Material elements incorporating tensile strands

• US 10,413,012 B2
• Filed: 11/09/2015
• Issued: 09/17/2019
• Est. Priority Date: 05/25/2006
• Status: Active Grant

• Current Assignee: Nike, Inc.
• Original Assignee: Nike, Inc.
• Inventors: Dojan, Frederick J., Huang, Chin-Chen, Meschter, James C.
• Primary Examiner(s): Dodds, Scott W
• Application Number:
  US14/935,603
• Publication Number:
  US 20160058097A1
• Time in Patent Office: 1,408 Days
• Field of Search: 1563082, 1563096, 156176, 156179, 156297, 156 70, 1565831, 1565833, 12146 C, 12146 CK, 4282981, 4283007
• CPC Class Codes: A43B 1/00 Footwear characterised by the material
• CPC Class Codes: A43B 23/0235 Different layers of different material
• CPC Class Codes: A43B 23/026 Laminated layers
• CPC Class Codes: A43B 23/0275 with a part of the upper particularly rigid, e.g. resisting articulation or torsion
• CPC Class Codes: A43B 3/26 adjustable as to length or size
• CPC Class Codes: A43B 5/06 Running shoes; Track shoes
• CPC Class Codes: Y10T 156/1039 Surface deformation only of sandwich or lamina [e.g., embossed panels]
• CPC Class Codes: Y10T 428/24 Structurally defined web or sheet [e.g., overall dimension, etc.]
• CPC Class Codes: Y10T 428/2481 including layer of mechanically interengaged strands, strand-portions or strand-like strips
• CPC Class Codes: Y10T 428/24851 Intermediate layer is discontinuous or differential

Abstract

An article of footwear or other product may include a material element having a first layer, a second layer, a third layer, and at least one strand. The second layer is positioned between the first layer and the third layer, and the second layer is formed from a thermoplastic polymer material. The strand is located between the first layer and the second layer, and the strand lies substantially parallel to the second layer for a distance of at least five centimeters. In this configuration, the thermoplastic polymer material may join the first layer and the third layer to the second layer. The thermoplastic polymer material may also join the strand to the second layer.

Claims

1. An article of footwear comprising a material element, the material element comprising:

a first layer, a second layer, and a third layer, the second layer being positioned between the first layer and the third layer, and the second layer being formed from a thermoplastic polymer material; and

a plurality of strands located between the first layer and the second layer, wherein the strands are pre-formed and lying substantially parallel to surfaces of the first layer and the second layer for distances of at least five centimeters;

wherein heatbonds between the thermoplastic polymer material and each of the first layer and third layer join the second layer to the first layer and third layer, and

wherein the material element comprises at least two zones having different stretch characteristics, the at least two zones including a first zone in which none of the plurality of strands in the first zone cross another one of the plurality of strands in the first zone and a second zone in which all of the plurality of strands in the second zone cross at least one other one of the plurality of strands in the second zone,

wherein the plurality of strands comprises a first strand having a first thickness and a second strand having a second thickness that is the same or different from the first thickness, and the first strand crosses the second strand in the first zone at an overlapping region that has a third thickness that is greater than the first and second thickness, and

wherein at least one of the first layer and the third layer are a textile material; and

wherein the material element forms at least a portion of an upper of the article of footwear.

2. The article of footwear of claim 1, wherein heatbonds between the thermoplastic polymer material and the strands join the second layer to the strands.

3. The article of footwear of claim 1, wherein the first layer is a polymer sheet.

4. The article of footwear of claim 1, wherein a first group of the strands cross a second group of the strands in the second zone.

5. The article of footwear of claim 1, wherein a material forming at least one strand of the plurality of strands is selected from a group consisting of carbon fiber, aramid fiber, ultra-high molecular weight polyethylene, and liquid crystal polymer.

6. The article of footwear of claim 1, wherein ends of the strands are located at an edge of the first layer and an edge of the second layer.

7. The article of footwear of claim 1, wherein the third layer is positioned closer toward an interior of the upper of the article of footwear than the first layer;

and

wherein the first layer forms a portion of an exterior surface of the article of footwear.

8. The article of footwear of claim 7, wherein the third layer forms a backing layer positioned within the interior of the upper of the article of footwear.

9. The article of footwear of claim 1, wherein the plurality of strands extends from a lace area of the upper to an area where a sole structure is configured to be joined with the upper.

10. The article of footwear of claim 1, wherein at least one of the first layer, the second layer, and the third layer includes a plurality of apertures.

11. The article of footwear of claim 10, wherein the plurality of apertures extends through both the first layer and the second layer.

12. The article of footwear of claim 10, wherein the plurality of apertures extends through each of the first layer, the second layer, and the third layer so as to extend entirely through the material element.

13. The article of footwear of claim 10, wherein the second layer comprises a polymer sheet defining the plurality of apertures.

15. The article of footwear of claim 1, further comprising strands of the plurality of strands that are located between the second layer and the third layer, wherein the strands are pre-formed and lying substantially parallel to surfaces of the second layer and the third layer for distances of at least five centimeters.

16. The article of footwear of claim 15, wherein the strands located between the first layer and the second layer are aligned with the strands located between the second layer and the third layer.

18. The article of footwear of claim 1, wherein the at least two zones includes a third zone in which no strands are present.

14. The article of footwear of 13, wherein both the first layer and the third layer comprise textiles.

17. The article of footwear of 15, wherein the strands located between the first layer and the second layer are offset with the strands located between the second layer and the third layer.