Article of footwear having an upper with a matrix layer

• US 20060283042A1
• Filed: 01/26/2006
• Published: 12/21/2006
• Est. Priority Date: 06/20/2005
• Status: Active Grant

• Current Assignee: Nike, Inc.
• Original Assignee: Nike, Inc.
• Inventors: Hurd, John, Greene, Pamela S., Hoke, John III
• Granted Patent: US 7,540,097 B2
• Time in Patent Office: Days
• US Class Current: 36/3.A
• CPC Class Codes: A43B 19/00 Shoe-shaped inserts; Inserts covering the instep
• CPC Class Codes: A43B 23/0215 Plastics or artificial leather
• CPC Class Codes: A43B 23/0265 having different properties in different directions
• CPC Class Codes: A43B 23/042 Uppers made of one piece one piece slippers A43B3/106; one piece sandals A43B3/124
• CPC Class Codes: A43B 9/00 Footwear characterised by the assembling of the individual parts
• CPC Class Codes: A43C 1/04 with rings or loops
• CPC Class Codes: A43C 5/00 Eyelets machines for setting eyelets A43D100/00
• CPC Class Codes: B29D 35/126 Uppers

Abstract

An article of footwear is disclosed that includes an upper and a sole structure. The upper includes a matrix structure that defines a plurality of apertures. The apertures may have an elongate configuration to impart differences in the extensibility of the upper in different directions. For example, the matrix layer may be formed from a plurality of segments that cross each other to define the apertures. A method of manufacturing the article of footwear is also disclosed.

Claims

1. An article of footwear comprising:

an upper including a matrix structure extending along at least one of a medial side and a lateral side of the footwear, the matrix structure being formed from a plurality of segments that cross each other to define a plurality of intersections and apertures, at least a portion of the intersections each defining a first angle and a second angle, the first angle being an acute angle oriented in a substantially vertical direction, and the second angle being an obtuse angle oriented in a substantially horizontal direction; and

a sole structure secured to the upper.

2. The article of footwear recited in claim 1, wherein at least a portion of the segments exhibit a curved configuration.

3. The article of footwear recited in claim 1, wherein the apertures exhibit a substantially quadrilateral shape.

4. The article of footwear recited in claim 1, wherein the matrix structure is formed from a unitary polymer element.

5. The article of footwear recited in claim 1, wherein an edge of the matrix structure defines a throat area of the upper, and a lace extends through the apertures that are positioned adjacent the throat area.

6. The article of footwear recited in claim 5, wherein the edge of the matrix structure defines an ankle opening of the upper, and a cord extends through the apertures that are positioned adjacent the ankle opening.

7. The article of footwear recited in claim 1, wherein a pair of edges of the matrix structure extend vertically through an ankle area of the footwear and are positioned adjacent to each other, and a cord extends through the apertures that are positioned adjacent the pair of edges to join the pair of edges to each other.

8. The article of footwear recited in claim 1, wherein an area of the apertures is greater than an area of the segments.

9. The article of footwear recited in claim 1, wherein a ratio of an area of the segments to an area of the apertures varies throughout the matrix structure, and the ratio in a midfoot region of the footwear is greater than the ratio in a forefoot region and a heel region of the footwear.

10. The article of footwear recited in claim 1, wherein a connecting element extends through an aperture to bisect the aperture, and the connecting element extends between two of the second pair of angles.

11. The article of footwear recited in claim 1, wherein the footwear includes another matrix structure that is coextensive with the matrix structure.

12. The article of footwear recited in claim 1, wherein the matrix structure defines various loops located on an edge of the matrix structure.

13. The article of footwear recited in claim 12, wherein the loops receive a cord.

14. The article of footwear recited in claim 12, wherein the loops are rotated with respect to a plane of a remainder of the matrix layer.

15. An article of footwear comprising:

an upper including a matrix structure that defines a first edge and an opposite second edge, the matrix structure being formed from a plurality of elongate segments that extend between the first edge and the second edge, the segments defining a plurality of intersections and apertures, the intersections being locations where two of the segments cross each other, and the apertures being areas between the segments, at least a portion of the intersections defining a first pair of angles and a second pair of angles, the first pair of angles being acute angles oriented in a direction that is substantially perpendicular to the first edge and the second edge, and the second pair of angles being obtuse angles oriented in a direction that is substantially parallel to the first edge and the second edge; and

a sole structure secured to the upper.

16. The article of footwear recited in claim 15, wherein the matrix structure is formed from a unitary polymer element.

17. The article of footwear recited in claim 15, wherein the matrix structure has a U-shaped configuration.

18. The article of footwear recited in claim 17, wherein the U-shaped configuration of the matrix structure has a central area and a pair of side areas extending from the central area, the central area being positioned in a forefoot region of the footwear, and the pair of side areas being positioned to extend through a midfoot region and a heel region of the footwear.

19. The article of footwear recited in claim 18, wherein end portions of the pair of side areas are joined together in the heel region.

20. The article of footwear recited in claim 15, wherein a lasting element is secured to the first edge, and the lasting element extends along at least a portion of the first edge to join the matrix structure to the sole structure.

21. The article of footwear recited in claim 20, wherein the lasting element is formed from a material that is different from a material of the matrix structure.

22. The article of footwear recited in claim 20, wherein the lasting element is formed from a textile material.

23. The article of footwear recited in claim 15, wherein the first edge is positioned adjacent the sole structure the second edge defines a throat area and an ankle opening of the upper.

24. The article of footwear recited in claim 23, wherein a lace extends through the apertures that are positioned adjacent the throat area.

25. The article of footwear recited in claim 23, wherein end portions of the segments positioned adjacent the second edge define a plurality of openings, and a cord extends through the openings and around the throat area and the ankle opening.

26. The article of footwear recited in claim 25, wherein the matrix structure includes a pair of third edges that extend between the first edge and the second edge, the third edges being positioned in a heel region of the upper, and the cord joining the third edges to each other.

27. The article of footwear recited in claim 15, wherein an area of the apertures is greater than an area of the segments.

28. The article of footwear recited in claim 15, wherein a ratio of an area of the segments to an area of the apertures varies throughout the matrix structure, and the ratio in a midfoot region of the footwear is greater than the ratio in a forefoot region and a heel region of the footwear.

29. The article of footwear recited in claim 15, wherein the apertures exhibit a substantially quadrilateral shape.

30. The article of footwear recited in claim 15, wherein a connecting element extends through an aperture and in the direction that is substantially parallel to the first edge and the second edge.

31. The article of footwear recited in claim 30, wherein the connecting element extends between two of the second pair of angles.

32. The article of footwear recited in claim 15, wherein at least a portion of the segments exhibit a curved configuration.

33. The article of footwear recited in claim 15, wherein the sole structure has a first length and another article of footwear has a sole structure with a second length, the first length being less than the second length, the matrix structure of the article of footwear and a matrix structure of the another article of footwear having substantially identical dimensions, and the matrix structure of the another article of footwear being stretched in a direction that is parallel to the first edge and the second edge to accommodate the sole structure of the another article of footwear.

34. The article of footwear recited in claim 15, wherein the acute angles in a forefoot region of the footwear are less than the acute angles in a midfoot region of the footwear.

35. The article of footwear recited in claim 15, wherein the footwear includes another matrix structure that is coextensive with the matrix structure.

36. The article of footwear recited in claim 15, wherein the matrix structure defines various loops located on an edge of the matrix structure.

37. The article of footwear recited in claim 36, wherein the loops receive a cord.

38. The article of footwear recited in claim 36, wherein a portion of at least one of the loops is rotated with respect to a plane of a remainder of the matrix layer.

39. An article of footwear comprising:

an upper having a polymer layer extending along at least a medial side and a lateral side of the footwear, the polymer layer defining a plurality of apertures with an elongate configuration oriented to extend substantially perpendicular to a longitudinal axis of the footwear, the longitudinal axis extending between a forefoot region and a heel region of the footwear; and

a sole structure secured to the upper.

40. The article of footwear recited in claim 39, wherein the apertures exhibit a substantially quadrilateral shape.

41. The article of footwear recited in claim 39, wherein the apertures exhibit a substantially quadrilateral shape that defines a first pair of angles and a second pair of angles, the first pair of angles being acute angles oriented substantially perpendicular to the longitudinal axis, and the second pair of angles being obtuse angles oriented in a direction that is substantially parallel to the longitudinal axis.

42. The article of footwear recited in claim 39, wherein the polymer layer defines a first edge and an opposite second edge, the polymer layer being formed from a plurality of segments that extend in a direction between the first edge and the second edge, the segments defining the apertures.

43. The article of footwear recited in claim 42, wherein at least a portion of the segments exhibit a curved configuration.

44. The article of footwear recited in claim 39, wherein the polymer layer is formed from a unitary polymer element.

45. The article of footwear recited in claim 39, wherein a lasting element is secured to an edge of the polymer layer, and the lasting element extends along at least a portion of the edge to join the polymer layer to the sole structure, and the lasting element is formed from a material that is different from a material of the polymer layer.

46. The article of footwear recited in claim 45, wherein the lasting element is formed from a textile material.

47. The article of footwear recited in claim 39, wherein a first edge of the polymer layer is positioned adjacent the sole structure and a second edge of the polymer layer defines a throat area and an ankle opening of the upper.

48. The article of footwear recited in claim 47, wherein a lace extends through the apertures that are positioned adjacent the throat area.

49. The article of footwear recited in claim 47, wherein end portions of the segments positioned adjacent the second edge define a plurality of openings, and a cord extends through the openings and around the throat area and the ankle opening.

50. The article of footwear recited in claim 39, wherein an area of the apertures is greater than an area of the polymer layer.

51. The article of footwear recited in claim 39, wherein a ratio of an area of the polymer layer to an area of the apertures varies throughout the polymer layer, and the ratio in a midfoot region of the footwear is greater than the ratio in the forefoot region and the heel region of the footwear.

52. The article of footwear recited in claim 39, wherein the sole structure has a first length and another article of footwear has a sole structure with a second length, the first length being less than the second length, the polymer layer of the article of footwear and a polymer layer of the another article of footwear having substantially identical dimensions, and the polymer layer of the another article of footwear being stretched in a direction that is parallel to the first edge and the second edge to accommodate the sole structure of the another article of footwear.

53. The article of footwear recited in claim 39, wherein the footwear includes another polymer layer that is coextensive with the polymer layer.

54. An article of footwear having an upper and a sole structure secured to the upper, at least a portion of the upper consisting of a polymer layer extending along at least a medial side and a lateral side of the footwear, the polymer layer having a plurality of intersected segments that define a plurality of apertures, the apertures having an elongate configuration oriented to extend substantially perpendicular to a longitudinal axis of the footwear, the longitudinal axis extending between a forefoot region and a heel region of the footwear.

55. The article of footwear recited in claim 54, wherein the apertures exhibit a substantially quadrilateral shape.

56. The article of footwear recited in claim 54, wherein at least a portion of the segments exhibit a curved configuration.

57. The article of footwear recited in claim 54, wherein the apertures exhibit a substantially quadrilateral shape that defines a first pair of angles and a second pair of angles, the first pair of angles being acute angles oriented substantially perpendicular to the longitudinal axis, and the second pair of angles being obtuse angles oriented in a direction that is substantially parallel to the longitudinal axis.

58. The article of footwear recited in claim 54, wherein an area of the apertures is greater than an area of the segments.

59. A method of manufacturing a first article of footwear and a second article of footwear, the method comprising steps of:

forming a first polymer element with a mold, the first polymer element defining a plurality of first apertures with an elongate configuration;

securing the first polymer element to a first sole structure to form at least a portion of a first upper, the first sole structure having a first length;

forming a second polymer element that is substantially identical to the first polymer element with the mold; and

securing the second polymer element to a second sole structure to form at least a portion of a second upper, the second sole structure having a second length, the second length being greater than the first length.

60. The method recited in claim 59, further including steps of:

lengthening the first polymer layer prior to securing the first polymer element to the first sole structure; and

lengthening the second polymer layer to a length that is greater than a length of the first polymer layer prior to securing the second polymer element to the second sole structure.

61. The method recited in claim 59, wherein the step of forming the first polymer layer includes forming a plurality of elongate and intersecting segments, the first apertures being formed between the segments.

62. The method recited in claim 61, wherein the step of forming the first polymer layer further includes forming at least a portion of the segments to exhibit a curved configuration.

63. The method recited in claim 59, wherein the step of forming the first polymer layer includes forming the apertures to exhibit a substantially quadrilateral shape.

64. The method recited in claim 63, wherein the step of forming the first polymer layer further includes forming the apertures to define a first pair of angles and a second pair of angles, the first pair of angles being acute angles oriented substantially perpendicular to a direction of the first length, and the second pair of angles being obtuse angles oriented in a direction that is substantially parallel to the direction of the first length.

65. The method recited in claim 59, wherein the step of securing the first polymer element to the first sole structure includes joining the first polymer element to a lasting element.

66. The method recited in claim 59, further including a step of threading a lace through the first apertures that are positioned adjacent a throat area of the first upper.