Articles of footwear with tensile strand elements

• US 9,402,444 B2
• Filed: 10/03/2014
• Issued: 08/02/2016
• Est. Priority Date: 02/24/2012
• Status: Active Grant

• Current Assignee: Nike, Inc.
• Original Assignee: Nike, Inc.
• Inventors: Dojan, Frederick J., Kohatsu, Shane S., Huang, Chin-Chen, Johnson, Daniel A.
• Primary Examiner(s): BAYS, MARIE D
• Application Number:
  US14/505,598
• Publication Number:
  US 20150082557A1
• Time in Patent Office: 669 Days
• Field of Search: 36/501, 36/45, 36/3.A, 36/3.R, 36/115, 121/42.R, 121/46.C
• US Class Current: 1/1
• CPC Class Codes: A43B 13/04 Plastics, rubber or vulcanised fibre
• CPC Class Codes: A43B 13/125 characterised by the midsole or middle layer
• CPC Class Codes: A43B 13/181 Resiliency achieved by the structure of the sole
• CPC Class Codes: A43B 13/187 Resiliency achieved by the features of the material, e.g. foam, non liquid materials
• CPC Class Codes: A43B 23/0215 Plastics or artificial leather
• CPC Class Codes: A43B 23/0245 characterised by the constructive form
• CPC Class Codes: A43B 23/026 Laminated layers
• 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 23/0275 with a part of the upper particularly rigid, e.g. resisting articulation or torsion
• CPC Class Codes: A43B 23/028 Resilient uppers, e.g. shock absorbing
• CPC Class Codes: A43B 23/0295 Pieced uppers
• CPC Class Codes: A43C 1/04 with rings or loops
• CPC Class Codes: A43C 11/002 Fastenings using stretchable material attached to cuts in the uppers

Abstract

An upper for an article of footwear may have material layers and a plurality of strand segments. The material layers are located adjacent to each other and in an overlapping configuration, and the material layers are located in a lace region and a lower region of the upper. The strand segments extend from the lace region to the lower region. The strand segments may be located and secured between the material layers in the lace region and the lower region. The strand segments may form both an exterior surface of the upper and an opposite interior surface of the upper in an area between the lace region and the lower region. The material layers may define an opening between the lace region and the lower region, and the strand segments extend across the opening.

Claims

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

providing a first material layer and a second material layer in at least one of a lace region and a lower region, the lower region being spaced apart from the lace region and located proximal to an area for securing the sole structure to the upper;

locating a plurality of strand segments extending from the lace region to the lower region and securing the strand segments to the upper in the lace region and the lower region, the strand segments being unsecured for a distance of at least four centimeters in an area between the lace region and the lower region, the strand segments forming both an exterior surface of the upper and an opposite interior surface of the upper in the area between the lace region and the lower region; and

securing the strand segments between the first material layer and the second material layer in the lace region.

2. The method recited in claim 1, wherein the step of providing includes locating the first material layer and the second material layer in the lower region;

and

wherein the step of securing includes securing the strand segments between the first material layer and the second material layer in the lower region.

3. The method recited in claim 1, further comprising:

providing a third material layer and a fourth material layer in the lower region, the third material layer and the fourth material layer being separate elements from the first material layer and the second material layer; and

wherein the step of locating the strand segments includes securing the strand segments between the third material layer and the fourth material layer in the lower region.

4. The method recited in claim 1, further comprising providing a plurality of lace-receiving elements in the lace region.

5. The method recited in claim 4, wherein the lace-receiving elements are apertures extending through the first material layer and the second material layer.

6. The method recited in claim 5, wherein the step of locating the strand segments includes extending the strand segments at least partially around the apertures.

7. The method recited in claim 1, wherein the step of providing includes locating the first material layer and the second material layer to be absent from at least a portion of the area between the lace region and the lower region.

8. The method recited in claim 1, wherein the strand segments include a first strand segment and a second strand segment;

and

wherein the step of locating the strand segments includes (a) locating the first strand segment to have a substantially vertical orientation in the area between the lace region and the lower region, and (b) locating the second strand segment to extend towards a heel region of the footwear in the area between the lace region and the lower region.

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

providing a base material layer having (a) a first surface and an opposite second surface and (b) a first area and a second area spaced from each other;

locating a first strand adjacent to the first surface and securing the first strand to the first surface, multiple segments of the first strand extending from the first area to the second area;

locating a second strand adjacent to the second surface and securing the second strand to the second surface, multiple segments of the second strand extending from the first area to the second area, and the segments of the second strand being angled with respect to the segments of the first strand; and

incorporating the base material layer, the first strand, and the second strand into a side area of the upper, the first area being located in a lace region of the upper, and the second area being located in a lower region of the upper, the lower region being spaced from the lace region and located proximal to an area for securing the sole structure to the upper.

10. The method recited in claim 9, wherein the step of providing includes defining an opening in the base material layer between the first area and the second area.

11. The method recited in claim 10, wherein the step of locating the first strand includes extending the segments of the first strand across the opening.

12. The method recited in claim 11, wherein the step of locating the second strand includes extending the segments of the second strand across the opening.

13. The method recited in claim 9, further including a step of securing a cover material layer and a backing material layer to the base material layer, the cover material layer being secured to the first surface of the base material layer, and the first strand being located between the cover material layer and the base material layer, the backing material layer being secured to the second surface of the base material layer, and the second strand being located between the backing material layer and the base material layer.

14. The method recited in claim 9, wherein the step of incorporating includes (a) orienting the segments of first strand to have a substantially vertical orientation in an area between the lace region and the lower region (b) orienting the segments of the second strand to extend toward a heel region of the footwear in the area between the lace region and the lower region.

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

providing at least two material layers located adjacent to each other and in an overlapping configuration, the material layers being located in (a) a lace region that includes a plurality of lace-receiving elements and (b) a lower region proximal to an area for securing the sole structure to the upper, the material layers being spaced apart between the lace region and the lower region to define an opening between the lace region and the lower region;

locating a plurality of strand segments extending from the lace region to the lower region and securing the strand segments between the material layers in the lace region and the lower region, and the strand segments extending across the opening between the lace region and the lower region.

16. The method recited in claim 15, wherein the step of providing includes providing (a) a first pair of material layers located in the lace region and (b) a second pair of material layers located in the lower region, the first pair of material layers being separate elements from the second pair of material layers;

and

wherein the step of locating the strand segments includes locating and securing the strand segments between each of the first pair of material layers and the second pair of material layers.

17. The method recited in claim 15, wherein the opening extends from an exterior surface of the upper to an interior surface of the upper, the interior surface defining a void within the upper.

18. The method recited in claim 15, wherein the plurality of strand segments includes a first strand segment and second strand segment;

wherein the step of locating the strand segments further comprises;

locating a first strand segment with a substantially vertical orientation in the area between the lace region and the lower region; and

locating the second strand segment extending toward a heel region of the footwear in the area between the lace region and the lower region.

19. The method recited in claim 15, further comprising locating the opening on a lateral side of the upper, and providing another opening located on a medial side of the upper.

20. The method recited in claim 15, further comprising locating the opening to extend from a heel region of the article of footwear to a midfoot region of the article of footwear.