The present invention relates to articles of footwear, and in particular, a mechanical lock sole structure for a braided article of footwear.
Traditional shoes are often made from textiles or materials that have uppers that are cut to a desired shape and stitched together. Newer methods also now include forming shoe uppers from a knitted textile. Still newer methods involve braiding a tubular textile for use as the shoe upper. Aspects herein relate to braiding tubular structures that in some aspects are used in articles of footwear.
An article of braided footwear having a mechanical lock sole structure and a braided upper is provided. Some aspects generally include a braided upper and an integrated sole structure that mechanically engages at least a portion of the braided upper, such as a locking midsole having a bottom surface keyed with surface features that interact with a shoe bottom and/or shoe side surface of the braided upper. The integrated midsole may engage at least a portion of the braided upper by extending through a plurality of mesh-like braided apertures of the braided upper and into contact with a ground surface, providing outsole functionality in addition to midsole support. Additionally, based on engaging a perimeter of each sole surface feature with a corresponding and surrounding braid aperture, in some aspects, an interlocked sole and braided upper may become stabilized into a secured/keyed position within the braided upper.
This Summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This Summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used as an aid in determining the scope of the claimed subject matter.
Illustrative aspects of the present invention are described in detail below with reference to the attached drawing figures, which are incorporated by reference herein and wherein:
The subject matter of the present invention is described with specificity herein to meet statutory requirements. However, the description itself is not intended to limit the scope of this patent.
Generally, articles of footwear have two major components, an upper that provides the enclosure for receiving the foot and a sole secured to the upper. The upper may be adjustable using laces, hook-and-loop fasteners, or other devices to secure the shoe to the foot. The upper may further be engineered to provide the appropriate type of protection to the foot and to maximize the wearer's comfort. A sole may comprise a midsole and an outsole. The outsole portion usually has primary contact with the ground and may be designed to absorb shock as the footwear contacts the ground or other surfaces.
In the aspects discussed herein, the article of footwear is in the form of different athletic shoes. However, in some other aspects, the provisions discussed herein for the braided article of footwear could be incorporated into various other kinds of footwear including, but not limited to, basketball shoes, hiking boots, soccer shoes, football shoes, sneakers, running shoes, cross-training shoes, and other types of footwear. Moreover, in some aspects, the provisions discussed herein for an article of footwear could be incorporated into various other kinds of non-sports related footwear, including, but not limited to slippers, sandals, high heeled footwear, loafers, as well as other kinds of footwear.
At a high level, aspects herein are directed to a braided article of footwear that comprises a flexible shoe sole that is secured to the braided upper. A braided upper is defined as a unitary braid structure manufactured using a braiding technique. Braiding is the process of interlacing or interweaving three or more yarns diagonally to a product axis in order to obtain a thicker, wider or stronger product or in order to cover (overbraid) some profile. Interlacing diagonally means that the yarns make an angle with the product axis, which can be between 1° and 89° but is usually in the range of 30°-80°. This angle is called the braiding angle. Braids can be linear products (ropes), hollow tubular shells or solid structures (one, two or three-dimensional textiles) with constant or variable cross-section, and of closed or open appearance.
As used herein, the yarns used for braiding may be formed of different materials having different properties. The properties that a particular yarn will impart to an area of a braided component partially depend upon the materials that form the yarn. Cotton, for example, provides a softer product, natural aesthetics, and biodegradability. Elastane and stretch polyester each provide substantial stretch and recovery, with stretch polyester also providing recyclability. Rayon provides high luster and moisture absorption. Wool also provides high moisture absorption, in addition to insulating properties and biodegradability. Nylon is a durable and abrasion-resistant material with relatively high strength. Polyester is a hydrophobic material that also provides relatively high durability. In addition to materials, other aspects of the yarn selected for formation of a braided component may affect the properties of the braided component. For example, a yarn may be a monofilament or a multifilament. The yarn may also include separate filaments that are each formed of different materials. In addition, the yarn may include filaments that are each formed of two or more different materials, such as a bicomponent yarn with filaments having a sheath-core configuration or two halves formed of different materials.
By using a braiding technique, the articles of footwear may be engineered with specific features tailored to a particular athletic or recreational activity and are characterized by close containment over the wearer's foot. Different regions of the braided upper may have different braided configurations. For example, higher braid densities may be used in specific areas of the footwear to provide additional structural support or compression. The different braid densities are incorporated with one another to form a seamless braided upper. The term braided density refers to the number and/or concentration of the particular yarn used in braiding the different regions and is measured by the number of yarn interlacings per unit area. Additionally, yarns of different material may be incorporated in different regions of the braided upper to provide specific properties to the footwear in those areas. For example, yarns made of material with a greater tensile strength may be used in sections of the footwear that undergo higher stress during a specific activity. Softer and more pliable yarns may be used in sections of the footwear that are not subject to high stress, to provide a more comfortable and closely-fitting upper in those sections. Further, the different braid densities may vary in structural properties such as the number of yarns in the braid, the diameter of one or more yarns of the braid, the density of the yarns, and the material properties of the yarns such as elasticity, rigidity, tensile strength, compressibility, and other material properties.
The braided upper formed using a braiding technique is secured to the sole structure which extends between the foot and the ground when the article is worn. In different aspects, the sole structure may include different components. For example, a sole structure may include a midsole only or a midsole and an outsole. Sole structures may also provide one or more functions for the article. For example, a sole structure may be configured to provide traction for an article when worn. Additionally, the midsole may include a polymer foam material that attenuates ground reaction forces when compressed between the foot and the ground during walking, running, or other ambulatory activities. The midsole may also be made of relatively soft material to provide cushioning. The outsole is generally made of harder, more abrasion resistant material such as rubber or EVA. The outsole is secured to a lower surface of the midsole and provides a ground-engaging portion of the sole structure formed from a durable and wear-resistant material, such as rubber.
The figures depict articles of footwear with braided uppers comprising a braided tubular structure with a plurality of apertures on the bottom surface of the braided upper. The braided upper extends beneath the foot of the wearer, thereby providing 360-degree containment around the bottom of the foot. The midsole comprises a plurality of protruding studs that are keyed to receive the plurality of apertures of the braided upper. In other words, the plurality of apertures of the braided upper and the plurality of protruding studs are configured so that the plurality of protruding studs fit through the plurality of apertures and extend below the bottom surface of the plurality of apertures of the braided upper. When the plurality of studs of the midsole receive the plurality of apertures of the braided upper, at least one of the plurality of apertures encircles the plurality of protruding studs to provide 360-degree containment. Additionally, each of the plurality of studs comprises at least one ground-contact outer surface that extends below the bottom surface of the braided upper. The at least one ground-contact outer surface comprises a non-compressible material that maintains a primary configuration upon ground contact. Further, the plurality of protruding studs of the midsole may comprise all or a portion of the midsole.
In some aspects, a mechanical lock sole structure may include an interlocking midsole having one or more surface features keyed to a sole portion of a braided upper. For example, a midsole may include multiple protruding studs along a bottom surface of the midsole. In further aspects, the midsole material may include various materials that provide cushioning, such as polyurethane foam, compression-molded EVA, leather or polyurethane.
In one aspect, a uniform size, spacing, height, and/or dimension may be associated with the plurality of protruding studs on the midsole. In other aspects, the plurality of protruding studs may vary in size, spacing, height, dimension, location, and/or configuration on the midsole depending on the type of footwear. For example, in certain athletic shoes, the plurality of protruding studs may be located in a specific pattern to aid in directional movement when worn and may consist of one or more shapes. The plurality of apertures in the braided upper structure are keyed to mate to the plurality of protruding studs and may correspond to the circumference of a particular protruding stud. For example, a hexagonal protruding stud extending from a bottom surface of the midsole may correspond to a hexagonal aperture in the braid structure.
In one aspect, the midsole may be pre-molded with the plurality of protruding studs prior to being received by the plurality of apertures of the braided upper. In other aspects, the midsole compromises a co-molded midsole associated with the braided upper during the three dimensional assembly processes, wherein the co-molded midsole comprises a flexible joining with the braided upper. In yet another aspect, the braided article of footwear comprises a sprayed outsole. The sprayed outsole comprises a spray component which is applied to both the plurality of studs extending below the bottom surface of the braided upper and the bottom surface of the braided upper. In this aspect, the outsole is sprayed onto the plurality of studs and the bottom surface of the braided upper after the outsole and bottom surface of the braided upper are “locked” together. The spray component applied may, for example, comprise a sprayed polyurethane, which provides an additional covering to the article of footwear and strengthens the flexible joining of the midsole and braided upper.
In yet another aspect, the braided upper comprises a tubular braided structure and a plurality of apertures and the midsole comprises a planar surface comprising a plurality of braid-receiving features that mate to the plurality of apertures. The braided upper and midsole are secured together based on the plurality of apertures coupling to the plurality of braid receiving features. In some aspects, an outsole may also be coupled to the braided upper and midsole.
In yet another aspect, the braided article of footwear comprises a braided upper and a midsole. The braided upper comprises a tubular braided structure and a plurality of apertures. The plurality of apertures are keyed to surround the plurality of protruding studs of a midsole when secured together to provide 360-degree containment of the protruding studs.
As stated above, braided structures can be formed as tubular braids on a braiding machine, such as a radial, axial or lace braiding machine. One example of a lace braiding machine can be found in Ichikawa, EP 1 486 601, granted May 9, 2007, entitled “Torchon Lace Machine” and EP No. 2 657 384, published Oct. 30, 2013 entitled “Torchon Lace Machine,” the entirety of which are hereby incorporated by reference. The upper portion of an exemplary braiding machine 10 is shown in
As best seen in
In some aspects, the size of braiding machine 10 may be varied. It should be understood that the braiding machine 10 shown and described is for illustrative purposes only. In some aspects, braiding machine 10 may be able to accept 144 carriages, although other sizes of braiding machines, carrying different numbers of carriages and spools is possible and is within the scope of this disclosure. By varying the number of carriages and spools within a braiding machine, the density of the braided structure as well as the size of the braided component may be altered.
Turning now to
The protruding studs 102 extend a particular distance 103 below the midsole 100 depending on the location of the stud, shape of the stud, and type of article of footwear. In some aspects, each protruding stud 102 has at least one ground-contact outer surface 132. It is also contemplated that the protruding studs 102 may cover all or a portion of the bottom surface 101 of the midsole 100. In
The tubular braided structure 114 is a unitary braided structure when formed as a one-piece element through a braiding process, which forms the various features and structures of the braided component without the need for significant additional manufacturing steps or processes. The density and composition of the braiding of the braided upper 104 may vary from the top portion 120 of the braided upper 104 to the bottom surface 118 of the braided upper 104, resulting in zonal braiding where the density of the braid changes in different areas of the braided upper or from zone-to-zone. The braided upper 104 depicted in
From the foregoing, it will be seen that this invention is one well adapted to attain all the ends and objects hereinabove set forth together with other advantages that are obvious and are inherent to the structure. It will be understood that certain features and subcombinations are of utility and may be employed without reference to other features and subcombinations. This is contemplated by and is within the scope of the claims.
While specific elements are discussed in connection to one another, it is understood that any element provided herein is contemplated as being combinable with any other elements regardless of explicit provision of the same while still being within the scope provided herein. Since many possible aspects may be made of the disclosure without departing from the scope thereof, it is to be understood that all matter herein set forth or shown in the accompanying drawings is to be interpreted as illustrative and not in a limiting sense.
This application, having U.S. Non Provisional Application No. 15/933,105, filed on May 30, 2018 and entitled “Mechanical Lock Sole Structure For Braided Footwear,” claims priority to U.S. Provisional Patent Application No. 62/512,557, filed May 30, 2017, and entitled “Mechanical Lock Sole Structure For Braided Footwear,” the entirety of which is incorporated herein by reference.
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