency of the upper (with no human hands touching it as it goes down a stitching line) will be vastly improved.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Materials Engineering (AREA)
  • Footwear And Its Accessory, Manufacturing Method And Apparatuses (AREA)

Abstract

L'invention concerne un composant de chaussure, le composant de chaussure étant formé d'un tissage en 3 dimensions de façon que le composant de chaussure comporte une ou plusieurs couches tissées, chacune avec un sens de chaîne et un sens de trame, le composant de chaussure ayant une direction d'étirement ; une chaussure comprenant au moins un des composants de chaussure dans une tige ; et une chaussure dans laquelle toute la tige, et facultativement la semelle intercalaire et/ou la semelle extérieure, sont complètement formées par un tissage en 3 dimensions.
PCT/US2013/031340 2012-03-27 2013-03-14 Chaussure tissée en 3 dimensions WO2013148244A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US201261616235P 2012-03-27 2012-03-27
US61/616,235 2012-03-27

Publications (1)

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WO2013148244A1 true WO2013148244A1 (fr) 2013-10-03

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WO (1) WO2013148244A1 (fr)

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WO2018031616A1 (fr) * 2016-08-12 2018-02-15 Nike Innovate C.V. Article ayant une première zone ayant un premier et un deuxième fils
US10060054B2 (en) 2014-05-09 2018-08-28 The North Face Apparel Corp. Unitary woven fabric construct of multiple zones
US10463106B2 (en) 2014-02-13 2019-11-05 Nike, Inc. Sole assembly with textile shell and method of manufacturing same
US11457682B2 (en) 2015-04-30 2022-10-04 The North Face Apparel Corp. Baffle constructs for insulative fill materials

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US5187883A (en) * 1990-08-10 1993-02-23 Richard Penney Internal footwear construction with a replaceable heel cushion element
US5896758A (en) * 1997-04-17 1999-04-27 Malden Mills Industries, Inc. Three-dimensional knit spacer fabric for footwear and backpacks
US20060059715A1 (en) * 2004-09-22 2006-03-23 Nike, Inc. Woven shoe with integral lace loops
US20070043630A1 (en) * 2000-03-10 2007-02-22 Lyden Robert M Custom article of footwear and method of making the same
US20080110048A1 (en) * 2006-11-10 2008-05-15 Nike, Inc. Article of footwear having a flat knit upper construction or other upper construction
US20100018075A1 (en) * 2008-07-25 2010-01-28 Nike, Inc. Composite Element With A Polymer Connecting Layer
US7836917B1 (en) * 2009-11-18 2010-11-23 Paradox LLC Weaving connectors for three dimensional textile products
US20110113650A1 (en) * 2009-11-18 2011-05-19 Nike, Inc. Footwear with Counter-Supplementing Strap

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Publication number Priority date Publication date Assignee Title
US5187883A (en) * 1990-08-10 1993-02-23 Richard Penney Internal footwear construction with a replaceable heel cushion element
US5896758A (en) * 1997-04-17 1999-04-27 Malden Mills Industries, Inc. Three-dimensional knit spacer fabric for footwear and backpacks
US20070043630A1 (en) * 2000-03-10 2007-02-22 Lyden Robert M Custom article of footwear and method of making the same
US20060059715A1 (en) * 2004-09-22 2006-03-23 Nike, Inc. Woven shoe with integral lace loops
US20080110048A1 (en) * 2006-11-10 2008-05-15 Nike, Inc. Article of footwear having a flat knit upper construction or other upper construction
US20100018075A1 (en) * 2008-07-25 2010-01-28 Nike, Inc. Composite Element With A Polymer Connecting Layer
US7836917B1 (en) * 2009-11-18 2010-11-23 Paradox LLC Weaving connectors for three dimensional textile products
US20110113650A1 (en) * 2009-11-18 2011-05-19 Nike, Inc. Footwear with Counter-Supplementing Strap

Cited By (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US10463106B2 (en) 2014-02-13 2019-11-05 Nike, Inc. Sole assembly with textile shell and method of manufacturing same
US10060054B2 (en) 2014-05-09 2018-08-28 The North Face Apparel Corp. Unitary woven fabric construct of multiple zones
US11457682B2 (en) 2015-04-30 2022-10-04 The North Face Apparel Corp. Baffle constructs for insulative fill materials
WO2018031616A1 (fr) * 2016-08-12 2018-02-15 Nike Innovate C.V. Article ayant une première zone ayant un premier et un deuxième fils
US10895025B2 (en) 2016-08-12 2021-01-19 Nike, Inc. Article having a first zone with first and second yarns
TWI722230B (zh) * 2016-08-12 2021-03-21 荷蘭商耐克創新有限合夥公司 具有含第一紗及第二紗之第一區域之鞋類物件及用於一鞋類物件之鞋面

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