CN201108086Y - Footwear products with uppers having wire structural parts - Google Patents

Abstract

An article of footwear includes an upper made at least in part of a base layer and a strand segment located proximate a surface of the base layer. The wire segments are positioned so as to provide structural features that for example limit expansion in line with the direction of the longitudinal axis of the wire segments. In some constructions of the shoe, a first portion of the thread segments may extend between a forefoot region and a heel region of the shoe, and a second portion of the thread segments may extend vertically. The thread segments are embroidered on the base layer.

Description

Footwear products with uppers having wire structural parts

technical field

The utility model relates to a shoe product.

Background technique

Conventional footwear generally includes two main components, an upper and a sole structure. The upper is secured to the sole structure and forms the interior space of the shoe for comfortably and safely receiving the foot. The sole structure is secured to a lower surface of the upper so as to be positioned between the upper and the ground. For example, in some athletic footwear products, the sole structure may include a midsole and an outsole. The midsole may be made of a polymer foam material that attenuates ground reaction forces to reduce stress on the foot and leg during running, walking, and other walking movements. The outsole is secured to the lower surface of the midsole and forms the ground-contacting portion of the sole structure, which is made of a durable and wear-resistant material. The sole structure may also include a sockliner positioned within said void and proximate to the bottom surface of the foot to enhance the comfort of the shoe.

The upper generally extends over the instep and toe areas of the foot, along the medial and lateral sides of the foot, and around the heel area of the foot. In some products of footwear, such as basketball shoes and boots, the upper may extend up and around the ankle to provide support for the ankle. Access to the interior volume of the upper is typically provided by an ankle opening in the heel area of the shoe. Lacing systems are often incorporated into the upper to adjust the comfort of the upper, allowing entry and removal of the foot from the void within the upper. The lacing system also allows the wearer to vary certain dimensions of the upper, particularly the girth, to accommodate the foot to the changing dimensions. Additionally, the upper may include a tongue that extends under the lacing system to enhance the adjustability of the shoe, and the upper may incorporate a heel counter to limit heel movement.

Different materials are commonly used in the production of shoe uppers. For example, the upper of an athletic shoe may be formed from multiple layers of material including an outer layer, a mid layer, and an inner layer. The material forming the outer layer of the upper may be selected for properties such as stretch resistance, abrasion resistance, bendability, and breathability. With regard to the outer layer, the toe and heel regions may be made of leather, synthetic leather, or rubber materials to impart a relatively high degree of wear resistance. Leather, synthetic leather, and rubber materials may not exhibit the desired degree of flexibility and breathability for various other areas of the outer layer of the upper. Thus, other areas of the outer layer may be made of synthetic fabric, for example. Thus, the outer layer of the upper may be made from many material components, each of which imparts different properties to the upper. The middle layer of the upper is usually made of lightweight polymer foam, which provides cushioning and enhanced comfort. Similarly, the inner layer of the upper may be made of a comfortable and moisture-wicking fabric that wicks away sweat from the area immediately surrounding the foot. In some athletic footwear products, different layers may be joined with adhesives, and stitching may be used to join components within individual layers or to reinforce specific areas of the upper. Thus, conventional uppers have a layered structure, with each individual layer imparting different properties to different areas of the shoe.

Utility model content

One aspect of the present invention is an article of footwear having an upper and a sole structure secured to the upper. The upper includes a base layer, threads, and fastening components. The substrate layer defines a first surface and an opposing second surface. The wire has, for example, segments located close to the first surface and substantially parallel to the first surface at intervals greater than twelve millimeters. Additionally, the fixed component connects wires to the base layer.

Another aspect of the present invention is an article of footwear having an upper with a base layer and a plurality of strand segments. The base layer has a first surface and an opposite second surface. A wire segment is separate from the base layer and located proximate to at least a portion of the first surface. At least some of said line segments are substantially aligned. The upper defines a first direction corresponding to a longitudinal axis of a line segment, and the upper defines a second direction orthogonal to the first direction. The upper is substantially inextensible in a first direction, and the upper is extensible at least ten percent in a second direction.

Yet another aspect of the present invention is a method of manufacturing a product of footwear having an upper and a sole structure. The method includes embroidering the base layer with at least one thread to position segments of thread proximate to a surface of the base layer for a length greater than twelve millimeters. The base layer and the at least one thread are incorporated into the upper, the upper being secured to the sole structure.

The utility model provides a shoe product, which has an upper and a sole structure fixed to the upper, and the upper includes:

a base layer having a first surface and an opposing second surface, the base layer being formed from a bi-extensible material having the ability to stretch at least ten percent before tensile failure;

a plurality of threads separate from the base layer and located adjacent at least a portion of the first surface, the threads being formed of a non-stretch material,

The lines are oriented to form:

a first area, wherein said lines do not appear on said first surface;

a second region, wherein the lines are substantially parallel to each other, and the lines do not cross each other; and

A third region, wherein the wire is oriented such that a first portion of the wire extends in a first direction and a second portion of the wire extends in a second direction, the first portion of the wire is in contact with the wire The second portion of the intersects, and the first direction deviates from the second direction by at least sixty degrees.

The upper may have bi-directional stretch properties in the first region, uni-directional stretch properties in the second region, and non-stretch properties in the third region.

The material of the base layer is fabric.

The wire may have a securing member attached to the base layer and the securing member may be a layer of polymeric material.

The thread may be connected to the base layer by a fixing member and the fixing member may be an adhesive applied to at least the base layer.

The utility model provides a shoe product, which has an upper and a sole structure fixed to the upper, at least a part of the upper includes:

a base layer having a first surface and an opposing second surface, the first surface defining at least a portion of the outer surface of the shoe, and the second surface defining at least a portion of an inner surface forming the shoe The space in the plane for accommodating the feet;

a plurality of strands located adjacent one of the first surface and the second surface, a first portion of the strands being oriented to extend between a forefoot region and a heel region of the upper, and the a second portion of the strand is oriented to extend between an upper region and a lower region of the upper;

a fixing member that connects the wire to the base layer; and

A lace extending through the lace aperture in the base layer.

A third portion of the thread may extend around the lace aperture.

A third portion of the thread may be positioned at the heel region and extend from the upper region to the lower region.

A third portion of the wire may be positioned near an edge of the base layer.

The fixing member may be at least one of a layer of polymer material and an adhesive applied to at least the base layer.

The utility model also provides a shoe product, which has a vamp and a sole structure, which includes

a base layer and at least one thread by which the base layer is embroidered to position segments of the thread proximate to a surface of the base layer for a distance greater than twelve millimeters;

the base layer and the at least one thread are incorporated into the upper; and

The upper is secured to the sole structure.

The segments of the thread may be embroidered to extend from a forefoot region of the base layer to a heel region of the base layer.

The segments of the thread may be embroidered to extend from the lace-receiving portion of the base layer to a lower portion of the base layer.

The thread or another thread may be positioned by embroidery to form the outline of a component of the upper.

The base layer adjacent to the profile may be cut.

The thread or another thread may be embroidered positioned around the lace-receiving portion of the base layer.

The base layer may be joined to another component to be embroidered.

The utility model also provides a shoe product, which has a vamp and a sole structure, which includes

basal layer;

first line segment;

second line segment;

a plurality of first line segments positioned near the surface of the base layer such that the first line segments do not pass through the base layer for a distance of at least five centimeters;

a plurality of second line segments are also positioned adjacent the surface of the base layer such that the second line segments do not pass through the base layer for a distance of at least five centimeters;

the second line segment is oriented at least sixty degrees from the first line segment;

the base layer, the first thread segment and the second thread segment are incorporated into the upper; and

The upper is secured to the sole structure.

The first line segment may extend from a forefoot region of the base layer to a heel region of the base layer.

The article of footwear may further include a plurality of third line segments that may be positioned to form contours of components of the upper.

The base layer adjacent to the profile may be cut.

The article of footwear may further include a plurality of third strand segments that may be positioned about the lace-receiving portion of the base layer.

The base layer may have additional embroidered components attached thereto.

The utility model also provides a shoe product with a vamp and a sole structure, the vamp includes:

a substrate layer having a first surface and an opposing second surface, the substrate layer defining first and second points separated by a distance of at least five centimeters; and

a line extending from the first point to the second point, the line having a segment between the first point and the second point, the segment being located adjacent to the first surface and continuously exposed throughout said distance of at least five centimeters.

The segments of the line may be generally parallel to the first surface.

The base layer may be a fabric material capable of stretching at least ten percent before tensile failure.

The wire may primarily constrain the expansion of the base layer in a direction coincident with the longitudinal axis of the wire.

The segments may be connected to the base layer by a securing member, and the securing member may be a layer of polymeric material.

The segments may be connected to the base layer by fixing means, and the fixing means may be an adhesive applied to at least the base layer.

The utility model also provides a shoe product, which has an upper and a sole structure fixed to the upper, and the upper includes:

a base layer having a first surface and an opposite second surface, the base layer being formed of a material having bi-directional stretch; and

a plurality of wires, separated from the base layer and located adjacent at least a portion of the first surface, the wires being oriented to form:

a first area, wherein said lines do not appear on said first surface;

a second region, wherein the lines are substantially parallel to each other, and the lines do not cross each other; and

A third region, wherein the wire is oriented such that a first portion of the wire extends in a first direction and a second portion of the wire extends in a second direction, the first portion of the wire is in contact with the wire The second part of the cross.

The upper may have bi-directional stretch properties in the first region, uni-directional stretch properties in the second region, and non-stretch properties in the third region.

The material of the base layer may be fabric.

The wires may be connected to the base layer by a securing means, and the securing means may be a layer of polymeric material.

The wire may be connected to the base layer by a fixing member, and the fixing member may be an adhesive applied to at least the base layer.

The utility model provides a shoe product, which has an upper and a sole structure fixed to the upper, and the upper includes:

Multiple lace-accommodating holes;

a first set of wires extending at least partially around at least one of said apertures; and

a second set of wires extending outwardly from said first set of wires,

Wherein the wires originating from at least one of the first group of wires and the second group of wires overlap the wires originating from the other of the first group of wires and the second group of wires.

The threads originating from the first set of threads and the second set of threads may be entangled.

The strands originating from the first set of strands and the second set of strands may be separated from a textile component within the upper.

The second set of wires may include a plurality of wire segments that may be generally aligned and extend toward a lower region of the upper.

The wires of the second wire group may be connected to the base layer by a fixing member.

The second set of wires may include a plurality of wire segments that may be continuously exposed over a distance of at least five centimeters.

The second wire group may radially extend outward from a region adjacent to the first wire group.

The strand portions of the second set of strands may be closer together in an area adjacent the lace-receiving aperture than in an area remote from the lace-receiving aperture.

However, for a better understanding of the novel advantages and features, reference is made to the following descriptive matter and accompanying drawings, which describe and illustrate various embodiments and concepts related to the invention.

Description of drawings

The foregoing Summary of the Utility Model, and the following Detailed Description of the Utility Model will be better understood when read in conjunction with the accompanying drawings.

FIG. 1 is a lateral front view of an article of footwear having an upper according to aspects of the present invention;

Fig. 2 is a front view of the inner side of the shoe product;

Figure 3 is a top plan view of the shoe product;

Figure 4 is a bottom plan view of the shoe product;

Fig. 5 is a rear front view of the footwear product;

Figure 6 is a top plan view of a first embroidered component forming at least part of the lateral side of the upper;

Figure 7 is a top plan view of a second embroidered element forming at least part of the medial side of the upper;

8A-8O are top plan views illustrating steps for forming a first embroidery component and a second embroidery component;

9A-9D are front views of steps for assembling a shoe;

10A-10D are perspective views of a first step for securing a wire to a base portion;

11A-11D are perspective views of a second step for securing the wire to the base portion;

12A-12C are perspective views of a third step for securing the wire to the base portion.

Detailed ways

The following discussion and accompanying figures disclose an article of footwear having an upper with embroidered structures. Additionally, different methods of producing the upper are disclosed. The disclosed upper and method relate to a shoe having a structure suitable for running, especially sprinting. However, the concept of an upper is not limited to shoes designed for running, but can be used in a wide variety of sports shoes including, for example, baseball shoes, basketball shoes, cross-training shoes, bicycle shoes, soccer shoes, Tennis shoes, rugby shoes, walking shoes, and hiking shoes. The concepts can be applied to types of shoes that are generally considered non-athletic, including dress shoes, loafers, sandals, and work boots. Accordingly, the concepts disclosed herein apply to a wider variety of shoe types.

shoe structure

An article of footwear 10 is depicted in FIGS. 1-5 as having the general construction of a running shoe and including a sole structure 20 and an upper 30 . For reference purposes, shoe 10 may be divided into three general regions: forefoot region 11 , midfoot region 12 , and heel region 13 , as shown in FIGS. 1 and 2 . The shoe 10 also includes a lateral side 14 and a medial side 15 . Forefoot region 11 generally includes the portion of shoe 10 that corresponds to the toes and the joints connecting the metatarsals to the phalanges. Midfoot region 12 generally includes the portion of shoe 10 that corresponds to the arch region of the foot, and heel region 13 corresponds to the rear portion of the foot, including the calcaneus. A lateral side 14 and a medial side 15 extend through each region 11 - 13 and correspond to opposite sides of the shoe 10 . Regions 11 - 13 and sides 14 - 15 are not used to precisely delineate areas of shoe 10 . Rather, regions 11-13 and sides 14-15 are intended to represent general regions of shoe 10 to aid in the following discussion. In addition to shoe 10, regions 11-13 and sides 14-15 may also be used for sole structure 20, and upper 30 and its individual components.

Sole structure 20 is secured to upper 30 and extends between the foot and the ground when shoe 10 is worn. In addition to providing traction, the sole structure 20 relieves ground reaction forces when the sole structure 20 is squeezed between the foot and the ground during walking, running, and other foot movements. The configuration of sole structure 20 may vary considerably to include a variety of conventional and non-conventional configurations. However, as an example, a suitable structure such as for a sole structure 20 is depicted in FIGS. 1 and 2 as comprising a first sole component 21 and a second sole component 22 .

First sole member 21 extends through the longitudinal length of shoe 10 (ie, through each region 11-13) and may be made of a polymer foam material, such as polyurethane and ethylvinylacetate. The partial upper 30 wraps around the sides of the first sole component 21 and is secured to the lower region of the first sole component 21 . In each region 11 - 13 , a lower region of the first sole component 21 is exposed to form a portion of the ground contact surface of the shoe 10 . Portions of upper 30 secured to the lower region of first sole component 21 may also be exposed in regions 12 and 13 and may contact the ground in use. The upper region of first sole component 21 is configured to contact the bottom surface of the foot (ie, the sole) and thus form a foot-supporting surface within upper 30 . However, in some constructions, a sockliner may be located within upper 30 proximate an upper region of first sole component 21 to form the foot-supporting surface of shoe 10 .

A second sole component 22 is positioned in each region 11 and 12 and secured to either or both of the first sole component 21 and upper 30 . Whereas part of the first sole component 21 extends into the upper 30 , the second sole component 22 is located on the outer surface of the shoe 10 to form a portion of the ground contact surface in regions 11 and 12 . In order to impart traction, the second sole part 22 includes a plurality of protrusions 23, which may have removable stud structures. Suitable materials for the second sole component 22 include various rubber or other polymeric materials that are both durable and abrasion resistant.

Upper 30 defines a void within shoe 10 for receiving and securing a foot relative to sole structure 20 . More specifically, the void is shaped to receive the foot and extend along the lateral side of the foot, the medial side of the foot, above the foot, and below the foot. Access to the space is provided through an ankle opening 31 located at least in the heel region 13 . Lace 32 extends through various lace apertures 33 in upper 30 and allows the wearer to vary the size of upper 30 to accommodate different sized feet. Lace 32 also allows the wearer to loosen upper 30 and facilitate movement of the foot out of the void. Even if not depicted, upper 30 may include a tongue that extends beneath lace 32 to enhance the comfort and adjustability of shoe 10 .

Apart from lace 32 , the main components of upper 30 are first embroidered component 40 and second embroidered component 50 . A first embroidered component 40 forms a portion of upper 30 corresponding to lateral side 14 and a second embroidered component 50 forms a portion of upper 30 corresponding to medial side 15 . Thus, each embroidery component 40 and 50 extends through each region 11-13. Generally speaking, and as described in more detail below, upper 30 is assembled substantially by joining the edges of embroidered elements 40 and 50 in forefoot region 11 and heel region 13 to give the void a general shape. Furthermore, fitting upper 30 includes a covering portion incorporating lace 32 and embroidered elements 40 and 50 around the sides of first sole element 21 , and securing said portions to the lower region of first sole element 21 .

first embroidery part

The first embroidery component 40 is depicted separately in FIG. 6 as including a base layer 41 and a plurality of threads 42 . One embroidery method, which will be described in more detail below, is used to secure or position thread 42 relative to base layer 41 . Typically, base layer 41 is the substrate to which thread 42 is secured during embroidery and positioned to form structural components in upper 30 . As a structural component, for example, strands 42 may limit the stretch of upper 30 in a particular direction or strands 42 may reinforce areas of upper 30 .

Although the base layer 41 is described as a single material part, the base layer 41 may also be formed from a plurality of connected parts. Similarly, the base layer 41 may be a single layer of material, or the base layer may be formed from multiple coextensive layers. As an example, base layer 41 may include a tie layer or other securing member that bonds, secures, or otherwise connects portion of wire 42 to base layer 41 .

The base layer 41 defines various edges 43a-43d, which are used as reference in the following material. Edge 43a extends across each region 11 - 13 and defines a portion of ankle opening 31 . The edge 43b is mainly located in the forefoot area 11 and forms an end point for the different lines 42 . An edge 43 c situated opposite to edge 43 b is mainly located in the heel region 13 and forms the opposite end point for the different lines 42 . During the production of the shoe 10, the edges 43a and 43c are joined to the second embroidery element 50 in the forefoot region 11 and the heel region 13, respectively. An edge 43d disposed opposite edge 43a extends through each region 11 - 13 and encases the first sole part 21 and is secured to the lower region of the first sole part 21 . The specific configuration of base layer 41, and the corresponding location and shape of edges 43a-43d, can vary significantly depending on the configuration of shoe 10.

The base layer 41 can be made of any common two-dimensional material. As used in accordance with the present invention, the term "two-dimensional material" or variations thereof is meant to include generally flat materials that exhibit a length and width that are substantially greater than thickness. Accordingly, suitable materials for the base layer 41 include, for example, various fabrics, polymer sheets, or combinations of fabrics and polymer sheets. Fabrics are typically made from fibers, filaments, or yarns, for example, either of which can be (a) formed directly from webs, by bonding, fusing, or interlocking to form nonwovens and felts, or (b) by mechanically Operates yarn formation to produce woven fabrics. The fabric may incorporate fibers that may be aligned to impart stretch in one direction or stretch in multiple directions, and may include, for example, a coating that forms a breathable and waterproof barrier. The polymer sheet can be extruded, laminated, or otherwise formed from a polymer material to exhibit a generally flat appearance. Two-dimensional materials may also include laminated or otherwise layered materials comprising two or more layers of fabric, polymer sheet, or a combination of fabric and polymer sheet. In addition to fabrics and polymer sheets, other two-dimensional materials can be used for the base layer 41 . While two-dimensional materials can have smooth or generally non-textured surfaces, some two-dimensional materials exhibit texture or other surface features such as, for example, dimples, protrusions, ribs, or various patterns. Despite the presence of surface features, two-dimensional materials typically remain flat and exhibit lengths and widths substantially greater than thickness.

The partial line 42 extends through the base layer 41 or is located close to the base layer 41 . In regions where the wire 42 extends through the base layer 41 , the wire 42 is directly connected or otherwise secured to the base layer 41 . Wires 42 are located in regions proximate to base layer 41 , wires 42 may not be secured to base layer 41 or may be attached with a tie layer or other securing member that bonds, secures, or otherwise connects portions of wires 42 to base layer 41 . To form structural components in upper 30, multiple strands 42 or segments of a single strand 42 may be collected in one of the different strand groups 44a-44e. Thread set 44a includes thread 42 extending between edges 43b and 43c, thereby extending through various regions 11-13 of shoe 10. As shown in FIG. The wire set 44b includes the wires 42 positioned adjacent to the shoelace holes 33 and extending radially outward from the shoelace holes 33 . Set of strands 44c includes strands 42 extending from set of strands 44b (ie, the area proximate lace aperture 33) to an area proximate edge 43d. Thread set 44d includes thread 42 extending from edge 43c to edge 43d and located primarily in heel region 13 .

Article of footwear 10 is described as having the general construction of a running shoe. During walking, running, or other foot motions, forces generated in shoe 10 may tend to stretch upper 30 in different directions, and the forces may be focused at different locations. Each strand 42 is positioned to form a structural component in upper 30 . More specifically, wire groups 44a-44d are collections of multiple wires 42 or segments of individual wires 42 that form structural members to resist stretching in different directions or reinforce where forces are concentrated. Thread set 44a extends through portions of first embroidery component 40 corresponding to regions 11-13 to resist longitudinal stretch (ie, in a direction extending through each region 11-13 and between edges 43b and 43c). String set 44b is located proximate to lace aperture 33 to resist the buildup of forces due to tension in lace 32 . Strand set 44c generally extends in a direction normal to strand set 44a to resist stretch in the medial-lateral direction (ie, in a direction extending around upper 30). Additionally, a wire set 44d is located in the heel region 13 to form a heel counter that limits heel movement. The set of wires 44e extends around the periphery of the base layer 41 and corresponds to the location of the edges 43a-43d. Accordingly, strands 42 are positioned to form structural components in upper 30 .

Thread 42 may be made of any conventional one-dimensional material. As used in connection with the present invention, the term "one-dimensional material" or variations thereof is meant to include generally elongated materials that exhibit a length substantially greater than width and thickness. Thus, suitable materials for thread 42 include, for example, various filaments and yarns. Silk can be made from a variety of synthetic materials, such as rayon, nylon, polyester, and polyacrylic, in addition to the principal, naturally occurring silk. In addition, different engineered fibers such as aramid fibers, para-aramid fibers, and carbon fibers can be used. A yarn can be made of at least one filament or a plurality of fibers. Filaments are of indeterminate length, while fibers are of relatively short length and are usually spun or twisted to produce yarn of suitable length. As for yarns formed from filaments, these yarns may be formed from a single filament or from a plurality of individual filaments combined together. A yarn may also include separate filaments made of different materials, or a yarn may include multiple filaments, each filament made of two or more different materials. A similar concept also applies to yarns made from fibers. Thus, filaments and yarns can have various structures exhibiting lengths substantially greater than widths and thicknesses. In addition to filaments and yarns, other one-dimensional materials may be used for thread 42 . While one-dimensional materials will generally have a cross-section that is substantially equal in width and thickness (eg, a circular or square cross-section), some one-dimensional materials may have a width that is greater than the thickness (eg, a rectangular cross-section). A material can be considered a one-dimensional structure if the length of the material is sufficiently greater than the width and thickness of the material despite the greater width.

Second embroidery part

The second embroidery component 50 is depicted separately in FIG. 7 as including a base layer 51 and a plurality of threads 52 . An embroidery method similar to the embroidery method used to form the first embroidery component 50 is used to fix or position the thread 52 relative to the base layer 51 . Typically, base layer 51 is the substrate to which thread 52 is secured during embroidery and positioned to form structural components in upper 30 . As a structural component, for example, the threads 52 may limit the stretching of the upper 30 in a particular direction or the threads 52 may reinforce regions of the upper 30 , for example.

Base layer 51 may be made of any generally two-dimensional material, including any of the two-dimensional materials used for base layer 41 described above. Although the base layer 51 is described as a single material part, the base layer 51 may be formed from a plurality of connected parts. Similarly, the base layer 51 may be a single layer of material, or the base layer may be formed from multiple coextensive layers. As an example, base layer 51 may include a tie layer or other securing member that bonds, secures, or otherwise connects portion of wire 52 to base layer 51 . Furthermore, thread 52 may be made of any generally one-dimensional material, including any one-dimensional material used for thread 42 described above.

The base layer 51 defines various edges 53a-53d, which are referenced in the following material. Edge 53a extends across each region 11 - 13 and defines a portion of ankle opening 31 . The edge 53b is mainly located in the forefoot area 11 and forms an end point for the different lines 52 . The edge 53c situated opposite the edge 53b is mainly located in the heel region 13 and forms the opposite end point for the different lines 52 . During the production of the shoe 10, the edges 53a and 53c are joined to the second embroidery element 40 in the forefoot region 11 and in the heel region 13, respectively. An edge 53d disposed opposite edge 53a extends through each region 11 - 13 and encases the first sole part 21 and is secured to the lower region of the first sole part 21 . The specific configuration of base layer 51, and the corresponding location and shape of edges 53a-53d, can vary significantly depending on the configuration of shoe 10.

The partial line 52 may extend through the base layer 51 or be located close to the base layer 51 . In the region where the wire 52 extends through the base layer 51 , the wire 52 is directly connected or otherwise secured to the base layer 51 . Wires 52 are located in areas proximate to base layer 51 , wires 52 may not be secured to base layer 51 or may be attached with a tie layer or other securing member that bonds, secures, or otherwise connects portions of wires 52 to base layer 51 . To form structural components in upper 30, multiple strands 52 or segments of a single strand 52 may be collected in one of the different strand groups 54a-54e. String set 54a includes strands 52 located in forefoot region 11 and an anterior portion of midfoot region 12, and a different strand 52 in strand set 54a extends rearwardly and longitudinally from edge 53b. The wire set 54b includes the wires 52 positioned adjacent to the shoelace holes 33 and extending radially outward from the shoelace holes 33 . Set of strands 54c includes strands 52 that extend from set of strands 54b (ie, an area proximate lace aperture 33 ) to an area proximate edge 53d. Thread set 54d includes thread 52 extending from edge 53c to edge 53d and located primarily in heel region 13 . String set 54e includes strands 52 located in heel region 13 and in the rear portion of midfoot region 12, and different strands 52 in strand set 54e extend forwardly and longitudinally from edge 53c. The wire group 54f extends around the periphery of the base layer 51 and corresponds in position to the edges 53a-53d.

As discussed with respect to first embroidered component 40, forces generated in shoe 10 may tend to stretch upper 30 in different directions, and the forces may be focused in different locations. Each strand 52 is positioned to form a structural component in upper 30 . More specifically, wire groups 54a-54e are collections of multiple wires 52 or segments of a single wire 52 that form structural members to resist stretching in different directions or reinforce where forces are concentrated. Thread set 54a extends through a portion of second embroidery component 50 corresponding to at least forefoot region 11 to resist longitudinal stretching. String set 54b is located proximate to lace aperture 33 to resist the buildup of forces due to tension in lace 32 . Strand set 54c generally extends in a direction normal to strand sets 54a and 54e to resist stretch in the medial-lateral direction (ie, in a direction extending around upper 30). Sets of wires 54d are located in the heel region 13 to form opposing sides of the heel counter that limit heel movement. Additionally, strand set 54e is located in at least heel region 13 to resist longitudinal stretching. Accordingly, strands 52 are positioned to form structural components in upper 30 .

Structural components

As discussed in the background section above, conventional uppers may be formed from multiple layers of material, each layer imparting different properties to different areas of the upper. In use, the upper may be subjected to considerable tension, and one or more layers of material are located in various regions of the upper to resist the tension. That is, a single layer may be incorporated into specific portions of the upper to resist tension that occurs during use of the shoe. As an example, a woven fabric may be incorporated into the upper to impart longitudinal stretch resistance. Woven fabrics are made from yarns that are interwoven at right angles to each other. If a woven fabric is incorporated into the upper for longitudinal stretch resistance, only yarns oriented in the longitudinal direction will contribute to longitudinal stretch resistance, and yarns oriented orthogonally to the longitudinal direction will generally not contribute to longitudinal stretch resistance. Stretchability. Therefore, about half of the yarns in the woven fabric are superfluous for longitudinal stretch resistance. As another example, the degree of stretch resistance desired may vary in different regions of the upper. Some areas of the upper may require a relatively high degree of stretch resistance, while other areas of the upper may require a relatively low degree of stretch resistance. Because woven fabrics can be used in areas that require both high and low degrees of stretch resistance, some of the yarns in the woven fabric are redundant in areas that require low degrees of stretch resistance. In each of these examples, the excess yarn adds to the overall mass of the shoe without adding beneficial properties to the shoe. Similar concepts apply to other materials such as leather and polymer sheets, which are exploited for one or more of, for example, abrasion resistance, bendability, breathability, cushioning, and water absorption.

From the above discussion, the materials used in conventional uppers made from multiple layers of material may have excess portions that are significantly detrimental to the desired characteristics of the upper. For example, with respect to stretch resistance, a layer may have a material that imparts either (a) more directional stretch resistance or (b) a greater degree of stretch resistance than necessary or desired. Thus, excess portions of these materials can increase the overall mass of the shoe without contributing beneficial properties.

Upper 30 is manufactured with minimal excess material present compared to conventional layered structures. Base layers 41 and 51 provide coverage to the foot, but appear to be of relatively low quality. Some of the wires 42 and 52 (i.e., wire groups 44a, 54a, 44c, 54c, 44d, 54d, and 54e) are positioned to provide specific, desired directions of stretch resistance, and the number of wires 42 and 52 is selected to provide only Imparts the desired degree of stretch resistance. Other strands 42 and 52 (ie, strand groups 44b , 44e , 54b , and 54f ) are positioned to reinforce specific areas of upper 20 . Accordingly, the orientation, location, and number of wires 42 and 52 are selected to provide a structural component that is customized for a particular purpose.

Each wire group 44a-44d and 54a-54e is a group of wires 42 and 52 that provide a structural component as described above. More specifically, however, strand set 44a is positioned to provide longitudinal stretch resistance on lateral side 14, and the number of strands 42 in strand set 44a is selected to provide a particular degree of stretch resistance. Similarly, sets of strands 54a and 54e are positioned to provide longitudinal stretch resistance in regions 11 and 13 of medial side 15, and the number of strands 52 in sets of strands 54a and 54e is selected to provide specific stretch resistance in regions 11 and 13. degree of stretch resistance. Each set of strands 44b and 54b reinforces lace aperture 33, and the number of strands surrounding each lace aperture is selected to provide a particular degree of reinforcement. Each strand set 44c and 54c extends from lace aperture 33 and is selected to provide a particular degree of stretch resistance in a direction extending around upper 30, and the number of strands 42 in strand sets 44c and 54c is selected to provide a particular degree of stretch resistance. degree of stretch resistance. Additionally, the wire sets 44d and 54d are positioned to form a heel counter, the number of wires in the wire sets 44d and 54d imparting a certain degree of stability to the heel counter. Thread sets 44e and 54f reinforce the edges of embroidered components 40 and 50 , including portions of embroidered components 40 and 50 that form ankle opening 31 , and portions of embroidered components 40 and 50 that are joined to each other or to other portions of shoe 10 . Thus, this characteristic is provided by the wires 42 and 52 at least in part based on their orientation, position and number.

Depending on the particular structure of shoe 10 and the intended use of shoe 10 , base layers 41 and 51 may be, for example, non-stretch materials, unidirectional stretch materials, or bi-directional stretch materials. Generally, materials with two-way stretch provide upper 30 with a greater ability to conform to the contours of the foot, thereby enhancing the comfort of shoe 10 . In constructions in which base layers 41 and 51 are bi-directionally stretchable, the combination of base layers 41 and 51 and strands 42 and 52 effectively alters the stretch characteristics of upper 30 at specific locations. For the first embroidered component 40, the combination of the base layer 41 and the thread 42 having bi-directional stretchability forms regions of the upper 30 with different stretch properties, including (a) a first region where the thread 42 does not appear and upper 30 exhibits bidirectional stretchability, (b) a second region where lines 42 appear and do not intersect each other, said upper 30 exhibits unidirectional stretchability, said direction being orthogonal to lines 42, and ( c) A third area, where the lines 42 occur and do not cross each other, the upper 30 appears substantially unstretched. A similar concept applies to the second embroidery component 50 .

The first area includes an area where no lines appear. Referring to FIG. 6, an example of a first area is marked by reference numeral 54a and is the location where no line 42 appears. Because the threads 42 do not appear in the first area, the base layer 41 is not bounded by the threads 42 and the upper 30 is free to stretch in both directions. Said second region comprises the regions where the lines 42 occur but do not intersect each other at substantially right angles. Referring to FIG. 6, an example of the second area is marked by reference numeral 45b. Because the wires 42 are substantially aligned in the second region, the wires 42 resist stretching in a direction parallel to the direction in which the wires 42 lie. However, the wire 42 does not resist stretching in a direction normal to the wire 42 . Accordingly, base layer 41 is free to stretch in a direction normal to strands 42 , thereby providing unidirectional stretchability to upper 30 . In some constructions, base layer 41 may stretch at least ten percent in a direction normal to line 42 , whereas base layer 41 is substantially not stretchable in a direction parallel to line 42 . The third region includes the region where the lines 42 occur and intersect each other at a substantially right angle (ie, an angle greater than 60 degrees). Referring to Fig. 6, an example of the third area is marked by reference numeral 45c. Because the wires 42 cross each other generally at right angles, the wires 42 resist stretching in substantially all directions. Accordingly, base layer 41 is not free to stretch in any direction, thereby providing a relatively non-stretchable structure to upper 30 in the third region. A similar concept is applied to the second embroidery component 50, an example of an area corresponding to the first area is marked by reference numeral 55a among Fig. 7, an area corresponding to the second area is marked by reference numeral 55b among Fig. 7, and The area of the third area is marked by reference numeral 55c in FIG. 7 .

Transitions between regions occur at the junctions between regions where the relative numbers and orientations of lines 42 and 52 change. At the interface between regions, for example, upper 30 may change from having two-way stretch to one-way stretch, from having two-way stretch to not having stretch, or from having one-way stretch to not having stretch . Assuming that the difference between regions is the relative number and orientation of lines 42 and 52, transitions between regions may appear abruptly. That is, in the thickness space of one of lines 42 and 52, upper 30 may transition from one region to the other. A different structure can be used to reduce the abruptness of transitions between regions. For example, lines 42 and 52 near a zone transition may have stretch properties. For example, when transitioning from a first region to a second region, the stretched nature of the lines 42 and 52 at the interface will reduce the abruptness of the transition. Structurally, the lines 42 and 52 near the transition (i.e., near the boundary of the line group) may have more stretch than the lines 42 and 52 farther from the transition (i.e., near the center of the line group) . In addition to stretchability, the strands 42 and 52 made of non-stretch material may have a corrugated (ie, zigzag) shape to allow for stretch at transitions.

Threads 42 and 52 may be used to alter properties of shoe 10 other than stretch resistance. For example, strands 42 and 52 may be used to provide additional wear resistance in specific areas of upper 30 . For example, strands 42 and 52 may be concentrated in areas of upper 30 that are subject to wear, such as in forefoot region 11 and near sole structure 20 . If used for wear resistance, wires 42 and 52 may be selected from materials that also exhibit relatively high wear resistance. Threads 42 and 52 may also be used to alter the flex properties of upper 30 . That is, areas of a relatively high concentration of lines 42 and 52 may be less curved than areas of a relatively low concentration of lines 42 and 52 . Similarly, areas with a relatively high concentration of threads 42 and 52 may be less breathable than areas with a relatively low concentration of threads 42 and 52 .

The orientation, location and number of lines 42 and 52 in FIGS. 1-7 are used to provide examples of suitable configurations for shoe 10 within various aspects of the present invention. In other constructions for shoe 10 , the different sets of strands 44a - 44d and 54a - 54e may not be present, or additional sets of strands may be present to provide additional structural components in shoe 10 . If further longitudinal stretch resistance is desired, a strand set similar to strand set 44a can be included on lateral side 14 , or strand sets 54a and 54e can be altered to extend across midfoot region 12 . If further stretch resistance around upper 30 is desired, additional strands 42 and 52 may be added to strand sets 44c and 54c. Similarly, further stretch resistance around upper 30 may be provided by adding a set of strands extending around forefoot region 11 or a set of strands extending around heel region 13 .

The style of running and individual preference also determines the orientation, location and number of lines 42 and 52 . For example, some individuals may have a relatively high degree of pronation (ie, pronation of the foot), and having a greater number of strands 42 in strand set 44c may reduce the degree of pronation. Some also desire greater longitudinal stretch resistance, and shoe 10 may be modified to include more strands 42 in strand set 44a. Some people may also prefer that upper 30 fit better, which may require adding more strands 42 and 52 to strand sets 44b, 44c, 54b, and 54c. Thus, by varying the orientation, location, and number of strands 42 and 52, shoe 10 can be customized to suit a running style or an individual's preferences.

Base layers 41 and 51 are described as having a structure that together covers substantially all of the medial and lateral sides of the foot. As mentioned above, the base layers 41 and 51 are the substrates to which the threads 42 and 52 are secured during the embroidery process. However, in some constructions, portions of base layers 41 and 51 may be absent so that threads 42 and 52 are positioned against the foot or a sock worn on the foot. That is, the base layers 41 and 51 may be formed with holes or cut-outs exposing the feet. In other constructions, base layers 42 and 52, or portions thereof, may be made of water-soluble materials that are removed after the embroidery step. That is, upper 30 may be dissolved after threads 42 and 52 are secured to base layers 41 and 51 . Accordingly, base layers 41 and 51 may be partially or completely absent in some constructions of shoe 10 .

A substantial portion of the total length of the wires 42 and 52 is located close to the base layers 41 and 51 , but is not directly secured to the base layers 41 and 51 . For example, to ensure that wires 42 remain in place, a tie layer or other connection means that bonds, secures, or otherwise connects portions of wires 42 to base layer 41 may be employed. For example, the connecting member or other securing member may be a thermoplastic polymer sheet positioned between the wire 42 and the base layer 41 and heated to bond the wire 42 and the base layer 41 together. The connecting means or other securing means may also be, for example, a thermoplastic polymer sheet or fabric extending across the thread 42 and base layer 41 to bond the thread 42 and base layer 41 together. Additionally, the connecting means or other securing means may be an adhesive that bonds the wire 42 and the base layer 41 together. In some constructions, additional thread may be sewn onto thread 42 to secure thread 42 to base layer 41 . In addition, various structures or methods may be used to secure the wire 42 to the base layer 41 . A similar concept can be applied to connecting the base layer 51 and the wire 52 .

Partial wires 42 within different wire groups 44a, 44c, and 44d may be substantially parallel to each other. For example, as depicted in FIG. 6, the distance between partial lines 42 actually changes. That is, the lines 42 are radially outward. As for the strand group 44 a , the different strands 42 are relatively close to each other in the midfoot region 12 . However, as the strands 42 extend toward the forefoot region 11 and the heel region 13, the distance between the individual strands 42 increases. Thus, threads 42 radiate outward in forefoot region 11 and heel region 13 . Similarly, the different strands 42 in strand set 44c also radiate outwardly and away from the lace holes 33 . In portions of upper 30 close to lace holes 33 , threads 42 are relatively close to each other, but tend to separate or radiate outward in portions of upper 30 farther from lace holes 33 . The radial nature discussed above may serve, for example, to distribute forces from a relatively small area (eg, each lace aperture 33 ) to a larger area. That is, the radial properties may be used to distribute force throughout various areas of upper 30 .

As discussed above, upper 30 is formed at least in part by an embroidery process, which forms structural components from threads 42 and 52 . Depending on the orientation, location, and number of strands 42 and 52 , various structural components may be formed in upper 30 . As examples, structural components may impart stretch resistance to specific regions, strengthen regions, enhance abrasion resistance, alter bendability, or provide breathable regions. Thus, by controlling the orientation, location, and number of strands 42 and 52, the characteristics of upper 30 and shoe 10 may be controlled.

embroidery steps

8A-8O depict an example of a method of producing each embroidery component 40 and 50 . In general, the steps for forming the first embroidery component 40 are similar to the steps for forming the second embroidery component 50 . Accordingly, the following discussion focuses on the method of production of the first embroidery component, with the understanding that the second embroidery component 50 can be produced in a similar manner.

The first embroidered component 40 can be made at least in part by an embroidery step, which can be made by either mechanical or manual methods. As with mechanical embroidery, various conventional embroidery machines may be used to form the first embroidered component 40, and the embroidery machines may be programmed to embroider a particular pattern or design from one or more threads. Typically, embroidery machines create patterns and designs by repeatedly securing thread to different positions so that portions of the thread extend between the positions and are visible. More specifically, the embroidery machine forms a series of lock-stitches by (a) piercing the base layer 41 at a first location with a needle so that a first loop of thread 42 passes through the base layer 41, (b) securing the first loop of thread 42 with another thread passed through the first loop, (c) moving the needle to the second position so that the thread 42 extends from the first position to the second position, and The surface of the base layer 41 is visible, (d) piercing the second location of the base layer 41 with a needle so that the second loop of the thread 42 passes through the base layer 41, and (e) connecting the second loop of the thread 42 with the threaded loop. Secure with another wire passing through the second loop. Thus, the embroidery machine operates to secure thread 42 to two defined positions and also to extend thread 42 between said two positions. By repeatedly operating these steps, embroidery is formed from the thread 42 on the base layer 41 .

Conventional embroidery machines can form patterns and designs on base layer 41 by forming satin-stitches, running-stitches, or fill-stitches, each of which Lock stitch may be used to secure the wire 42 to the base layer 41 . Satin stitches are a series of zigzag stitches that are brought close together. The jersey stitch runs between two positions and is often used for fine details, contours, and underlayment. A condense stitch is a series of flat stitches formed close together to create different patterns and stitch directions, and is often used to cover relatively large areas. As for satin stitches, conventional embroidery machines usually limit satin stitches to twelve millimeters. That is, when the embroidery machine forms satin stitches, the distance between the first location where the thread is secured to the base layer and the second location is typically limited to twelve millimeters. Thus, conventional satin stitch embroidery includes threads extending between locations twelve millimeters apart or less. However, forming embroidered component 40 may require the embroidery machine to be modified to form satin stitches extending between locations greater than twelve millimeters apart. In some aspects of the invention, for example, the stitches may be separated by more than five centimeters. That is, for example, the wires can be continuously exposed on the surface of the base layer 41 at a distance greater than twelve millimeters or greater than five centimeters.

With respect to Figure 8A, base layer 41 is depicted as being combined with loop 60, which has the configuration of a conventional rectangular loop for embroidery operations. The main components of ring 60 are outer ring 61 , inner ring 62 , and tensioner 63 . As is known in the art, the outer ring 61 extends around the inner ring 62 , and a peripheral portion of the base layer 41 extends between the outer ring 61 and the inner ring 62 . Tensioner 63 adjusts the tension in outer ring 61 so that inner ring 62 is positioned within outer ring 61 and base layer 41 is held securely in place. In this configuration, the central region of the base layer 41 lies on a single plane and may be under slight tension in order to ensure that the base layer 41 is securely positioned in the following steps of the production method. Generally, therefore, the loop 60 is used as a frame for securely positioning the base layer 41 during the embroidery operation for forming the first embroidery component 40 .

Once the base layer 41 is secured within the loop 60 , the embroidery machine begins positioning and securing the thread 42 to the base layer 41 . Initially, the embroidery machine forms the outline of the first embroidery component 40, as depicted in Figure 8B. The outline comprises a set of threads 44e extending around the periphery of the first embroidery component 40 and corresponding to the edges 43a-43d. Part of the edge 43a forming the ankle opening 31 is depicted as having a thicker structure than other areas of the string set 44e which imparts reinforcement to the ankle opening 31 . In other configurations of the first embroidery component 40, all thread groups 44e may exhibit a thicker configuration, or a portion of the edge 43a forming the ankle opening 31 may have a relatively thin configuration. In addition, in some configurations of the first embroidery component 40, the thread group 44e may be partially or completely absent. Different types of stitches may be used to form the set of threads 44e, including satin stitches, flat stitches, condensed stitches, or combinations thereof.

After the wire group 44e is formed, the wire group 44a may be formed. Referring to FIG. 8C , portion 42a of thread 42 extends between two points, the end points being positioned outside of first embroidery component 40 . The endpoints of portion 42a are secured with lock stitches, and the central region of portion 42a (ie, the non-terminal region of portion 42a ) is spread adjacent to, and not secured to, base layer 41 . That is, the central area of the portion 42 a is continuously exposed on the surface of the base layer 41 . The embroidery machine then forms a relatively short portion 42b of thread 42, and also forms another portion 42c that traverses portion 42a, as depicted in Figure 8D. This general step is then repeated until wire group 44a is complete, as depicted in Figure 8E.

The wire group 44c is formed in a similar manner to the wire group 44a. Referring to FIG. 8F , portion 42d of line 42 extends between two endpoints that lie within the outline formed by set of lines 44e. The endpoints of portion 42d are secured with lock stitches, and the central region of portion 42d (ie, the non-terminal region of portion 42d ) is spread out adjacent to base layer 41 and is not secured to base layer 41 . Furthermore, the central region traverses the set of lines 44a. The embroidery machine then forms a relatively short portion 42e of thread 42, and also forms another portion 42f that also traverses thread set 44a, as depicted in FIG. 8G. This general procedure is then repeated until one of the various sections of wire group 44c is completed, as depicted in Figure 8H. The embroidery machine then forms one of the various sections of thread set 44b using, for example, a plurality of breeches, as depicted in FIG. 81 . The steps discussed above for forming one of the respective portions of wire set 44c and one of the respective portions of wire set 44b are repeated an additional four times to form each of the wire sets 44c and 44b, as depicted in FIG. 8J .

In some constructions, the ends of the wire group 44c may abut the outer perimeter of the wire group 44b. However, as depicted in the Figures, wire set 44c extends beyond the periphery of wire set 44b. That is, wire group 44c may extend over wire 42 forming wire group 44b, or wire group 44b may extend over wire 42 forming wire group 44c. More specifically, wire 42 from each wire group 44b and 44c may be interwine. As lace 32 extends through lace aperture 33 and is tensioned, strand set 44b reinforces lace aperture 33 and strand set 44c distributes tension along the sides of upper 30 . By winding the wire sets 44b and 44c, the force on the shoelace eye 33 is more effectively transmitted to the wire set 44c.

Wire group 44d is formed in a similar manner to wire groups 44a and 44c. Referring to FIG. 8K , portion 42g of wire 42 extends between two endpoints located near the contour formed by wire set 44e in heel region 13 . The ends of portion 42d are secured with bartack stitches, and the central area of portion 42d (ie, the area of portion 42d that is not the end points) is spread adjacent to and not secured to base layer 41 . That is, the central area of the portion 42d is continuously exposed on the surface of the base layer 41 . In addition, the central region traverses the set of lines 44a. This general procedure is then repeated until wire group 44d is complete, as depicted in FIG. 8L.

Once the wire group 44d is complete, holes 33 may be formed through the base layer 41 in certain regions corresponding to the center of the wire group 44b. Additionally, the first embroidery component 40 may be cut from portions of the base layer 41 outside of the set of threads 44e to form edges 43a-43d, as depicted in FIG. 8M. When the first embroidery component 40 is cut from the outer portion of the base layer 41, the partial threads 42 forming the thread group 44a are cut. As noted above, base layer 41 may include a tie layer or other securing member that bonds, secures, or otherwise secures portions of wire 42 to base layer 41 . The tie layer or other securing means, described in more detail below, may be added or used prior to cutting the first embroidery element 40 from the outer portion of the base layer 41 .

The general steps for forming first embroidery component 40 described above and depicted in FIGS. 8A-8M discuss a specific order in which each thread group 44a-44e is formed. In the sequence discussed, wire groups 44c and 44d pass through wire group 44a, which places wire group 44a between substrate layer 41 and wire groups 44c and 44d. The discussed sequence also forms wire groups 44b and 44c in a generally consistent manner. That is, partial wire group 44c is formed, then partial wire group 44b is formed, and this step is repeated until each wire group 44b and 44c is completed. However, the sequence discussed above is one example of various sequences that may be used to form first embroidery component 40, and various other sequences for forming each thread set 44a-44e may also be used. Thus, the general steps discussed above and depicted in FIGS. 8A-8M provide an example of one way in which first embroidery component 40 may be manufactured, and various other steps may be used instead.

The second embroidered part 50 is formed through an embroidery step which may be similar to the steps used to form the first embroidered part 40 . Referring to Figure 8N, the second embroidery component 50 is depicted after the embroidery step of forming the thread groups 54a-54f. Lace apertures 33 may then be formed through base layer 51 in areas corresponding to the centers of strand groups 54b. In addition, the second embroidery component 50 may be cut from portions of the base layer 51 outside of the set of threads 54f to form edges 53a-53d, as depicted in FIG. 8O. Before cutting the second embroidery component 50 from the outer portion of the base layer 51, a tie layer or other securing component that bonds, secures, or otherwise connects the partial thread 52 to the base layer 51 may be added, as described in detail below. . As with the first embroidery component 40, various sequences for forming the respective thread groups 54a-54f may be used.

shoe assembly

Once the embroidered parts 40 and 50 are formed in the manner described above, the shoe 10 is assembled. An example of one way in which shoe 10 may be assembled is depicted in FIGS. 9A-9D . Initially, manufacture of upper 30 is substantially complete by securing together embroidered components 40 and 50 of forefoot region 11 and heel region 13, as depicted in FIG. 9A. More specifically, the front portions of the edges 43a and 53a are connected, as are the respective edges 43c and 53c. For example, different types of stitching or adhesives may be used to join embroidery components 40 and 50 .

After upper 30 is complete, sole components 21 and 22 are placed, as depicted in FIG. 9B. The first sole part 21 is then positioned between the embroidered parts 40 and 50 such that the lower parts of the embroidered parts 40 and 50 wrap around the sides of the first sole part 21 . For example, adhesive is used to secure the lower portions of embroidery components 40 and 50 to the lower region of first sole component 21, as depicted in FIG. 9C. When combined in this manner, the upper region of first sole component 21 is then positioned to provide a foot-supporting surface within upper 30 . However, in some constructions, a sockliner may be located within upper 30 adjacent an upper region of first sole component 21 to form the foot-supporting surface of shoe 10.

The second sole component is then secured (eg, using adhesive) to the first sole component 21 and embroidery components 40 and 50, as depicted in Figure 9D. In this case, each of the embroidery components 40 and 50 , the first sole component 21 , and the second sole component 22 form part of the ground contact surface of the shoe 10 . In order to impart additional traction, projections 23 in the form of removable cleats may be incorporated into the second sole part 22 . Finally, lace 32 is threaded through lace aperture 33 in a conventional manner to substantially complete assembly of shoe 10 .

fixed parts

Each segment of line 42 (eg, portions 42a-42g) has two end points and a central portion extending between the end points. The ends are secured with bartack stitches, and the central region (ie, the non-terminal region of the segment) is located adjacent to the base layer 41 and is not secured to the base layer 41 . To secure the central region to base layer 41 , a tie layer that bonds, secures, or otherwise connects portion of wire 42 to base layer 41 may be used. The following discussion presents the different methods by which a tie layer or other fixing agent may be added to the first embroidery component 40 . A similar concept can be applied to the second embroidery component 50 .

One step for securing the partial wire 42 to the base layer 41 is depicted in FIGS. 10A-10D . Referring to Figure 10A, the first embroidery component 40 is depicted as being formed by an embroidery step, but not cut from the outer portion of the base layer 41 (ie, as in Figure 8L). Furthermore, the connecting layer 70 is depicted as covering the surface of the first embroidery component 40 including the thread 42 .

The tie layer 70 is a thin sheet of thermoplastic polymer material, for example between one thousandth of a millimeter and three millimeters thick. Suitable polymeric materials for tie layer 70 include, for example, polyurethane and ethylene vinyl acetate copolymer. In order to heat the connection layer 70 and bond the connection layer 70 to the first embroidery component 40, the connection layer 70 and the first embroidery component 40 are placed between a pair of platens 71 and 72 of a heated press. , as depicted in Figure 10B. When the temperature of the connection layer 70 is increased, the polymer material forming the connection layer 70 is increased so that the polymer material penetrates the structure of the base layer 41 and the wire 42 . Once removed from the heat press, the tie layer 70 cools and effectively bonds the wires 42 to the base layer 41, as depicted in FIG. 1OC. The first embroidery component 40 may then be cut from the outer portion of the base layer 41 .

The connecting layer 70 ensures that the thread set 44a remains intact after the first embroidery component 40 is removed from the outer portion of the base layer 41 . Furthermore, the connection layer 70 ensures that the partial wire groups 44c and 44d, for example, remain in a proper position relative to the base layer 41 . While the ends of the different segments of wire 42 forming wire groups 44c and 44d are secured to base layer 41 with lock stitches, the central portion is not secured to base layer 41 and no connection layer 70 is present. Thus, the connection layer 70 effectively bonds each wire 42 to the base layer 41 .

Base layer 41 may exhibit a breathable structure that allows perspiration and heated air to escape upper 20 . However, the addition of tie layer 70 may reduce the degree of breathability of upper 20 . While the tie layer 70 is depicted in FIG. 10A as having a discontinuous structure, the tie layer 70 may also be formed with different apertures corresponding to areas of the first embroidery component 40 where the tie layer 70 is not desired. Thus, the apertures in connecting layer 40 may serve to enhance the breathable properties of upper 30 . Furthermore, reducing the amount of material used for connection layer 70 has the advantage of minimizing the mass of shoe 10 .

A further step for securing the portion of the wire 42 to the base layer 41 is depicted in FIGS. 11A-11D . Referring to FIG. 11A , base layer 41 is depicted as being connected to connection layer 70 prior to adding wires 42 . An embroidery step is then used to form sets of threads 44a-44e so that the tie layer is between the base layer 41 and the threads 42, as depicted in FIG. 11B. To heat tie layer 70 and bond thread 42 to base layer 41, tie layer 70 and first embroidery element 40 are placed between platens 71 and 72 of a heat press, as depicted in Figure 11C. Once removed from the heat press, tie layer 70 cools and effectively bonds wire 42 to base layer 41 . The first embroidery component 40 may then be cut from the outer portion of the base layer 41, as depicted in Figure 11D. During the embroidery step, thread 42 is placed under tension, which tends to pull inwardly on base layer 41 . One advantage of applying tie layer 70 to base layer 41 prior to the embroidery step is that tie layer 70 helps resist inward pull of thread 42 .

Another step for securing part of the wire 42 to the base layer 41 is depicted in Figures 12A-12C. Referring to Figure 12A, the first embroidery component 40 is depicted as being formed by an embroidery step, but not cut from an outer portion of the base layer 41 (ie, as in Figure 8L). The adhesive securing component is then sprayed or otherwise applied to the first embroidery component 40 as depicted in FIG. 12B , thereby securing the thread 42 to the base layer 41 . The first embroidery component 40 may then be cut from the outer portion of the base layer 41, as depicted in Figure 12C.

in conclusion

As discussed above, upper 30 is made at least in part through an embroidery step that forms structural components from threads 42 and 52 . Depending on the orientation, location, and number of strands 42 and 52 , different structural components may be formed in upper 30 . As examples, structural components may impart stretch resistance to specific regions, strengthen regions, increase wear resistance, improve bendability, or provide regions of breathability. Thus, by controlling the orientation, location, and number of strands 42 and 52, the characteristics of upper 30 and shoe 10 may be controlled.

The invention is disclosed above and in the drawings referring to various embodiments. However, the purpose of the disclosure is to provide examples of different features and concepts related to various aspects of the present invention, not to limit the scope of various aspects of the present invention. Those skilled in the art will appreciate that many changes and modifications can be made to the above described embodiments without departing from the scope of the invention as defined by the appended claims.

Claims (42)

1. A product of footwear having an upper and a sole structure fixed to said upper, characterized in that said upper comprises: a base layer having a first surface and an opposing second surface, the base layer being formed from a bi-extensible material having the ability to stretch at least ten percent before tensile failure; a plurality of threads separate from the base layer and located adjacent at least a portion of the first surface, the threads being formed of a non-stretch material, The lines are oriented to form: a first area, wherein said lines do not appear on said first surface; a second region, wherein the lines are substantially parallel to each other, and the lines do not cross each other; and A third region, wherein the wire is oriented such that a first portion of the wire extends in a first direction and a second portion of the wire extends in a second direction, the first portion of the wire is in contact with the wire The second portion of the intersects, and the first direction deviates from the second direction by at least sixty degrees. 2. The article of footwear according to claim 1, wherein said upper has bidirectional stretch properties in said first region, unidirectional stretch properties in said second region, and unidirectional stretch properties in said second region. The third region has non-stretchable properties. 3. The article of footwear recited in claim 1, wherein said material of said base layer is a fabric. 4. The article of footwear of claim 1, wherein a securing member connects the thread to the base layer and wherein the securing member is a layer of polymeric material. 5. The article of footwear according to claim 1, wherein a securing member connects the thread to the base layer and the securing member is an adhesive applied to at least the base layer. 6. An article of footwear having an upper and a sole structure secured to said upper, wherein at least a portion of said upper comprises: a base layer having a first surface and an opposing second surface, the first surface defining at least a portion of the outer surface of the shoe, and the second surface defining at least a portion of an inner surface forming the shoe The space in the plane for accommodating the feet; a plurality of strands located adjacent one of the first surface and the second surface, a first portion of the strands being oriented to extend between a forefoot region and a heel region of the upper, and the a second portion of the strand is oriented to extend between an upper region and a lower region of the upper; a fixing member that connects the wire to the base layer; and A lace extending through the lace aperture in the base layer. 7. The article of footwear according to claim 6, wherein the third portion of the thread extends around the lace aperture. 8. The article of footwear according to claim 6, wherein a third portion of the thread is positioned in the heel region and extends from the upper region to the lower region. 9. The article of footwear recited in claim 6, wherein the third portion of the strand is positioned near an edge of the base layer. 10. The article of footwear recited in claim 6, wherein the securing member is at least one of a layer of polymeric material and an adhesive applied to at least the base layer. 11. A shoe product having an upper and a sole structure, characterized in that it comprises a base layer and at least one thread by which the base layer is embroidered to position segments of the thread proximate to a surface of the base layer for a distance greater than twelve millimeters; the base layer and the at least one thread are incorporated into the upper; and The upper is secured to the sole structure. 12. The article of footwear recited in claim 11, wherein the segments of the thread are embroidered to extend from a forefoot region of the base layer to a heel region of the base layer. 13. The article of footwear according to claim 11, wherein said segments of said thread are embroidered to extend from a lace-receiving portion of said base layer to a lower portion of said base layer. 14. The article of footwear according to claim 11, wherein the thread or another thread is embroidered positioned to outline a component forming the upper. 15. The article of footwear recited in claim 14, wherein the base layer is cut adjacent to the profile. 16. The article of footwear according to claim 11, wherein the thread or another thread is embroidered positioned about the lace-receiving portion of the base layer. 17. The article of footwear of claim 11, wherein the base layer is joined to another component that is embroidered. 18. A product of footwear having an upper and a sole structure characterized by comprising basal layer; first line segment; second line segment; a plurality of first line segments positioned near the surface of the base layer such that the first line segments do not pass through the base layer for a distance of at least five centimeters; a plurality of second line segments are also positioned adjacent the surface of the base layer such that the second line segments do not pass through the base layer for a distance of at least five centimeters; the second line segment is oriented at least sixty degrees from the first line segment; the base layer, the first thread segment and the second thread segment are incorporated into the upper; and The upper is secured to the sole structure. 19. The article of footwear recited in claim 18, wherein the first line segment extends from a forefoot region of the chassis layer to a heel region of the chassis layer. 20. The article of footwear recited in claim 18, the article of footwear further comprising a plurality of third line segments positioned to form the contours of components of the upper. 21. The article of footwear recited in claim 20, wherein the base layer is cut adjacent to the profile. 22. The article of footwear recited in claim 18, further comprising a plurality of third thread segments positioned about the lace-receiving portion of the base layer. 23. The article of footwear of claim 18, wherein additional embroidered components are attached to the base layer. 24. An article of footwear having an upper and a sole structure, the upper comprising: a substrate layer having a first surface and an opposing second surface, the substrate layer defining first and second points separated by a distance of at least five centimeters; and a line extending from the first point to the second point, the line having a segment between the first point and the second point, the segment being located adjacent to the first surface and continuously exposed throughout said distance of at least five centimeters. 25. The article of footwear recited in claim 24, wherein the segment of the line is parallel to the first surface. 26. The article of footwear recited in claim 24, wherein the base layer is a textile material capable of stretching at least ten percent before tensile failure. 27. The article of footwear recited in claim 26, wherein the strands primarily limit the expansion of the base layer in a direction coincident with the longitudinal axis of the strands. 28. The article of footwear recited in claim 24, wherein a securing member connects the segments to the base layer, and wherein the securing member is a layer of polymeric material. 29. The article of footwear recited in claim 24, wherein a securing member connects the segments to the base layer, and the securing member is an adhesive applied to at least the base layer. 30. An article of footwear having an upper and a sole structure secured to the upper, wherein the upper comprises: a base layer having a first surface and an opposite second surface, the base layer being formed of a material having bi-directional stretch; and a plurality of wires separated from the base layer and located adjacent to at least a portion of the first surface, The lines are oriented to form: a first area, wherein said lines do not appear on said first surface; a second region, wherein the lines are substantially parallel to each other, and the lines do not cross each other; and A third region, wherein the wire is oriented such that a first portion of the wire extends in a first direction and a second portion of the wire extends in a second direction, the first portion of the wire is in contact with the wire The second part of the cross. 31. The article of footwear recited in claim 30, wherein said upper has bi-directional stretch properties in said first region, unidirectional stretch properties in said second region, and The third region has non-stretchable properties. 32. The article of footwear recited in claim 30, wherein said material of said base layer is fabric. 33. The article of footwear recited in claim 30, wherein a securing member connects the strand to the base layer, and wherein the securing member is a layer of polymeric material. 34. The article of footwear recited in claim 30, wherein a securing member connects the thread to the base layer, and the securing member is an adhesive applied to at least the base layer. 35. An article of footwear having an upper and a sole structure secured to the upper, wherein the upper comprises: Multiple lace-accommodating holes; a first set of wires extending at least partially around at least one of said apertures; and a second set of wires extending outwardly from said first set of wires, Wherein the wires originating from at least one of the first group of wires and the second group of wires overlap the wires originating from the other of the first group of wires and the second group of wires. 36. The article of footwear recited in claim 35, wherein strand entanglements originating from the first set of strands and the second set of strands. 37. The article of footwear recited in claim 35, wherein the strands originating from the first set of strands and the second set of strands are separate from a textile component within the upper. 38. The article of footwear recited in claim 35, wherein the second set of strands includes a plurality of strand segments generally aligned and extending toward a lower region of the upper. 39. The article of footwear recited in claim 35, wherein an securing member connects the strands of the second set of strands to the base layer. 40. The article of footwear recited in claim 35, wherein the second set of threads includes a plurality of thread segments that are continuously exposed through a distance of at least five centimeters. 41. The article of footwear recited in claim 35, wherein the second set of strands extends radially outward from a region adjacent the first set of strands. 42. The article of footwear recited in claim 35, wherein the strand portions of the second set of strands are closer together in an area adjacent the lace-receiving aperture than in an area remote from the lace-receiving aperture.

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