HK1215364B - Braided upper with overlays for article of footwear and method for producing the same - Google Patents

Description

Braided upper with overlay for an article of footwear and method of making the same

Cross Reference to Related Applications

This application claims priority from U.S. provisional patent application No. 61/839,097 (attorney docket No. 51-3210), filed on 25.6.2013 and entitled "Article of Footwear with BraidedUpper," which is incorporated herein by reference in its entirety and described in detail throughout as an application referred to as "BraidedUpper. This application is also related to the present U.S. patent application ________, filed 24/1 2014, and co-pending U.S. patent application publication No. 14/163,392, entitled "Article of Footwear with branched Upper" (attorney docket No. 51-3642), the entire contents of which are incorporated herein by reference.

Technical Field

This embodiment relates to an article of footwear, and in particular to an upper for an article of footwear.

Background

Athletic shoes generally have two main components: an upper that provides an enclosure for receiving a foot of a wearer, and a sole secured to the upper. The upper may be adjustable using laces, hook and loop fasteners, or other devices to properly secure the shoe to the foot. The sole has primary contact with the playing surface. The sole may be designed to absorb impact when the shoe contacts the ground or other surface. The upper may be designed to provide the appropriate type of protection for the foot and maximize wearer comfort.

SUMMARY

The present invention provides the following aspects:

(1) in one aspect, an article of footwear includes an upper and a sole system, where the upper is made of a braided structure and an overlay portion. The overlay portion is bonded to the braided structure, the overlay portion having a lower stretch resistance than the braided structure.

(2) The article of footwear according to (1), wherein the overlay portion is disposed on an edge of the upper associated with an opening of the upper that receives a foot.

(3) The article of footwear of (1), wherein the overlay portion includes eyelets for receiving fasteners.

(4) The article of footwear according to (1), wherein the overlay portion is disposed at a toe portion of the upper.

(5) The article of footwear according to (1), wherein the overlay portion includes a section disposed on a lower side of the upper.

(6) The article of footwear according to (1), wherein the overlay portion is made of a polymeric material.

(7) In another aspect, an article of footwear includes an upper and a sole system, the upper being further associated with a lace member. The upper is made of a braided structure and an overlay portion, and the overlay portion includes a plurality of eyelets for receiving lace members.

(8) The article of footwear according to (7), wherein the overlay portion forms an eyelet support for the upper.

(9) The article of footwear according to (7), wherein the overlay portion is disposed on a lateral edge of a fastening region of the upper, and wherein the overlay portion is disposed on a medial edge of the fastening region.

(10) The article of footwear of (7), wherein the overlay portion extends on a lateral side of the upper, a medial side of the upper, and a lower side of the upper.

(11) The article of footwear of (7), wherein the overlay portion is a first overlay portion, and wherein the article of footwear includes a second overlay portion different from the first overlay portion.

(12) The article of footwear according to (11), wherein the first overlay portion overlaps the second overlay portion at an overlap region.

(13) The article of footwear according to (11), wherein the second overlay portion covers a lower side of the upper.

(14) The article of footwear according to (13), wherein the second overlay portion is engageable to the sole system to secure the sole system in place on the article of footwear.

(15) In another aspect, a method of manufacturing an article of footwear includes: forming a braided structure with an inner cavity; cutting an opening in the woven structure, thereby creating an opening in the woven structure and an edge associated with the opening; and bonding an overlay portion to the edge, wherein the overlay portion includes a plurality of eyelets. The method also includes inserting a lace through the eyelets and associating the sole system with the braided structure to form an article of footwear.

(16) The method of (15), wherein forming the braided structure comprises creating the braided structure with a central lumen.

(17) The method of (15), wherein forming the braided structure includes overbraiding the braided structure on a last.

(18) The method of (15), wherein bonding the overlay portion comprises welding the overlay portion to the edge.

(19) The method of (15), wherein bonding the overlay portion comprises securing at least one open end of a thread of the braided structure to the overlay portion.

(20) The method of (15), wherein the overlay portion is a first overlay portion, and wherein a second overlay portion is bonded to a bottom side of the braided structure, and wherein the sole system is attached to the second overlay portion.

(21) The method of (15), wherein the overlay portion is bonded to the edge such that at least one thread of the braided structure extends around at least one eyelet of the overlay portion.

Other systems, methods, features and advantages of the embodiments will be or will become apparent to one with skill in the art upon examination of the following figures and detailed description. It is intended that all such additional systems, methods, features and advantages be included within this description and this summary, be within the scope of the embodiments, and be protected by the following claims.

Brief description of the drawings

The embodiments may be better understood with reference to the following drawings and description. The components in the figures are not necessarily to scale, emphasis instead being placed upon illustrating the principles of the embodiments. Moreover, in the figures, like reference numerals designate corresponding parts throughout the different views.

FIG. 1 is a schematic isometric view of an embodiment of an article of footwear including a woven upper having an overlay;

FIG. 2 is an exploded isometric view of the article of footwear of FIG. 1;

FIG. 3 is a schematic isometric view of the article of footwear of FIG. 1, including an enlarged view of the lines disposed against the overlay;

FIG. 4 is a schematic isometric view of another embodiment of an arrangement of wires bonded to an overlay;

FIG. 5 is a schematic isometric view of the article of footwear of FIG. 1, including an enlarged cross-sectional view of the eyelets of the overlay;

FIG. 6 is a schematic enlarged view of an embodiment of an overlay including eyelets, wherein each eyelet is partially surrounded by a wire of the braided upper;

FIG. 7 is a schematic enlarged view of another embodiment of an overlay including eyelets, wherein the strands of the braided upper do not surround each eyelet;

FIG. 8 is a schematic rear isometric view of an embodiment of an article of footwear including a woven upper having an overlay;

FIG. 9 is a schematic, exploded isometric view of an embodiment of an article of footwear including a woven upper having a plurality of different overlay surfaces;

FIG. 10 is a schematic side view of the article of footwear of FIG. 9;

FIG. 11 is a schematic top view of the article of footwear of FIG. 9;

FIG. 12 is a schematic isometric view of an embodiment of an article of footwear having two different knit regions and an overlay covering the knit regions;

FIG. 13 is a schematic isometric view of the article of footwear of FIG. 12, with a portion of the braided upper and the overlay seen in cross-section;

FIG. 14 is a side schematic view of an embodiment of a pre-cut braided structure formed into an upper for an article of footwear;

FIG. 15 is a schematic illustration of a step of cutting the braided structure of FIG. 14 to form openings in the upper according to an exemplary process;

FIG. 16 is an isometric view of a step of joining an overlay to the upper of FIG. 15 according to an exemplary process;

FIG. 17 is an isometric view of an embodiment of a final article of footwear constructed using the example process of FIGS. 14-16;

FIG. 18 is an isometric view of an embodiment of a woven upper having an overlay associated with a sole member on an upper surface; and

fig. 19 is an isometric view of the woven upper of fig. 18 engaged with a sole member.

Detailed description of the invention

Fig. 1 is an isometric view of an embodiment of an article of footwear 100, with article of footwear 100 also referred to simply as article 100. Article 100 may be configured for different types of footwear, including but not limited to: hiking boots, soccer shoes, athletic shoes, running shoes, cross-training shoes, football shoes, basketball shoes, baseball shoes, and other types of shoes. Furthermore, in some embodiments, article 100 may be configured for different types of non-athletic related footwear, including but not limited to: slippers, sandals, high-heeled footwear, sandals, and any other type of footwear, apparel, and/or athletic equipment (e.g., gloves, helmets, etc.).

In some embodiments, article of footwear 100 may include upper 102 and sole system 110. Sole system 110 is secured to upper 102 and extends between the foot and the ground when article 100 is worn. In different embodiments, sole system 110 may include different components. For example, sole system 110 may include an outsole, a midsole, and/or an insole. In some cases, one or more of these components may be optional.

Sole system 110 may provide one or more functions for article 100. For example, in some embodiments, sole system 110 may be configured to provide traction for article 100. In addition to providing traction, sole system 110 may attenuate ground reaction forces when compressed between the foot and the ground during walking, running, or other ambulatory activities. The configuration of sole system 110 may vary significantly in different embodiments to include a variety of conventional or non-conventional structures. In some cases, the configuration of sole system 110 may be selected based on one or more types of ground surfaces on which sole system 110 may be used. Examples of ground surfaces include, but are not limited to: natural turf, synthetic turf, mud, and other surfaces.

In general, upper 102 may be any type of upper. In particular, upper 102 may have any design, shape, size, and/or color. For example, in embodiments where article 100 is a basketball shoe, upper 102 may be a high-top upper shaped to provide high support at the ankle. In embodiments where article 100 is a running shoe, upper 102 may be a low top upper.

Referring to fig. 1, for reference purposes, components of article 100, such as upper 102, may be divided into a forefoot portion 10, a midfoot portion 12, and a heel portion 14. Forefoot portion 10 may be generally associated with the toes and the joints connecting the metatarsals with the phalanges. In-shoe portion 12 may be generally associated with the arch of the foot. Likewise, heel portion 14 may be generally associated with the heel of the foot, including the calcaneus bone. In addition, upper 102 may include a lateral side 16 and a medial side 18. In particular, lateral side 16 and medial side 18 may be opposite sides of article 100. In addition, both lateral side 16 and medial side 18 may extend through forefoot portion 10, midfoot portion 12, and heel portion 14.

It should be understood that forefoot portion 10, midfoot portion 12, and heel portion 14 are intended for descriptive purposes only and are not intended to demarcate precise areas of upper 102. Likewise, lateral side 16 and medial side 18 are intended to generally represent two sides of upper 102, rather than precisely divide upper 102 into two halves.

Directional adjectives are used throughout this detailed description corresponding to the illustrated embodiments for consistency and convenience. The term "longitudinal" as used throughout this detailed description and in the claims refers to a direction that extends the length of a component. For example, the longitudinal direction of upper 102 may extend from forefoot portion 10 to heel portion 14 of upper 102. Furthermore, the term "transverse" as used throughout this detailed description and in the claims refers to a direction extending along the width of a component. For example, the lateral direction of upper 102 may extend between medial side 18 and lateral side 16 of upper 102. Additionally, the term "vertical" as used throughout this detailed description and in the claims refers to a direction that is perpendicular to both the longitudinal and transverse directions.

Additionally, the term "proximal" refers to a portion of the footwear component that is closer to a portion of the foot when the article of footwear is worn. Likewise, the term proximal direction refers to a direction that is oriented toward the foot when the article is worn. The term "distal" refers to a portion of the footwear component that is distal from a portion of the foot when the article of footwear is worn. The distal direction refers to a direction that is positioned away from the foot when the article is worn.

In some embodiments, upper 102 may be comprised of a knitted structure, such as a knitted fabric or other knitted structure. The braided structure may be formed by interweaving three or more yarns, filaments, or other fibers to form the structure. By way of example, upper 102 as seen in fig. 1 is formed from a plurality of strands 130, the plurality of strands 130 being woven together to form a shape that globally resembles the shape of a foot.

Knitting may be used to form a three-dimensional structure by knitting yarns on a mold or last. The threads of the braided structure, such as the plurality of threads 130 of the exemplary embodiment, may be formed from fibers such as nylon, carbon, polyurethane, polyester, cotton, aramid (e.g.,) Polyethylene or polypropylene. These threads can be woven to form three-dimensional structures for a variety of applications.

The braided structures may be manufactured manually or may be manufactured using automated braiding machines, such as the machines disclosed in U.S. patent nos. 7,252,028, 8,261,648, 5,361,674, 5,398,586, and 4,275,638, all of which are incorporated herein by reference in their entirety. Such three-dimensional woven structures can also be made to a specific design by, for example, TEF weaving, warrenburg, n.y or a & P technology, Cincinnati, Ohio.

By using knitting, an upper for an article of footwear may be designed with specific features that suit a particular sport or recreational activity. The woven upper may be very lightweight while conforming closely and comfortably to the foot of the wearer. In some embodiments, the fit of the upper may be adjusted to provide a particular degree of tension or tightness that the wearer may prefer. The woven upper is characterized by a tight fit over the foot of the wearer. In some embodiments, the woven fabric may wrap all the way around the footwear, as shown in the figures. This structure has tensile integrity or "tensegrity" because the wearer's foot is in compression and the braided wires are in tension around the wearer's foot.

Some embodiments may include a woven upper that extends under the foot, providing 360 degrees of coverage in some areas of the foot. However, other embodiments need not include an upper that extends under the foot. In other embodiments, for example, the braided upper can have a lower perimeter that is joined together with the sole structure and/or sock liner.

Fig. 2 shows an exploded isometric view of an embodiment of article 100, including upper 102 composed of a braided structure. Referring to fig. 1-2, upper 102 is seen to have an opening 120 for receiving a foot. In addition, upper 102 has a fastening region 124. The fastening region 124 may also include a fastening gap 125 (see fig. 2) that spaces the outboard fastening edge 126 from the inboard fastening edge 127.

The fastening region 124 may be further associated with a fastening member 160. In an exemplary embodiment, the fastening member 160 may be a lace. In other embodiments, however, the fastening component 160 may be any other type of fastener, including but not limited to: straps, snaps, buttons, zippers, hook and loop fasteners (e.g., Velcro), and other types of fasteners.

Embodiments utilizing a woven upper may include provisions that help provide additional structure to the upper. In some embodiments, for example, the article may include one or more additional material portions that are bonded or otherwise attached to particular portions of the woven upper in order to increase various properties of the upper. For example, these material portions may be utilized to increase strength and durability, provide stretch resistance in certain locations of the upper, and facilitate engagement of other components with the braided structure.

Throughout the detailed description and claims, the term "overlay portion," or simply overlay, refers to any material portion that is attached to a surface of a woven structure, such as a woven upper. In some embodiments, the overlay portion is made of a different material than the threads of the woven structure. Further, in some embodiments, the overlay portion may have material properties that are substantially different from the threads of the woven structure. In an exemplary embodiment, the overlay portion may resist stretching as compared to a corresponding portion of the woven structure.

In general, the overlay portion may be formed of any material. Exemplary materials include, but are not limited to: textiles (including woven and non-woven textiles), leather (including natural and synthetic leather), polymeric materials, and other types of materials. In one embodiment, one or more of the cover portions may be made from Thermoplastic Polyurethane (TPU).

In an exemplary embodiment, article 100 may be associated with an overlay component 140. The cover component 140 may further be comprised of several different overlapping portions including a first cover portion 150, a second cover portion 152, and a third cover portion 154. Each overlay portion may be provided at a particular location on the upper. For example, first overlay portion 150 may be associated with fastening region 124 of upper 102. Likewise, the second cover portion 152 may be associated with the opening 120. Finally, third overlay portion 154 may be associated with heel portion 14 and portions of both lateral side 16 and medial side 18 of upper 102.

Referring now to fig. 2, in some embodiments, the first cover portion 150 extends along an edge of the fastening region 124. In particular, the first cover portion 150 comprises a first section 181 associated with the outer fastening edge 126 of the fastening zone 124. Furthermore, the first cover part 150 comprises a second section 182 associated with the inner fastening edge 127 of the fastening zone 124. In some embodiments, an intermediate section 183 extends along the foremost edge 129 of the fastening region 124 and connects the first section 181 and the second section 182 of the first cover portion 150.

Using this configuration, first overlay portion 150 may form an eyelet support (eyestay) on the lateral and medial sides of upper 102 or form a portion of an eyelet support on the lateral and medial sides of upper 102. In particular, first overlay portion 150 may facilitate attachment of upper 102 with fastening member 160. As discussed in further detail below, the use of an overlay portion along the edges of fastening region 124 may help to more evenly distribute the tensioning force applied by fastening member 160 to upper 102.

In at least some embodiments, first overlay portion 150 may help complete the knit structure of upper 102 along lateral fastening edge 126, medial fastening edge 127, and forward-most edge 129 of fastening region 124. In particular, in embodiments where the strands of the braided structure may be open at any of the outer fastening edge 126, the inner fastening edge 127, or the forwardmost edge 129, the first cover portion 150 may help bond, fuse, or otherwise hold the ends of the strands in place to prevent the strands from unraveling along these edges.

In some embodiments, the second cover portion 152 extends along an edge of the opening 120. In particular, the second cover portion 152 is associated with an opening edge 195. In some embodiments, moreover, second cover portion 152 is substantially continuous with first cover portion 150 such that all edges of upper 102 associated with openings 120 and/or openings of fastening regions 124 are covered by either first cover portion 150 or second cover portion 152.

This arrangement helps complete the opening edge 195 by bonding any opening lines to the second cover section 152. Additionally, the second cover portion 152 may help to reinforce the opening 120 so that the braided structure in the vicinity of the opening 120 may not be overstretched. Such reinforcement may be particularly useful at opening 120 because opening 120 may experience significant pulling and other stresses as a user inserts and/or removes his or her foot.

In some embodiments, third cover portion 154 may include a first section 171 that extends along lateral side 16 and a second section 172 that extends along medial side 18 of upper 102. Additionally, a third section 173 of third overlay portion 154 may extend along an underside (e.g., on a lower side) of upper 102 in heel region 14. In some embodiments, third section 173 connects first section 171 and second section 172 such that third overlay portion 154 wraps continuously around the sides and bottom of upper 102.

In some embodiments, the first section 171 of the third cover portion 154 extends from the first section 181 of the first cover portion 150 and is formed continuously with the first section 181 of the first cover portion 150. Additionally, in some embodiments, the second section 172 of the third cover portion 154 extends from the second section 182 of the first cover portion 150 and is formed continuously with the second section 182 of the first cover portion 150. Because the third cover portion 154 may act to reduce stretch along its length, this configuration may help increase support under the heel by resisting stretching of the upper between the first cover portion 150 (at the top of the foot) and the underside 199 (see fig. 8) of the heel portion 14.

Fig. 3 shows an enlarged view of a portion of article 100, where some of the threads may be bonded to second cover portion 152. Referring to fig. 3, some of the wires 304 may be disposed against the inner surface 302 of the second cover portion 152. In this example embodiment, strands 304 may form a portion of closed woven edge 305 of upper 102, the closed woven edge 305 being free of any loose or free ends of the strands. In this case, the thread 304 may be bonded to the second cover portion 152 to reinforce the continuous woven section of the braided structure.

In an alternative embodiment, shown in fig. 4, some of the wires 470 may be configured with loose or free ends 472. In this configuration, open end 472 may be secured to cover portion 452 to hold wire 470 in place and help prevent wire 470 from unraveling or unraveling. Thus, it can be seen that in some embodiments, the overlay portion may serve to retain the loose or free ends associated with the edges of the braided structure. This arrangement may provide a means of finishing the cut edges of the braided structure or any edges including loose or free ends that may unravel.

The arrangement described herein provides an overlay portion that may act to reinforce the edges of the woven structure at the opening 120. This may help reduce stretch in upper 102 at opening 120 in order to maintain the structural integrity of upper 102. Additionally, the second cover portion 152 may help secure any loose or open ends of the braided structure to prevent disassembly of the ends and/or unraveling of the braided structure.

Various processes for joining the overlay portion to a knitted structure, such as a knitted upper, are discussed in further detail below. Exemplary materials for bonding may include any well-known adhesive, melt, resin, or other bonding agent.

Fig. 5 shows an isometric view of article 100, including an enlarged schematic cross-sectional view of first cover portion 150 and a portion of fastening component 160. Referring to fig. 5, first overlay portion 150 includes a plurality of eyelets 400. Specifically, a plurality of eyelets 400, including eyelet 402 shown in an enlarged cross section, is an opening in first overlay portion 150 configured to receive a portion of fastening member 160.

In contrast to alternative embodiments in which the strands of upper 102 may directly secure portions of the fastening members, the exemplary embodiment is configured such that the strands of upper 102 are indirectly secured to fastening members 160 via eyelets 400 in the first overlay portion. Specifically, thread 410 is seen to be secured directly to first cover portion 150, while fastener 160 is secured by a plurality of eyelets 400 in first cover portion 150. This configuration may more evenly distribute the force exerted by fastening members 160 across the woven structure of upper 102. This may prevent fastening member 160 from pulling too much on a particular line, for example, thereby promoting a more comfortable fit of article 100 on the foot.

Fig. 6 and 7 show two possible configurations of the lines of eyelets attachment on the overlay portion. Referring first to FIG. 6, in some embodiments, one or more threads may extend around the eyelets, thereby functioning to reinforce the eyelets. For example, in fig. 6, first strand 512 and second strand 514 encircle first eyelet 502 and second eyelet 504, respectively. This may have the effect of reinforcing first eyelet 502 and second eyelet 504, as well as providing a more direct transfer of tension between fastening member 160 and the knit lines of upper 102.

Referring to the alternative embodiment shown in fig. 7, first eyelet 502 and second eyelet 504 are not surrounded by any strands of the upper. In particular, it can be seen that line 610 is bonded to first overlay portion 150 without encircling first eyelet 502 and second eyelet 504. Of course, in other embodiments, some eyelets may be surrounded or reinforced by a thread, while other eyelets may not be surrounded or reinforced.

Figure 8 illustrates a rear isometric view of upper 102, where lines 130 of upper 102 are indicated by dashed lines. Referring to fig. 8, third overlay component 156 is seen enclosed under bottom side 199 of upper 102 in heel portion 14. In some cases, this configuration allows third cover portion 156 to support the heel of the foot. Thus, this arrangement may provide further support to the heel of the foot by reducing stretch throughout heel portion 14 when article 100 is worn.

In some embodiments, a plurality of different overlay components may be used. In some embodiments, the different overlay components may be configured to intersect or overlap at predetermined portions of the upper. This configuration of overlapping overlay components may provide a means for increasing the strength and tensile resistance over a large portion of the upper, possibly including the entire upper.

Figures 9-11 illustrate an embodiment of an article of footwear 800 that includes an upper 802 and a sole structure 805 (shown only in figure 10). Referring first to fig. 9, upper 802 is formed from a braided structure that is braided from a plurality of strands 830. Additionally, a plurality of overlay components are associated with upper 802, including a first overlay component 810, a second overlay component 812, a third overlay component 814, and a fourth overlay component 816.

In an exemplary embodiment, each overlay component is associated with a particular portion of upper 802. For example, first cover component 810 is associated with edge 870 and fastening area 862 of opening 860. Thus, in some cases, first overlay component 810 may be used to trim plurality of lines 830 along edge 870. Additionally, first cover component 810 can provide stretch resistance in the vicinity of opening 860.

Second cover surface component 812 is associated with forward toe portion 868 of upper 802. In some embodiments, the second cover component 812 can help improve the stretch resistance at the forward toe portion 868. Additionally, in some embodiments, the second cover component 812 can provide coverage for the forward toe portion 868. In particular, the presence of second cover component 812 may help prevent debris from entering upper 802 via forward toe portion 868.

Third cover component 814 may be associated with forefoot portion 811 of upper 802. In some embodiments, the third cover component 814 may be positioned forward of the fastening region 862. Additionally, as best seen in fig. 9, third overlay component 814 may completely surround upper 802 (and the foot within upper 802). In an exemplary embodiment, third cover component 814 is comprised of a first strip 817 and a second strip 819, with first strip 817 and second strip 819 integrally joined at top intersection region 815. Thus, this arrangement may provide directional stretch resistance in forefoot portion 811, which may enhance foot support during activities in which forefoot portion 811 may be securely placed on the ground.

Fourth overlay component 816 may be associated with a heel portion 813 of upper 802. In some embodiments, the fourth cover member 816 can provide a heel counter-like cover portion 825, and a strap-like cover portion 827. In combination, overlay portion 825 and overlay portion 827 may help limit stretch in heel portion 813, thereby enhancing heel support in upper 802.

As seen in fig. 10-11, some of the overlay components may overlap one another when assembled with upper 802. For example, it can be clearly seen that the third cover component 814 overlaps a portion of the first cover component 810 in the overlap region 902. In addition, it can be seen that the third cover component 814 overlaps portions of the second cover component 812 in the overlap region 903. Likewise, it can be clearly seen that the fourth cover component 816 overlaps with a portion of the first cover component 810 in the overlap region 904. This overlapping arrangement helps promote the structural integrity of upper 802 because portions of one overlay component may enhance the support of the overlapping overlay component. In addition, by overlapping and joining portions of different overlay components together, the overlay components may act as a single frame for supporting the woven structure of upper 802.

Embodiments utilizing knit regions with different properties may include provisions for further enhancing some regions but not others. In some embodiments, the article may include an overlay portion configured to cover a predetermined area of the article.

Fig. 12 and 13 show isometric views of article 1100, article 1100 being configured with an overlay portion that covers two particular areas of upper 1102. In particular, fig. 12 shows an isometric exploded view of article 1100, while fig. 13 shows an isometric view including an enlarged cross-sectional view. Referring to fig. 12 and 13, article 1100 includes an upper 1102 and a sole system 1110. Upper 1102 is further configured with at least four distinct zones, including a first zone 1151, a second zone 1152, a third zone 1153, and a fourth zone 1154. In this exemplary embodiment, first region 1151 is a toe region of upper 1102. The second region 1152 is disposed immediately adjacent to and behind the first region 1151. The third region 1153 is disposed immediately adjacent to the second region 1152 and behind the second region 1152. Finally, the fourth region 1154 extends behind the third region 1153. Additionally, fourth region 1154 is a substantially larger region than the remaining regions and includes all of midfoot portion 1103 and heel portion 1105 of upper 1102. Accordingly, the first, second, and third zones 1151, 1152, 1153 can be characterized as strips of the upper 1102 that extend laterally across the upper 1102.

Each region of upper 1102 may be associated with a particular material property, such as a weave density. In an exemplary embodiment, both the first and third zones 1151, 1153 are associated with a first braid density, while the second and fourth zones 1152, 1154 are associated with a second braid density. In some embodiments, the first braid density may be greater than the second braid density. Thus, the first and third zones 1151, 1153 are more tightly woven and may provide zones of increased strength and may also resist stretching in some embodiments.

Article 1100 may be further interconnected with first cover portion 1160 and second cover portion 1162. First overlay portion 1160 may be shaped to cover first region 1151 of upper 1102. Second overlay portion 1162 may be shaped to cover third zone 1153 of upper 1102. For example, as shown in the enlarged cross-sectional view of fig. 13, the second overlay portion 1162 can be disposed over a line 1170 of the third zone 1153. With this arrangement, first and second cover portions 1160, 1162 may further reinforce first and second regions 1151, 1153, thereby enhancing support and stretch resistance in these regions.

The exemplary embodiments are only intended to illustrate some possible configurations for the overlay portion of the upper. It should be understood that some other embodiments may include overlay portions configured in a variety of different shapes, sizes, and locations. Further, any number of different overlay components may be used in alternative embodiments. The number, shape, size, and location of the overlay component or overlay portion may be selected to achieve a desired property at any location on the article of footwear, including tensile resistance, increased strength, support, comfort, or any other desired property.

As discussed in the Braided Upper application, the Braided Upper may be configured with a variety of different features and functions. It should be understood that the overlay portions described in this detailed description may be used with various embodiments of a woven Upper, which may or may not include some of the features discussed in the Braided upperer application. As an example, in some embodiments, strands having different material properties can be woven together or otherwise associated with one another to provide specific properties in one or more areas of the upper. For example, the upper may be made of fibers that stretch to some extent as the wearer's foot moves through each stride he or she takes, thereby increasing the comfort of the wearer. In that case, the high tensile strength, non-stretch fibers may penetrate those particular areas of the footwear where additional structural support is desired. As another example, in some areas, the upper may be made of a more open weave, for example, to improve breathability or comfort. In this case, additional fibers may be passed through the knit to provide additional support in certain portions of those areas or to provide increased durability for high impact areas of the footwear. An upper having any of these configurations may be further associated with one or more overlay portions to further control the properties and functions of the upper, including support and/or stretch resistance in various areas of the upper.

The upper may also have floating cables, i.e., cables that are not woven into the fabric of the upper may be used to relieve stress on certain sections of the upper. The floating cables may be made of a different material that is separate from and not attached to the braided structure. The cable may also be used as a lace to secure the footwear to the foot or to tighten certain portions of the footwear, as described below. For example, the cable may be anchored at a first end to a sole of the footwear and at a second end to an eyelet, for example. Such floating cables may also be used to add support and stability to certain portions of the footwear, such as around the ankle opening. In some embodiments, the overlay portion may be used with a braided upper incorporating floating cables, and in some cases, the overlay portion may be used to reinforce portions with or without cables. In some embodiments, the overlay portion can be used to help anchor the ends of the floating cables to the upper.

The combination of these features, including any of the features described in the Braided Upper application, along with the overlay portion described above and shown in the figures, may facilitate the manufacture of an Upper that is suitable for a particular athletic or recreational activity. A woven upper having a combination of these features can be very lightweight while conforming closely and comfortably to the foot of the wearer. In some embodiments, the fit of the upper may be adjusted to provide a particular degree of tension or tightness that the wearer may prefer.

14-17 illustrate several steps of an exemplary process for forming an article that includes a woven upper and an overlay portion. Initially, as shown in FIG. 14, braided upper 1402 may be formed using any variety of braiding processes. Exemplary processes for forming woven articles are disclosed in the Braided Upper application, which has been previously discussed and incorporated by reference. Next, as shown in fig. 15, in some embodiments, an opening 1502 may be cut in upper 1402. This may create a new edge 1504 that borders the opening 1502. Opening 1502 may be used for foot insertion and may provide a region for fasteners, such as laces.

In an exemplary embodiment, overlay portion 1510 may then be bonded along edge 1504 (see fig. 15) of upper 1402, as shown in fig. 17. In some embodiments, the bonding may be accomplished using a welding process, such as an ultrasonic welding process. The exposed lines along the edge 1504 can thus be fused to the cover portion 1510 to form ends, and to reinforce and support the edge 1504 when the article is fastened. Finally, as shown in fig. 17, lace 1602 may be inserted through eyelets 1610. Additionally, in some embodiments, sole system 1620 may be added to the bottom of upper 1402.

Some embodiments may include provisions for facilitating engagement of an upper and a sole system. In some embodiments, an overlay portion may be provided between the upper and the sole system, thereby facilitating engagement of the upper and the sole system.

Figures 18 and 19 illustrate isometric views of embodiments in which an overlay portion may be used to help attach a sole system to an upper. Referring to fig. 18 and 19, upper 1702 may be associated with an overlay component 1720 and an overlay component 1722. In some embodiments, overlay component 1720 may be associated with opening 1716 of upper 1702. Overlay component 1722 may be associated with underside 1703 of upper 1702. In some embodiments, overlay component 1722 may extend over the entire underside 1703, although in some embodiments, overlay component 1722 may extend over only some portions of underside 1703. Moreover, in some cases, overlay component 1722 may extend partially upward around lower perimeter 1705 of upper 1702.

In some embodiments, sole system 1730 may be associated with upper 1702. In some embodiments, in addition, overlay component 1722 may facilitate bonding or engagement of sole system 1730 to upper 1702. For example, as best seen in the enlarged cross-sectional view of fig. 19, overlay component 1722 may be disposed between sole system 1730 and underside 1703 of upper 1702 to facilitate engagement of sole system 1730 and upper 1702.

In some embodiments, the material properties of overlay component 1722 and sole system 1730 may be selected so that overlay component 1722 and sole system 1730 may be easily joined using adhesives or other processes. For example, it is contemplated that in some embodiments, overlay component 1722 may be made from a thermoplastic urethane (TPU) material and sole system 1730 may be made from a similar material or a material that is readily bonded with TPU. In still other embodiments, however, overlay component 1722 and sole system 1730 can be made of any other material that can be joined with or without a separate adhesive.

While various embodiments have been described, the present description is intended to be illustrative, and not restrictive, and it will be apparent to those of ordinary skill in the art that many more embodiments and implementations are possible that are within the scope of the embodiments. Accordingly, the embodiments are not to be restricted except in light of the attached claims and their equivalents. Further, various modifications and changes may be made within the scope of the appended claims.

Claims (20)

1. An article of footwear comprising:

an upper and a sole system;

wherein the upper further comprises a braided structure and an overlay portion;

wherein the overlay portion is bonded to the woven structure;

wherein the overlay portion has a lower stretch resistance than the woven structure; and is

Wherein the overlay portion covers at least a portion of the braided structure and includes a section disposed on a lower side of the upper.

2. The article of footwear according to claim 1, wherein the overlay portion is disposed on an edge of the upper associated with an opening of the upper that receives a foot.

3. The article of footwear according to claim 1, wherein the overlay portion includes eyelets for receiving fasteners.

4. The article of footwear according to claim 1, wherein the overlay portion is disposed at a toe portion of the upper.

5. The article of footwear according to claim 1, wherein the overlay portion is made of a polymeric material.

6. An article of footwear comprising:

an upper and a sole system, the upper further associated with a lace member;

the upper includes a braided structure and an overlay portion;

wherein the overlay portion includes a plurality of eyelets for receiving the lace members; and is

Wherein the overlay portion covers at least a portion of the braided structure.

7. The article of footwear according to claim 6, wherein the overlay portion forms an eyelet support for the upper.

8. The article of footwear according to claim 6, wherein the overlay portion is disposed on a lateral edge of a fastening region of the upper, and wherein the overlay portion is disposed on a medial edge of the fastening region.

9. The article of footwear according to claim 6, wherein the overlay portion extends on a lateral side of the upper, a medial side of the upper, and a lower side of the upper.

10. The article of footwear according to claim 6, wherein the overlay portion is a first overlay portion, and wherein the article of footwear includes a second overlay portion that is different than the first overlay portion.

11. The article of footwear according to claim 10, wherein the first overlay portion overlaps the second overlay portion at an overlap region.

12. The article of footwear according to claim 10, wherein the article of footwear includes a third overlay portion and the third overlay portion covers an underside of the upper.

13. The article of footwear according to claim 12, wherein the third overlay portion is engageable to the sole system to secure the sole system in place on the article of footwear.

14. A method of manufacturing an article of footwear, the method comprising:

forming a braided structure with an inner cavity;

cutting an opening in the woven structure, thereby creating an opening in the woven structure and an edge associated with the opening;

bonding an overlay portion to the edge, wherein the overlay portion includes a plurality of eyelets;

inserting a shoelace through the eyelets; and is

Associating a sole system with the braided structure to form the article of footwear.

15. The method of claim 14, wherein forming the braided structure includes creating the braided structure with a central lumen.

16. The method according to claim 14, wherein forming the braided structure includes overbraiding the braided structure on a last.

17. The method of claim 14, wherein bonding the overlay portion comprises welding the overlay portion to the edge.

18. The method of claim 14, wherein bonding the overlay portion comprises securing at least one open end of a thread of the braided structure to the overlay portion.

19. The method according to claim 14, wherein the overlay portion is a first overlay portion, and wherein a second overlay portion is bonded to a bottom side of the knitted structure, and wherein the sole system is attached to the second overlay portion.

20. The method of claim 14, wherein the overlay portion is bonded to the edge such that at least one thread of the braided structure extends around at least one eyelet of the overlay portion.