Components for articles of footwear including lightweight, selectively supported textile components

• US 9,861,161 B2
• Filed: 11/10/2015
• Issued: 01/09/2018
• Est. Priority Date: 04/08/2014
• Status: Active Grant

• Current Assignee: Nike, Inc.
• Original Assignee: Nike, Inc.
• Inventors: Meschter, James C., Kilgore, Bruce J.
• Primary Examiner(s): Hurley, Shaun R
• Assistant Examiner(s): Nguyen, Bao-Thieu L
• Application Number:
  US14/937,586
• Publication Number:
  US 20160058126A1
• Time in Patent Office: 791 Days
• Field of Search: 12146, 12146 C, 12 51, 12 535, 121294, 12133 R, 12142 R, 361177, 36127, 36 49, 36 45, 36 501, 2169, 156499, 223 66, 223 78
• 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 23/0255 assembled by gluing or thermo bonding
• CPC Class Codes: A43B 23/0275 with a part of the upper particularly rigid, e.g. resisting articulation or torsion
• CPC Class Codes: A43B 23/042 Uppers made of one piece one piece slippers A43B3/106; one piece sandals A43B3/124
• CPC Class Codes: A43B 23/227 fixed on the outside of the shoe
• CPC Class Codes: A43B 7/1495 with arch-supports of the bracelet type
• CPC Class Codes: A43D 25/00 Devices for gluing shoe parts
• CPC Class Codes: A43D 25/20 Arrangements for activating or for accelerating setting of adhesives, e.g. by using heat

Abstract

Footwear components are made from lightweight textile structures (e.g., including circular knitted structures made from natural or synthetic fibers, such as socks or sock-type structures). The textile structures are selectively supported at various areas to provide desired local characteristics. Methods are provided for making such components, precursors to such components, and articles of footwear containing such components.

Claims

1. A method of forming an upper for an article of footwear, comprising:

engaging an upper base member with a jig such that the upper base member surrounds a first portion of the jig, wherein the first portion of the jig has a substantially planar first surface, a substantially planar second surface opposite the first surface, and a thickness greater than zero inches and less than ½

inch between the first and second surfaces;

positioning a first support member adjacent a surface of the upper base member such that the upper base member is located between the first support member and the jig and placing the first support member on a first pressure plate, wherein at least a portion of a surface of the first support member adjacent the surface of the upper base member includes a bonding or adhesive material;

placing a second support member on a second pressure plate; and

moving the first pressure plate and first support member to a first location adjacent the surface of the upper base member and moving the second pressure plate and second support member to a second location adjacent the surface of the upper base member, wherein the second support member is separated from the first support member by a distance of less than 1 inch at a midfoot area of a plantar support surface of the upper base member;

applying a compressive force to the first and second surfaces of the jig through the upper base member and the first support member;

heating the jig, wherein the jig is heated so as to transfer heat from inside the upper base member to the bonding or adhesive material of the first support member through the upper base member and so as to engage the first support member to the upper base member via the bonding or adhesive material.

2. A method according to claim 1, wherein the upper base member constitutes a continuous structure that includes a first side located adjacent the first surface of the jig and a second side located adjacent the second surface of the jig, and wherein the first support member is a continuous structure that includes a first side positioned adjacent the first side of the upper base member and a second side positioned adjacent the second side of the upper base member.

3. A method according to claim 1, wherein the upper base member constitutes a continuous structure that includes a first side located adjacent the first surface of the jig and a second side located adjacent the second surface of the jig, and wherein the first support member is positioned adjacent the first side of the upper base member, and wherein the method further comprises:

positioning a second support member adjacent the second side of the upper base member such that the upper base member is located between the second support member and the jig, wherein a surface of the second support member adjacent the second side of the upper base member includes a bonding or adhesive material.

4. A method according to claim 1, further comprising:

positioning a second support member separate from the first support member adjacent the surface of the upper base member such that the upper base member is located between the first support member and the jig, wherein a surface of the second support member adjacent the surface of the upper base member includes a bonding or adhesive material.

5. A method according to claim 4, wherein the first and second support members are positioned on a common side of the jig.

6. A method according to claim 4, wherein the first and second support members are positioned on opposite sides of the jig.

7. A method according to claim 4, wherein the applying a compressive force step further applies a compressive force to the first and second surfaces of the jig through the upper base member and the second support member.

8. A method according to claim 1, wherein the heating step includes inductive heating of the jig or activating one or more heating elements engaged with or formed as part of the jig.

9. A method according to claim 1, wherein the upper base member constitutes a sock or a circular knitted body.

10. A method according to claim 1, wherein the positioning step includes placing the first support member on a first pressure plate and moving the first pressure plate and first support member to a location adjacent the surface of the upper base member.

11. A method according to claim 1, wherein the applying a compressive force step includes simultaneously pressing the first and second pressure plates against opposite sides of the jig.

12. A method according to claim 1, wherein the first support member includes an outsole component.

13. A method according to claim 1, wherein the positioning step includes positioning the first support member such that it wraps around a bottom of the upper base member and along a first side and a second side of the upper base member.

14. A method according to claim 13, wherein the first support member includes a first inelastic band, strap, or strand for supporting a lace, and wherein the positioning includes positioning the first inelastic band, strap, or strand such that it extends continuously from the first side to the second side of the upper base member.

15. A method according to claim 1, wherein the first support member provides support for a lateral side surface and a medial side surface of the upper base member.

16. A method according to claim 15, wherein the first support member includes structure for supporting a lace.

17. A method according to claim 16, wherein the first support member includes a first inelastic band, strap, or strand for supporting a lace and a second inelastic band, strap, or strand for supporting the lace, and wherein the positioning includes positioning the first inelastic band, strap, or strand such that it extends along a first side of the upper base member and positioning the second inelastic band, strap, or strand such that it extends along a second side of the upper base member.

18. A method according to claim 17, wherein the first inelastic band, strap, or strand engages the second inelastic band, strap, or strand.

19. A method of forming an upper for an article of footwear, comprising:

positioning a support base in contact with a first surface of an upper base member;

positioning a first support member adjacent a second surface of the upper base member such that the upper base member is located between the first support member and the support base and placing the first support member on a first pressure plate, wherein at least a portion of a surface of the first support member adjacent the second surface of the upper base member includes a bonding or adhesive material;

placing a second support member on a second pressure plate; and

moving the first pressure plate and first support member to a first location adjacent the surface of the upper base member and moving the second pressure plate and second support member to a second location adjacent the surface of the upper base member, wherein the second support member is separated from the first support member by a distance of less than 1 inch at a midfoot area of a plantar support surface of the upper base member;

applying a compressive force to hold at least a portion of the upper base member between the first support member and the support base; and

heating the support base so as to transfer heat from the support base to the first support member through the upper base member and so as to engage the first support member to the upper base member via the bonding or adhesive material.

20. A method according to claim 19, wherein the upper base member includes a sock or a circular knitted body, the sock or circular knitted body having an open end through which the support base is inserted and a closed end, and wherein the support base positioning step includes positioning the support base within an interior chamber defined by the sock or the circular knitted body.

21. A method according to claim 19, wherein the heating step includes at least one of inductive heating the support base or activating one or more heating elements engaged with or formed as part of the support base.

22. A method of forming an upper for an article of footwear, comprising:

engaging an upper base member with a jig such that the upper base member surrounds a first portion of the jig, wherein the first portion of the jig has a substantially planar first surface, a substantially planar second surface opposite the first surface, and a thickness greater than zero inches and less than ½

inch between the first and second surfaces;

positioning a first support member adjacent a surface of the upper base member such that the upper base member is located between the first support member and the jig and placing the first support member on a first pressure plate, wherein at least a portion of a surface of the first support member adjacent the surface of the upper base member includes a bonding or adhesive material;

placing a second support member on a second pressure plate;

moving the first pressure plate and first support member to a first location adjacent the surface of the upper base member and moving the second pressure plate and second support member to a second location adjacent the surface of the upper base member, wherein the second support member is separated from the first support member by a distance of less than 1 inch at a midfoot area of a plantar support surface of the upper base member; and

engaging the first support member with the upper base member via the bonding or adhesive material including at least one of;

(a) applying a compressive force to the first and second surfaces of the jig through the upper base member and the first support member, and

(b) heating the jig, wherein the jig is heated so as to transfer heat from inside the upper base member to the bonding or adhesive material of the first support member through the upper base member and so as to engage the first support member to the upper base member via the bonding or adhesive material.