Patent Application
20190110557
The described embodiments generally relate to articles of footwear having an upper including a leno woven fabric. More specifically, the described embodiments relate to articles of footwear having a leno woven upper with a bladder component.
Individuals are often concerned with the comfort and fit of an article of footwear. An upper of the article of footwear may function to secure the article of footwear to the wearer's foot. Characteristics of the upper, such as durability, weight, and breathability, may contribute to the comfort and fit of the footwear. Because these and other desired upper characteristics may conflict with each other, a continuing need exists for innovations in footwear, including in the fabrics and other components used to manufacture an upper.
Articles of footwear with a leno woven upper and a bladder component are disclosed. In some embodiments, an article of footwear includes a sole, an upper including a leno woven fabric having a continuous leno weave pattern of a plurality of warp yarns extending in a longitudinal direction and a plurality of weft yarns extending in a transverse direction, and an inflatable bladder disposed on the upper. In some embodiments, the weft yarns include an elastic material.
In some embodiments, the weft yarns include spandex. In some embodiments, the weft yarns include spandex with polyester.
In some embodiments, a weft yarn extends from the sole on a lateral side of the article of footwear to the sole on a medial side of the article of footwear. In some embodiments, a warp yarn extends from the sole to a collar of the upper. In some embodiments, a warp yarn extends from the sole to a heel counter of the upper.
In some embodiments, the inflatable bladder is disposed on an exterior surface of the upper. In some embodiments, the inflatable bladder extends from a heel region on a lateral side of the article of footwear across a throat of the article of footwear to a heel region on a medial side of the article of footwear.
In some embodiments, an upper for an article of footwear includes a leno woven fabric including a continuous leno weave pattern and an inflatable bladder disposed only on the leno woven fabric. In some embodiments, the leno woven fabric extends across the entire length of the upper. In some embodiments, the leno woven fabric extends across the entire width of the upper.
In some embodiments, the inflatable bladder is disposed on an outside of the leno woven fabric. In some embodiments, the inflatable bladder is disposed on an underside of the leno woven fabric.
In some embodiments, the leno woven fabric includes a single layer that forms a portion of an exterior surface of the upper and a portion of an interior surface of the upper. In some embodiments, the leno woven fabric includes an outermost layer of the upper and an innermost layer of the upper.
In some embodiments, the inflatable bladder is adhered to the leno woven fabric with an adhesive. In some embodiments, the adhesive is a hot melt adhesive.
In some embodiments, an article of footwear includes a sole, an upper including a leno woven fabric having a continuous leno weave pattern, and an inflatable bladder disposed only on the leno woven fabric. In some embodiments, the leno woven fabric includes an outermost layer of the upper and an innermost layer of the upper. In some embodiments, the leno woven fabric includes an elastic material.
The accompanying drawings, which are incorporated herein and form a part of the specification, illustrate the present invention and, together with the description, further serve to explain the principles of the invention and to enable a person skilled in the pertinent art to make and use the invention.
The present invention will now be described in detail with reference to embodiments thereof as illustrated in the accompanying drawings, in which like reference numerals are used to indicate identical or functionally similar elements. References to “one embodiment”, “an embodiment”, “an example embodiment”, etc., indicate that the embodiment described may include a particular feature, structure, or characteristic, but every embodiment may not necessarily include the particular feature, structure, or characteristic. Moreover, such phrases are not necessarily referring to the same embodiment. Further, when a particular feature, structure, or characteristic is described in connection with an embodiment, it is submitted that it is within the knowledge of one skilled in the art to affect such feature, structure, or characteristic in connection with other embodiments whether or not explicitly described.
The term “invention” or “present invention” as used herein is a non-limiting term and is not intended to refer to any single embodiment of the particular invention but encompasses all possible embodiments as described in the application.
The following examples are illustrative, but not limiting, of the present invention. Other suitable modifications and adaptations of the variety of conditions and parameters normally encountered in the field, and which would be apparent to those skilled in the art, are within the spirit and scope of the invention.
An article of footwear has many purposes. Among other things, an article of footwear may serve to provide cushioning for a wearer's foot, support a wearer's foot, and protect a wearer's foot. Each of these purposes, alone or in combination, provides for a comfortable article of footwear suitable for use in a variety of scenarios (e.g., exercise and every day activities). The features of an article of footwear (e.g., shape and materials used to make footwear) may be altered to produce desired characteristics, for example, comfort and fit.
Embodiments of the present invention provide articles of footwear having a highly breathable upper comprising a fabric with a leno weave (i.e., a leno woven fabric) and a component, such as an inflatable bladder, that together provide a comfortable and secure fit around the wearer's foot. In some embodiments, the leno woven fabric may form the entire (or substantially the entire) exterior and/or interior surface of the upper. In some embodiments, the upper may comprise a single layer leno woven fabric. In some embodiments, an inflatable bladder component is coupled to the leno woven fabric. The leno woven fabric and the inflatable bladder may be configured to provide desired characteristics of the upper. For example, a leno weave construction facilitates breathability of the upper while maintaining structural integrity by the weaving of weft yarns and warp yarns in the leno weave. At the same time, the inflatable bladder, when inflated, may operate to provide additional cushioning to the wearer's foot and/or to cinch down the upper to ensure the wearer's foot is securely fitted within the upper. In some embodiments, the leno woven fabric may be constructed to further facilitate the effect of the inflatable bladder. For example, the weft yarns and/or the warp yarns may be elastic to allow portions of the upper to stretch as the bladder is inflated. In some embodiments, the amount of stretch can control the amount of movement of the inflatable bladder in certain directions. In some embodiments, the amount of stretch may hold the inflatable bladder closer to the wearer's foot.
In some embodiments, an article of footwear 100, as shown, for example, in
All or a portion of upper 120 may comprise leno woven fabric 130. In some embodiments, leno weave fabric 130 comprises a continuous leno weave pattern. In some embodiments, leno woven fabric 130 extends from the foremost part of upper 120 to the rearmost part of upper 120. Thus, leno woven fabric 130 may extend across the entire length of upper 120. In some embodiments, leno woven fabric 130 extends from sole 110 on a medial side 106 of article of footwear 100 to sole 110 on a lateral side 108 of article of footwear 100. Thus, leno woven fabric 130 may extend across the entire width of upper 120.
In some embodiments, leno woven fabric 130 may define at least 50% of upper 120. In embodiments including a single layer leno woven fabric 130, single layer woven fabric 130 may completely define at least 50% of upper 120. In other words, at least 50% of the composition of upper 120 may be defined by single layer leno woven fabric 130. In some embodiments, leno woven fabric 130 may occupy at least 50% of the outer surface area of upper 120.
In some embodiments, leno woven fabric 130 forms an outer surface 132 of upper 120. In some embodiments, leno woven fabric 130 forms the entire outer surface 132 of upper 120. In some embodiments, leno woven fabric 130 forms an inner surface 134 of upper 120. In some embodiments, leno woven fabric 130 forms the entire inner surface 134 of upper 120. In some embodiments, leno woven fabric 130 comprises an outermost layer of upper 120 and an innermost layer of upper 120. In some embodiments, leno woven fabric 130 is a single layer woven fabric. In some embodiments, leno woven fabric 130 comprises a single layer that forms all or a portion of an exterior surface of upper 120 (e.g., outer surface 132) and all or a portion of an interior surface of upper 120 (e.g., inner surface 134). In some embodiments, leno woven fabric 130 includes more than one layer.
In some embodiments, leno woven fabric 130 comprises a plurality of warp yarns 138 extending in a longitudinal direction 10 and a plurality of weft yarns 136 extending in a transverse direction 12 substantially perpendicular to warp yarns 138. As shown in
In some embodiments, one or more of weft yarns 136 extend across the entire width of upper 120. In some embodiments, one or more of weft yarns 136 extend from sole 110 on medial side 106 of article of footwear 100 to sole 110 on lateral side 108 of article of footwear 100. In some embodiments, one or more of weft yarns 136 extend from sole 110 on medial side 106 of article of footwear 100 to collar 124. In some embodiments, one or more of weft yarns 136 extend from sole 110 on lateral side 108 of article of footwear 100 to collar 124.
In some embodiments, one or more warp yarns 138 extend across the entire length of upper 120. In some embodiments, one or more of warp yarns 138 extend from sole 110 to collar 124 in longitudinal direction 10. In some embodiments, one or more of warp yarns 138 extend from sole 110 to heel counter 122 in longitudinal direction 10. In some embodiments, one or more of warp yarns 138 extend from the foremost part of upper 120 to collar 124 (e.g., along a throat region 104 of upper 120). Thus, in some embodiments, leno woven fabric 130 may have a continuous leno weave pattern of weft yarns 136 and warp yarns 138.
In some embodiments, leno woven fabric 130 comprises a stretch leno weave (i.e., a leno woven fabric that has stretch characteristics). In some embodiments, leno woven fabric 130 comprises a two-way stretch material. In some embodiments, leno woven fabric 130 provides a desired stretchability because of the weaving pattern. In some embodiments, leno woven fabric 130 provides a desired stretchability because of the material of weft yarns 136 and/or warp yarns 138. In some embodiments, leno woven fabric 130 provides a desired stretchability because of a combination of the weaving pattern and the material of weft yarns 136 and/or warp yarns 138. In some embodiments, weft yarns 136 comprise an elastic material. In some embodiments, weft yarns 136 comprise spandex. In some embodiments, weft yarns 136 comprise polyester. In some embodiments, weft yarns 136 comprise spandex with polyester. In some embodiments, weft yarns 136 comprise a thermoplastic elastomer. In some embodiments, weft yarns 136 comprise a material that provides little to no stretch.
The weaving of warp yarns 138 in leno woven fabric 130 may form a plurality of twists 137 and a plurality of eyelets 139, as shown, for example, in
For example, various leno woven fabrics 200, 210, 220, 230, 240, 250, 260, 270, 280, and 290 with different patterns are shown in
In some embodiments, leno woven fabric 200 comprises an engineered jacquard leno weave, as shown, for example, in
In some embodiments, leno woven fabric 210 comprises a custom jacquard leno weave, as shown, for example, in
In some embodiments, a leno woven fabric (e.g., leno woven fabrics 220, 230, 240, and 250) comprise a repeat jacquard leno weave, as shown, for example, in
In some embodiments, leno woven fabric 260 comprises a custom leno weave, as shown, for example, in
In some embodiments, a leno woven fabric (e.g., leno woven fabrics 270, 280, and 290) comprise a repeat leno weave, as shown, for example, in
In some embodiments, inflatable bladder 140 is disposed on upper 120. In some embodiments, inflatable bladder 140 is disposed only on leno woven fabric 130 (i.e., rather than being disposed on other components, such as heel counter 122). In some embodiments, inflatable bladder 140 is disposed both on leno woven fabric 130 and other components, such as heel counter 122. In some embodiments, inflatable bladder 140 is coupled to leno woven fabric 130, as shown, for example, in
Inflatable bladder 140 may be coupled to any portion of leno woven fabric 130. In some embodiments, inflatable bladder 140 extends from heel region 102 on lateral side 108 of article of footwear 100 across the throat 104 of article of footwear to heel region 102 on medial side 106 of article of footwear 100, as shown, for example, in
In some embodiments, inflatable bladder 140 comprises an inflation mechanism 142. In some embodiments, inflation mechanism 142 comprises an on-board pump. Other types of inflation mechanisms may also be used. In some embodiments, inflatable bladder 140 comprises a deflation mechanism (e.g., deflation mechanisms 344 and 444 shown in
In some embodiments, inflatable bladder 140 is disposed on an outside of leno woven fabric 130 (i.e., outer surface 132 of upper 120). In some embodiments, inflatable bladder is disposed on an underside of leno woven fabric 130 (i.e., inner surface 134 of upper 120). In some embodiments, the outside of leno woven fabric 130 is opposite the underside of leno woven fabric 130. In some embodiments, the outside of leno woven fabric 130 is the outermost surface of upper 120. In some embodiments, the underside of leno woven fabric is the innermost surface of upper 120. In some embodiments, inflatable bladder 140 is disposed only on leno woven fabric 130. In some embodiments, inflatable bladder 140 is attached to leno woven fabric 130 by stitching, adhesive, bonding, heat sealing, or other suitable fastening means. For example, as shown in
Any suitable type or shape of bladder suitable for footwear may be utilized within the scope of the present invention as inflatable bladder 140. In some embodiments, inflatable bladder 140 is a printed bladder as is described in commonly owned U.S. Pat. No. 8,572,786, entitled “Method for Manufacturing Inflatable Bladders for Use in Footwear and Other Articles of Manufacture,” the disclosure of which is incorporated herein by reference thereto.
For example, according to some embodiments, inflatable bladder 140, as illustrated in
According to some embodiments, release agent 145 is disposed on first film 141. Alternatively, release agent 145 may be disposed on both first film 141 and second film 146. First film 141 and second film 146 may be identical or different materials; but they must be each made from a material that may be adhered together to form a fluid-tight seal. Films can be formed from a variety of polymers such as thermoplastic resins, other elastomeric materials, thermoset materials, and composites thereof, including but not limited to, thermoplastic polyurethane (TPU), ethylenevinylacetate/polyethylene copolymer, polyester elastomer (e.g. Hytrel® material available from DuPont), polyethylene, polypropylene, neoprene, natural rubber, dacron/polyester, polyvinylchloride, thermoplastic rubbers, nitrile rubber, butyl rubber, sulfide rubber, methyl rubber, silicone rubber, polyvinyl acetate, Buna-N, Buna-S, polystyrene, ethylene propylene, polybutadiene, chlorfulfonated polythylene, nylon, partially set thermoset materials, ethylene vinyl acetate (EVA) foam, thermoset rubber, prepreg, and others.
Release agent 145 can be formed from a variety of materials, such as paint, ink, paper, textile, particulate, photosensitive agent, TEFLON®, silicone, plastic, acid, or any other material suitable for preventing first film 141 and second film 146 from adhering to each other where the release agent 145 has been disposed. In some embodiments, release agent 145 is cured to first film 141. For example, release agent 145 may be cured to first film 141 by the application of ultraviolet light. In some embodiments, release agent 145 may be silicone fortified.
After release agent 145 is applied to, disposed on, and/or cured to first film 141, first film 141 and second film 146 are bonded together by the application of heat and/or pressure. However, where release agent 145 is disposed between first film 141 and second film 146, there exists an inflatable compartment 143 with a peripheral edge 148. In some embodiments, this method may be used to create multiple inflatable compartments 143.
In other embodiments, alternative methods of creating inflatable bladder 140 may be used. In some embodiments, an additional layer 147 may be disposed on an outer surface of bladder 140. In some embodiments, additional layer 147 comprises a coating (e.g., a polyurethane coating).
The size, shape, and pattern of inflatable bladders may vary from shoe to shoe to accommodate various needs and preferences. For example, in some embodiments, an inflatable bladder 340 may be used, as shown, for example, in
As an additional example, in some embodiments, inflatable bladder 440 may be used, as shown, for example, in
A method 500 for making an upper (e.g., upper 120) is shown, for example, in
In some embodiments, at operation 520, an inflatable bladder (e.g., inflatable bladder 140) is attached to an outside surface of the leno woven upper. In some embodiments, the inflatable bladder is attached to the outside surface of the leno woven upper by adhering the inflatable bladder with a hot melt adhesive to the outside surface of the leno woven upper. In some embodiments, the leno woven upper may be pre-shrunk. In some embodiments, pre-shrinking the leno woven upper results in a more consistent final shape of the leno woven upper. In some embodiments, the leno woven upper is pre-shrunk before a hot melt adhesive is applied.
In some embodiments, at operation 530, an adhesive is applied to the leno woven upper. In some embodiments, the adhesive is applied to an inside surface of the leno woven upper.
Various embodiments described herein allow for articles of footwear that provide a comfortable and secure fit around the wearer's foot. Further variations of the embodiments described above may also be provided. For example, the location and shape of inflatable bladders is not limited to the inflatable bladders shown in
The foregoing description of the specific embodiments will so fully reveal the general nature of the invention that others can, by applying knowledge within the skill of the art, readily modify and/or adapt for various applications such specific embodiments, without undue experimentation, without departing from the general concept of the present invention. Therefore, such adaptations and modifications are intended to be within the meaning and range of equivalents of the disclosed embodiments, based on the teaching and guidance presented herein. It is to be understood that the phraseology or terminology herein is for the purpose of description and not of limitation, such that the terminology or phraseology of the present specification is to be interpreted by the skilled artisan in light of the teachings and guidance.
The breadth and scope of the present invention should not be limited by any of the above-described exemplary embodiments, but should be defined only in accordance with the following claims and their equivalents.
