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

• US 9,861,162 B2
• Filed: 04/08/2014
• Issued: 01/09/2018
• Est. Priority Date: 04/08/2014
• Status: Active Grant

• Current Assignee: Nike, Inc.
• Original Assignee: Nike, Inc.
• Inventors: Kilgore, Bruce
• Primary Examiner(s): Pierce, Jeremy R
• Application Number:
  US14/247,981
• Publication Number:
  US 20150282565A1
• Time in Patent Office: 1,372 Days
• CPC Class Codes: A43B 1/04 braided, knotted, knitted or crocheted
• CPC Class Codes: A43B 23/0205 characterised by the material material of the lining A43B23/07, material of toe stiffeners or heel stiffeners A43B23/08
• CPC Class Codes: A43B 23/0235 Different layers of different material
• CPC Class Codes: A43B 23/04 Uppers made of one piece; Uppers with inserted gussets
• CPC Class Codes: A43B 23/08 Heel stiffeners; Toe stiffeners
• CPC Class Codes: A43B 23/227 fixed on the outside of the shoe
• CPC Class Codes: B05D 3/0254 After-treatment
• CPC Class Codes: B29D 35/0054 by compression moulding, vulcanising or the like; Apparatus therefor
• CPC Class Codes: B29D 35/02 made in one piece using a moulding technique, e.g. by injection moulding or casting
• CPC Class Codes: B29D 35/126 Uppers

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. Additional aspects relate to methods of making such components, precursors to such components, and articles of footwear containing such components.

Claims

1. A component for an article of footwear formed from a process comprising:

applying a first reactive polymeric material to a first portion of an upper base member, the first portion of the upper base member including at least a portion of a bottom surface of the upper base member, wherein the first reactive polymeric material exhibits a first set of thermoplastic properties as long as it is not exposed to thermoset curing conditions and thermosetting properties after it is exposed to thermoset curing conditions;

applying a second reactive polymeric material to a second portion of an upper base member, wherein the second reactive polymeric material exhibits a second set of thermoplastic properties as long as it is not exposed to thermoset curing conditions and thermosetting properties after it is exposed to thermoset curing conditions;

exposing the first reactive polymeric material on the first portion of the upper base member to thermoset curing conditions after the first reactive polymeric material is applied to the upper base member so as to convert the first reactive polymeric material at the first portion of the upper base member to a thermoset condition; and

exposing the second reactive polymeric material on the second portion of the upper base member to thermoset curing conditions after the second reactive polymeric material is applied to the upper base member so as to convert the second reactive polymeric material at the second portion of the upper base member to a thermoset condition;

wherein the first reactive polymeric material is different than the second reactive polymeric material, and wherein the component for the article of footwear is a circular knitted body having an open end and a closed end.

2. A component for an article of footwear formed from a process comprising:

applying a first reactive polymeric material to a first portion of an upper base member at a first application density level, the first portion of the upper base member including at least a portion of a bottom surface of the upper base member, wherein the first reactive polymeric material exhibits thermoplastic properties as long as it is not exposed to thermoset curing conditions and thermosetting properties after it is exposed to thermoset curing conditions;

applying a second reactive polymeric material to a second portion of the upper base member at a second application density level, wherein the second reactive polymeric material is different from the first reactive polymeric material and exhibits thermoplastic properties as long as it is not exposed to thermoset curing conditions and thermosetting properties after it is exposed to thermoset curing conditions, wherein the first application density level is greater than the second application density level;

exposing the first reactive polymeric material on the first portion of the upper base member to thermoset curing conditions so as to convert the first reactive polymeric material to a thermoset condition; and

exposing the second reactive polymeric material on the second portion of the upper base member to thermoset curing conditions so as to convert the second reactive polymeric material to a thermoset condition;

wherein the component for the article of footwear is a circular knitted body having an open end and a closed end.

3. A component for an article of footwear, comprising:

an upper base member including a textile material made from natural or synthetic fibers, wherein the upper base member is a circular knitted body having an open end and a closed end; and

a first cured, thermoset polymeric material coating provided in interstitial spaces between individual fibers of a first portion of the upper base member, the first portion of the upper base member including an area that extends from a lateral side of the upper base member, around a rear heel area of the upper base member, and to a medial side of the upper base member, wherein the first cured, thermoset polymeric material is formed at the first portion of the upper base member by curing a reactive polymeric material that was coated and/or was provided in interstitial spaces between individual fibers of the textile material at the first portion of the upper base member, and wherein the first portion of the upper base member has a greater hardness or stiffness as compared to a portion of the textile material that does not include the first cured, thermoset polymeric material;

a second cured, thermoset polymeric material coating provided in interstitial spaces between individual fibers of a second portion of the upper base member, wherein the second cured, thermoset polymeric material is formed at the second portion of the upper base member by curing a reactive polymeric material that was coated and/or was provided in interstitial spaces between individual fibers of the textile material at the second portion of the upper base member, and wherein the second portion of the upper base member has a greater hardness or stiffness as compared to a portion of the textile material that does not include the first or second cured, thermoset polymeric materials;

wherein the first cured, thermoset polymeric material has different hardness characteristics than the second cured, thermoset polymeric material.

4. A component for an article of footwear according to claim 3, wherein the reactive polymeric material includes a member selected from the group of:

a water-based reactive polymer;

an acrylic acid copolymer and a cross-linking agent; and

a polymeric binder material free of formaldehyde, phenols, and isocyanates.

5. A component for an article of footwear according to claim 3, wherein the textile material of the upper base member includes a second portion having uncured reactive polymeric material coating provided in interstitial spaces between individual fibers of the textile material at the second portion of the upper base member, and wherein the second portion of the upper base member has thermoplastic properties.

6. A component for an article of footwear, comprising:

an upper base member including a textile material made from natural or synthetic fibers, wherein the upper base member is a circular knitted body having an open end and a closed end; and

a first reactive polymeric material coating having a first application density level and provided in interstitial spaces between individual fibers of a first portion of the upper base member, the first portion of the upper base member including an area extending in a top-to-bottom direction of the upper base member at a medial or lateral side of the instep area, wherein the first reactive polymeric material exhibits thermoplastic properties as long as it is not exposed to thermoset curing conditions and is capable of becoming a first cured, thermoset polymeric material after it is exposed to thermoset curing conditions;

a second reactive polymeric material coating having a second application density level and provided in interstitial spaces between individual fibers of a second portion of the upper base member, wherein the second polymeric material exhibits thermoplastic properties so long as it is not exposed to thermoset curing conditions and is capable of become a second cured, thermoset polymeric material after it is exposed to thermoset curing conditions;

wherein the first cured, thermoset polymeric material has different hardness characteristics than the second cured, thermoset polymeric material, and wherein the first application density level is greater than the second application density level.