Article Of Footwear With Multiple Layers

• US 20160227881A1
• Filed: 02/05/2015
• Published: 08/11/2016
• Est. Priority Date: 02/05/2015
• Status: Active Grant

• Current Assignee: Nike, Inc.
• Original Assignee: Nike, Inc.
• Inventors: Beers, Tiffany A., Gilbreath, Nathan T.
• Granted Patent: US 11,470,918 B2
• Time in Patent Office: Days
• US Class Current: 1/1
• 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 23/027 with a part of the upper particularly flexible, e.g. permitting articulation or torsion
• CPC Class Codes: A43B 23/028 Resilient uppers, e.g. shock absorbing

Abstract

An article of footwear has a multi-layer upper, where the outermost layers of the upper are cut into a pattern. The cut portions of the upper are mounted on a contiguous substrate layer so that the edges of the cut portions are visible and perceptible to touch. The upper remains durable in terms of abrasion resistance, ply adhesion, tensile strength, and flex testing.

Claims

1. An upper configured to receive a foot, the upper comprising:

a first layer;

a second layer; and

a compressible material layer positioned between the first layer and the second layer,

wherein the first layer and the compressible material layer are cut into a pattern while the second layer remains intact to form a substrate for the first layer and the compressible material layer.

2. The upper of claim 1, wherein the first layer and the compressible material layer are cut entirely through along at least a portion of the pattern.

3. The upper of claim 2, wherein the first layer and the compressible material layer remain uncut along at least one edge.

4. The upper of claim 3, wherein the pattern extends away from the at least one edge.

5. The upper of claim 1, wherein the pattern is visible on an outer surface of the upper.

6. The upper of claim 1, wherein the first layer forms an outermost surface of the upper.

7. An article of footwear comprising:

an upper configured to receive a foot, wherein the upper comprises

a first fabric layer cut into a first fabric portion and a second fabric portion,

a second fabric layer, and

a foam layer disposed between the first fabric layer and the second fabric layer, wherein the foam layer is cut into a first foam portion and a second foam portion, wherein the first fabric portion corresponds to the first foam portion to form a first cut portion and the second fabric portion corresponds to the second foam portion to form a second cut portion,

wherein the first fabric layer forms an outer surface of the upper; and

a sole associated with the upper around a perimeter of the sole.

8. The article of footwear of claim 7, wherein substantially all of the upper includes cut portions that form a pattern on an outer surface of the upper.

9. The article of footwear of claim 7, wherein, in an unflexed configuration, a first edge of the first cut portion abuts a second edge of the second cut portion, and, in a flexed configuration, the first edge is separated from the second edge.

10. The article of footwear of claim 9, wherein when the upper is in the flexed configuration, the first edge and the second edge form a V-shaped gap between the first cut portion and the second cut portion, wherein the gap is widest proximate the first fabric layer.

11. The article of footwear of claim 7, wherein the first fabric layer and the second fabric layer are made of the same material.

12. The article of footwear of claim 7, wherein the foam layer is made of a polyurethane material.

13. The article of footwear of claim 12, wherein the foam layer is an open-cell polyurethane foam material having a thickness between 3 mm and 5 mm.

14. The article of footwear of claim 7, wherein the upper is cut into an undulate pattern.

15. A material designed to be used in an article of footwear, the material comprising:

a first fabric layer cut into a first fabric portion and a second fabric portion;

a second fabric layer; and

a foam layer disposed between the first fabric layer and the second fabric layer, wherein the foam layer is cut into a first foam portion and a second foam portion,

wherein the first fabric portion corresponds to the first foam portion to form a first cut portion and the second fabric portion corresponds to the second foam portion to form a second cut portion, and

wherein the second fabric layer forms an intact substrate that supports the first cut portion and the second cut portion.

16. The material of claim 15, wherein the material is cut into an undulate pattern.

17. The material of claim 15, wherein the foam layer includes a polyurethane foam.

18. The material of claim 15, wherein the first fabric layer is made from the same material as the second fabric layer.

19. The material of claim 15, wherein the first fabric layer is made from a different material from the second fabric layer.

20. The material of claim 15, wherein the first cut portion includes a first edge and the second cut portion includes a second edge, and wherein, in a flexed configuration, the first edge and the second edge form a first separation width that is widest at the first fabric layer and tapers to an original manufacturing width proximate the second fabric layer.