WO2015023755A1

WO2015023755A1 - Performance footwear

Info

Publication number: WO2015023755A1
Application number: PCT/US2014/050900
Authority: WO
Inventors: Kevin Fallon; David Dombrow
Original assignee: Under Armour, Inc
Priority date: 2013-08-13
Filing date: 2014-08-13
Publication date: 2015-02-19
Also published as: CN105491905B; EP3032980A1; US20190239595A1; CN107581703A; US20150047227A1; CN105491905A; EP3032980B1; EP3032980A4

Abstract

The present invention is directed toward footwear including an upper connected to a sole structure. The upper includes two portions formed via compression molding in which textile layers are compressed to form a fabric laminate. One of the upper portions generally defines a seamless heel cup. The other upper portion generally defines a toe cage. The toe cage includes one or more integrated toe guides operable to position a toe of a wearer in a predetermined position within the cavity.

Description

PERFORMANCE FOOTWEAR

CROSS REFERENCE TO RELATED APPLICATIONS

[001] The present application claims priority to provisional application number 61 /865,384, filed 13 August 2013 and entitled "Performance Footwear," the disclosure of which is hereby incorporated by reference in its entirety.

FIELD OF THE INVENTION

[002] The present invention is directed toward an article of footwear and, in particular, to a running shoe.

BACKGROUND OF THE INVENTION

[003] Performance footwear such as running shoes is designed for comfort and durability. To provide these features, performance footwear is typically constructed from a material or a combination of materials having insulative, moisture resistant, and/or abrasion resistant characteristics. The processes for constructing performance footwear can be labor intensive, often requiring sophisticated and expensive stitching and/or injection molding equipment. For example, conventional uppers may are constructed via stitching, i.e., by cutting material according to a pattern to form a series of individual pieces, and then stitching the individual pieces of the pattern together to form the upper. The end result is a shoe having a significant number of seams. Seams, which are friction points, are located throughout the upper and, in particular, in the heel and bottom areas. In light of this, conventional footwear requires an insole or other covering to hide the stitched seam along the bottom of the upper.

[004] In another conventional method is formed via injection. This type of footwear is designed for harsh weather conditions (e.g. rubber boots). While generally seamless, this type of footwear is water and vapor impermeable, resulting in footwear lacking breathability. In the context of athletic footwear, this process results in wearer discomfort because airflow into and out of the shoe is prevented. Accordingly, heat and perspiration from the wearer cannot be evacuated to the ambient environment, resulting in wearer discomfort,

[005] Thus, it would be desirable to provide performance footwear that is lightweight, breathable, and durable, but avoids seams and'Or stitches in the heel and'Or footpad areas. BRIEF SUMMARY OF THE INVENTION

[006] The present invention is directed toward footwear including an upper connected to a sole structure. In an embodiment, the upper includes a first upper portion secured to a second upper portion. Each upper portion is formed via compression molding in which textile layers are compressed to form a fabric laminate. With this process, the macrostructure and microsiructure of each portion upper is controlled. Specifically, the first upper portion includes a macrostructure that generally defines the insole and heel cup of the upper. The heel cup, moreover, is seamless. The second upper portion includes a macrostructure that generally defines the instep and toe cage areas of the upper. The toe cage may further include an engineered microstructure. In an embodiment, the toe cage includes one or more integrated toe guides operable to position a toe of a wearer in a predetermined position within the cavity.

[007] In another embodiment, the upper is configured with a microstructure formed of protrusions along the interior and/or exterior upper surface.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

[008] FIG. 1A is a side perspective view an article of footwear in accordance with an embodiment of the invention, showing the medial footwear side (footwear configured for a left foot).

[009] FIG. IB is a side view in elevation of an article of footwear in accordance with an embodiment, showing the lateral side footwear side (footwear configured for left foot).

[0010] FIG. 1C is a rear perspective view of the article of footwear shown in FIG. IB.

[0011] FIG. 2 is an exploded view of the article of footwear shown in FIG. 1 A.

[0012] FIG. 3 is a top perspective view of the planum portion of the upper in accordance with an embodiment of the invention (upper configured for the right foot),

[0013] FIG. 4 is a top perspective view of the dorsum portion of the upper in accordance with an embodiment of the invention (adapted for right foot).

[0014] FIGS. 5A is a perspective, close-up view of a toe cage in accordance with an embodiment of the invention.

[0015] FIG. 5B is top plan view of the toe cage of FIG. 5A.

[0016] FIG, 5C is a cross sectional view of the toe cage shown in FIG. 5A, [0017] FIG. 6 illustrates a cross sectional view of compression molding apparatus, showing upper formation.

[0018] FIG. 7 is a top perspective view of a sole structure in accordance with an embodiment of the invention, showing the medial side of the sole structure (adapted for the right foot).

[001 ] FIG. 8 is a bottom plan view of a sole structure in accordance with an embodiment of the invention.

[0020] FIG. 9A is a perspective, close-up view of a toe cage in accordance with an embodiment of the invention.

[0021] FIG, 9B is a top plan v iew of the toe cage of FIG. 9A,

[0022] FIG. 9C is a cross-section view of a toe cage in accordance with an embodiment of the invention.

[0023] Like numerals identify like components throughout the figures.

DETAILED DESCRIPTION OF THE INVENTION

[0024] Turning to FIGS. I A, I B, and 1C, an article of footwear 10 in accordance with an embodiment of the present invention includes an upper 105 coupled to (e.g., mounted on) a sole structure 1 10. The article of footwear 10 defines several regions corresponding with various parts of a foot. Specifically, the footwear 10 defines a rear footwear region 1 15 generally corresponding with the rear of the foot (e.g., the hindfoot including the heel); an intermediate footwear region 120 disposed forward the rear region and generally

corresponding to the midfoot (e.g., the arched, instep, and ball areas of the foot); and a forward footwear region 125 disposed forward of intermediate region and generally corresponding to the forefoot (e.g., the toes of the foot). The article of footwear 10 may further include a fastener 127 (e.g., a shoe lace) and a heel counter 129 (discussed in greater detail below).

[0025] The upper 105 includes a heel 130, a lateral side 135, a medial side 140, an instep 145, and a toe cage or box 150. The heel 130 forms a rear portion of upper 105 and is generally configured to extend along the heel of the foot. The lateral side 135 spans through a longitudinal length of footwear 10, extending along the lateral side of the foot. Similarly, the medial side 140 extends along the longitudinal length of footwear 10 such that it extends along the medial side 140 of the foot. The instep 145, positioned between the lateral side and the medial side, extends over the instep of the foot and generally includes tongue 147.

Finally, the toe cage 150 defines the forward area of the upper 105, being configured to house the toes of the foot.

[0026] The upper 105 defines a cavity that receives the foot. Specifically, the heel 130, lateral side 135, medial side 140, instep 145, and toe cage 150 cooperate to define an interior cavity into which a foot is inserted by way of an access opening or collar 155. The collar 155 may be finished with, e.g., fabric tape applied via adhesive. In an embodiment, a strip of material is applied around an inside edge of collar 155 to allow the edge of collar to be finished without a binding to reduce fraying and/or to help collar adhere to the skin of the user. The material may be an elastomeric and/or tacky polymer such as, but not limited to, polyurethane, silicone, nylon, and polyester.

[0027] In the embodiment shown in FIG. 2, the upper 105 is formed of two portions, a first or planum portion 205 coupled (e.g., connected) to a second or dorsum portion 210 via a seamless coupling member 215. Referring to FIG. 3, the planum portion 205, which generally covers the heel and planum areas of the foot, includes a heel cup 315 A and a planum support 315B extending forward from the heel cup. The heel cup 315A is a self- supporting structure configured to surround the lateral side, medial side, and bottom of the heei bone (calcaneus). As shown, the heel cup 315A is defined by a wall 325 with a lateral portion 330A terminating in a forward lateral edge 335 A and a medial portion 330B terminating in a forward medial edge 335B. The vertical wall 325 curves forward at its lower end, transitioning to the planum support 315B, with the vertical wall and planum support cooperating to define a curved heel pocket or cup 340. In a further embodiment, the vertical wall may curve inward (toward the foot) as it travels upward (in the direction of the collar 155).

[0028] The planum support 315B extends forward from the curved heel pocket 340 to define a midfoot support region 345A and a forefoot support region 345B. The midfoot support region 345A may be a generally U-shaped structure defining a bottom wall 350; a generally vertical, lateral tab or wail 355A terminating in a lateral forward edge 360A; and a generally vertical, medial tab or wall 355B terminating in a medial forward edge 360B. The forefoot support region 345B defines a generally planar member configured to span the ball and toes of the foot. [0029] The heel cup 340 of the planum portion 205 is seamless. Conventional footwear typically includes a seam (e.g., a welded seam or a stitched seam) within the heel cup. For example, a conventional heel cup includes a vertical seam along the connection between two heel halves (lateral and medial halves) and a longitudinal seam along the connection between the two halves of the footpad. The heel 130 of the article of footwear 10 discussed herein, in contrast, does not include a seam. Instead, the heel 130 is a unitary- structure shaped to define a seamless, unitary heel cup 340. in a further embodiment, the entire planum portion 205 is seamless, with the heel cup 315A and the planum support 315B forming a unitary and/or one- piece structure.

[0038] Additionally, the upper 105 in accordance with an embodiment of the invention is sockiess, defining a shell that encloses the foot. Conventional footwear typically includes an upper with an opened bottom that is attached (e.g., stitched) to the sole. A layer of material is then set inside the footwear to create a cushioned layer between the sole and the foot that hides the joint between the upper and the sole stracture. In contrast, the "insole" of the article of footwear 10 in accordance with an embodiment of the invention is effecti v ely integrated into the upper 105 such that the heel and insole form a unitary stracture (e.g., the interior layer of the textile laminate forming the upper 105 functions as the sock). Thus, no further sock or insole is required.

[0031] Referring to FIG. 4, the dorsum portion 210, which generally covers the dorsum of the foot, includes a proximal section 405A and a distal section 405B. The proximal section 405 A generally defines the lateral 135, medial 140, instep 145 areas of the upper 105. As illustrated, the proximal section 405A of the dorsum portion 210 includes a lateral flap 410A and a medial flap 410B separated by a central opening 415. The lateral flap 41 OA is a generally planar member including a plurality of tabs or loops 420A - 420D extending laterally inward (toward the central opening 415), A loop includes two fabric elements oriented parallel to each, being fixed (connected) to each other at two longitudinaliy-spaced- a art locations. With this configuration, each loop 420A - 420D defines a channel through which the fastener 127 may be passed, thereby creating a connection point for the fastener (see FIG, IB). It should be understood, however, that other fastener connections such as eyelets/grommets 422 may be utilized to secure the fastener 127,

[0032] The proximal section 405A further includes a. tongue connection 425 to which a tongue 147 may be attached (e.g., via thermal tape). The tongue 147 may be formed of materials similar to that of the upper, and may be formed utilizing the same method (discussed in greater detail below). Specifically, the tongue 147 may include a three dimensional macrostructure where the tongue curves in the transverse dimension (e.g., it curves along its width) such that it follows the contour of the foot instep 145. The tongue 147, moreover, may be configured such that it tapers along its transverse and/or longitudinal edges, being thicker in the tongue central region and gradually thinning toward its edges (e.g., the edge may be 1/16 the thickness of the central region). This may be achieved by compressing the fabric laminate of the tongue to a greater degree along the edges, and/or by utilizing a skived foam layer as the layer of the fabric laminate.

[0033] Alternatively, the tongue 147 may be formed of different materials including, but not limited to, fabric, mesh, etc.

[0034] In an embodiment, one or more portions 205, 210 of the upper 105 may include perforations to permit the flow of fluid (e.g., air and/or water) therethrough. In other embodiments, the upper 105 contains no perforations to lessen or prevent the flow of fluid through the upper.

[0035] While not described in detail, it should be understood that the medial flap 410B is a mirror image of the lateral flap 41 OA, including loops and or perforations as explained above.

[0036] The distal section 405B of the dorsum portion 2.10 includes the toe cage 150, which covers/houses the toes of the wearer. In the illustrated embodiment, the toe cage 150 includes a generally horizontal top cover 435 A (configured to span over the toes of the foot) and a rim or lip 435B extending downward from the top cover (e.g., the rim may be oriented substantially orthogonal to the cover 435A). The toe cage 150 is configured to cooperate with the forefoot support region 345B of the planum support to define a single cavity within the upper 105 that receives ail of the f oes of the foot. As with the proximal section 405A, the distal section 405B may further include perforations 430 operable to permit fluid flow therethrough.

[0037] In an embodiment, the dorsum portion 210 possesses a unitary (one piece) construction. The toe cage 150, furthermore, may be a stitch! ess, contoured (three- dimensional) structure. In a further embodiment, the toe cage 150 is seamless.

[0038] Each of the planum portion 2.05 and the dorsum portion 210 may be formed/shaped via a compression molding process (discussed in greater detail below). Compression molding permits formation of a textile laminate having unique geometries (e.g.,

predetermined macrostruciures and microstructures). That is, in addition to the seamless heel cup 340 of the planum portion 205 (macrosture), the toe cage 150 may further include an undulating topography defining one or more toe guides integrated into the dorsum portion 210 (microstructure). Referring to FIGS, 5 A, 5B, and 5C, the toe cage 150 includes a plurality of toe guides 505A, 505B, 505C, 505D, 505E, each operable to position a toe in a predetermined position within the toe cage cavity 507 (e.g., in a specified lateral position within the upper) and/or in a predetermined position relative to an adjacent foe. By way of example, the distal section 405B of the dorsum portion 210 includes one or more truncated walls or partitions (also called a terminal digit baffle) extending into the toe cage cavity 507. The partitions deflect or guide a toe into a predetermined position relative to the upper 105 and/or adjacent toes. In an embodiment, the partitions extend downward (toward the sole structure 1 10) from the ceiling of the toe cage 150. in another embodiment, the partitions extend upward from the planum support 315B of the planum portion 205 (not illustrated).

[0039] In a preferred embodiment, the toe guides 505A - 505E are defined by a series of recessed areas and raised areas integrated (e.g., molded) into the upper 105 and, in particular, the toe cage 150. Specifically, the fop of the toe cage 150 undulates, defining one or more raised areas 515A - 515E (each having an apex 520A - 520E), as well as one or more recessed areas 525A - 525D (each having a nadir 530A - 530D). With this configuration, each raised area 5 ISA - 515E defines an elongated, open channel or half cylinder 517A - 517E operable to receive a portion of a toe (in a preferred embodiment, a channel 517 A - 517E does not completely enclose the toe). The recessed areas 525 A - 525D that border a raised area, moreover, extend downward at a depth sufficient to direct a toe into the channel 517 A - 517E of the raised area 515 A - 515E. Each raised area 515 A - 515E generally aligns with a corresponding toe, while each recess 525A - 525D generally aligns with an associated space between the toes. Accordingly, each channel 517A - 517E receives a toe of the wearer. Specifically, in the illustrated embodiment, the first toe guide 505A (the channel 517A defined by the raised area 515A) receives the hallux (the big foe), the second toe guide 505B (the channel 517B defined by the raised area 515B) receives the second toe (the long toe), the third toe guide 505C (the channel 517C defined by the raised area 515C) receives the third toe (the middle toe), the fourth toe guide 505D (the channel 5 I7D defined by the raised area 515D) receives the fourth toe (the ring toe), and the fifth toe guide 505E (the channel 517E defined by the raised area 515E) receives the fifth toe (the pinky toe). The outer walls 540, 545 of the cage, moreover, guide the medial (big) toe and the lateral (pinky) toe into its corresponding toe guide 505A and 505E, respectively. [0040] The height of each raised 515A - 515E and/or recessed 525 A - 525D area may similar among the toe guides; alternatively, the height of the areas may differ. That is, the distance measured from the top side of the sole structure 1 10 (and/or the planum support 315B) to the apex 520A - 520E or nadir 530 - 530D may equal or differ. By way of example, the heights of the raised areas 515A - 515E may successively lessen in the lateral direction of the shoe, with the first toe guide 505A possessing the greatest height and the fifth toe guide 505E possessing the lowest height.

[0041] In an embodiment, the nadir 530A - 530D extends into the toe cage cavity 507 at a depth that enables the partition to interact with (contact/deflect) a toe positioned within the cavity, but still permits passage of a toe underneath the recess 525 A - 525D, thereby permitting a user to manually reposition/move/flex toes as desired. Stated another way, since the partitions defined by the recessed areas 525A - 525D do not extend completely through the toe cage cavity 507, a space or gap exists between the distal end of the partition (i.e., the nadir 530A - 530D of the recessed area 525 A - 525D) and the planum support 315B to form a nadir or recess gap 532. The recess gap 532 may possess any height hi suitable for its described purpose. By way of example, the height hi of the recess gap 532 is selected to permit a user to manually reposition the toes within the toe cage 150 if desired. The height hi of the recess gap 532 may be consistent across each recessed area 525A - 525D, or may differ between recessed areas.

[0042] Similarly, the apex height h2, i.e., the height h2 measured from the planum support 315B to the apex 520A - 520E of a raised area 515A (the apex gap), may be any suitable for its described purpose, and may be the same or differ between toe guides 5Q5A - 505E. In the illustrated embodiment, the apex height h2 is greater than the recess height hi .

[0043] With this configuration, each toe guide 505A - 505E— each raised area— possesses a depth effective to receive a portion of a toe (i.e., the upper portion/area of the toe). By way of example, the depth of the toe guide 505A - 505E may be configured to receive/enclose from about 10% to about 50% of a toe, and preferably about 15% - 40% of the toe.

[0044] Each raised area 515A - 515E and recessed area 525A - 525D may extend longitudinally along the toe cage 150, being laterally spaced from each other in the transverse direction (i.e., across width of shoe) such that the walls are generally parallel. The toe guides 505A - 505E may possess any length suitable for its described purpose. By way of example, each raised area 515A - 515E and recessed area 525 A - 525D may extend from the front of the toe cage 150 and terminate proximate the instep 145 (e.g., proximate the tongue connection 425 of the article of footwear 10).

[0045] As shown, each raised area 515 A - 515E and recessed area 525A - 525D define a gently curved surface, being contoured with the outer surface of a toe. The width wl, w2, w3, w4, w5 of each toe guide 505A - 505E may be the same, or may differ to accommodate the differing widths of the toe on the foot. By way of example, the width wl of the first toe guide 505 A (configured to receive the big toe) may be greater than the width w3 of the third toe guide 505C (configured to receive the middle toe). The width w3 of the third toe guide 505C, moreover, may be greater than the width w5 of the fifth toe guide 505 E (configured to receive the pinky toe).

[0046] With the above described configuration, the toe guides 505A - 505E maintain each toe in its natural position, guiding or limiting the lateral movement of each toe. in operation, as a wearer inserts a foot into the proper article of footwear, the partitions formed by the recessed areas 525A - 525D guide each toe into its corresponding raised area channel.

During use (i.e., with the foot at rest or in motion), the partitions continuously guide its associated toe to the raised area channel to maintain the toe within its respective guide 505A - 505E. Stated another way, the toe guides 505A - 505E may be configured to laterally flex each toe, driving adjacent toes away from each other such that each toe may be slightly spaced/separated from its adjacent toes. Additionally, the toe guides 505A - 505E maintain the position of each toe by preventing the lateral movement of a toe during use (e.g., while running). Accordingly, the toe guides 505A - 505E stabilize each toe, reducing the internal movement or slipping of the user's foot and facilitating the ability of each individual toe to provide balance. This, in turn, optimizes the performance and comfort of the wearer.

[0047] The configuration of the upper 105 described above provides a single, open ca vity toe cage 150 that receives all the toes and, while restricting their lateral movement, still permits a user to manipulate the toes and reposition them within the toe cage cavity 507 as desired. This is in contrast to known upper configurations that provide a series of individual cavities, one for each toe. In these configurations, each toe is completely enclosed within its own cavity, with each cavity being individually articulable. Thus, conventional configurations do not provide a single, open cavity.

[0048] With the above-described upper configuration, two levels of motion are provided during use. First, the entire toe cage 150 moves as a single unit, pivoting about the ball of the foot (e.g., along the flex line of the sole structure 1 0, discussed in greater detail below). Second, while the natural movemeni of the toes is stiil permitted, the toes are spread within the toe cage by the toe guides 5Q5A - 505E, which alleviates toe crowding. This, in turn, increases wearer comfort during use and provides a more natural (barefoot) feel to the wearer.

[0049] As noted above, the planum portion 205 may be connected to the dorsum portion 210 in a seamless and/or stitchless manner. In an embodiment, a coupling member 215 couples (e.g., connects) the dorsum portion 2.10 to ihe planum portion 205. Specifically, the upper 105 includes a lateral coupling member 215 disposed along the lateral side of the upper and a medial coupling member disposed along the medial side of the upper. By way of example, the portions 205, 210 of the upper 105 may be connected via a fabric tape such as a thermal adhesive tape (e.g., BEMIS seam (ape, available from Bemis Associates, Inc., Shirley, MA). In a preferred embodiment, the coupling member 215 comprises fabric similar to the fabric forming the upper (e.g., polyester, spandex, etc.).

[0050] As noted above, the flaps of the dorsum portion 210 are generally contoured to the edges 355A, 355B, 360A, 360B of the planum portion 210. Accordingly, the planum portion 205 mates with the dorsum portion 210. Specifically, the lateral 41 OA and medial 41 OB Haps of the dorsum portion 210, cut in a fashion complementary to that of the planum portion 205, are each brought into adjacent relationship with the lateral 330A, 355 A and medial 330B, 355B walls of a heel cup 340 and the planum portion 205, respectively . The corresponding edges 235A, 235B, 260A, 260B are stitched together, and the coupling member 215 (e.g., fabric tape) is applied such that the coupling member bridges the connection between the portions 205, 210, covering the stitching. Preferably, the coupling member 215 is disposed on both the interior and exterior surfaces of the upper 105. Heat is then applied to the coupling member 215 to seal the seam, fixing the member to the upper 105.

[0051] With this configuration, the coupling member 215 provides a seamless connection that minimizes and/or eliminates the friction caused by conventional (exposed) seams. That is, a seamless connection is provided because the coupling member 215 creates a generally uninterrupted and/or continuous surface along the interior surface and/or exterior surface of the upper 105.

[0052] Alternatively, the planum 205 and dorsum 210 portions may be connected without stitching, instead utilizing a thermoplastic film that traverses the seam between adjacent portions, bonding the portions 205, 210 together (e.g., SEWFREE tape, available from Bemis Associates, Inc., Shirley, MA).

[0053] m other embodiments, ultrasonic welding could be utilized. In an embodiment, individual pieces are joined by ultrasonic welding, and the weld is covered by a strip of heat sealable film,

[0054] In either embodiment, the coupling member 215 may possess a curved or undulating shape to track the contours of the connected upper portions 205, 210.

[0055] Once formed, the resulting upper is coupled (e.g., mounted) to the sole structure 1 10, e.g., via an adhesive, welding (e.g., ultrasonic welding), etc.

[0056] The upper 105 may comprise any materials suitable for its described purpose. In particular, the upper 105 may be formed of material capable of forming a three dimensional structure as described above (e.g., a structure including a toe guide). By way of example, the upper 105 may be formed of a fabric laminate. By way of further example, the upper 105 may be formed of fabric laminate that is capable of being shaped via compression molding. By way of still further example, the upper 105 is formed of a fabric lamination including a foam layer.

[0057] Compression molding is a method of molding in which the molding material is first placed in an open, heated mold cavity. The moid is closed with a. top force or plug member, pressure is applied to force the material into contact with ail mold areas, while heat and pressure are maintained until the molding material has cured. An exemplary compression molding apparatus is illustrated in FIG. 6. As shown, the compression molding apparatus 605 includes a first or female molding portion 610 configured to receive a second or male molding portion 615 possessing a shape complementary to the shape of the first molding portion. The apparatus 605 may be utilized to shape a single layer, or may be utilized to shape a multilayered structure. In the embodiment shown in FIG. 6, the formed upper 105 includes three layers— an outer or exterior layer 620, a middle or intermediate layer 625, and an inner or interior layer 630. By way of example, the exterior layer 620 may be a breathable, synthetic fabric (e.g., a polyester fabric), the intermediate layer 625 may be open- celled foam (e.g., ethylene vinylacetaie), and the interior layer 630 may be a breathable, synthetic fabric (e.g., a polyester fabric).

[0058] Additionally, the exterior layer 620 and/or the interior layer 630 may further include an elastic fiber (e.g., spandex or elastane) to provide the layers with elastic properties. In an embodiment, the exterior layer 620 is fabric including 85% polyester and 15 % spandex (weight 215 g/m^"), the intermediate layer 625 is polyurethane foam, and the interior layer 630 is fabric including 79% polyester and 21% spandex (weight 210 g/m²).

[0059] The exterior 620 and interior 630 fabric layers may possess similar or different properties such as elongation properties. By way of example, the exterior layer 620 may possess greater elongation along its length than the interior layer 630, while the interior layer 630 may possess greater elongation along its width then the exterior layer 620.

[0060] In other embodiments, the outer 620 and/or inner 630 layers may be formed of leather, OORETEX, etc.

[0061] Upon compression (and the application of heat), the layers 620, 625, 630 adhere, forming a fabric laminate. Additionally, the fabric laminate conforms to the shape of the molding portions 610, 615, permanently holding its shape. Tn this manner, the planum portion 205 and dorsum portion 210 of the upper 105 may be formed, possessing the shape of the mold.

[0062] This formation process enables the creation of the macrostructure of the upper 105 (the general shape of the planum 205 and dorsum 210 portions of the upper), but also the microstructure of the upper (the toe guide structure). In an embodiment, the microstructure may further include protrusions, e.g., generally rounded nubs or bosses extending outward from either the interior surface or the exterior surface of the upper. When extending from the exterior surface of the upper, the protrusions may provide abrasion resistance or impact protection in specified areas of the upper, in addition, the protrusions may define contact areas configured to improve contact with a ball during game play (e.g., a soccer ball, kickbail, etc.).

[0063] When disposed on the interior surface of the upper 105, the protrusions act as spacers to create air gaps or channels between the upper and the foot of the wearer, enabling airflow within the channels. The protrusions are integrated into the upper 105, being formed as the result of the shape of the mold portions 610, 615 (a negative of the protrusion pattern is formed into the appropriate moid portion 610, 615). The protrusions may be any size and shape suitable for their described purpose, and may be disposed in any predetermined pattern along a portion of the upper, or along the entire upper 105.

[0064] In addition, a reinforcing element may be inserted between the interior layer 630 and the foam layer 625 and/or the exterior layer 620 and the foam layer. A reinforcing element is a component possessing rigidity that is equal to or greater than that of the interior layer/and/or exterior layer. By way of example, a generally U-shaped reinforcing plate may^¬ be located within the heel portion of the upper 105. The reinforcing plate, formed of, e.g., fabric or plastic, provides additional support to the ankle, functioning as an internal heel counter. Additionally, the plate may provide protection to the ankle that may occur during use (e.g., contact with other shoes).

[0065] The sole structure 1 10 is a durable, wear-resistant component configured to provide cushioning as the article footwear 10 impacts the ground. In an embodiment, the sole structure 1 10 may include an insole, a midsole, and an outsole. In other embodiments, the sole may be a unitary and/or one-piece structure. Turning to the embodiment illustrated in FIG. 7, the sole structure 1 10 includes a first, upper- facing side 705 (also called a top side) and a second, ground-facing side 710 (also called a bottom side). The fop side 705 may- possess a generally planar surface having a gently curved rim or wall 715 that defines the sole perimeter.

[0066] The sole structure 1 10 may further include a heel counter 129 adapted to surround the heel portion of the upper 105. The heel counter 129 is an external strengthening device in the heel area of the upper 105 configured to control and stabilize the wearer's heel inside the shoe and to minimize excessive supination or pronation of the foot. As shown, the heel counter 12.9 includes a generally central leg 720 mounted on and extending distally (upward) from the first side 705 of the sole structure 1 10. A pair of arms 725A, 725B extends from the distal portion of ihe central leg. Specifically, a first arm 725A extends laterally toward the lateral side of the footwear and a second arm 725B extends laterally toward the medial side of the footwear. As shown, each arm 725A, 725B is generally horizontal, curving outward (radially from the longitudinal axis of the sole structure) in the forward direction.

[0067] The first arm 725A terminates in a first lateral leg 730A. Similarly, the second arm 725B terminates in a second lateral leg 730B. Each leg 730A, 730B extends downward (ioward the sole structure 110), being angled slightly forward (toward the toe cage 150). The proximal end of each lateral leg 730A, 730B, similar to that of ihe central leg 720, is mounted on the top side 705 of the sole structure. With this configuration, the heel counter 12.9 defines a cage structure having a first lateral window 735A on the lateral side of the shoe and a second lateral window 735B on the medial side of the shoe. As shown, the heel counter 129 may possess a generally cupped shaped, with each leg initially curving outward, beyond the rim of the sole structure, then curving inward. [0068] The heel counter 29 may be formed of any material suitable for its described purpose. By way of example, the heel counter 129 is formed of a thermoplastic elastomer such as ethylene vinyl acetate or polyurethane. The heel counter 129, moreover, may be flexible, semi-rigid, or rigid. With this configuration, the heel counter 129 provides rearfoot stability, preventing injury and prolonging the life of the article of footwear.

[0069] Referring to FIG. 8, the bottom side 7.10 of the sole structure 1 10 may define a generally planar surface. The surface of the bottom side 710, moreover, may be textured. In the illustrated embodiment, the bottom side 710 of ihe sole struciure 110 includes a plurality of friction ridges 805 disposed along the sole in a predetermined pattern. By way of example, the friction ridges 805 may be provided in a fingerprint pattern including one or more of an arch pattern, a loop pattern (right or left), and/or a whorl pattern.

[0070] Additionally, the bottom side 710 of the sole structure 1 10 may include one or more recesses formed therein. In the illustrated embodiment, the bottom side 710 of the sole struciure 1 10 includes a first, generally- transverse recess or flex line 810 disposed forward of the heel and a second, generally -transverse recess or flex line 815 disposed rearward of the toe cage 150 (e.g., forward of the ball of the foot). The first 810 and second 815 flex lines are configured to provide flexure to the sole, enabling movement (pivoting) along the lines. Additionally, the bottom side 710 of the sole structure 1 10 may further include one or more of a continuous (closed-loop) recess 82.0 disposed at an intermediate location between the transverse recesses 810, 815 (e.g., proximate the plantar fascia region of the foot) and a plurality of longitudinal recesses 825 disposed at selected locations along the sole structure 1 10.

[0071] The sole structure 1 10 may be formed of a single material or may be formed of a plurality of materials. By way of example, the sole structure may include a primary structure formed of a first material (e.g., ethylene vinyl acetate) and a secondary structure formed of a second material (e.g., thermoplastic polyurethane). In an embodiment, the primary structure is a midsole and the secondary structure is an outsole. In the illustrated embodiment, the outsole structure 830 is provided as a series of individual pads disposed at predetermined locations along the bottom side 710 of the midsole. The material forming the outsole 830 differs from that of the material forming the midsole by possessing different mechanical properties. By way of example, the materials may possess different relative wear ratios. By way of further example, the materials may possess different Shore Hardness values. The outsole pads 830, then, are a secondary structure formed of material possessing a different wear rate than that of the material forming the primary structure. Specifically, the sole structure 1 10 includes a first toe pad disposed proximate the big toe of the wearer, one or more ball pads disposed proximate the ball of the foot and spaced laterally across the sole structure, and a heel pad disposed proximate the heel of the foot.

[0072] While the invention has been described in detail and with reference to specific embodiments thereof, it will be apparent to one skilled in the art that various changes and modifications can be made therein without departing from the spirit and scope thereof. For example, portions 1 15, 120, 125 are not necessarily intended to demarcate precise areas of footwear 10 and may simply represent general areas of footwear to provide a frame of reference.

[0073] The upper 105 may possess any dimensions or shapes suitable for its described purpose. Additionally, the dorsum portion 210 of the upper 105 may include any number of toe guides. By way of example, referring to FIGS. 9 A, 9B, and 9C, instead of including a toe guide for each toe (all five toes), the foe cage 1 0 may include a guide for a single toe. As shown, the toe cage includes a single toe guide 905 is provided that receives the big toe. The toe guide is defined by the raised area 910 bounded by a recessed area or partition 915 on one side and the medial outer wall 920 of the toe cage on the opposite side, thereby forming an open channel 925 that receives a portion of the toe (i.e. the channel does not completely enclose the toe). With this configuration, the big toe is directed into the toe guide 905, with the remaining toes (the second through fifth toes) being positioned within the remaining area 935 of the toe cage 150. Accordingly, the big toe is slightly separated from its adjacent (second) toe and/or is the lateral positioned of the toe is maintained during use. The second through fifth toes are left unguided (save for the second toe being driven away from the big toe by the partition). In the illustrated embodiment, the height of the toe guide 905 is greater than the height of the remaining cav ity 930. The width wl of the foe guide 905, moreover, is less than the width w2 of remaining upper portion 935.

[0074] The upper 105 may be stylized as any shoe type. For example, the upper 105 may be stylized as a boot or high top athletic shoe that rises above the ankle of the wearer, terminating in a collar positioned above the inner ankle bone of the user, thereby providing a gapless gasket seal above the user's ankle. In such an embodiment, the upper includes a dorsum portion and a planum portion as described abo ve. [0075] The materials forming the planum portion 205 of the upper 105 may be the same or different as that forming the dorsum portion 210 of the upper. For example, the planum portion 205 may be formed of a different material than the dorsum portion 210. Specifically, the dorsum portion may be formed of a breathable fabric similar to that described above, which is compression molded to include a plurality of toe guides operable to adjust the position of each toe relative to the upper 105. The planum portion 205, however, is composed of non-breathable fabric operable to prevent the passage of fluid (e.g., water) therethrough.

[0076] Additionally, the interior layer 630 and the exterior layer 620 may be formed of the same textile or may be formed of different textiles. For example, the interior layer 630 may be a breathable fabric, while the exterior layer 620 may be formed of a natural or synthetic rubber such as polychioroprene (neoprene). Additionally, the rubber may be blended with other materials to provide desired properties (e.g., spandex to improve elasticity).

[0077] The sole structure 110 may further include an extension (operable to provide toe protection) overmolded onto the toe cage 150 of the upper 105.

[0078] Also, the planum portion 205 and the dorsum portion 210 portions may include different graphics thereon.

[0079] While the planum portion 205 of the upper 105 may be secured to the sole structure 1 10 via welding or adhesive, all or a part of the planum portion may be secured to the sole structure via stitching. Additionally, while the illustrated embodiment does not include an insole, an insole may be added, being secured to the planum portion 205 of the upper 105 via adhesive, welding, stitching, etc.

[0080] A s noted above, the upper 105 or porti ons thereof may be formed of any material suitable for its described purpose. By way of example, the upper 105 maybe formed of flexible textile material of a predetermined gauge or density. Specifically, the upper 105 or portions thereof may be formed of, for example, knit, woven or non-woven material made using fibers such as, but not limited to, nylon, polyester, polyurethane and or spandex, with elastomeric properties. The fabric may be breathable (permitting the passage of fluid such as air or water therethrough), or may be non-breathable (preventing passage of fluid therethrough).

[0081] A protective coating may also be applied to seams and/or stitching on other portions of the article of footwear 10 for the purpose of durability and to pre vent the textile from fraying. For example, stitching that secures the sole structure 110 to the upper 105 may have such a coating. Additionally, coatings may also be applied to the textile upper 105, either internally or externally, to provide enhanced textile durability in high wear areas such as, but not limited to, the areas above and beneath the toes and the instep.

[0082] Additionally, the upper 105 and sole structure 1 10 may have external polyurethane or silicone coatings to provide regional properties such as tacky grip for improved ball control.

[0083] In other embodiments, the sole structure 1 10 may include one or more of an insole, a midsole, and an outsole. For example, the midsole may be a polymer foam material such as ethylene vinylacetate or polyurethane, while the outsole may be formed of various rubber compounds (blown rubber, carbon reinforced rubber) operable to provide a durable, wear- resistant surface for engaging the ground. The insole, a relatively thin cushioning member located within the upper 105 and adjacent to a plantar surface of the foot, is provided to enhance the comfort of wearer.

[0084] Thus, it is intended that the present invention covers the modifications and variations of this invention provided they come within the scope of the appended claims and their equivalents. It is to be understood that terms such as "top," "bottom," "front," "rear," "side," "height," "length," "width," "upper," "lower," "interior," "exterior," "medial," "lateral," and the like as may be used herein, merely describe points of reference and do not limit the present invention to any particular orientation or configuration.

Claims

We claim:

1. An article of footwear comprising:

a sole structure; and

an upper secured to the sole structure,

wherein the article of footwear includes a hindfoot section, a midfoot section, and a forefoot section, the sections cooperating to define a cavity operable to receive a foot of a wearer,

and wherein the article of footwear comprises a single compartment toe cage operable to house all toes of the foot, the toe cage including a toe guide extending into the cavity, the toe guide operable to orient a toe of the foot in a predetermined position relative to at least one of the upper and an adjacent toe.

2. The article of footwear of claim 1, wherein the upper comprises a planum portion including a seamless heel cup and a dorsum portion including a toe cap disposed above the toes of the foot.

3. The article of footwear of claim 2, wherein the toe cap includes the toe guide operable to position the toe within the footwear.

4. The article of footwear of claim 3, wherein the toe guide comprises a truncated wall extending downward from the toe cap.

5. The article of footwear of claim 1 , wherein the upper comprises a laminate comprising an interior layer facing the cavity, an exterior layer forming an exterior of the shoe, and an intermediate layer disposed between mterior and exterior layers.

6. The article of footwear of cl aim 5, wherein at least one of the interior layer and the exterior layer comprises fabric.

7. The article of footwear of claim 1, wherein the upper comprises a planum portion including a seamless heel cup and a dorsum portion including a seamless toe cap, the toe cap being disposed above the toes of the foot.

8. The article of footwear of claim 7, wherein:

the toe cap comprises an undulating surface defined by a plurality of raised areas and recesses; and

the toes of the foot align with the raised areas of the toe cap.

9. The article of footwear of claim 1, wherein the toe guide is formed into the upper via compression molding.

10. The article of footwear of claim 1, wherein the t oe guide is effective to deflect and receives the hallux, thereby separating it from the second toe.

1 1. An article of footwear comprising:

a sole structure; and

an upper secured to the sole structure, the upper comprising:

a planum section including a seamless heel cup, and

a dorsum section including a toe cap,

wherein the planum section is connected to the dorsum section, the planum and dorsum sections cooperating to define a cavity operable to receive a foot of a wearer.

12. The article of footwear of claim 11 , wherein at least one of the planum section and the dorsum section comprises a laminate including an interior layer facing the cavity, an exterior layer forming an exterior of the shoe, and an intermediate layer disposed between interior and exterior layers.

13. The article of footwear of claim 12, wherein at least one of the interior layer and the exterior layer comprises fabric.

14. The article of footwear of claim 12, wherein:

the interior layer comprises a synthetic fabric including an elastic fiber;

the intermediate layer comprises foam; and

the exterior layer comprises a synthetic fabric including an elastic fiber.

15. The article of footwear of claim 14, wherein the laminate is capable of being formed into a three-dimensional shape via compression molding.

16. The article of footwear of claim 11, wherein the toe cap is seamless.

17. The article of footwear of claim 1 1, wherein:

the sole structure includes a first, upper-facing surface and a second, ground-facing surface; and

the second surface of the sole structure further comprises a generally transverse groove, the groove defining a flection line of the sole structure.

18. The article of footwear of claim 1 1 , wherein:

the toe cap cooperates with the planum portion to form a toe cage; and

the toe cap is a molded structure including a generally horizontal toe cover portion bordered by rim extending toward the sole structure.

19. An article of footwear comprising:

a sole structure:

an upper coupled to the sole structure;

a toe cage operable to house a plurality of toes; and

a partition extending into the cavity, the partition operable to orient a toe of the plurality of toes in a predetermined position,

20. The articie of footwear of claim 19, wherein:

the toe cage defines a ceiling; and

the partition extends dsstally from the ceiling toward the sole structure such that a gap exists between a distal end of the partition and sole structure.

21. The article of footwear of claim 19, wherein:

the upper defines a toe cage having a ceiling and a floor; and

the partition extends dsstally from the ceiling toward the floor such that a gap exists between a distal end of the partition and floor of the toe cage.

22. The articie of footwear of claim 21, wherein the upper further mcludes a seamless heel cup.

23. The article of footwear of claim 19, wherein the article of footwear includes a hindfoot section, a midfoot section, and a forefoot section, ihe sections cooperating to define a cavity operable to receive a foot of a wearer.

24. The article of footwear of claim 19, wherein the partition is truncated.

25. The article of footwear of claim 19, wherein the partition is defined by a curved recess molded into the toe cage.

26. The article of footwear of claim 19 further including a raised area formed into the upper, the raised area being operable to receive a single toe.