CROSS-REFERENCE TO RELATED APPLICATIONS
BACKGROUND
[0002] The present invention relates generally to a material construction for an article
of footwear and, more particularly, to material construction for an upper of an article
of footwear.
[0003] Conventional articles of athletic footwear include two primary elements, an upper
and a sole structure. The upper provides a covering for the foot that comfortably
receives and securely positions the foot with respect to the sole structure. The sole
structure is secured to a lower portion of the upper and is generally positioned between
the foot and the ground. In addition to attenuating ground reaction forces (that is,
providing cushioning) during walking, running, and other ambulatory activities, the
sole structure may influence foot motions (for example, by resisting pronation), impart
stability, and provide traction, for example. Accordingly, the upper and the sole
structure operate cooperatively to provide a comfortable structure that is suited
for a wide variety of athletic activities.
[0004] The upper is often formed from a plurality of material elements, which may be stitched
or adhesively bonded together to define a void or cavity on the interior of the footwear
for comfortably and securely receiving a foot. More particularly, the upper forms
a structure that extends over instep and toe areas of the foot, along medial and lateral
sides of the foot, and around a heel area of the foot. The upper may also incorporate
a lacing system to open and close an opening to the void or cavity and adjust fit
of the footwear, within the upper. In addition, the upper may include a tongue that
extends under the lacing system to enhance adjustability and comfort of the footwear,
and the upper may incorporate a heel counter or other stabilizing structure.
[0005] The upper may also include provisions to improve fit, comfort, and performance. Materials
selection and placement may be utilized to achieve certain desired characteristics.
The design of many types of footwear is often driven by conflicting considerations.
As but one example, it is normally desirable for an athletic shoe to have a construction
that supports and protects a wearer's foot during a particular athletic endeavor.
However, "breathability" is also a desirable quality for many types of athletic shoes.
Specifically, air flow through a shoe upper between the shoe interior and exterior
can help relieve the effects of heat and perspiration that typically build up around
a foot during sporting activities. However, many materials that provide support and
foot protection can block air and moisture flow through the upper. Conversely, many
materials that facilitate air and moisture flow provide little support or protection
to the wearer's foot.
[0006] One solution is to fabricate a shoe in which some portions are formed from supportive/protective
materials and some portions are formed from breathable materials. However, this can
increase the complexity of the fabrication process and increase cost. In addition,
material joining techniques, such as stitching and use of adhesives, can add weight
to footwear. Moreover, footwear design (including athletic footwear design) is also
driven by aesthetics. A complex production process developed to fabricate a complex
shoe can potentially limit a manufacturer's ability to vary that shoe's design to
achieve different aesthetic effects.
SUMMARY
[0007] In one aspect, the present disclosure is directed to an article of footwear having
a sole structure fixedly attached to an upper configured to receive a foot of a wearer.
The upper may include a skin layer forming at least a portion of an external surface
of the upper. The upper may also include a reinforcing material selectively located
internal and adjacent to portions of the skin layer, thereby defining reinforced portions
of the skin layer and unreinforced portions of the skin layer. The reinforcing material
may be selectively joined with the skin layer at a bonded area by welding, the bonded
area having an externally exposed surface that defines a portion of the external surface
of the upper. In addition, the skin layer may have a first color and the externally
exposed surface of the bonded area may have a second color that is different from
the first color.
[0008] In another aspect, the present disclosure is directed to an article of footwear having
a sole structure fixedly attached to an upper defining an internal void configured
to receive a foot of a wearer. The upper may include a skin layer forming at least
a portion of an external surface of the upper, the skin layer being formed of a mesh
material. In addition, the upper may include a reinforcing material selectively located
internal and adjacent to the skin layer, thereby defining reinforced portions of the
skin layer and unreinforced portions of the skin layer. The unreinforced portions
of the skin layer may provide direct ventilation through the mesh material of the
skin layer, to the internal void defined by the upper. In addition, the reinforcing
material may be selectively joined with the skin layer at a bonded area by welding,
the bonded area having an externally exposed surface that defines a portion of the
external surface of the upper. Also, the skin layer may have a first color and the
externally exposed surface of the bonded area may have a second color that is different
from the first color.
[0009] In another aspect, the present disclosure is directed to an article of footwear having
a sole structure fixedly attached to an upper configured to receive a foot of a wearer.
The upper may include a skin layer forming at least a portion of an external surface
of the upper. The upper may also include a reinforcing material selectively located
internal and adjacent to portions of the skin layer, thereby defining reinforced portions
of the skin layer and unreinforced portions of the skin layer. The reinforcing material
may be selectively joined with the skin layer at a bonded area by welding, the bonded
area having an externally exposed surface that defines a portion of the external surface
of the upper. In addition, the skin layer may have a first color and the reinforcing
material may have a second color that is different from the first color. Also, the
externally exposed surface of the bonded area may include portions of the reinforcing
material, thus providing the externally exposed surface of the bonded area with substantially
the same color as the reinforcing material.
[0010] In another aspect, the present disclosure is directed to a method of making an article
of footwear, including forming an upper configured to receive a foot of a wearer.
The method may include selectively attaching an inner reinforcing material to a skin
layer using welding. The method may also include arranging the skin layer to form
at least a portion of an external surface of the upper. The skin layer may have a
first color and the reinforcing material may have a second color that is different
from the first color. Welding the inner reinforcing material to the skin layer may
form a bonded area having an externally exposed surface that defines a portion of
the external surface of the upper, the externally exposed surface of the bonded area
including portions of the reinforcing material, thus providing the externally exposed
surface of the bonded area with a different color than the skin layer.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] The invention can be better understood with reference to the following drawings and
description. The components in the figures are not necessarily to scale, emphasis
instead being placed upon illustrating the principles of the invention. Moreover,
in the figures, like reference numerals designate corresponding parts throughout the
different views.
FIG. 1 shows a perspective view of an embodiment of an article of footwear;
FIG. 2 shows exploded view of the article of footwear shown in FIG. 1;
FIG. 3 shows another perspective view of the article of footwear shown in FIG. 1;
FIG. 4 shows a rear perspective and interview view of the article of footwear shown
in FIG. 1;
FIG. 5 shows an enlarged version of a portion of the view of the article of footwear
shown in FIG. 4;
FIG. 6 shows a perspective view of an article of footwear and an enlarged portion
of the upper of the article of footwear;
FIG. 7 shows a cross sectional view taken at line 4-4 of FIG. 3;
FIG. 8 shows an enlarged view of a portion of an upper of an article of footwear according
to another embodiment;
FIGS. 9-11 show an exemplary process of ultrasonic welding layers of an upper;
FIG. 12 shows an exemplary tongue portion of an article of footwear;
FIG. 13 shows a cross-sectional view of the tongue taken at line 13-13 in FIG. 12;
and
FIG. 14 shows a cross-sectional view of the tongue taken at line 14-14 in FIG. 12.
DETAILED DESCRIPTION
[0012] The following discussion and accompanying figures disclose a sole structure for an
article of footwear. Concepts associated with the footwear disclosed herein may be
applied to a variety of athletic footwear types, including running shoes, basketball
shoes, soccer shoes, baseball shoes, football shoes, and golf shoes, for example.
Accordingly, the concepts disclosed herein apply to a wide variety of footwear types.
[0013] To assist and clarify the subsequent description of various embodiments, various
terms are defined herein. Unless otherwise indicated, the following definitions apply
throughout this specification (including the claims). For consistency and convenience,
directional adjectives are employed throughout this detailed description corresponding
to the illustrated embodiments.
[0014] The term "longitudinal," as used throughout this detailed description and in the
claims, refers to a direction extending a length of a sole structure, i.e., extending
from a forefoot portion to a heel portion of the sole. The term "forward" is used
to refer to the general direction in which the toes of a foot point, and the term
"rearward" is used to refer to the opposite direction, i.e., the direction in which
the heel of the foot is facing.
[0015] The term "lateral direction," as used throughout this detailed description and in
the claims, refers to a side-to-side direction extending a width of a sole. In other
words, the lateral direction may extend between a medial side and a lateral side of
an article of footwear, with the lateral side of the article of footwear being the
surface that faces away from the other foot, and the medial side being the surface
that faces toward the other foot.
[0016] The term "lateral axis," as used throughout this detailed description and in the
claims, refers to an axis oriented in a lateral direction.
[0017] The term "horizontal," as used throughout this detailed description and in the claims,
refers to any direction substantially parallel with the ground, including the longitudinal
direction, the lateral direction, and all directions in between. Similarly, the term
"side," as used in this specification and in the claims, refers to any portion of
a component facing generally in a lateral, medial, forward, or rearward direction,
as opposed to an upward or downward direction.
[0018] The term "vertical," as used throughout this detailed description and in the claims,
refers to a direction generally perpendicular to both the lateral and longitudinal
directions. For example, in cases where a sole is planted flat on a ground surface,
the vertical direction may extend from the ground surface upward. It will be understood
that each of these directional adjectives may be applied to individual components
of a sole. The term "upward" refers to the vertical direction heading away from a
ground surface, while the term "downward" refers to the vertical direction heading
towards the ground surface. Similarly, the terms "top," "upper," and other similar
terms refer to the portion of an object substantially furthest from the ground in
a vertical direction, and the terms "bottom," "lower," and other similar terms refer
to the portion of an object substantially closest to the ground in a vertical direction.
[0019] The "interior" of a shoe refers to space that is occupied by a wearer's foot when
the shoe is worn. The "inner side" of a panel or other shoe element refers to the
face of that panel or element that is (or will be) oriented toward the shoe interior
in a completed shoe. The "outer side" of an element refers to the face of that element
that is (or will be) oriented away from the shoe interior in the completed shoe. In
some cases, the inner side of an element may have other elements between that inner
side and the interior in the completed shoe. Similarly, an outer side of an element
may have other elements between that outer side and the space external to the completed
shoe. Further, the terms "inward" and "inwardly" shall refer to the direction toward
the interior of the shoe, and the terms "outward" and "outwardly" shall refer to the
direction toward the exterior of the shoe.
[0020] For purposes of this disclosure, the foregoing directional terms, when used in reference
to an article of footwear, shall refer to the article of footwear when sitting in
an upright position, with the sole facing groundward, that is, as it would be positioned
when worn by a wearer standing on a substantially level surface.
[0021] In addition, for purposes of this disclosure, the term "fixedly attached" shall refer
to two components joined in a manner such that the components may not be readily separated
(for example, without destroying one or both of the components). Exemplary modalities
of fixed attachment may include joining with permanent adhesive, rivets, stitches,
nails, staples, welding or other thermal bonding, or other joining techniques. In
addition, two components may be "fixedly attached" by virtue of being integrally formed,
for example, in a molding process.
[0022] FIG. 1 depicts an embodiment of an article of footwear 100. Footwear 100 may include
a sole structure 105 and an upper 110 secured to sole structure 105 and configured
to receive a foot. For reference purposes, footwear 100 may be divided into three
general regions: a forefoot region 115, a midfoot region 120, and a heel region 125.
Forefoot region 115 generally includes portions of footwear 100 corresponding with
the toes and the joints connecting the metatarsals with the phalanges. Midfoot region
120 generally includes portions of footwear 100 corresponding with an arch area of
the foot. Heel region 125 generally corresponds with rear portions of the foot, including
the calcaneus bone. Regions 115, 120, and 125 are not intended to demarcate precise
areas of footwear 10. Rather, regions 115, 120, and 125 are intended to represent
general relative areas of footwear 100 to aid in the following discussion. Since various
features of footwear 100 extend beyond one region of footwear 100, the terms forefoot
region 115, midfoot region 120, and heel region 125 apply not only to footwear 100,
but also to the various features of footwear 100.
[0023] As shown in FIG. 1, upper 110 may include one or more material elements (for example,
meshes, textiles, foam, leather, and synthetic leather), which may be joined to define
an interior void 130 configured to receive a foot. The material elements may be selected
and arranged to selectively impart properties such as light weight, durability, air-permeability,
wear-resistance, flexibility, and comfort. Upper 110 may define an opening 135 configured
to receive a foot of a wearer into interior void 130. In addition, upper 110 may include
a lace 140, which may be utilized to modify the dimensions of interior void 130, thereby
securing the foot within interior void 130 and facilitating entry and removal of the
foot from interior void 130. Lace 140 may extend through lace receiving loops 145
in upper 110. Lace receiving loops 145 may extend from a reinforcing strip 150 bordering
a lace region 155 of upper 110, which may be in an instep region 157 of footwear 100.
As further shown in FIG. 1, footwear 100 may also include a tongue 800.
[0024] In some embodiments, reinforcing strip 150 may include eyelets or holes configured
to receive lace 40. Further, upper 110 may alternatively implement any of a variety
of other configurations, materials, or closure mechanisms. For example, alternative
closure mechanisms, such as hook and loop fasteners (for example, straps), buckles,
clasps, cinches, or any other arrangement for securing a foot within interior void
130 defined by upper 110.
[0025] Sole structure 105 may be fixedly attached to upper 110 (for example, with adhesive,
stitching, welding, or other suitable techniques) and may have a configuration that
extends between upper 110 and the ground. Sole structure 105 may include provisions
for attenuating ground reaction forces (that is, cushioning and stabilizing the foot
during vertical and horizontal loading). In addition, sole structure 105 may be configured
to provide traction, impart stability, and control or limit various foot motions,
such as pronation, supination, or other motions.
[0026] The configuration of sole structure 105 may vary significantly according to one or
more types of ground surfaces on which sole structure 105 may be used. For example,
the disclosed concepts may be applicable to footwear configured for use on any of
a variety of surfaces, including indoor surfaces or outdoor surfaces. The configuration
of sole structure 105 may vary based on the properties and conditions of the surfaces
on which footwear 100 is anticipated to be used. For example, sole structure 105 may
vary depending on whether the surface is harder or softer. In addition, sole structure
105 may be tailored for use in wet or dry conditions.
[0027] In some embodiments, sole structure 105 may be configured for a particularly specialized
surface or condition. For example, in some embodiments, footwear 100 is illustrated
in the accompanying figures as a running shoe and, accordingly, the illustrated sole
structure 105 is configured for providing cushioning, stability, and traction on hard,
smooth surfaces, such as pavement. The proposed footwear upper construction may be
applicable to any kind of footwear, however, such as basketball, soccer, football,
and other athletic activities. Accordingly, in some embodiments, sole structure 105
may be configured to provide traction and stability on hard indoor surfaces (such
as hardwood), soft, natural turf surfaces, or on hard, artificial turf surfaces. In
some embodiments, sole structure 105 may be configured for use on a multiple different
surfaces.
[0028] In some embodiments, sole structure 105 may include multiple components, which may
individually or collectively provide footwear 100 with a number of attributes, such
as support, rigidity, flexibility, stability, cushioning, comfort, reduced weight,
or other attributes. In some embodiments, sole structure 105 may include an insole/sockliner
(See FIG. 4), a midsole 160, and a ground contacting sole component 165, which may
have an exposed, ground contacting lower surface 170, as shown in FIG. 1. In some
cases, however, one or more of these components may be omitted.
[0029] The insole may be disposed in void 130 defined by upper 110. The insole may extend
through each of forefoot region 115, midfoot region 120, and heel region 125, and
between a lateral side 175 and medial side 180 of footwear 100. The insole may be
formed of a deformable (for example, compressible) material, such as polyurethane
foams, or other polymer foam materials. Accordingly, the insole may, by virtue of
its compressibility, provide cushioning, and may also conform to the foot in order
to provide comfort, support, and stability.
[0030] Midsole 160 may be fixedly attached to a lower area of upper 110 (for example, through
stitching, adhesive bonding, thermal bonding (such as welding), or other techniques),
or may be integral with upper 110. Midsole 160 may extend through each of forefoot
region 115, midfoot region 120, and heel region 125, and between a lateral side 175
and medial side 180 of footwear 100. In some embodiments, portions of midsole 160
may be exposed around the periphery of footwear 100, as shown in FIG. 1. In other
embodiments, midsole 160 may be completely covered by other elements, such as material
layers from upper 110. Midsole 160 may be formed from any suitable material having
the properties described above, according to the activity for which footwear 100 is
intended. In some embodiments, midsole 160 may include a foamed polymer material,
such as polyurethane (PU), ethyl vinyl acetate (EVA), or any other suitable material
that operates to attenuate ground reaction forces as sole structure 105 contacts the
ground during walking, running, or other ambulatory activities.
[0031] In some embodiments, at least a portion of the upper of the article of footwear may
be formed from a skin layer. In some embodiments, an inner reinforcing material may
be welded to the skin layer in select areas. The welded areas may provide a color
variation from the externally exposed skin layer. The inner reinforcing material may
provide support, protection, and comfort in appropriate regions based on activities
for which the footwear is intended. Further, additional layers may cover the skin
layer in one or more areas (such as the heel and toe region) to provide additional
durability. In some embodiments, such additional layers may also be utilized for decorative
purposes.
[0032] As utilized herein, the term "welding" (and variants thereof) is defined as a securing
technique between two elements that involves a softening or melting of the material
of at least one of the elements such that the materials of the elements are secured
to each other when cooled. Similarly, the term "weld" or variants thereof is defined
as the bond, link, or structure that joins two elements through a process that involves
a softening or melting of material within at least one of the elements such that the
elements are secured to each other when cooled. In some embodiments, welding may involve
the melting or softening of two components such that the materials from each component
intermingle with each other, that is, the materials may diffuse across a boundary
layer between the materials, and are secured together when cooled. In some embodiments,
welding may involve the melting or softening of a material in a first component such
that the material extends into or infiltrates the structure of a second component,
for example, infiltrating crevices or cavities in the second component or extending
around or bonding with filaments or fibers in the second component to secure the components
together when cooled. Thus, welding of two components together may occur when material
from one or both of the components melts or softens. Accordingly, a weldable material,
such as a polymer material, may be provided in one or both of the components. Additionally,
welding does not generally involve the use of stitching or adhesives, but involves
directly bonding components to each other with heat. In some situations, however,
stitching or adhesives may be utilized to supplement the weld or the joining of the
components through welding.
[0033] A variety of heating techniques may be utilized to weld components to each other.
In some embodiments, suitable heating techniques may include conduction heating, radiant
heating, high frequency heating, laser heating, or combinations of such techniques.
In some embodiments, the welding method used to join portions of the upper may include
a high frequency welding method, such as ultrasonic welding or radio frequency (RF)
welding.
[0034] In embodiments where a high frequency welding method is used to form welds in the
upper, the materials of the upper may be any materials suitable for such a method.
For example, materials suitable for high frequency welding may include thermoplastic
material or natural material coated with a thermoplastic material. Examples of material
suitable for high frequency welding methods include an acrylic, a nylon, a polyester,
a polylactic acid, a polyethylene, a polypropylene, polyvinyl chloride (PVC), a urethane,
a natural fiber that is coated with one or more thermoplastic materials, and combinations
of such materials. In some embodiments, a natural fiber, such as cotton or wool, may
be coated with a thermoplastic material, such as an ethyl vinyl acetate or thermoplastic
polyurethane.
[0035] Use of welding can provide various advantages over use of adhesives or stitching.
For example, use of welding may produce a lighter weight shoe due to the absence of
stitching and adhesives. By eliminating stitching and adhesives, the mass that would
otherwise be imparted by stitching and adhesives may be utilized for other structural
elements that enhance the performance properties of the article of footwear, such
as cushioning, durability, stability, and aesthetic qualities. Another advantage relates
to manufacturing efficiency and expense. Stitching and application of adhesives can
be relatively time-consuming processes. By welding components, manufacturing time
may be reduced. Further, costs may be reduced by eliminating the expense of adhesives
or stitching materials. In addition, since adhesives and stitching can increase the
rigidity of upper materials, welding (that is, joining materials without using adhesives
or stitching) can preserve the flexibility of the upper of the article of footwear.
Flexibility of the upper can enable the upper to conform to the foot of a wearer,
thus providing improved fit. By conforming to the foot of the wearer, a flexible upper
may also provide improved comfort. In some embodiments, the skin layer may be a mesh
skin layer. In portions of the upper, the mesh skin layer may remain unreinforced,
permitting directed ventilation through the upper. That is, in unreinforced portions,
the skin layer may have an outwardly exposed outer surface and an inwardly exposed
inner surface. Accordingly, in such embodiments, the openings in the mesh of the unreinforced
skin layer may permit ventilation through the upper. In addition to ventilation, the
openings in the mesh skin layer may also provide other advantages, such as weight
reduction, flexibility, and other advantages. In some embodiments, in the unreinforced
portions of the skin layer, the upper may consist essentially of the skin layer, and
thus, may not include any additional layers. In some areas, the mesh may be provided
in panels that extend between reinforcing panels, the mesh and reinforcing panels
being joined only at abutting edges, for example with minimal overlap.
[0036] Upper 110 may include a skin layer 185 forming at least a portion of an external
surface of upper 110. Upper 110 may also include a reinforcing material 190 selectively
located internal and adjacent to portions of skin layer 185, thereby defining reinforced
portions 195 of skin layer 185 and unreinforced portions 200 of skin layer 185. As
shown in FIG. 1, reinforced portions 195 may include a plurality of striped line portions.
For example, reinforced portions 195 may include a first reinforced portion 301, a
second reinforced portion 302, a third reinforced portion 303, a fourth reinforced
portion 304, a fifth reinforced portion 305, a sixth reinforced portion 306, and a
seventh reinforced portion 307. The arrangement of reinforced portions 195 and unreinforced
portions 200 is discussed in greater detail below.
[0037] In some embodiments, reinforcing material 190 may be selectively joined with skin
layer 185. For example, reinforcing material 190 may be selectively joined with skin
layer 185 at a bonded area 205 by welding. As shown in FIG. 1, bonded area 205 may
have an externally exposed surface that defines a portion of the external surface
of upper 110.
[0038] Reinforcing material 190 may provide advantages with respect to various characteristics,
such as strength, durability, support, stability, and other attributes. In some embodiments,
reinforcing material 190 may be a material having a tensile strength or puncture strength
that is substantially the same or greater than skin layer 185. Thus, in some embodiments,
reinforcing material 190 may provide upper 110 with increased strength in select areas.
In some embodiments, reinforcing material 190 may be a material having an abrasion
resistance that is greater than skin layer 185. In such embodiments, reinforcing material
190 may provide upper 110 with increased durability. In some embodiments, reinforcing
material 190 may have an elasticity that is lower than the same or lower than skin
layer 185. In such embodiments, reinforcing material 190 may provide additional support
and stability to the wearer, for example, by limiting the amount to which skin layer
185 may stretch in reinforced portions 195.
[0039] In some embodiments, portions of upper 110 may include one or more additional layers/components
for reinforcement, support, padding, and stability. For example, in some embodiments,
upper 110 may include one or more panels affixed to an exterior of, or adjacent to,
skin layer 185. Reinforcing strip 150 is one example of such an additional layer/component.
Further, as shown in FIG. 1, upper 110 may include a heel panel 210. Additionally,
or alternatively, in some embodiments, upper 110 may include a toe panel 215. In some
embodiments, the additional panels of material, such as heel panel 210 and toe panel
215 may be welded to skin layer 185. Heel panel 210 and toe panel 215 may provide
additional protection for the foot of a wearer. In addition, heel panel 210 and toe
panel 215 may provide additional durability for upper 110. Further, in some embodiments,
heel panel 210 and toe panel 215 may provide additional stability for footwear 100.
In addition, heel panel 210 and toe panel 215 may be configured to provide aesthetic
appeal.
[0040] In some embodiments, the mesh skin layer may be a full-length layer. That is, skin
layer 185 may extend throughout all, or substantially all, of upper 110. In such embodiments,
the additional layers, such as heel panel 210 and toe panel 215 may be affixed to
an exterior surface of skin layer 185. In other embodiments, additional weight may
be saved by utilizing skin layer 185 only in the areas of footwear 100 where skin
layer 185 is exposed, for example between heel panel 210 and toe panel 215.
[0041] In some embodiments, padding can be included in one or more portions of the upper
to provide comfort and a close fit against the contours of the foot. For example,
in some embodiments, an ankle region 220 of upper 110 proximate to opening 135 may
include compressible padding, such as foam padding, in order to provide cushioning
and a close fit against the ankle of a wearer.
[0042] FIG. 2 is an exploded view of footwear 100 shown in FIG. 1. FIG. 2 shows sole structure
105 and the plurality of components from which the upper may be constructed. For example,
skin layer 185 is shown. Skin layer 185 is shown as a full length skin layer in FIG.
2.
[0043] In some embodiments, heel panel 210 and toe panel 215, such as shown in FIG. 2, may
be fixedly attached to an external surface of skin layer 185. Such fixed attachment
may be by welding. It will be noted, however, that, as discussed above, in some embodiments,
skin layer 185 may be less than a full length layer and, instead, may extend between
additional panel components, such as heel panel 210 and toe panel 215. In such embodiments,
heel panel 210 and toe panel 215 may overlap skin layer 185 only minimally, for example,
at the peripheral, adjoining edges of each panel. The shape and size of heel panel
210 and toe panel 215 may vary according to desired performance characteristics such
as weight, foot protection, durability, aesthetic design, and other such characteristics.
Further, the materials from which heel panel 210 and toe panel 215 may be formed may
vary according to the same or similar desired performance characteristics.
[0044] FIG. 2 shows strips of reinforcing material 190 in isolation. These strips may be
disposed against the inner surface of skin layer 185. The arrangement of reinforcing
material in footwear 100 is discussed in greater detail below.
[0045] Additional panels may also be provided around the throat opening of footwear 100.
For example, an inner liner panel 191 and a reinforcing collar panel 192 may be provided
inside skin layer 185. In some embodiments, however, reinforcing collar panel 192
may be provided external to skin layer 185. FIG. 2 also shows a foam collar piece
193, which may be disposed between inner liner panel 191 and reinforcing collar panel
192. Foam collar piece 193 may be a compressible component, which may conform to the
contours of the foot proximate the ankle, thus improving fit and comfort. Such a compressible
foam collar piece 193 may also provide protection for the ankle against impact and
shifting of footwear 100 due to loading experienced during athletic activities.
[0046] As further illustrated in FIG. 2, tongue 800 may include multiple components. For
example, as shown in FIG. 2, tongue 800 may include a grip portion 875, which may
form an external surface of an upper portion of tongue 800. Grip portion 875 may provide
a suitable area at which to grip tongue 800 when putting footwear 100 on the foot.
Further, grip portion 875 may provide a location to display indicia, such as a logo
or other graphic or text. In addition, tongue 800 may include a skin layer 885. Skin
layer 885 may be formed of the same or similar material as skin layer 185, such as
a mesh material. In some embodiments, skin layer 885 may form the exterior surface
of a substantial majority of tongue 800. That is, the area of skin layer 885 which
is not covered by grip portion 875 may form a substantial majority of the exterior
exposed surface of tongue 800. As shown in FIG. 2, skin layer 885 may extend the full
length of tongue 800, and thus, grip portion 875 may overlay skin layer 885. However,
in other embodiments, skin layer 885 and grip portion 875 may be joined at their peripheral
edges and thus may not overlap, or may overlap minimally. This may save weight, by
reducing the amount of skin layer material is used to form tongue 800.
[0047] As shown in FIG. 2, tongue 800 may also include a plurality of foam pads 880 and
a liner 890. Foam pads 880 may be disposed between skin layer 885 (or grip portion
875) and liner 890. Foam pads 880 may be compressible, and thus, may provide comfort
and improved fit in the instep region of footwear 100. Liner 890 may be formed of
a material that is suitable for contacting the skin of a foot or a sock-covered foot
of a wearer. Thus, liner 890 may be formed of a material that enables the sock-covered
foot to slide into and out of footwear 100 with minimal effort. In addition, liner
890 may also have moisture wicking properties to absorb sweat from a wearer's foot.
[0048] The layers of tongue 800 may be joined using one or more joining techniques, such
as welding, stitching, heat bonding, or other suitable construction methods. Additional
details of the construction of tongue 800 are discussed below with regard to FIGS.
12-14.
[0049] In some embodiments, the skin layer may be exposed over a relatively large area of
the upper. Accordingly, the reinforcing material and the bonded area in which the
reinforcing material is bonded to the skin layer may be used to reinforce a span of
skin layer between other shoe components. That is, strips of the reinforcing material
may extend between components of the shoe. Similarly, the bonded area may include
lines of bonded material extending between components of the article of footwear.
For example, strips of reinforcing material and lines of bonded area may extend from
a midsole of the article of footwear to a reinforcing strip bordering the lacing region
of the article of footwear. This configuration may provide structural support in a
generally vertical direction. In some embodiments, however, the strips and lines of
bonded area may be angled in order to strategically reinforce the upper in certain
directions and orientations.
[0050] In some embodiments, first reinforced portion 301 may extend from reinforcing strip
150 to sole structure 105, for example to midsole 160, as shown in FIG. 3. First reinforced
portion 301 may extend, not only vertically, but also in a forward direction as it
approaches midsole 160. The angling of first reinforced portion 301 may provide structural
support in a forward-rearward direction. For example, first reinforced portion 301
may operate in tension to resist forces that tend to translate upper 110 in a rearward
direction relative to sole structure 105. Such forces may occur, for example, when
an athlete accelerates in a forward direction. In addition, first reinforced portion
301 may also span between reinforcing strip 150 and toe portion 215, providing further
reinforcement to upper 110 by connecting skeletal structures of upper 110.
[0051] Second reinforced portion 302 may also extend from reinforcing strip 150 to midsole
160, as shown in FIG. 3. Further, second reinforced portion 302 may extend in a substantially
vertical direction when viewed from the side of footwear 100. In addition, second
reinforced portion 302 may be joined to reinforcing strip 150 proximate to first reinforced
portion 301.
[0052] Third reinforced portion 303 may extend from reinforcing strip 150 to midsole 160,
as shown in FIG. 3. Third reinforced portion 303 may extend, not only vertically,
but also in a rearward direction as it approaches midsole 160. The angling of second
reinforced portion 303 may provide structural support in a forward-rearward direction.
For example, third reinforced portion 303 may operate in tension to resist forces
that tend to translate upper 110 in a forward direction relative to sole structure
105. Such forces may occur, for example, when an athlete slows or stops their forward
movement. In addition, third reinforced portion 303 may be joined to reinforcing strip
150 proximate to second reinforced portion 302.
[0053] Each of first reinforced portion 301, second reinforced portion 302, and third reinforced
portion 303 may connect to reinforcing strip 150 adjacent one another and provide
supportive reinforcement in different directions (fore, aft, and vertically). This
may contribute the stability of footwear 100, by maintaining the relative positioning
of upper 110 relative to sole structure 105. In some embodiments, first reinforced
portion 301, second reinforced portion 302, and third reinforced portion 303 may connect
to reinforcing strip 150 adjacent one another in a forefoot portion of footwear 100,
for example in the area corresponding with the first metatarsal head and the first
metatarsal-phalangeal joint. This joint is a point of flexion of the forefoot. Accordingly,
it is advantageous to maintain the positioning of upper 110 relative to sole structure
105 in the region of this joint. This may promote, comfort, fit, and performance of
footwear 100.
[0054] The strategic positioning of first reinforced portion 301, second reinforced portion
302, and third reinforced portion 303 in the orientations discussed above on the lateral
and medial sides of footwear 100 to thereby provide fore-aft stability in the first
metatarsal-phalangeal joint region, may enable a first unreinforced region 311 in
the forefoot region to be a relatively wide span of skin layer that is unreinforced.
This may provide additional ventilation and weight reduction.
[0055] Fourth reinforced portion 304 and fifth reinforced portion 305 may extend from reinforcing
strip 150 to midsole 160, as shown in FIG. 3. In addition, fifth reinforced portion
305 may be joined to reinforcing strip 150 proximate to fourth reinforced portion
304, and may separate as fourth reinforced portion 304 and fifth reinforced portion
305 approach midsole 160. Also, sixth reinforced portion 306 and seventh reinforced
portion 307 may be arranged similarly to fourth reinforced portion 304 and fifth reinforced
portion 305, that is, in an inverted "V" formation. This inverted "V" formation may
provide structural support in a similar manner to first reinforced portion 301, second
reinforced portion 302, and third reinforced portion 303 discussed above.
[0056] It is also noted that the arrangement of reinforced portions with upper ends converging
in various regions of reinforcing strip 150 and diverging proximate midsole 160 may
enable structural connection between reinforcing strip 150 and diverging proximate
midsole 160 despite these two components having differing lengths. That is, reinforcing
strip 150 has a first length corresponding with the lacing region, whereas midsole
160 has a second length that extends the full length of footwear 100 and is, thus,
longer than the first length of reinforcing strip 150.
[0057] In other embodiments, the reinforced portions of upper 110 may have other arrangements
to provide strength, support, durability, and other performance characteristics. For
example, in some embodiments, instead of an inverted "V" arrangement, reinforcing
portions may be arranged in an "X" configuration between various components of footwear
100. Other arrangements are also possible according to the locations at which reinforcement
is desired for performance benefits.
[0058] By strategically arranging the reinforced portions of upper 110, relatively large
amounts of surface area of upper 110 may be formed of unreinforced skin layer. For
example, in addition to first unreinforced portion 311, a second unreinforced portion
312 may be disposed between first reinforced portion 301 and second reinforced portion
302. In addition, a third unreinforced portion 313 may be disposed between second
reinforced portion 302 and third reinforced portion 303. A fourth unreinforced portion
314 may be disposed between third reinforced portion 303 and fourth reinforced portion
304. Further, a fifth unreinforced portion 315 may be disposed between fourth reinforced
portion 304 and fifth reinforced portion 305. Also, a sixth unreinforced portion 316
may be disposed between fifth reinforced portion 305 and sixth reinforced portion
306. A seventh unreinforced portion 317 may be disposed between sixth reinforced portion
306 and seventh reinforced portion 307. And an eighth unreinforced portion 318 may
be disposed between seventh reinforced portion 307 and ankle region 220.
[0059] Additional unreinforced portions similar to second unreinforced portion 312, third
unreinforced portion 313, fourth unreinforced portion 314, fifth unreinforced portion
315, sixth unreinforced portion 316, seventh unreinforced portion 317, and eight reinforced
portion 318 may be provided on the opposite side of footwear 100. Thus, in some embodiments,
the medial and lateral sides of upper 110 may be substantial mirror images in terms
of the arrangement of reinforcing material. In some embodiments, the collective surface
area of unreinforced portions may form a substantial majority of the surface area
of exposed skin layer.
[0060] Further, in some embodiments, the collective surface area of unreinforced portions
may constitute a substantial majority of the surface area of upper 110. By providing
relatively large amounts of upper 110 as unreinforced, upper 110 may be provided with
ventilation, flexibility, and reduced weight.
[0061] In some embodiments, the welding may be used to, not only join components, but also
change the outward appearance of those components by changing the apparent color of
the exterior portion of the footwear upper. For example, in some embodiments, the
unreinforced skin layer may have a first color. As discussed in greater detail below,
the skin layer may be a mesh material, and thus, portions of underlying reinforcing
material may show through the openings in the mesh skin layer. If the reinforcing
material has a second color that is different than the first color of the skin layer,
the appearance of a reinforced portion of skin layer may have a third color that is
a blend of first color of the skin layer and the second color of the reinforcing material
color. In addition, the bonded areas, where reinforcing material is bonded to the
skin layer may have a fourth color. This fourth color may be substantially the same
as the second color of the reinforcing material, as the skin layer may become embedded
in the reinforcing material during the welding process. In some embodiments, however,
the bonded area may have a color that is a blend of the first color of the skin layer
and the second color of the reinforcing material. In addition, other portions of the
footwear may have a fifth color, which may be the same or different as other components
of the footwear. The color differences may be utilized for aesthetic design purposes.
Further, the color differences may be utilized to show, through the color arrangement,
various structural aspects of the footwear construction.
[0062] Unreinforced skin layer may have a first color. For example, as shown in FIG. 3,
first unreinforced portion 311, second unreinforced portion 312, third unreinforced
portion 313, fourth unreinforced portion 314, fifth unreinforced portion 315, sixth
unreinforced portion 316, seventh unreinforced portion 317, and eight reinforced portion
318 may have a first color represented in FIG. 3 simply as a grid. Reinforcing material,
although not shown exposed in FIG. 3, may have a second color. For purposes of discussion,
FIG. 3 illustrates a configuration in which the second color of the reinforcing material
is substantially the same as a fifth color of other footwear components, such as heel
panel 210, toe panel 215, and reinforcing strip 150, which are shown with a relatively
dark stipple.
[0063] The appearance of reinforced portions of skin layer may have a third color that is
a blend of the first color of the skin layer and the second color of the reinforcing
material color. For example, as shown in FIG. 3, first reinforced portion 301, second
reinforced portion 302, third reinforced portion 303, fourth reinforced portion 304,
fifth reinforced portion 305, sixth reinforced portion 306, and seventh reinforced
portion 307 may have a third color that is an intermediate color between the first
color of the skin layer and the second color of the reinforcing material. Accordingly,
first reinforced portion 301, second reinforced portion 302, third reinforced portion
303, fourth reinforced portion 304, fifth reinforced portion 305, sixth reinforced
portion 306, and seventh reinforced portion 307 are shown with a medium darkness stipple.
[0064] In addition, bonded areas 205, where reinforcing material is bonded to the skin layer
may have a fourth color. This fourth color may be substantially the same as the second
color of the reinforcing material. Accordingly, bonded areas 205 are shown in FIG.
3 as having a relatively dark stipple. By welding reinforcing material to the skin
layer, the externally exposed surface of bonded area 205 may be given a fourth color
that is different from the first color. It will be noted that, in some embodiments,
the additional layers/components discussed above, such as reinforcing strip 150, heel
panel 210, and toe panel 215, may be formed of the same or similar material as reinforcing
material 190. For example, all of these components may be formed of a relatively lightweight
fabric. In some embodiments, the lines of bonded area 205 may match in color with
other footwear components to provide various decorative appearances. In some embodiments,
one or more footwear components may have a different color than the reinforcing material
and bonded area 205 to provide a different visual appearance.
[0065] The welding process may change the apparent color of the exterior surface of upper
110 by relocating portions of reinforcing material to the exterior surface of upper
110. For example, the process of welding may involve the melting of reinforcing material
190 such that the reinforcing material flows from the inner side of skin layer 185
between the fibers of skin layer 185 (for example through the openings in a skin layer
mesh material) to the outer, exposed side of skin layer 185. Thus, the externally
exposed surface of bonded area 205 may include portions of reinforcing material, thus
providing the externally exposed surface of the bonded area 205 with substantially
the same color as the reinforcing material. The mechanism by which the relocation
of portions of reinforcing material takes place is explained in more detail below.
[0066] Although the colors of footwear 100 are shown in FIG. 3 as being varying shades of
grey, it will be understood that the components of footwear 100 may have any suitable
colors. Further, the differences in color between components may be varying shades
of a given color, such as dark red and light red. In addition, blends of colors may
produce not only varying shades, but different colors altogether. For example, in
some embodiments, a yellow skin layer may be combined with a blue reinforcing material
to form reinforced portions or bonded areas that have a green appearance.
[0067] FIG. 4 illustrates a perspective view through opening 135 into void 130 within upper
110 of footwear 100. FIG. 4 shows an insole 225, and shows strips of reinforcing material
190 extending upward from beneath insole 225. As shown in FIG. 4, portions of skin
layer 185 are inwardly exposed between the strips of reinforcing material 190. Thus,
these unreinforced portions of skin layer 185 are exposed both externally and internally.
Accordingly, as skin layer 185 may be a mesh material in some embodiments, the unreinforced
portions of skin layer 185 may provide direct ventilation through skin layer 185,
to internal void 130 defined by upper 110.
[0068] FIG. 5 is an enlarged illustration of a portion of FIG. 4 showing the inner surface
of upper 110. As shown in FIG. 5, unreinforced portions 196, such as sixth unreinforced
portion 316, seventh unreinforced portion 317, and eighth unreinforced portion 318
may be disposed between reinforced portions 190, such as sixth reinforced portion
306 and seventh reinforced portion 307. The reinforced portions may be welded to the
skin layer, for example in a first bonded area 321, a second bonded area 322, a third
bonded area 323, and a fourth bonded area 324. It will be noted that, first bonded
area 321, second bonded area 322, third bonded area 323, and fourth bonded area 324
are shown in FIG. 5 as having the same color as the reinforcing material. Because
FIG. 5 shows an inner side of upper 110, the skin layer is not shown, since the skin
layer is not internally exposed proximate to the bonded areas. Thus, the bonded areas
may have the same color as the reinforcing material on the inner side of upper 110.
[0069] It will also be noted that in some places, two bonded areas may join to form a more
complex pattern. For example, as shown in FIG. 5, second bonded area 322 and third
bonded area 323 may converge to form an inverted "V" arrangement. This joining of
bonded areas may provide a structural connection between skeletal components of upper
110. Further, in some embodiments, sixth reinforced portion 306 and seventh reinforced
portion 307 may be formed by separate strips of reinforcing material. In such embodiments,
joining the bonded areas that secure these separate strips to the skin layer may provide
a structural connection between these separate strips, thus creating a truss-like
structure.
[0070] FIGS. 6 and 7 illustrate, in greater detail, the structure of the reinforced portions
of upper 110. The arrangement of skin layer 185, reinforcing material 190, and bonded
area 205 is illustrated in greater detail in FIG. 6, which shows an enlarged view
of one of the striped regions of upper 110 created by reinforced portion 195 of skin
layer 185. As shown in FIG. 6, skin layer 185 may be formed of a mesh material. As
shown in the enlarged view portion of FIG. 6, skin layer 185 may include a plurality
of openings 230, which may provide weight reduction and ventilation. In unreinforced
portions 200, openings 230 may provide direct ventilation with an interior of footwear
100. In some embodiments, the mesh material may have more than 50% open area (e.g.,
more than 50% of the material surface area comprises open space through which air
can freely flow from one side to the other).
[0071] In a substantial majority of reinforced portion 195, reinforcing material 190 may
be visible behind skin layer 185 through openings 230. In this substantial majority
of reinforced portion 195, reinforcing material 190 may remain adjacent to, but detached
from, skin material 185. In select portions of reinforced portion 195, reinforcing
material 190 may be affixed to skin layer 185 to form bonded areas 205. It will be
noted that unreinforced portions 200 of skin layer 185 appear as generally white,
while reinforced portion 195 appears generally grey due to the combination of the
dark reinforcing material 190 with the white mesh of skin layer 185. Bonded areas
205 appear darker still as no white grid lines interrupt the dark color of reinforcing
material 190 in bonded areas 205.
[0072] It will be noted that the skin material is illustrated, in the accompanying drawings,
as a relatively simple grid representation. This grid representation is schematic
only, and is provided in this manner for convenience and to avoid obscuring the drawings
with excessive detail. Nevertheless, actual materials used for the mesh of the skin
layer, examples of which are provided below, may have a relatively simple square or
rectangular grid structure, similar to that shown in the drawings. The orientation
of the grid may vary. Further, in some embodiments, other more complicated grid structures
may be utilized for the mesh material of the skin layer. In addition, the size of
the grid openings may also vary. The configuration of the skin layer mesh may be selected
according to desired performance characteristics, including weight, strength, puncture
resistance, ventilation, and other attributes.
[0073] In at least some embodiments, the mesh material of skin layer 185 may be a single
layer warped knit with an open structure (or other type of woven material) and may
be formed from nylon, polyester, nylon/polyester blends, recycled polyethylene terephthalate
(rePET), or other material. However, the mesh material of skin layer 185 may be made
of any desired materials, with any desired mesh opening size(s). Reinforcing material
190 may be any suitable material, including fabrics, textiles, weaves, knits, and
other such materials. Reinforcing material 190 may be a material that is adhesively
compatible with skin layer 185 and other materials of the shoe. In some embodiments,
reinforcing material 190 may be a material that is adhesively compatible with skin
layer 185 during welding. Suitable materials may include crystalline or semi crystalline
materials. In some embodiments, such materials may include thermoplastics. For example,
suitable materials may include polyalkylenes, such as polyethylene and polypropylene.
Other materials may also be suitable for use as reinforcing materials, such as nylons,
polyesters, and other such materials. In some embodiments, reinforcing material 190
may be configured to melt under welding, and thereby flow through openings 230 in
the mesh of skin layer 185, thus resulting in skin layer 185 embedding within reinforcing
material 190 in bonded regions. In other embodiments, skin layer 185 and reinforcing
material 190 may be configured to slightly melt during welding and adhesively attach
to one another (without skin layer 185 becoming embedded). In some embodiments, reinforcing
material may be melted slightly, enabling the mesh of skin layer 185 to become partially
embedded in reinforcing material 190 during welding. In such embodiments, reinforcing
material 190 and skin layer 185 may rely not only on the partially embedded construction,
but also on the adhesive bonding created by the partial melting of the reinforcing
material. In order to achieve the welding, the reinforcing material may have the same
or lower melting point as the skin layer. This may enable the reinforcing material
to melt and flow through the openings in the mesh while the fibers of the mesh remain
substantially intact.
[0074] As shown in FIG. 6, bonded areas 205 may span one or more of openings 230. Further,
the amount of reinforced portion 195 in which reinforcing material 190 is affixed
to skin layer 185 may vary. That is, the ratio of bonded area 205 to reinforced portion
195 may vary from relatively low, for example, 1:20, to relatively high, for example,
19:20. In some exemplary embodiments, stripes on the medial and lateral side of upper
110 may have a ratio of bonded area 205 to reinforced portion 195 of approximately
1:3. For example, as shown in FIG. 6, the combined widths of bonded areas 205 may
be approximately one third of the total width of reinforced portion 195.
[0075] Because skin layer 185 is directly bonded to reinforcing material 190, the combined
strength of the mesh skin layer 185 and reinforcing material 190 may obviate the need
for another material on the outside or inside surface of upper 110 to provide tensile
strength, puncture strength, durability, stability, or other performance characteristics.
This permits upper 110 to be much lighter than is possible using various conventional
shoe construction techniques.
[0076] Openings 230 in skin layer 185 allow air to flow through. This air flow helps to
cool and dry the foot of a wearer of footwear 100. In some embodiments, skin layer
185 may be the only layer of upper 110 in certain portions of upper 110. In other
embodiments, however, additional reinforcing materials may be utilized. For example,
reinforcing material 190 may be selectively located at various portions of skin layer
185, and an additional inner reinforcing material may be provided for more comfort
and moisture control (for example, wicking moisture away from the foot). This additional
inner liner (not shown) may extend over otherwise unreinforced portions of skin layer
185. In some embodiments, this additional inner liner may be a relatively breathable
material, and thus, may preserve the ventilation benefits of a mesh skin layer 185.
[0077] FIG. 7 is a cross-sectional view of upper 110 taken at line 7-7 in FIG. 6. As shown
in FIG. 7, upon welding, bonded areas 205 may be created by embedding the mesh fibers
of the skin layer 185 into reinforcing material 190. The fibers of skin layer 185
may melt to a greater or lesser degree during the welding process. Accordingly, in
some embodiments, when forming bonded areas 205, the fibers of skin layer 185 may
remain substantially intact. In other embodiments, the fibers of skin layer 185 may
substantially melt and mix with the reinforcing material 190. In some cases, it may
be desirable for the fibers of skin layer 185 to remain substantially intact in order
to preserve the strength and durability of skin layer 185. In some embodiments, the
fibers of skin layer 185 may deform slightly, as shown in FIG. 7. This slight deformation
may result from slight melting, which may improve the bonding between the fibers of
skin layer 185 and reinforcing material 190, while substantially preserving the tensile
strength of skin layer 185 since the fibers of skin layer 185 remain substantially
intact.
[0078] FIG. 7 further illustrates the deformation of reinforcing material 190 in bonding
areas 205. This deformation may be created by heat and pressure applied by the welding
process, which may compress the reinforcing material 190. In addition, FIG. 7 also
shows reinforced portion 195 where reinforcing material 190 extends beneath skin layer
185, as well as unreinforced portions 200 where reinforcing material 190 does not
extend.
[0079] FIG. 8 provides a schematic illustration of an alternative configuration of the mesh
material of the skin layer. For example, FIG. 8 shows a mesh skin layer 700 backed
in a reinforced portion 730 by a reinforcing material 705. Reinforced portion 730
extends to edges 710 of reinforcing material 705. Further, reinforcing material 705
is welded to skin layer 700 in a first bonded area 720 and a second bonded area 725.
[0080] As shown in FIG. 8, the mesh of skin layer 700 may have a hexagonal configuration.
This hexagonal configuration may provide improved strength and inelasticity in multiple
directions as compared to a square or rectangular grid configuration. Meshes having
grid with other geometrically-shaped configurations may also be used. For example,
the skin layer may be formed of a mesh material having a triangular or octagonal configuration.
The varying shapes may be selected to provide desired performance characteristics,
such as directional strength and inelasticity.
[0081] Although the mesh of the skin layer is shown as having generally two-dimensional
configurations, in some embodiments, the mesh may have a three-dimensional configuration.
For example, in some embodiments, the skin layer may be formed of a spacer mesh or
spacer textile. Three-dimensional mesh configurations may provide more complex and
tailored performance characteristics, such as directional tensile strength and inelasticity,
as well as puncture strength, abrasion resistance, and ventilation.
[0082] Some embodiments may use one or more spacer meshes or spacer textile materials that
are discussed in
Hazenberg et al., U.S. Patent Application Publication No. 2013/0266773, published
October 10, 2013, and entitled "Spacer Textile Materials And Methods For Manufacturing The Spacer
Textile Materials," and
Chao et al., U.S. Patent Application Publication No. 2013/0263391, published October
10, 2013, and entitled "Methods for Manufacturing Fluid-Filled Chambers Incorporating Spacer
Textile Materials." The entire disclosures of these two patent applications are incorporated
herein by referenced in their entirety. In some embodiments, a double needle bar raschel
knit or other three-dimensional knit may be used to form a mesh material for the skin
layer. Exemplary three-dimensional knits that may be used, including the double needle
bar raschel knit, are disclosed in
Bruer et al., "Three-Dimensionally Knit Spacer Fabrics: A Review of Production Techniques
and Applications," Journal of Textile and Apparel, Technology and Management, Vol.
4, Iss. 4, Summer 2005, the entire disclosure of which is incorporated herein by reference.
[0083] In some embodiments, a bonded mesh composite panel of an upper may be created by
assembling individual panels of material for the various layers in a flat configuration.
The panels and other elements are assembled so as to have an arrangement in which
the relative locations of the panels and elements correspond to the locations those
panels and elements will have in the completed shoe. After assembling the individual
panels and other elements into the proper arrangement and tacking the assembly at
several locations, the assembly undergoes a series of pressing operations to bond
the assembled elements. These operations create a flat, one-piece unibody upper shell
that can contain many or all elements to be included in the finished upper. Edges
of the unibody upper shell can then be joined to create a three-dimensional upper
body ready for further finishing and attachment to a midsole. Some embodiments may
use one or more of the assembly procedures disclosed in
Shaffer et al., U.S. Patent Application Publication No. 2012/0297643, published November
29, 2012, and entitled "Shoe with Composite Upper and Method of Making the Same," the entire
disclosure of which is incorporated herein by reference. Additionally, some embodiments
may use one or more of the footwear assembly methods disclosed in (a)
Dojan et al., U.S. Patent Application No. 13/029,502, filed February 17, 2011 and entitled "Shoe with Composite Upper and Foam Element and Method of Making Same,"
(now abandoned), (b)
Dojan et al., U.S. Patent Application Publication No. 2011/0088285, published April.
21, 2011, and entitled "Composite Shoe Upper and Method of Making Same," and (c)
Dojan et al., U.S. Patent Application Publication No. 2011/0088282, published April.
21, 2011 and entitled "Composite Shoe Upper and Method of Making Same." Each of these applications
listed above is incorporated by reference in its entirety.
[0084] FIGS. 9-11 illustrate an exemplary ultrasonic welding process in greater detail.
As shown in FIG. 9, skin layer 185 and reinforcing material 190 (or other components
of the upper) may be ultrasonically welded on an anvil 235. Anvil 235 may be a relatively
rigid body on which the components may be ultrasonically welded. In some embodiments,
anvil 235 may be a relatively flat surface, such as a table. In other embodiments,
anvil 235 may be a last upon which the article of footwear may be assembled. The schematic
illustrations of FIGS. 9-11 are intended to encompass use of an anvil generally, and
thus, are not specific to any particular anvil configuration.
[0085] As further shown in FIG. 9, an ultrasonic horn 240 may be provided to effectuate
the ultrasonic welding. As shown in FIG. 10, ultrasonic horn 240 may compress skin
layer 185 and reinforcing material 190 against anvil 235. Also, ultrasonic horn 240
may be vibrated at an ultrasonic frequency, as illustrated by vibration lines 245.
This ultrasonic vibration may create friction, which may create heat, which, along
with the pressure of ultrasonic horn 240 pressing against anvil 235, may at least
partially melt a portion of reinforcing material 190. As a result of this melting,
the fibers of skin layer 185 may embed within reinforcing material 190, effectively
relocating portions of reinforcing material 190 to an exterior surface of the upper,
thereby forming bonded area 205, as shown in FIG. 11.
[0086] Using the technique schematically illustrated in FIGS. 9-11, a method of making an
article of footwear may be performed. The method may include forming an upper configured
to receive a foot of a wearer. Forming the upper may include selectively attaching
inner reinforcing material 190 to skin layer 185 using ultrasonic welding. (In some
embodiments, other welding techniques may be utilized.) The method may further include
arranging skin layer 185 to form at least a portion of the external surface of the
upper. Ultrasonically welding inner reinforcing material 190 to skin layer 185 may
form bonded area 205 having an externally exposed surface that defines a portion of
the external surface of the upper. In some embodiments, skin layer 185 may have a
first color and the reinforcing material 190 may have a second color that is different
from the first color.
[0087] The externally exposed surface of bonded area 205 may be formed to include portions
the reinforcing material 190, thus providing the externally exposed surface of bonded
area 205 with a different color than skin layer 185. For example, ultrasonically welding
the inner reinforcing material 190 to skin layer 185 to form bonded area 205 may relocate
portions of reinforcing material 190 to the external surface of the upper at the externally
exposed surface of bonded area 205, thereby providing the externally exposed surface
of bonded area 205 with substantially the same color as reinforcing material 190.
In some embodiments, relocating portions of reinforcing material 190 to the external
surface of the upper may include pressing the portions of reinforcing material 190
through openings in the mesh material of skin layer 185. Further, selectively attaching
the inner reinforcing material 190 to certain portions of skin layer 185 may form
reinforced portions of skin layer 185, leaving unreinforced portions of skin layer
185 that provide direct ventilation, through the mesh material of skin layer 185,
to an internal void defined by the upper.
[0088] Ultrasonically welding reinforcing material 190 to skin layer 185 to form bonded
area 205 may include forming lines of bonded material extending between components
of the article of footwear. For example, forming lines of bonded material may include
forming lines of bonded material extending from the sole structure of the article
of footwear to the reinforcing strip proximate to the instep region of the article
of footwear.
[0089] In order to form lines of bonded material, a stylus-like ultrasonic horn 240 may
be moved in a desired pattern. In other embodiments, ultrasonic horn 240 may be an
elongate structure formed in the desired pattern. Such an elongate ultrasonic horn
may simply be pressed against the material to be welded and the ultrasonic vibrations
activated. Some embodiments may use one or more ultrasonic welding techniques using
an elongate horn that are discussed in Beye et al., U.S. Patent Application Publication
No.______, published______, (now
U.S. Patent Application No. 13/741,428, filed January 15, 2013, and entitled "Spacer Textile Material with Tensile Strand Having Multiple Entry
and Exit Points" (Attorney Docket No. 51-2687)), the entire disclosure of which is
incorporated herein by reference.
[0090] In some embodiments, exemplary articles of footwear may include an additional layer
of material located between a portion of the skin layer and a portion of the reinforcing
material. For example, an additional layer of material may include a compressible
foam material, which may provide comfort, protection, and a close fit. Such a compressible
foam layer may be provided, for example, in a tongue portion of the upper of the article
of footwear. Lines of bonded area may enclose a pocket between the skin layer and
the reinforcing material, in which the compressible foam layer may be disposed. In
some embodiments, multiple compressible foam pads may be provided proximate one another.
For example, multiple compressible foam pads may be separated by lines of bonded area.
Such an arrangement may produce a quilted configuration, which may provide comfort
to the instep region of the footwear.
[0091] FIG. 12 illustrates a view of footwear 100 with tongue 800 substantially exposed.
As shown in FIG. 12, upper 110 may include a tongue 800, which may be formed of multiple
layers that may be joined using welding or stitching. For example, multiple bonded
areas 805, in the form of lines, may be provided to selectively attach reinforcing
material 190 to skin layer 885. In addition, stitching 840 may secure reinforcing
material 190 to skin layer 885 in certain portions of tongue 800, such as a peripheral
edge, as shown in FIG. 12.
[0092] As further shown in FIG. 12, in some embodiments, footwear 100 may include an additional
layer of material located between a portion of skin layer 885 and a portion of reinforcing
material 190. For example, the additional layer of material may include a compressible
foam material. As shown in FIG. 12, a first pocket 810 between skin layer 885 and
reinforcing material 190 may house a first foam pad 815. First pocket 810 may be enclosed
by a plurality of bonded area lines that define a polygonal pocket. For example, as
shown in FIG. 12, a first bonded area line 820, a second bonded area line 825, a third
bonded area line 830, and a fourth bonded area line 835 may enclose first pocket 810.
[0093] In addition, at least one additional foam pad may be provided in tongue 800. For
example, a second foam pad 845 may be provided in a second pocket 850. Second pocket
850 may be enclosed by a fifth bonded area line 855, a sixth bonded area line 860,
a seventh bonded area line 865, and fourth bonded area line 835. First foam pad 815
and second foam pad 845 may be disposed substantially proximate one another, thereby
forming a substantially quilted configuration.
[0094] FIG. 13 shows a cross-sectional view taken at line 13-13 of FIG. 12. As shown in
FIG. 13, first foam pad 815 may be disposed within first pocket 810 between skin layer
885 and reinforcing material 190. Similarly, foam pad 845 may be disposed within second
pocket 850. As shown in FIG. 12, second bonded area line 825 and third bonded area
line 830 define boundaries of first pocket 810. Similarly, sixth bonded area line
860 and seventh bonded area line 865 define boundaries of second pocket 850.
[0095] FIG. 14 shows a cross-sectional view taken at line 14-14 of FIG. 12, which is substantially
perpendicular to line 13-13 at which the cross section in FIG. 13 is taken. As shown
in FIG. 14, in addition to first foam pad 815, tongue 800 may also include a third
foam pad 846 and a fourth foam pad 847 disposed between liner 890 and skin layer 885.
In some embodiments, liner 890 may be formed of reinforcing material 190. Therefore,
liner 890 may provide structural support to tongue 800.
[0096] As shown in FIG. 14, reinforcing material 190 may be joined to skin layer 885 to
form a plurality of bonded areas. For example, reinforcing material 190 may be welded
to skin layer 885 to form an eighth bonded area line 901 and a ninth bonded area line
902. Eighth bonded area line 901 and ninth bonded area line 902 may separate third
foam pad 846 from first foam pad 815. In addition, fourth bonded area line 835 and
a tenth bonded area line 904 may separate first foam pad 815 and fourth foam pad 847.
Further, upper edge 905 may be formed using welding or by another bonding process.
Upper edge 905 may form at least one side of the pocket within which third foam pad
846 is disposed. Similarly, a lower edge 906 may be formed using welding or by another
bonding process. Lower edge 905 may form at least one side of the pocket within which
fourth foam pad 847 is disposed.
[0097] While various embodiments of the invention have been described, the description is
intended to be exemplary, rather than limiting and it will be apparent to those of
ordinary skill in the art that many more embodiments and implementations are possible
that are within the scope of the invention. Although many possible combinations of
features are shown in the accompanying figures and discussed in this detailed description,
many other combinations of the disclosed features are possible. Therefore, it will
be understood that any of the features shown and/or discussed in the present disclosure
may be implemented together in any suitable combination. Accordingly, the invention
is not to be restricted except in light of the attached claims and their equivalents.
Also, various modifications and changes may be made within the scope of the attached
claims.
[0098] The invention also contains the following items:
Item 1. An article of footwear including a sole structure fixedly attached to an upper
configured to receive a foot of a wearer, the upper comprising:
a skin layer forming at least a portion of an external surface of the upper; and
a reinforcing material selectively located internal and adjacent to portions of the
skin layer, thereby defining reinforced portions of the skin layer and unreinforced
portions of the skin layer;
wherein the reinforcing material is selectively joined with the skin layer at a bonded
area by welding, the bonded area having an externally exposed surface that defines
a portion of the external surface of the upper; and
wherein the skin layer has a first color and the externally exposed surface of the
bonded area has a second color that is different from the first color.
Item 2. The article of footwear of item 1, wherein the externally exposed surface
of the bonded area includes portions of the reinforcing material, thus providing the
externally exposed surface of the bonded area with substantially the same color as
the reinforcing material.
Item 3. The article of footwear of item 1, wherein the skin layer is formed of a mesh
material.
Item 4. The article of footwear of item 3, wherein the unreinforced portions of the
skin layer include an outwardly exposed surface and an inwardly exposed surface.
Item 5. The article of footwear of item 3, wherein the unreinforced portions of the
skin layer provide direct ventilation, through the mesh material of the skin layer,
to an internal void defined by the upper.
Item 6. The article of footwear of item 1, wherein the bonded area includes lines
of bonded material extending between components of the article of footwear.
Item 7. The article of footwear of item 6, wherein the lines of bonded material extend
from the sole structure to a reinforcing strip proximate to an instep region of the
article of footwear.
Item 8. The article of footwear of item 1, wherein the article of footwear includes
additional panels of material that are welded to the skin layer.
Item 9. An article of footwear including a sole structure fixedly attached to an upper
defining an internal void configured to receive a foot of a wearer, the upper comprising:
a skin layer forming at least a portion of an external surface of the upper, the skin
layer being formed of a mesh material; and
a reinforcing material selectively located internal and adjacent to the skin layer,
thereby defining reinforced portions of the skin layer and unreinforced portions of
the skin layer;
wherein the unreinforced portions of the skin layer provide direct ventilation, through
the mesh material of the skin layer, to the internal void defined by the upper;
wherein the reinforcing material is selectively joined with the skin layer at a bonded
area by welding, the bonded area having an externally exposed surface that defines
a portion of the external surface of the upper; and
wherein the skin layer has a first color and the externally exposed surface of the
bonded area has a second color that is different from the first color.
Item 10. The article of footwear of item 9, wherein the bonded area includes lines
of bonded material extending between components of the article of footwear.
Item 11. The article of footwear of item 10, wherein the lines of bonded material
extend from the sole structure to a reinforcing strip proximate to an instep region
of the article of footwear.
Item 12. The article of footwear of item 9, wherein the article of footwear includes
an additional layer of material located between a portion of the skin layer and a
portion of the reinforcing material.
Item 13. The article of footwear of item 12, wherein the additional layer of material
includes a compressible foam material.
Item 14. The article of footwear of item 9, wherein a surface area of the unreinforced
portions of the skin layer form a substantial majority of a surface area of an externally
exposed surface of the skin layer; and
wherein, in the unreinforced portions of the skin layer, the upper consists essentially
of the skin layer.
Item 15. An article of footwear including a sole structure fixedly attached to an
upper configured to receive a foot of a wearer, the upper comprising:
a skin layer forming at least a portion of an external surface of the upper; and
a reinforcing material selectively located internal and adjacent to portions of the
skin layer, thereby defining reinforced portions of the skin layer and unreinforced
portions of the skin layer;
wherein the reinforcing material is selectively joined with the skin layer at a bonded
area by welding, the bonded area having an externally exposed surface that defines
a portion of the external surface of the upper;
wherein the skin layer has a first color and the reinforcing material has a second
color that is different from the first color; and
wherein the externally exposed surface of the bonded area includes portions of the
reinforcing material, thus providing the externally exposed surface of the bonded
area with substantially the same color as the reinforcing material.
Item 16. The article of footwear of item 15, wherein the bonded area includes lines
of bonded material extending between components of the article of footwear.
Item 17. The article of footwear of item 16, wherein the lines of bonded material
extend from the sole structure to a reinforcing strip proximate to an instep region
of the article of footwear.
Item 18. The article of footwear of item 15, wherein the article of footwear includes
an additional layer of material located between a portion of the skin layer and a
portion of the reinforcing material.
19. The article of footwear of item 18, wherein the additional layer of material includes
a compressible foam material.
Item 20. The article of footwear of item 19, wherein the additional layer of material
is provided in a tongue portion of the upper.
Item 21. The article of footwear of item 19, wherein the additional layer of compressible
foam material is provided in a pocket between the skin layer and the reinforcing material
and enclosed by the bonded area.
Item 22. A method of making an article of footwear, including forming an upper configured
to receive a foot of a wearer, comprising:
selectively attaching an inner reinforcing material to a skin layer using welding;
and
arranging the skin layer to form at least a portion of an external surface of the
upper;
wherein the skin layer has a first color and the reinforcing material has a second
color that is different from the first color; and
wherein welding the inner reinforcing material to the skin layer forms a bonded area
having an externally exposed surface that defines a portion of the external surface
of the upper, the externally exposed surface of the bonded area including portions
of the reinforcing material, thus providing the externally exposed surface of the
bonded area with a different color than the skin layer.
Item 23. The method of item 22, wherein welding the inner reinforcing material to
the skin layer to form the bonded area relocates portions of the reinforcing material
to the external surface of the upper at the externally exposed surface of the bonded
area, thereby providing the externally exposed surface of the bonded area with substantially
the same color as the reinforcing material.
Item 24. The method of item 23, wherein the skin layer is formed of a mesh material.
Item 25. The method of item 24, wherein relocating portions of the reinforcing material
to the external surface of the upper includes pressing the portions of the reinforcing
material through openings in the mesh material.
Item 26. The method of item 24, wherein selectively attaching the inner reinforcing
material to the skin layer forms unreinforced portions of the skin layer that provide
direct ventilation, through the mesh material of the skin layer, to an internal void
defined by the upper.
Item 27. The method of item 22, wherein welding the inner reinforcing material to
the skin layer to form the bonded area includes forming lines of bonded material extending
between components of the article of footwear.
Item 28. The method of item 27, further including fixedly attaching a sole structure
to the upper;
wherein forming lines of bonded material includes forming lines of bonded material
extending from a sole structure of the article of footwear to a reinforcing strip
proximate to an instep region of the article of footwear.
Item 29. The method of item 22, wherein welding the inner reinforcing material to
the skin layer includes one of ultrasonic welding and radio frequency welding.