Patent Application
20170035149
The present embodiments relate generally to braiding machines and articles of footwear made using braiding machines. Braiding machines are used to form braided textiles and to over-braid composite parts.
Braiding machines may form structures with various kinds of braiding patterns. Braided patterns are formed by intertwining three or more tensile strands (e.g., thread). The strands may be generally tensioned along the braiding direction.
In one aspect, an upper assembly for an article of footwear, includes an outer braided structure and an inner braided structure. The outer braided structure includes a first portion having a jacquard braid pattern. The inner braided structure includes a second portion having a non-jacquard braid pattern.
In another aspect, article of footwear includes an upper assembly further comprised of an outer braided structure and an inner braided structure. The article also includes a sole structure. The outer braided structure has a first opening and the inner braided structure has a second opening. A collar portion of the inner braided structure extends through the first opening of the outer braided structure and wherein the second opening of the inner braided structure is configured to receive a foot. The outer braided structure includes a first portion having a jacquard braid pattern. The sole structure is disposed against the outer braided structure.
A method of making an upper assembly for an article of footwear includes moving a last and a braid point of a braiding machine relative to on another, where the braiding machine includes at least a first ring of spools and a second ring of spools, the second ring of spools being disposed concentrically within the first ring of spools on a surface of the braiding machine. The method also includes moving one or more spools along the second ring of spools to form an inner braided structure around an outer surface of the last. The method also includes moving one or more spools along the first ring of spools to form an outer braided structure around the inner braided structure, thereby forming the upper assembly comprised of the inner braided structure and the outer braided structure.
Other systems, methods, features and advantages of the embodiments will be, or will become, apparent to one of ordinary skill in the art upon examination of the following figures and detailed description. It is intended that all such additional systems, methods, features and advantages be included within this description and this summary, be within the scope of the embodiments, and be protected by the following claims.
The embodiments 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 embodiments. Moreover, in the figures, like reference numerals designate corresponding parts throughout the different views.
The detailed description and the claims may make reference to various kinds of tensile elements, braided structures, braided configurations, braided patterns, and braiding machines.
As used herein, the term “tensile element” refers to any kinds of threads, yarns, strings, filaments, fibers, wires, cables as well as possibly other kinds of tensile elements described below or known in the art. As used herein, tensile elements may describe generally elongated materials with lengths much greater than their corresponding diameters. In some embodiments, tensile elements may be approximately one-dimensional elements. In some other embodiments, tensile elements may be approximately two-dimensional (e.g., with thicknesses much less than their lengths and widths). Tensile elements may be joined to form braided structures. A “braided structure” may be any structure formed by intertwining three or more tensile elements together. Braided structures could take the form of braided cords, ropes, or strands. Alternatively, braided structures may be configured as two-dimensional structures (e.g., flat braids) or three-dimensional structures (e.g., braided tubes) such as with lengths and width (or diameter) significantly greater than their thicknesses.
A braided structure may be formed in a variety of different configurations. Examples of braided configurations include, but are not limited to, the braiding density of the braided structure, the braid tension(s), the geometry of the structure (e.g., formed as a tube, an article, etc.), the properties of individual tensile elements (e.g., materials, cross-sectional geometry, elasticity, tensile strength, etc.) as well as other features of the braided structure. One specific feature of a braided configuration may be the braid geometry, or braid pattern, formed throughout the entirety of the braided configuration or within one or more regions of the braided structure. As used herein, the term “braid pattern” refers to the local arrangement of tensile strands in a region of the braided structure. Braid patterns can vary widely and may differ in one or more of the following characteristics: the orientations of one or more groups of tensile elements (or strands), the geometry of spaces or openings formed between braided tensile elements, the crossing patterns between various strands as well as possibly other characteristics. Some braided patterns include lace-braided or jacquard patterns, such as Chantilly, Bucks Point, and Torchon. Other patterns include biaxial diamond braids, biaxial regular braids, as well as various kinds of triaxial braids.
Braided structures may be formed using braiding machines. As used herein, a “braiding machine” is any machine capable of automatically intertwining three or more tensile elements to form a braided structure. Braiding machines may generally include spools, or bobbins, that are moved or passed along various paths on the machine. As the spools are passed around, tensile strands extending from the spools toward a center of the machine may converge at a “braiding point” or braiding area. Braiding machines may be characterized according to various features including spool control and spool orientation. In some braiding machines, spools may be independently controlled so that each spool can travel on a variable path throughout the braiding process, hereafter referred to as “independent spool control.” Other braiding machines, however, may lack independent spool control, so that each spool is constrained to travel along a fixed path around the machine. Additionally, in some braiding machines, the central axes of each spool point in a common direction so that the spool axes are all parallel, hereby referred to as an “axial configuration.” In other braiding machines, the central axis of each spool is oriented toward the braiding point (e.g., radially inward from the perimeter of the machine toward the braiding point), hereby referred to as a “radial configuration.”
One type of braiding machine that may be utilized is a radial braiding machine or radial braider. A radial braiding machine may lack independent spool control and may therefore be configured with spools that pass in fixed paths around the perimeter of the machine. In some cases, a radial braiding machine may include spools arranged in a radial configuration. For purposes of clarity, the detailed description and the claims may use the term “radial braiding machine” to refer to any braiding machine that lacks independent spool control. The present embodiments could make use of any of the machines, devices, components, parts, mechanisms, and/or processes related to a radial braiding machine as disclosed in Dow et al., U.S. Pat. No. 7,908,956, issued March 22, 2011, and titled “Machine for Alternating Tubular and Flat Braid Sections,” and as disclosed in Richardson, U.S. Pat. No. 5,257,571, issued Nov. 2, 1993, and titled “Maypole Braider Having a Three Under and Three Over Braiding path,” with each application being herein incorporated by reference in its entirety. These applications may be hereafter referred to as the “Radial Braiding Machine” applications.
Another type of braiding machine that may be utilized is a lace braiding machine, also known as a Jacquard or Torchon braiding machine. In a lace braiding machine, the spools may have independent spool control. Some lace braiding machines may also have axially arranged spools. The use of independent spool control may allow for the creation of braided structures, such as lace braids, that have an open and complex topology, and may include various kinds of stitches used in forming intricate braiding patterns. For purposes of clarity, the detailed description and the claims may use the term “lace braiding machine” to refer to any braiding machine that has independent spool control. The present embodiments could make use of any of the machines, devices, components, parts, mechanisms, and/or processes related to a lace braiding machine as disclosed in Ichikawa, EP Patent Number 1486601, published on Dec. 15, 2004, and titled “Torchon Lace Machine,” and as disclosed in Malhere, U.S. Patent Number 165,941, issued Jul. 27, 1875, and titled “Lace-Machine,” with each application being herein incorporated by reference in its entirety. These applications may be hereafter referred to as the “Lace Braiding Machine” applications.
Spools may move in different ways according to the operation of a braiding machine. In operation, spools that are moved along a constant path of a braiding machine may be said to undergo “Non-Jacquard motions,” while spools that move along variable paths of a braiding machine are said to undergo “Jacquard motions.” Thus, as used herein, a lace braiding machine provides means for moving spools in Jacquard motions, while a radial braiding machine can only move spools in Non-Jacquard motions.
The embodiments may also utilize any of the machines, devices, components, parts, mechanisms, and/or processes related to a braiding machine as disclosed in Lee, U.S. Patent Publication Number ______, published ______ (now U.S. patent application Ser. No. 14/721563, filed May 26, 2015), titled “Braiding Machine and Method of Forming an Article Incorporating Braiding Machine,” (Attorney Docket No. 51-4260), the entirety of which is herein incorporated by reference and hereafter referred to as the “Fixed Last Braiding” application. The embodiments may also utilize any of the machines, devices, components, parts, mechanisms, and/or processes related to a lace braiding machine as disclosed in Lee, U.S. Patent Publication Number ______, published ______ (now U.S. patent application Ser. No. 14/721614, filed May 26, 2015), titled “Method of Forming a Braided Component Incorporating a Moving Object,” (Attorney Docket No. 51-4506), the entirety of which is herein incorporated by reference and hereafter referred to as the “Moving Last Braiding” application. Embodiments may also utilize any of the machines, devices, components, parts, mechanisms, and/or processes related to a braiding machine as disclosed in Lee, U.S. Patent Publication Number ______ (also U.S. patent application Ser. No. ______, filed on the same date as the current application), titled “Braiding Machine with Multiple Rings of Spools” (Attorney Docket No. 51-4508), the entirety of which is herein incorporated by reference and hereafter referred to as the “Multi-Ring Braid Machine application”. Embodiments may also utilize any of the machines, devices, components, parts, mechanisms and/or processes related to a braiding machine or article formed using a braiding machine as disclosed in Bruce et al., U.S. Patent Publication Number ______, published (now U.S. patent application Ser. No. 14/721507, filed May 26, 2015), titled “Hybrid Braided Article” (Attorney Docket No. 51-4509), the entirety of which is herein incorporated by reference and hereafter referred to as the “Hybrid Braided Article application”.
In some embodiments, article 100 may be characterized by various directional adjectives and reference portions. These directions and reference portions may facilitate in describing the portions of an article of footwear. Moreover, these directions and reference portions may also be used in describing sub-components of an article of footwear, for example, directions and/or portions of a midsole structure, an outer sole structure, an upper or any other components).
For consistency and convenience, directional adjectives are employed throughout this detailed description corresponding to the illustrated embodiments. The term “longitudinal” as used throughout this detailed description and in the claims refers to a direction extending a length of a component (e.g., an upper or sole component). A longitudinal direction may extend along a longitudinal axis, which itself extends between a forefoot portion and a heel portion of the component. Also, the term “lateral” as used throughout this detailed description and in the claims refers to a direction extending along a width of a component. A lateral direction may extend along a lateral axis, which itself extends between a medial side and a lateral side of a component. Furthermore, the term “vertical” as used throughout this detailed description and in the claims refers to a direction extending along a vertical axis, which itself is generally perpendicular to a lateral axis and a longitudinal axis. For example, in cases where an article is planted flat on a ground surface, a vertical direction may extend from the ground surface upward. Additionally, the term “inner” refers to a portion of an article disposed closer to an interior of an article, or closer to a foot when the article is worn. Likewise, the term “outer” refers to a portion of an article disposed further from the interior of the article or from the foot. Thus, for example, the inner surface of a component is disposed closer to an interior of the article than the outer surface of the component. This detailed description makes use of these directional adjectives in describing an article and various components of the article, including an upper, a midsole structure and/or an outer sole structure.
As shown in
For purpose of reference, article 100 may be divided into forefoot portion 104, midfoot portion 106, and heel portion 108. Forefoot portion 104 may be generally associated with the toes and joints connecting the metatarsals with the phalanges. Midfoot portion 106 may be generally associated with the arch of a foot. Likewise, heel portion 108 may be generally associated with the heel of a foot, including the calcaneus bone. Article 100 may also include an ankle portion 110 (which may also be referred to as a cuff portion). In addition, article 100 may include lateral side 112 and medial side 116. In particular, lateral side 112 and medial side 116 may be opposing sides of article 100. In general, lateral side 112 may be associated with the outside parts of a foot while medial side 116 may be associated with the inside part of a foot. Furthermore, lateral side 112 and medial side 116 may extend through forefoot portion 104, midfoot portion 106, and heel portion 108.
It will be understood that forefoot portion 104, midfoot portion 106, and heel portion 108 are only intended for purposes of description and are not intended to demarcate precise regions of article 100. Likewise, lateral side 112 and medial side 116 are intended to represent generally two sides rather than precisely demarcating article 100 into two halves.
Upper assembly 102 may include an ankle opening that provides access to interior cavity 118. In some embodiments, each layer may include an opening for an ankle. As seen in
Some embodiments may not include a separate sole structure. For purposes of clarity, article 100 is shown without a sole structure. In some cases, for example, some or all portions of an outer braided structure could be configured to provide durability, strength, cushioning and/or traction along a lower surface of the article. In other embodiments, however, including the embodiment depicted in
Other embodiments of an article with a braided upper assembly could incorporate any other provisions associated with other kinds of articles. Such provisions could include, but are not limited to: laces, straps, cords and other kinds of fasteners, eyestays, eyelets, trim elements, pads, heel counters, heel cups, to guards, separate material panels, as well as any other provisions.
As seen in
In different embodiments, the dimensions of each braided structure could vary. In some cases, one or more dimensions of a braided structure could be at least partially controlled by the thickness of tensile strands used to make the braided structure. In some embodiments, an outer braided structure and an inner braided structure could have similar thicknesses. In other embodiments, an outer braided structure and an inner braided structure could have different thicknesses. In the embodiment shown in
Braided articles or braided structures can be formed with various kinds of braid patterns, as described above. The present embodiments may be characterized as having braid patterns than are “jacquard braid patterns” or “non-jacquard braid patterns”. Jacquard braid patterns and non-jacquard braid patterns may refer to distinct classes of braid patterns. Thus jacquard braid patterns may comprise a variety of different braid patterns that share common features, and non-jacquard braid patterns may comprise a variety of different braid patterns that share common features. One type of jacquard braid pattern may be a lace braid pattern. Another type of jacquard braid pattern may be a Torchon braid pattern, or Torchon lace braid pattern. In contrast, non-jacquard braid patterns may be associated with bi-axial, tri-axial, diamond, or other kinds of regular braid patterns. In some cases, a non-jacquard braid pattern may be referred to as a radial braid pattern, as non-jacquard braid patterns can be easily formed using a radial braiding machine. However, it may be appreciated that in some cases non-jacquard braid patterns can also be formed from machines that may not be radial braiding machines. Thus, it should be appreciated that the terms “jacquard braid pattern” and “non-jacquard braid pattern” refer to the configuration of a braided structure, and may be independent of the type of machine, or method, used to make the braided structure.
Generally, jacquard braid patterns and non-jacquard braid patterns may have different characteristics. For example, jacquard braid patterns may be characterized as more open, with spacing between adjacent tensile strands varying in a non-uniform manner. In contrast, non-jacquard braid patterns may generally be uniform. In some cases, non-jacquard braid patterns may be grid or lattice like. Jacquard and non-jacquard braid patterns can also be characterized by the presence or absence of ornamental designs. Specifically, jacquard braid patterns may feature one or more ornamental designs whereas non-jacquard braid patterns may lack such ornamental designs due to the nature in which they are formed (by moving spools around on a constant path of a braiding machine). Further, the density of tensile strands (e.g., the average number of strands in a given area) may be highly variable in a jacquard braid pattern and may change along multiple directions of the braided structure. In contrast, the density of tensile strands in a non-jacquard braid pattern may generally be constant, or change only along a single axial direction dictated by the method of forming a braided structure. Thus, while some non-jacquard braid patterns could have densities that vary along one axis of the structure, they may generally not vary in density along multiple different directions of the structure.
As shown in
As seen in
As seen in
In some embodiments, an outer braided structure and an inner braided structure could be attached. In some cases, an outer braided structure and an inner braided structure could be bonded together using an adhesive, for example. In one example (not shown), an outer braided structure and an inner braided structure could be fused along one or more locations of an article using a resin or polymer film. In some cases, an outer braided structure and an inner braided structure could be attached by one or more tensile strands that are integrated into both braided structures (e.g., by intertwining tensile strands from each structure with one another). In still other embodiments, an outer braided structure and an inner braided structure may be separated and not attached at any locations. An exemplary embodiment of separate braided structures is discussed below and shown in
By intertwining tensile strands from outer braided structure 120 and inner braided structure 140, the two braided structures may be attached in a permanent manner that allows them to behave as a compound braided structure. Moreover, providing the intertwining at multiple different locations throughout the upper assembly allows for uniform attachment throughout upper assembly. This may be in contrast to other embodiments where two braided layers may be attached, or even integrally formed, along a single section, such as the collar or toe of an upper. Of course, the braided structures need not be attached at all locations. In the embodiment of
As shown in
For purposes of clarity, the embodiments depict intertwining between two tensile strands, one from each of two different braided structures. Of course in other embodiments intertwining of three or more tensile strands could occur, including two or more tensile strands from one of the outer braided structure or the inner braided structure.
It is to be appreciated that engagement between strands of an outer braided structure and an inner braided structure could occur at any locations throughout an upper assembly. Likewise, the number of locations where the strands engage could vary. Thus, the number of strands engaged (e.g., intertwined) at a single location, as well as the number and locations of the engagements, could vary to achieve different degrees of attachment of an outer braided structure and an inner braided structure. For example, in some embodiments, the inner and outer braided structures may only be attached in regions where both structures have a non-jacquard braid pattern. In other embodiments, such as the embodiment shown in
In some embodiments, tensile strands from different braided structures may simply wrap around one another at various engagement locations, but each tensile strand may be associated with a particular structure and/or pattern throughout a majority of the article. In other embodiments, as shown in
In some embodiments, base portion 410 may comprise one or more walls 420 of material. In the exemplary embodiment of
In some embodiments, top portion 412 may comprise a top surface 430, which may further include a central surface portion 431 and a peripheral surface portion 432. In some embodiments, top portion 412 may also include a sidewall surface 434 that is proximate peripheral surface potion 432. In the exemplary embodiment, top portion 412 has an approximately circular geometry, though in other embodiments, top portion 412 could have any other shape. Moreover, in the exemplary embodiment, top portion 412 is seen to have an approximate diameter that is larger than a width of base portion 410, so that top portion 412 extends beyond base portion 410 in one or more horizontal directions.
In order to provide means for passing lasts, mandrels, or similar provisions through braiding machine 400, the embodiment includes at least one sidewall opening 460 in base portion 410. In the exemplary embodiment, sidewall opening 460 may be disposed on wall 421 of walls 420. Sidewall opening 460 may further provide access to a central cavity 462 within base portion 410.
Braiding machine 400 may include central fixture 414. In the exemplary embodiment, central fixture 414 includes one or more legs 440 and a central base 442. Central fixture 414 also includes a dome portion 444. In other embodiments, however, central fixture 414 could have any other geometry. As seen in
Components of the support structure could be comprised of any materials. Exemplary materials that could be used include any materials with metals or metal alloys including, but not limited to, steel, iron, steel alloys, and/or iron alloys.
Spool system 404 may be comprised of various components for passing or moving spools along the surface of braiding machine 400. In some embodiments, spool system 404 may include one or more spool-moving elements. As used herein, the term “spool-moving element” refers to any provision or component that may be used to move or pass a spool along a path on the surface of a braiding machine. Exemplary spool-moving elements include, but are not limited to, rotor metals, horn gears as well as possibly other kinds of gears or elements. The exemplary embodiments shown in the figures make use of both rotor metals and horn hears that rotate in place and facilitate passing carrier elements to which spools are mounted around in paths on the surface of the braiding machines.
In some embodiments, spool system 404 may include one or more rotor metals. Rotor metals may be used in moving spools along a track or path in a lace braiding machine, such as a Torchon braiding machine.
An exemplary rotor metal 510 is depicted in
Rotor metals may rotate about an axis extending through a central opening. For example, a rotor metal 523 is configured to rotate about an axis 520 that extends through central opening 522. In some embodiments, central opening 522 may receive an axle or fastener (not shown) about which rotor metal 523 may rotate. Moreover, the rotor metals are positioned such that gaps may be formed between concave sides. For example, a gap 526 is formed between the concave sides of rotor metal 523 and an adjacent rotor metal 525.
As an individual rotor metal rotates, the convex portions of the rotating rotor metal pass by the concave sides of adjacent rotor metals without interference. For example, rotor metal 527 is shown in a rotated position such that the convex sides of rotor metal 527 fit into the concave sides of rotor metal 528 and rotor metal 529. In this way, each rotor metal can rotate in place so long as the opposing rotor metals are stationary during that rotation, in order to prevent interference (e.g., contact) between the convex sides of two adjacent rotor metals.
Spool system 404 may also include one or more horn gears. Horn gears may be used in moving spools along a track or path in a radial braiding machine. An exemplary horn gear 530 is depicted in
Spool system 404 may include additional components, such as one or more carrier elements, which are configured to carry spools. One exemplary carrier element 550 is depicted in
Spool system 404 may include additional components for controlling the motion of one or more rotor metals and/or horn gears. For example, embodiments can include one or more gear assemblies that act to drive the rotor metals and/or horn gears. Exemplary gear assemblies for controlling the rotation of rotor metals are disclosed in the Lace Braiding Machine applications, while gear assemblies for controlling the rotation of horn gears are disclosed in the Radial Braid Machine applications. It will be understood that still other gear assemblies are possible and one skilled in the art may choose types of gears and a particular arrangement of gears to achieve desired rotation speeds or other desired features for the rotor metals and horn gears of spool system 404.
Spool system 404 may also include one or more spools, which may alternatively be referred to as “spindles,” “bobbins,” and/or “reels.” Each spool may be placed on a carrier element, thereby allowing the spool to be passed between adjacent rotor metals and/or horn gears. As seen in
As seen in
The tensile elements, such as thread, carried on spools of a braiding machine (e.g., braiding machine 400) may be formed of different materials. The properties that a particular type of thread will impart to an area of a braided component partially depend upon the materials that form the various filaments and fibers within the yarn. Cotton, for example, provides a soft hand, 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 thread selected for formation of a braided component may affect the properties of the braided component. For example, a thread may be a monofilament thread or a multifilament thread. The thread may also include separate filaments that are each formed of different materials. In addition, the thread may include filaments that are each formed of two or more different materials, such as a bi-component thread with filaments having a sheath-core configuration or two halves formed of different materials.
The components of spool system 404 may be organized into three rings, including an inner ring 470, an intermediate ring 480 and an outer ring 490 (see
As best seen in
It may be appreciated that rotor metals may generally not be visible in the isometric view of
Although each ring has a different diameter, the components of each ring may be arranged such that rotor metals of one ring are proximate horn gears of another ring. For example, in
It is contemplated that in some embodiments spools could be controlled in a manner to avoid collisions along any of the rings as spools are passed between rings. For example, in operating configurations where there are no open gaps or spaces between rotor metals on either the inner or outer ring, spool movement between rings may be coordinated to ensure that spools don't collide when arriving at the inner or outer ring. In some embodiments, for example, the motions of spools may be coordinated so that as a spool leaves the outer ring to transition to the inner ring, another spool in the inner ring transitions out of the inner ring to the intermediate ring, thereby opening a space for the spool transitioning from the outer ring to the inner ring. Thus, it may be appreciated that the spool motions between rings may be coordinated to ensure no collisions between spools occur at the outer ring, at the intermediate ring or at the inner ring.
It is also contemplated that in at least some embodiments, the horn gears disposed in the intermediate ring (e.g., intermediate ring 180) may be capable of independent rotational motion, rather than being controlled such that each gear has a constant direction and rate of rotation. In other words, in some other embodiments, horn gears could be controlled in jacquard motions, rather than only non-jacquard motions. This independent control for each horn gear might allow for more refined control over the movement of spools passing between rings, and in some cases may allow spools to pass along the intermediate ring in a holding pattern until spaces are opened in either the inner or outer ring.
The embodiment of
The lasts of plurality of lasts 692 may have any size, geometry, and/or orientation. In the exemplary embodiment, each last of plurality of lasts 692 comprises a three-dimensional contoured last in the shape of a foot (i.e., last member 698 is a footwear last). However, other embodiments could utilize lasts having any other geometry that are configured for forming braided articles with a preconfigured shape.
Upon entering braiding machine 400, each last may move in an approximately horizontal direction, which is any direction approximately parallel with top surface 430. After passing through sidewall opening 460 and into cavity 462, each last may then be rotated by approximately 90 degrees so that the last begins moving in an approximately vertical direction. The vertical direction may be a direction that is normal or perpendicular to top surface 430 of braiding machine 400. It may be appreciated that in some embodiments each last may be quickly rotated through 90 degrees to change the direction of its path. In other embodiments, each last may be turned along a curve such that the last is slowly rotated through approximately 90 degrees.
A moveable last system may include provisions for moving lasts through a braiding machine, including provisions for changing the direction in which the lasts move. These provisions could include various tracks, rollers, cables or other provisions for supporting lasts along a predetermined path.
Referring now to
It may be appreciated that in a fixed spool path configuration, each spool of a braid machine makes a complete loop around the braid machine (either clockwise or counterclockwise in direction) before passing through the same region of the braiding machine. In contrast, in a variable spool path configuration, some spools can pass through a single region two or more times without making a complete loop around the braiding machine.
Some braiding machines (i.e., braiding machine 400) can be operated with spools running in a fixed spool path configuration or a variable spool path configuration, depending on the desired kind of braided pattern to be formed. Moreover, on a machine comprising multiple rings of spools (e.g., braiding machine 400), one ring may operate with a fixed spool path configuration while another ring is simultaneously operated with a variable spool path configuration, in order to simultaneously produce multiple braided layers having different braid patterns.
As seen in
In some embodiments, a sole structure could be added to an upper assembly during a step of making an article of footwear. In the exemplary embodiment of
In some embodiments, sole structure 1250 may be configured to provide traction for article 829. For example, sole structure 1250 may include one or more traction elements, such as grooves, protrusions, or other traction devices. In one embodiment, sole structure 1250 may include areas with siping along the underside (i.e., the outsole) of sole structure 1250. The siping may comprise thin slits across the surface of the outsole.
In addition to providing traction, sole structure 1250 may attenuate ground reaction forces when compressed between the foot and the ground during walking, running, pushing, or other ambulatory activities. The configuration of sole structure 1250 may vary significantly in different embodiments to include a variety of conventional or non-conventional structures. In some cases, the configuration of sole structure 1250 can be configured according to one or more types of surfaces on which sole structure 1250 may be used. Examples of surfaces include, but are not limited to, natural turf, synthetic turf, dirt, hardwood flooring, skims, wood, plates, footboards, boat ramps, as well as other surfaces.
Sole structure 1250 is secured to upper assembly 828 and extends between the foot and the ground when article 829 is worn. In different embodiments, sole structure 1250 may include different components. For example, sole structure 1250 may include an outsole, a midsole, and/or an insole. In some cases, one or more of these components may be optional.
While the embodiments depict manufacturing a braided upper assembly using a braiding machine having a horizontal configuration, and using a moving last system, other embodiments could include machines having vertical configurations and/or fixed last systems. In particular, embodiments could use any of the methods and braiding machine configurations as disclosed in the Multi-Ring Braiding Machine application. For example, in other embodiments, a vertical braiding machine with a moving last system could be used to form a braided upper assembly.
In another embodiment shown in
In yet another embodiment shown in
While the embodiments of the figures depict articles having low collars (e.g., low-top configurations), other embodiments could have other configurations. In particular, the methods and systems described herein may be utilized to make a variety of different article configurations, including articles with higher cuff or ankle portions. For example, in another embodiment, the systems and methods discussed herein can be used to form a braided upper with a cuff that extends up a wearer's leg (i.e., above the ankle). In another embodiment, the systems and methods discussed herein can be used to form a braided upper with a cuff that extends to the knee. In still another embodiment, the systems and methods discussed herein can be used to form a braided upper with a cuff that extends above the knee. Thus, such provisions may allow for the manufacturing of boots comprised of braided structures. In some cases, articles with long cuffs could be formed by using lasts with long cuff portions (or leg portions) with a braiding machine (e.g., by using a boot last). In such cases, the last could be rotated as it is moved relative to a braiding point so that a generally round and narrow cross-section of the last is always presented at the braiding point.
While various embodiments 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 embodiments. Any feature of any embodiment may be used in combination with or substituted for any other feature or element in any other embodiment unless specifically restricted. Accordingly, the embodiments are 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.
