FOOTWEAR UPPERS AND OTHER TEXTILE COMPONENTS INCLUDING REINFORCED AND ABUTTING EDGE JOINT SEAMS

• US 20100077634A1
• Filed: 09/29/2008
• Published: 04/01/2010
• Est. Priority Date: 09/29/2008
• Status: Active Grant

• Current Assignee: Nike, Inc.
• Original Assignee: Nike, Inc.
• Inventors: Bell, Thomas G.
• Granted Patent: US 8,347,438 B2
• Time in Patent Office: Days
• US Class Current: 36/54
• CPC Class Codes: A41D 27/24 Hems; Seams
• CPC Class Codes: A43B 1/04 braided, knotted, knitted or crocheted
• CPC Class Codes: A43B 23/0235 Different layers of different material
• CPC Class Codes: A43B 23/025 assembled by stitching
• CPC Class Codes: A43B 23/0255 assembled by gluing or thermo bonding
• CPC Class Codes: A43B 23/0295 Pieced uppers
• CPC Class Codes: A43B 23/04 Uppers made of one piece; Uppers with inserted gussets
• 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: A43D 111/00 Shoe machines with conveyors for jacked shoes or for shoes or shoe parts

Abstract

Textile Components, such as upper members for articles of footwear, include: (a) a first portion having a first edge, wherein the first edge includes a first portion of material engaged with a first seam support material via a first thermoplastic material; (b) a second portion having a second edge, wherein the second edge includes a second portion of material engaged with a second seam support material via a second thermoplastic material; and (c) structure to engage the first and second edges in an abutting edge joint (such as a zig-zag stitch). The resulting textile components may be lightweight and breathable (e.g., due to use of lightweight upper fabric), having a comfortable fit (e.g., due to the abutting edge joint), while still providing a strong, stable, and durable construction (e.g., due to the presence of the seam support member(s)).

Claims

1. An upper member, comprising:

a first upper portion having a first edge, wherein the first edge includes a first portion of upper material engaged with a first seam support material via a first thermoplastic material;

a second upper portion having a second edge, wherein the second edge includes a second portion of upper material engaged with a second seam support material via a second thermoplastic material, wherein the second thermoplastic material may be the same as or different from the first thermoplastic material, and wherein the second seam support material may be the same as or different from the first seam support material; and

means for engaging the first edge and the second edge in an abutting edge joint.

2. An upper member according to claim 1, wherein at least one of the first upper portion or the second upper portion is engaged with a strobel member.

3. An upper member according to claim 1, wherein the means for engaging the first edge and the second edge includes a sewn seam.

4. An upper member according to claim 3, wherein a thread material of the sewn seam is at least partially melted, absorbed, concealed, or masked.

5. An upper member according to claim 1, wherein the means for engaging the first edge and the second edge includes a sewn seam having a zig-zag stitch structure.

6. An upper member according to claim 5, wherein a thread material of the zig-zag stitch structure is at least partially melted, absorbed, concealed or masked.

7. An upper member according to claim 1, wherein the first upper portion is on a separate piece of upper material from the second upper portion.

8. An upper member according to claim 1, wherein the first upper portion and the second upper portion are provided on a single piece of upper material.

9. An upper member according to claim 1, wherein the first upper portion includes a footwear tongue portion.

10. An article of footwear, comprising:

an upper member composed of one or more upper pieces, wherein the upper member includes at least one seam made from a first edge of the upper member engaged with a second edge of the upper member in an abutting edge joint, wherein the first edge of the upper member includes a first portion of upper material engaged with a first seam support material via a first thermoplastic material, wherein the second edge of the upper member includes a second portion of upper material engaged with a second seam support material via a second thermoplastic material, wherein the second thermoplastic material may be the same as or different from the first thermoplastic material, and wherein the second seam support material may be the same as or different from the first seam support material; and

a sole structure engaged with the upper member.

11. An article of footwear according to claim 10, wherein one or more pieces of the upper member are engaged with a strobel member.

12. An article of footwear according to claim 10, wherein the sole structure includes a midsole member.

14. An article of footwear according to claim 10, wherein the sole structure includes an outsole member.

16. An article of footwear according to claim 10, wherein the abutting edge joint includes a sewn seam having a zig-zag stitch structure.

20. An article of footwear according to claim 10, wherein the first portion of the upper material includes a footwear tongue portion.

13. (canceled)

15. (canceled)

17-19. -19. (canceled)

21. A method of forming a seam in an upper member, comprising:

applying a first thermoplastic film material to a first seam support material;

applying a second thermoplastic film material to a second seam support material, wherein the second thermoplastic film material may be the same as or different from the first thermoplastic film material, and wherein the second seam support material may be the same as or different from the first seam support material;

providing an upper construction including a first portion having a first exposed edge and a second portion having a second exposed edge, wherein the upper construction may be composed of one or more separate upper pieces;

cutting the first seam support material and the first thermoplastic film into a shape that includes a third exposed edge that matches at least a portion of the first exposed edge;

cutting the second seam support material and the second thermoplastic film into a shape that includes a fourth exposed edge that matches at least a portion of the second exposed edge;

placing the first seam support material on the first portion of the upper construction such that the first exposed edge and the third exposed edge are in a layered relationship and such that the first thermoplastic film contacts the first portion of the upper construction;

placing the second seam support material on the second portion of the upper construction such that the second exposed edge and the fourth exposed edge are in a layered relationship and such that the second thermoplastic film contacts the second portion of the upper construction;

exposing the layered first seam support material and the first portion of the upper construction to conditions sufficient to engage the first seam support material with the first portion of the upper construction via the first thermoplastic film to thereby provide a first exposed composite edge corresponding to a location of the layered first exposed edge and the third exposed edge;

exposing the layered second seam support material and the second portion of the upper construction to conditions sufficient to engage the second seam support material with the second portion of the upper construction via the second thermoplastic film to thereby provide a second exposed composite edge corresponding to a location of the layered second exposed edge and the fourth exposed edge; and

joining the first exposed composite edge to the second exposed composite edge in an abutting edge joint.

23. A method according to claim 21, wherein the joining includes sewing the first exposed composite edge to the second exposed composite edge via a zig-zag stitch.

24. A method according to claim 21, wherein at least one of the cutting steps includes die-cutting.

25. A method according to claim 21, wherein at least one of the cutting steps includes laser cutting.

26. A method according to claim 21, wherein the exposing steps take place simultaneously.

27. A method according to claim 21, wherein the exposing steps include exposing the layered first seam support material and the first portion of the upper construction to at least one of increased heat or pressure conditions, and exposing the layered second seam support material and the second portion of the upper construction to at least one of increased heat or pressure conditions.

29. A method according to claim 21, wherein the exposing steps include exposing the layered first seam support material and the first portion of the upper construction to at least one of a laser beam or radio frequency waves, and exposing the layered second seam support material and the second portion of the upper construction to at least one of a laser beam or radio frequency waves.

33. An upper member including at least one seam made by the method of claim 21.

22. (canceled)

28. (canceled)

30-32. -32. (canceled)

34. (canceled)

35. A method of forming a seam in an upper member, comprising:

providing an upper construction including a first portion having a first exposed edge and a second portion having a second exposed edge, wherein the upper construction may be composed of one or more separate upper pieces;

providing a first seam support member including a first thermoplastic material, wherein the first seam support member is shaped to include a third exposed edge that matches at least a portion of the first exposed edge;

providing a second seam support member including a second thermoplastic material, wherein the second thermoplastic material may be the same as or different from the first thermoplastic material, and wherein the second seam support member is shaped to include a fourth exposed edge that matches at least a portion of the second exposed edge;

placing the first seam support member on the first portion of the upper construction such that the first exposed edge and the third exposed edge are in a layered relationship and such that the first thermoplastic material contacts the first portion of the upper construction;

placing the second seam support member on the second portion of the upper construction such that the second exposed edge and the fourth exposed edge are in a layered relationship and such that the second thermoplastic material contacts the second portion of the upper construction;

exposing the first seam support member and the first portion of the upper construction to conditions sufficient to engage the first seam support member with the first portion of the upper construction via the first thermoplastic material to thereby provide a first exposed composite edge corresponding to a location of the layered first exposed edge and the third exposed edge;

exposing the layered second seam support member and the second portion of the upper construction to conditions sufficient to engage the second seam support member with the second portion of the upper construction via the second thermoplastic material to thereby provide a second exposed composite edge corresponding to a location of the layered second exposed edge and the fourth exposed edge; and

joining the first exposed composite edge to the second exposed composite edge in an abutting edge joint.

37. A method according to claim 35, wherein the joining includes sewing the first exposed composite edge to the second exposed composite edge via a zig-zag stitch.

38. A method according to claim 35, wherein the exposing steps take place simultaneously.

39. A method according to claim 35, wherein the exposing steps include exposing the first seam support member and the first portion of the upper construction to at least one of increased heat or pressure conditions, and exposing the second seam support member and the second portion of the upper construction to at least one of increased heat or pressure conditions.

41. A method according to claim 35, wherein the exposing steps include exposing the first seam support member and the first portion of the upper construction to at least one of a laser beam or radio frequency waves, and exposing the second seam support member and the second portion of the upper construction to at least one of a laser beam or radio frequency waves.

45. An upper member including at least one seam made by the method of claim 35.

36. (canceled)

40. (canceled)

42-44. -44. (canceled)

46. (canceled)

47. A textile component, comprising:

a first material element having a first edge, wherein the first edge includes a first portion of material engaged with a first seam support material via a first thermoplastic material;

a second material element having a second edge, wherein the second edge includes a second portion of material engaged with a second seam support material via a second thermoplastic material, wherein the second thermoplastic material may be the same as or different from the first thermoplastic material, and wherein the second seam support material may be the same as or different from the first seam support material; and

means for engaging the first edge and the second edge in an abutting edge joint.

48. A textile component according to claim 47, wherein the means for engaging the first edge and the second edge includes a sewn seam, and wherein a thread material of the sewn seam is at least partially melted, absorbed, concealed, or masked.

50. A textile component according to claim 47, wherein the means for engaging the first edge and the second edge includes a sewn seam having a zig-zag stitch structure.

49. (canceled)

51. A method of forming a seam in a textile component, comprising:

applying a first thermoplastic film material to a first seam support material;

applying a second thermoplastic film material to a second seam support material, wherein the second thermoplastic film material may be the same as or different from the first thermoplastic film material, and wherein the second seam support material may be the same as or different from the first seam support material;

providing a textile component including a first portion having a first exposed edge and a second portion having a second exposed edge, wherein the textile component may be composed of one or more separate pieces;

cutting the first seam support material and the first thermoplastic film into a shape that includes a third exposed edge that matches at least a portion of the first exposed edge;

cutting the second seam support material and the second thermoplastic film into a shape that includes a fourth exposed edge that matches at least a portion of the second exposed edge;

placing the first seam support material on the first portion of the textile component such that the first exposed edge and the third exposed edge are in a layered relationship and such that the first thermoplastic film contacts the first portion of the textile component;

placing the second seam support material on the second portion of the textile component such that the second exposed edge and the fourth exposed edge are in a layered relationship and such that the second thermoplastic film contacts the second portion of the textile component;

exposing the layered first seam support material and the first portion of the textile component to conditions sufficient to engage the first seam support material with the first portion of the textile component via the first thermoplastic film to thereby provide a first exposed composite edge corresponding to a location of the layered first exposed edge and the third exposed edge;

exposing the layered second seam support material and the second portion of the textile component to conditions sufficient to engage the second seam support material with the second portion of the textile component via the second thermoplastic film to thereby provide a second exposed composite edge corresponding to a location of the layered second exposed edge and the fourth exposed edge; and

joining the first exposed composite edge to the second exposed composite edge in an abutting edge joint.

53. A method according to claim 51, wherein the joining includes sewing the first exposed composite edge to the second exposed composite edge via a zig-zag stitch.

52. (canceled)

54. (canceled)

55. A method of forming of forming a seam in a textile component, comprising:

providing a textile component including a first portion having a first exposed edge and a second portion having a second exposed edge, wherein the textile component may be composed of one or more separate pieces;

providing a first seam support member including a first thermoplastic material, wherein the first seam support member is shaped to include a third exposed edge that matches at least a portion of the first exposed edge;

providing a second seam support member including a second thermoplastic material, wherein the second thermoplastic material may be the same as or different from the first thermoplastic material, and wherein the second seam support member is shaped to include a fourth exposed edge that matches at least a portion of the second exposed edge;

placing the first seam support member on the first portion of the textile component such that the first exposed edge and the third exposed edge are in a layered relationship and such that the first thermoplastic material contacts the first portion of the textile component;

placing the second seam support member on the second portion of the textile component such that the second exposed edge and the fourth exposed edge are in a layered relationship and such that the second thermoplastic material contacts the second portion of the textile component;

exposing the first seam support member and the first portion of the textile component to conditions sufficient to engage the first seam support member with the first portion of the textile component via the first thermoplastic material to thereby provide a first exposed composite edge corresponding to a location of the layered first exposed edge and the third exposed edge;

exposing the layered second seam support member and the second portion of the textile component to conditions sufficient to engage the second seam support member with the second portion of the textile component via the second thermoplastic material to thereby provide a second exposed composite edge corresponding to a location of the layered second exposed edge and the fourth exposed edge; and

joining the first exposed composite edge to the second exposed composite edge in an abutting edge joint.

57. A method according to claim 55, wherein the joining includes sewing the first exposed composite edge to the second exposed composite edge via a zig-zag stitch.

56. (canceled)

58. (canceled)