Article of footwear having an upper with thread structural elements

• US 20070271821A1
• Filed: 05/25/2006
• Published: 11/29/2007
• Est. Priority Date: 05/25/2006
• Status: Active Grant

• Current Assignee: Nike, Inc.
• Original Assignee: Nike, Inc.
• Inventors: Meschter, James
• Granted Patent: US 7,870,681 B2
• Time in Patent Office: Days
• US Class Current: 36/45
• CPC Class Codes: A43B 23/0235 Different layers of different material
• CPC Class Codes: A43B 23/0265 having different properties in different directions
• CPC Class Codes: A43B 3/26 adjustable as to length or size
• CPC Class Codes: A43B 5/06 Running shoes; Track shoes

Abstract

An article of footwear includes an upper that is at least partially formed from a base layer and thread sections that lie adjacent a surface of the base layer. The thread sections are positioned to provide structural elements that, for example, restrain stretch in directions corresponding with longitudinal axes of the thread sections. In some configurations of the footwear, a first portion of the thread sections may extend between forefoot and heel regions of the footwear, and a second portion of the thread sections may extend vertically. An embroidering process may be utilized to position the thread sections on the base layer.

Claims

1. An article of footwear having an upper and a sole structure secured to the upper, the upper comprising:

a base layer having a first surface and an opposite second surface, the base layer being formed from a material with two-directional stretch, the material being capable of stretching at least ten percent prior to tensile failure; and

a plurality of threads that are separate from the base layer and lie adjacent to at least a portion of the first surface, the threads being formed from a non-stretch material, the threads being oriented to form;

a first zone wherein the threads area absent from the first surface;

a second zone wherein the threads are substantially parallel to each other and the threads do not cross each other; and

a third zone wherein the threads are oriented such that a first portion of the threads extend in a first direction and a second portion of the threads extend in a second direction, the first threads crossing the second threads, and the first direction being offset by at least sixty degrees from the second direction.

2. The article of footwear recited in claim 1, wherein the upper has two-directional stretch properties in the first zone, one-directional stretch properties in the second zone, and non-stretch properties in the third zone.

3. The article of footwear recited in claim 1, wherein the material of the base layer is a textile.

4. The article of footwear recited in claim 1, wherein a securing element joins the threads to the base layer, and the securing element is a layer of polymer material.

5. The article of footwear recited in claim 1, wherein a securing element joins the threads to the base layer, and the securing element is an adhesive applied to at least the base layer.

6. 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 base layer having a first surface and an opposite second surface, the first surface defining at least a portion of an exterior surface of the footwear, and the second surface defining at least a portion of an interior surface that forms a void within the upper for receiving a foot;

a plurality of threads lying adjacent one of the first surface and the second surface, a first portion of the threads being oriented to extend between a forefoot region and a heel region of the upper, and a second portion of the threads being oriented to extend between an upper area and a lower area of the upper;

a securing element that joins the threads to the base layer; and

a lace extending through lace apertures in the base layer.

7. The article of footwear recited in claim 6, wherein a third portion of the threads extend around the lace apertures.

8. The article of footwear recited in claim 6, wherein a third portion of the threads are positioned in the heel region and extend from the upper area to the lower area.

9. The article of footwear recited in claim 6, wherein a third portion of the threads are positioned adjacent edges of the base layer.

10. The article of footwear recited in claim 6, wherein the securing element is at least one of a layer of polymer material and an adhesive applied to at least the base layer.

11. A method of manufacturing an article of footwear having an upper and a sole structure, the method comprising steps of:

embroidering a base layer with at least one thread to locate a plurality of sections of the thread adjacent a surface of the base layer for a distance of more than twelve millimeters;

incorporating the base layer and the at least one thread into the upper; and

securing the upper to the sole structure.

12. The method recited in claim 11, wherein the step of embroidering includes extending the sections of the thread from a forefoot region to a heel region of the base layer.

13. The method recited in claim 11, wherein the step of embroidering includes extending the sections of the thread from a lace receiving portion of the base layer to a lower portion of the base layer.

14. The method recited in claim 11, wherein the step of embroidering includes locating the thread or another thread to form an outline of an element of the upper.

15. The method recited in claim 14, wherein the step of embroidering includes cutting the base layer adjacent to the outline.

16. The method recited in claim 11, wherein the step of embroidering includes locating the thread or another thread around lace receiving portions of the base layer.

17. The method recited in claim 11, wherein the step of incorporating includes joining the base layer with another element that is embroidered.

18. A method of manufacturing an article of footwear having ah upper and a sole structure, the method comprising steps of:

locating a plurality of first thread sections adjacent a surface of a base layer such that the first thread sections do not pass through the base layer for a distance of at least five centimeters;

locating a plurality of second thread sections adjacent the surface of the base layer such that the second thread sections do not pass through the base layer for a distance of at least five centimeters;

orienting the second thread sections to be offset from the first thread sections by at least sixty degrees;

incorporating the base layer, the first thread sections, and the second thread sections into the upper; and

securing the upper to the sole structure.

19. The method recited in claim 18, wherein the step of locating the plurality of first thread sections includes extending the first thread sections from a forefoot region of the base layer to a heel region of the base layer.

20. The method recited in claim 18, further including a step of locating a plurality of third thread sections to form an outline of an element of the upper.

21. The method recited in claim 20, wherein the step of locating the plurality of third thread sections includes cutting the base layer adjacent to the outline.

22. The method recited in claim 18, further including a step of locating a plurality of third thread sections around lace receiving portions of the base layer.

23. The method recited in claim 18, wherein the step of incorporating includes joining the base layer with another element that is embroidered.

24. An article of footwear having an upper and a sole structure secured to the upper, the upper comprising:

a base layer having a first surface and an opposite second surface, the base layer defining a first point and a second point spaced apart by a distance of at least five centimeters; and

a thread extending from the first point to the second point, the thread having a section that is located between the first point and the second point, the section lying adjacent to the first surface and continuously exposed throughout the distance of at least five centimeters.

25. The article of footwear recited in claim 24, wherein the section of the thread is substantially parallel to the first surface.

26. The article of footwear recited in claim 24, wherein the base layer is a textile material that stretches at least ten percent prior to tensile failure.

27. The article of footwear recited in claim 26, wherein the thread substantially restrains stretch of the base layer in a direction corresponding with a longitudinal axis of the thread.

28. The article of footwear recited in claim 24, wherein a securing element joins the section to the base layer, and the securing element is a layer of polymer material.

29. The article of footwear recited in claim 24, wherein a securing element joins the section to the base layer, and the securing element is an adhesive applied to at least the base layer.

30. An article of footwear having an upper and a sole structure secured to the upper, the upper comprising:

a base layer having a first surface and an opposite second surface, the base layer being formed from a material with two-directional stretch; and

a plurality of threads that are separate from the base layer and lie adjacent to at least a portion of the first surface,

the threads being oriented to form;

a first zone wherein the threads area absent from the first surface;

a second zone wherein the threads are substantially parallel to each other and the threads do not cross each other; and

a third zone wherein the threads are oriented such that a first portion of the threads extend in a first direction and a second portion of the threads extend in a second direction, the first threads crossing the second threads.

31. The article of footwear recited in claim 30, wherein the upper has two-directional stretch properties in the first zone, one-directional stretch properties in the second zone, and non-stretch properties in the third zone.

32. The article of footwear recited in claim 30, wherein the material of the base layer is a textile.

33. The article of footwear recited in claim 30, wherein a securing element joins the threads to the base layer, and the securing element is a layer of polymer material.

34. The article of footwear recited in claim 30, wherein a securing element joins the threads to the base layer, and the securing element is an adhesive applied to at least the base layer.

35. An article of footwear having an upper and a sole structure secured to the upper, the upper comprising:

a plurality of lace receiving apertures;

a first thread group extending at least partially around at least one of the apertures; and

a second thread group extending outward from the first thread group,

wherein threads from at least one of the first thread group and the second thread group overlap threads from the other of the first thread group and the second thread group.

36. The article of footwear recited in claim 35, wherein the threads from the first thread group and the second thread group are intertwined.

37. The article of footwear recited in claim 35, wherein the threads from the first thread group and the second thread group are separate from textile elements within the upper.

38. The article of footwear recited in claim 35, wherein the second thread group includes a plurality of thread sections that are substantially aligned and extend toward a lower area of the upper.

39. The article of footwear recited in claim 35, wherein a securing element joins the threads of the second thread group to the base layer.

40. The article of footwear recited in claim 35, wherein the second thread group includes a plurality of thread sections that are continuously exposed through a distance of at least five centimeters.

41. The article of footwear recited in claim 35, wherein the second thread group radiates outward from an area proximal the first thread group.

42. The article of footwear recited in claim 35, wherein thread portions of the second thread group are closer together in areas proximal the lace receiving apertures than in areas spaced from the lace receiving apertures.