US20170112228A1

US20170112228A1 - Shoe upper

Info

Publication number: US20170112228A1
Application number: US15/334,092
Authority: US
Inventors: Jürgen Weidl
Original assignee: Adidas AG
Current assignee: Adidas AG
Priority date: 2015-10-26
Filing date: 2016-10-25
Publication date: 2017-04-27
Also published as: JP2017099861A; EP3162240A1; CN107048577A; DE102015220865A1

Abstract

Described are shoe uppers for a shoe, in particular, for a sports shoe, with a rear section and a front section, wherein the front section is smaller graded than the rear section, and wherein the front section is more flexible than the rear section.

Description

CROSS REFERENCE TO RELATED APPLICATION

This application is related to and claims priority benefits from German Patent Application No. DE 10 2015 220 865.6, filed on Oct. 26, 2015, entitled “Shoe Upper” (“the '865.6 application”). The '865.6 application is hereby incorporated herein in its entirety by this reference.

FIELD OF THE INVENTION

The present invention relates to a shoe upper for a shoe, in particular, a sports shoe, and a method for manufacturing a shoe upper for a shoe, in particular, a sports shoe.

BACKGROUND

Shoes should fit a wearer most optimally and be neither too big nor too small. A shoe that is too big does not optimally enclose a foot, and does not provide sufficient stability for the foot, so the wearer may twist his or her ankle. Shoe fit is also important for sports shoes, because a wearer of sports shoes is likely to make sudden changes in direction, accelerations or stops. When the wearer of a shoe makes such movements, a shoe that is too big cannot sufficiently transmit the occurring forces between a foot and the ground, which creates a substantial risk of injury.
In team ball games such as soccer, rugby or football, a shoe that is too big is further disadvantageous with respect to ball control. Soccer players usually prefer shoes that provide a direct feeling for the ball to optimally control the ball, either during dribbling or shooting. A shoe that is too big cannot satisfy such requirements with respect to ball control.
On the other hand, a shoe should not be to© small. Shoes that are too small restrict the foot and impair blood circulation in the foot, which tires the foot faster or gives rise to numbness after wearing the shoe for some time. Further, shoes that are too small may result in bruises, blisters, and skin abrasions.
The above mentioned problems are aggravated by the fact that feet are usually not symmetrical. Usually one foot is slightly bigger and has a larger volume than the other one. Commonly, right-footers (those that preferably use the right foot) have a stronger right foot than left foot, and vice versa. Length and especially width of a foot may vary between right and left feet.
Different prior art approaches are known that purport to improve the footing and fit of shoes, and are described in more detail below.
For example, US 2014/0059889 A1 discloses a shoe that provides a variable length and flexible form by using a flexible sectional sole and a flexible shoe upper that corresponds to the forefoot section of a wearer.
US 2014/0041256 A1 discloses a shoe design which is expandable along its lengthwise axis by utilizing a sliding outsole configuration and/or a sliding insole configuration.
U.S. Pat. No. 7,055,268 B2 discloses a length-adjustable shoe. The shoe includes an outsole, an insole attached to the outsole, an upper attached to the insole, means for adjusting the length of the insole which is provided at the insole, an upper tension member provided at the upper, and means for fastening a front part and a rear part of the upper divided by the upper tension member to maintain a size of the shoe at a wearer's foot size.
U.S. Pat. No. 8,938,890 B2 discloses an expandable shoe which has a top portion, a pair of side portions, a back portion, a sole, a heel and a first elastic member. The first elastic member joins the top portion to the pair of side portions at a critical location, which is at the junction of the top portion and the side portions.
These known prior art solutions are very elaborate, expensive, and increase the weight of the shoe because special mechanical devices are installed to adjust the length of the shoe. Additionally, the length-adjustment of a shoe is often not sufficient, because width is the critical parameter that determines fit of a shoe to a foot.
Thus, an object of the present invention is to provide a shoe upper for a shoe, in particular, a sports shoe, which overcomes the above mentioned disadvantages of the prior art. More specifically, an object of the present invention is to provide a shoe upper that tightly encloses a foot of a wearer, is cost-effective production, and is light-weight.

SUMMARY

The terms “invention,” “the invention,” “this invention” and “the present invention” used in this patent are intended to refer broadly to all of the subject matter of this patent and the patent claims below. Statements containing these terms should be understood not to limit the subject matter described herein or to limit the meaning or scope of the patent claims below. Embodiments of the invention covered by this patent are defined by the claims below, not this summary. This summary is a high-level overview of various embodiments of the invention and introduces some of the concepts that are further described in the Detailed Description section below. This summary is not intended to identify key or essential features of the claimed subject matter, nor is it intended to be used in isolation to determine the scope of the claimed subject matter. The subject matter should be understood by reference to appropriate portions of the entire specification of this patent, any or all drawings and each claim.
According to certain embodiments of the present invention, a shoe upper comprises a rear section and a front section, wherein the front section is smaller graded than the rear section and the front section is more flexible than the rear section.
In some embodiments, the front section is smaller graded than the rear section by at least about a full shoe size. The front section, in certain embodiments, is smaller graded than the rear section at least with respect to width.
In certain embodiments, the front section is more flexible in one direction than in another direction. The front section, in some embodiments, is more flexible in the one direction perpendicular to a longitudinal axis of the shoe upper than in a direction parallel to the longitudinal axis of the shoe upper.
In some embodiments, the rear section is more flexible in at least two directions than in any other direction being different thereof. The rear section, in certain embodiments, is more flexible in the at least two directions perpendicular to and parallel to a longitudinal axis of the shoe upper than in a direction being different from the at least two directions.
In certain embodiments, the rear section and the front section are sewn together.
The rear section and the front section, in some embodiments, comprise a synthetic polyurethane material. In some embodiments, the synthetic polyurethane material is applied onto a carrier material.
In some embodiments, a layer that reduces flexibility is applied onto at least a portion of the front section. The layer, in certain embodiments, is a film of thermoplastic polyurethane. The film, in some embodiments, is applied onto the front section by welding.
In certain embodiments, the front section is adapted to cover a front portion of a foot during wear, and the rear section is adapted to cover a rear portion of the foot during wear.
According to some embodiments of the present invention, a shoe comprises a sole and a shoe upper comprising a rear section and a front section, wherein the front section is smaller graded than the rear section. The front section, in certain embodiments, is more flexible than the rear section.
In some embodiments, the sole is graded simultaneously with the rear section of the shoe upper.
According to certain embodiments of the present invention, a method for manufacturing a shoe upper for a shoe comprises providing a rear section of the shoe upper, providing a front section of the shoe upper, wherein the front section is smaller graded than the rear section and the front section is more flexible than the rear section, and connection the rear section and the front section. The front section, in certain embodiments, is smaller graded than the rear section by at least a full shoe size.
In some embodiments, the method comprises punching the rear section out from a first material layer. In certain embodiments, the method comprises punching the front section out from a second material layer. The first material layer, in some embodiments, is different from the second material layer. The second material layer, in certain embodiments, is more flexible than the first material layer. In some embodiments, the second material layer is more flexible in one direction than in any other direction being different thereof. The first material layer, in certain embodiments, is more flexible in at least two directions than in another direction.
In certain embodiments, the method comprises sewing the rear section together with the front section.
The method, in some embodiments, comprises applying a layer that reduces flexibility to at least one portion of the front section. In certain embodiments, the layer is welded to the at least one portion of the front section.
In some embodiments, the method comprises applying thermoplastic polyurethane onto a carrier material.

BRIEF DESCRIPTION OF THE DRAWINGS

In the following detailed description, embodiments of the invention are described referring to the following figures:

Possible embodiments of the present invention are further described in the following detailed description, with reference to the following figures:

FIG. 1A is a lateral view of a shoe with a shoe upper according to certain embodiments of the present invention.

FIG. 1B is a medial view of the shoe of FIG. 1A.

FIG. 1C is a front view of the shoe of FIG. 1A.

FIG. 2 is a schematic illustration of a conventional grading process of a shoe upper.

FIG. 3 is a schematic illustration of a grading process of a shoe upper according to certain embodiments of the present invention.

BRIEF DESCRIPTION

According to some embodiments of the present invention, a shoe upper for a shoe, in particular, a sports shoe, comprises a rear section and a front section, wherein the front section is smaller graded than the rear section, and wherein the front section is more flexible than the rear section.
Grading refers to the manufacturing of further shoe sizes departing from a sample last, a sample shoe, or a sample shoe upper. In other words, grading is downsizing or upsizing a sample. The sample last, the sample shoe, or the sample shoe upper (“the starting sample”) is scaled according to fixed standards of shoe sizes to obtain samples of other shoe sizes. For example, a starting sample that corresponds to a men's shoe size 43 (according to European size system) may be graded to obtain a sample, for example, a shoe of size 45. During grading, both the length and the width of the starting sample are enlarged by defined amounts. Usually, the size of a starting sample corresponds to a representative population average shoe size.
It has been found that grading a front section such that it is smaller graded than a rear section of a starting sample provides a shoe upper that has a very good footing and is suitable for sport activities. Smaller grading of the front section provides a tight fit of the shoe upper because the front section encloses the forefoot area tightly. This is particularly beneficial for team ball games where direct contact with the ball is indispensable. Further, the tight fit of the front section prevents a loose-fit of the shoe and thereby reduces the risk of the wearer twisting his or her ankle. Additionally, the shoe is not too small because the rear section is graded such that it corresponds to the shoe size that results from usual grading. For example, the front section of the shoe upper for a men's shoe may correspond to a shoe size of 44 (according to European size system) while the rear section may correspond to a shoe size of 45.
Moreover, the front section is more flexible than the rear section, so the front section may adapt to the foot and enclose it tightly. Simultaneously, this flexibility prevents development of bruises and impairment of blood circulation. The flexibility of the front section in combination with the front section's smaller grading further allows the shoe upper to adapt optimally to different foot volumes, which might differ, for example, between a right and a left foot.
According to some embodiments of the present invention, the transition from the front section to the rear section of a shoe upper may be localized in a mid foot area. For example, such transition may be arranged around the middle of the longitudinal axis of the shoe upper. Alternatively, such transition divide the longitudinal axis of the shoe upper intro a ratio of 2 to 1, wherein the smaller part is the front portion of the shoe upper.
The front section may be graded at least one shoe size smaller than the rear section. Thus, the front section may tightly enclose the forefoot area and ensure a good fit of the shoe upper to the foot. The benefit of grading the front section one shoe size smaller than the rear section has been demonstrated for soccer shoes because it improves a wearer's feeling for the ball.
The front section may be smaller graded than the rear section at least with respect to the width of the front section. For example, while a length of the shoe upper may correspond to a length of a commonly graded shoe upper, a width of the front section may be smaller than a width of a commonly graded shoe upper so that the foot may be enclosed particularly well without restricting the toes in the longitudinal direction.
The front section may be more flexible in one direction than in another direction. Thereby, the flexibility of the front section may be designed according to requirements of a wearer.
The front section may be more flexible in a direction perpendicular to the longitudinal axis of the shoe upper than in a direction parallel to the longitudinal axis of the shoe upper. In this way, the front section of the shoe upper may adapt to the foot width and prevent the shoe upper from slacking with respect to the longitudinal axis such that the foot is not supported optimally, and, for example, slips forward during rolling movements.
The rear section may be more flexible in at least two directions than it is in any other direction being different thereof. For example, the rear section may be more flexible in directions perpendicular and parallel to the longitudinal axis of the shoe upper, while not as flexible in a third direction (e.g. a diagonal direction). In this way, the rear section of the shoe upper may adapt to the length and width of a foot shape.
The rear section and the front section may be sewn together. For example, the front section and the rear section may be sewn together using a fully automated sewing machine, thereby reducing manufacturing costs of the shoe upper.
The rear section and the front section may be manufactured from synthetic polyurethane material. The polyurethane material may be applied onto a carrier material. The carrier material may be a layer of textile material. The textile material may be formed of microfibers. Alternatively, the carrier material may also be a woven fabric, a warp-knitted fabric, a weft-knitted fabric, or a combination thereof. Polyurethane may be easily processed and applied onto textiles, for example, in liquid form. Alternatively, the rear section and the front section may be produced from natural leather or synthetic leather. In some embodiments, the applied carrier material determines the flexibility of the rear section and the front section. In certain embodiments, the flexibility of the rear section and front section are adjustable via the carrier material. Different carrier materials may be used for the front section and the rear section.
A layer that reduces flexibility may be applied onto the front section in at least one portion of the front section. Thus, the flexibility of the front section may be adjusted selectively. For example, a first portion of the front section may not be coated with the layer that reduces flexibility, while a second portion may be coated with the layer that reduces flexibility. As a result, the first portion is flexible and allows the front section to adapt to the foot and the second portion is not as flexible and contributes to the stability of the shoe upper. For example, the second portion may be the toe section, which is often subjected to higher mechanical stresses.
The layer that reduces flexibility may be a film of thermoplastic polyurethane. Thermoplastic polyurethane is easy to process and has a low flexibility. Alternatively, non-flexible rubber may be used for the layer.
The film may be applied onto the front section by welding. Welding is a relatively fast process step to be performed and may be automated. For example, high frequency welding, ultrasonic welding, infrared welding or laser welding may be used.
The front section may be adapted to cover a front portion of a foot during wearing and the rear section may be adapted to cover a rear portion of a foot during wearing. This division between the front section and the rear section of the shoe upper allows the shoe upper to properly fit a foot shape and stabilize the foot.
A further aspect of the present invention is a shoe, comprising a sole and a shoe upper, as described above.
According to some embodiments of the present invention, the sole may be graded simultaneously with the rear section of the shoe upper. Thereby, the sole has a length and a width corresponding to a commonly graded shoe sole.
A further aspect of the present invention relates to a method for manufacturing a shoe upper for a shoe, in particular, a sports shoe, comprising steps of providing a rear section of the shoe upper, providing a front section of the shoe upper, wherein the front section is smaller graded than the rear section, and connecting the rear section and the front section.
According to the some embodiments of the method, the front section may be smaller graded by at least a full shoe size as compared to the rear section. Thus, the front section encloses the forefoot area tightly and allows the shoe upper to properly fit around a foot. With respect to soccer shoes, grading the front section smaller than the rear section has been proven beneficial because this improves a wearer's feeling for a ball.
The step of providing the rear section may comprise punching out the rear section from a first material layer. The step of providing the front section may comprise punching out the front section from a second material layer. Punching-out is a fast process step to be performed, and may be automated.
The first material layer may be different from the second material layer. Thus, the front section may be formed of a material that is different from that of the rear section. The materials may differ with respect to their properties. For example, the second material layer used for the front section may be more flexible than the first material layer so that the front section may adapt to the foot and enclose the foot tightly while preventing the development of bruises and impairment of blood circulation. The flexibility of the front section in combination with its smaller grading allows the manufactured shoe upper to optimally fit different foot volumes,for example, right and left feet having different foot volumes.
The second material layer may be more flexible in one direction than in another direction. Thus, the flexibility of the front section may be designed according to requirements of a wearer.
The first material layer may be more flexible in at least two directions than it is in any other direction. For example, the rear section may be more flexible in a direction perpendicular to the longitudinal axis and in a direction parallel to the longitudinal axis of the shoe upper and less flexible in a third direction, for example, a diagonal direction. In this way, the rear section of the shoe upper may adapt to the length and width of a foot shape.
The step of connecting the rear section and the front section may comprise sewing the rear section with the front section. For example, the front section and the rear section may he sewn together using a fully-automated sewing machine, thereby reducing the manufacturing costs for the shoe upper.
The method according to certain embodiments of the present invention may further comprise a step of applying a layer that reduces the flexibility of at least one portion of the front section. Thus, the flexibility of the front section may be selectively adjusted. For example, a first portion of the front section may not be coated with the layer that reduces flexibility while a second portion of the front section may be coated with the layer that reduces flexibility. Consequently, the first portion is flexible and allows the front section to adapt to the foot while the second portion is not as flexible and contributes to the stability of the shoe upper. The second portion may be the toe section, which is often subjected to higher mechanical stresses.
The step of applying the layer that reduces flexibility may comprise welding of the layer. Welding is a relatively fast process step to be performed and may be automated. For example, high frequency welding, ultrasonic welding, infrared welding or laser welding may be used.
The steps of providing the rear section and the front section may comprise applying synthetic polyurethane material onto a carrier material. The carrier material may be a textile material, for example, a textile material comprising microfibers. Alternatively, the carrier material may be a woven fabric, a warp-knitted fabric, a weft-knitted fabric, or a combination thereof. Synthetic polyurethane may be easily processed and has a lower flexibility. Alternatively, non-flexible rubber may be also used. In some embodiments, the carrier material determines the flexibility of the rear section and the front section. Different carder materials may be used for the front section and the rear section.
A shoe upper according to the present invention may be manufactured by a method according to certain embodiments of the invention, as mentioned above and described in more detail below.

DETAILED DESCRIPTION

The subject matter of embodiments of the present invention is described here with specificity to meet statutory requirements, but this description is not necessarily intended to limit the scope of the claims. The claimed subject matter may be embodied in other ways, may include different elements or steps, and may be used in conjunction with other existing or future technologies. This description should not be interpreted as implying any particular order or arrangement among or between various steps or elements except when the order of individual steps or arrangement of elements is explicitly described.
Hereafter, embodiments and examples of the present invention are described in detail.
FIGS. 1A, 1B, and 1C illustrate embodiments of a shoe 10 having a shoe upper 11 according to certain embodiments of the present invention. FIG. 1A illustrates a lateral view, FIG, 113 illustrates a medial view, and FIG. 1C illustrates a front view of the shoe 10. The shoe 10 comprises a shoe upper 11 and a sole The shoe 10 illustrated in FIGS. 1A, 1B, and 1C is a soccer shoe. Consequently, the sole 12 comprises studs 13. The present invention is not limited to soccer shoes, but may also be used for shoes in other sport disciplines, such as rugby, football, basketball, volleyball and golf. The invention may be further used for shoes that are not sports shoes, for example, casual shoes.
As illustrated in FIGS. 1A, 1B and 1C, the shoe upper 11 comprises a rear section 14 and a front section 15. The rear section 14 and the front section 15 may be sewn together along a seam 16. Sewing may be done on a suitable sewing machine. Alternatively, the rear section 14 and the front section 15 may be welded together (e.g. by high frequency welding, ultrasonic welding, infrared welding or laser welding).
In the embodiments of FIGS. 1A, 1B and 1C, the seam 16 extends between the rear section 14 and the front section 15 in an S-shape from a front portion of the instep to a portion in the transition of the tarsal to the metatarsal. Different arrangements of the seam 16 are possible, for example, the seam 16 may be in the middle of the shoe upper 11 or in the toe portion of the front section 15.
In the embodiments of FIGS. 1A, 1B and 1C, the front section 15 and the rear section 14 are manufactured from a synthetic polyurethane material. To this end, the synthetic polyurethane material was applied onto a layer of textile carrier material (not shown in the figures). The textile carrier material comprises microfibers. In accordance with the invention, different carrier materials and different coatings may be also used. Further, it is possible to manufacture the rear section 14 and/or the front section 15 from, for example, leather, synthetic leather, mesh, warp-knitted fabric, well-knitted fabric, or a combination thereof. It is also possible to coat the rear section 14 and/or the front section 15.
In general, both the rear section 14 and the front section 15 may be punched out from a material layer. The material layer for the rear section 14 may be different than the material layer fur the front section 15. For example, the material layer for the front section 15 may be more flexible. Alternatively, the rear section 14 and the front section 15 may be punched out from the same material layer. Further, it is possible to, for example, warp-knit or weft-knit the sections 14 and 15 into the desired shape.
According to some embodiments of the present invention, the front section 15 is smaller graded than the rear section 14. Grading refers the manufacturing of further shoe sizes departing from a sample last, a sample shoe, or a sample shoe upper. In other words, grading is downsizing or upsizing a sample. The sample last, the sample shoe, or the sample shoe upper (“the starting sample”) is scaled according to fixed standards to obtain samples of other shoe sizes. For example, a starting sample that corresponds to men's shoe size 43 (according to European size system) may be graded to obtain a sample with a shoe size 45. During grading, both the length and the width of the starting sample are enlarged by defined amounts. Usually, the starting sample corresponds to a representative population average.
With respect to FIG. 2, the conventional process of grading is described hereafter as required for the comprehension of the present invention. FIG. 2 is a schematic illustration of a starting sample shoe upper 21. The size of the starting sample shoe upper 21 corresponds to a representative population size and a specific shoe size, e.g. a men's shoe size 43 according to European size system. To provide sample shoe uppers for other shoe sizes on the basis of that starting sample shoe upper 21, said sample shoe upper 21 needs to be graded. Essentially, grading means that the starting sample shoe upper 21 is scaled such that sample shoe uppers for other shoe sizes may be obtained to suit a population share as large as possible. For example, during grading of the starting sample shoe upper 21 corresponding to a men's shoe size 43, a sample shoe upper corresponding to a men's shoe size 45 may be obtained and fit to a population share as large as possible wearing shoe size 45.
The starting sample shoe upper 21 of FIG. 2 is folded, i.e. the lateral side and the medial side overlap partially. The boundary of the lateral side is labelled with 21 a and the boundary of the medial side is labelled with 21 b. A sample last 22 (dashed line) is also shown in FIG. 2.
During grading, usually a middle line 23 of the starting sample shoe upper 21 is defined first. Then, a point 24, which is localized on the middle line 23, is defined. Said point 24 is called a grading center and represents a starting point for the grading process. Point 24 may be chosen such that it divides the middle line 23 into ratio of 1 to 2, but other ratios are also possible. During grading, the width and the length of the starting sample shoe upper 21 are scaled independently from each other. For example, starting from point 24, another point 25 of a certain distance (e.g. 20 mm) from point 24 may be defined for scaling of the width. Another point 26 defines the center between the lateral boundary 21 a and the medial boundary 21 b. The width 27 of the starting sample shoe upper 21 may be measured between point 25 and point 26, which are perpendicular to the middle line 23.
During grading, the width 27 may be altered according to defined, fixed values. For example, the width 27 may be increased by or reduced by 1 mm per half shoe size in the British size system (UK). If the starting sample shoe upper 21 has a width 27 of x mm, a sample shoe upper for the next bigger half shoe size in British size system would have a width of x+1 mm. Alternatively, a sample shoe upper for the next smaller half shoe size would have a width of x−1 mm. In the French size system (F), the width 27 may be increased by or reduced by 2 mm per full shoe size.
During grading, the length of the starting sample shoe upper 21 is also altered. However, this alteration is not based on the same values as the width 27 because a bigger foot usually has a disproportionately bigger length than width, as compared to a smaller foot. For example, the length may be increased or reduced by 4.23 mm per half shoe size in the British size system (UK). Thus, if the starting sample shoe upper 21 has a length of y mm, the sample shoe upper for the next bigger half shoe size in the British size system would have a length of y+4.23 mm while the next smaller half shoe size would have a length of y−4.23 mm. In the French size system (F), the length may be increased or reduced by 6.66 mm per full shoe size.
According to some embodiments of the present invention, the shoe upper 11 comprises a front section 15 that is smaller graded than a rear section 14. This aspect is described in detail hereafter with respect to FIG. 3. FIG. 3 illustrates a sample shoe upper 31 with a rear section 14 and a front section 15 and a boundary line 32 between sections 14 and 15. The boundary line 32 corresponds to the seam 16 that connects both sections 14 and 15 of the manufactured shoe upper 11.
According to certain embodiments of the invention, sections 14 and 15 are graded separately according to the grading rules as described exemplarily above with reference to FIG. 2. However, unlike the common grading described with respect to FIG. 2, front section 15 in FIG. 3 is graded such that it is smaller graded than the rear section 14. For example, according to some embodiments of the invention, if the sample shoe upper 31 corresponds to the shoe size 9 in the British size system (UK), the rear section 14 and the front section 15 are graded to obtain, for example, a sample shoe upper for the shoe size 10 (UK) as follows: To obtain the rear section 14, the width of the sample shoe upper 31 (size 9 UK) is increased by 3 mm (1 mm per half size), and the length of the sample shoe upper 31 is increased by 12.69 mm (4.23 per half size). To obtain the front section 15, unlike in common grading described for FIG. 2, the front section 15 is smaller graded. For example, the front section 15 may correspond to a sample shoe upper which is half a shoe size smaller graded than the shoe size for which the rear section 14 is graded. Accordingly, to obtain the front section 15, the width of the sample shoe upper 31 (size 9 UK) is increased by 2 mm (1 mm per half size), and the length of the sample shoe upper 31 is increased by 8.46 mm (4.23 mm per half size).
The front section 15 may also be smaller graded than the rear section 14 by more than half a shoe size, for example, a full shoe size. The choice of the difference in size between the front section 15 and the rear section 14 depends on the size system in which grading is performed because different size systems, for example the British size system and the European size system, are precisely subdivided differently. For example, in the British size system (UK), the difference between two full, adjacent shoe sizes (e.g. a size 9 UK compared to a size 10 UK) is larger than the difference between two full, adjacent shoe sizes in the European size system (EUR) (e.g. a size 43 EUR compared to a size 44 EUR).
According to some embodiments of the invention, it is also possible to only grade either the width or the length of the front section 15 smaller than the rear section 14. For example, the width of the front section 15 of the shoe upper 11 may be smaller graded than the width of the rear section 14 by one shoe size while the lengths of both sections 14 and 15 may be graded by the same value.
Sole 12 of the shoe 10, as illustrated in FIGS. 1A, 1B, and 1C, is graded continuously, such that the sole 10 is graded equally to the rear section 14 of the shoe upper 11. For example, if the rear section 14 corresponds to shoe size 45, the sole 10 equally corresponds to shoe size 45. However, it is also possible to grade the front portion 15 of the sole 10 smaller.
According to the embodiments of FIGS. 1A, 1B, and 1C, the front section 15 is more flexible than the rear section 14. This may be achieved by using a more flexible material for the front section 15 than for the rear section 14. For example, the front section 15 and the rear section 14 may comprise a carrier material with different respective flexibilities. The carrier material may be a layer of textile material, for example, a textile material comprising microfibers. Alternatively, the carrier material may be a woven fabric, a warp-knitted fabric, a weft-knitted fabric or a combination thereof. Different carrier materials may be used for the front section 15 and the rear section 14.
The front section 15 does not need to have the same flexibility in all directions. For example, the front section 15 may be more flexible in a direction perpendicular to the longitudinal axis of the shoe upper 11 than it is in a direction parallel to the longitudinal axis of the shoe upper 11. This flexibility may be achieved by using an appropriate textile material. For example, using specific weft-knitted fabrics or warp-knitted fabrics that have anisotropic flexibilities due to a specific loop structure may provide different flexibilities to the front section 15.
The rear section 14 may also have an anisotropic flexibility. For example, the rear section 14 may be more flexible in a direction perpendicular to the longitudinal axis and in a direction parallel to the longitudinal axis of the shoe upper than it is in any other direction being different thereof (e.g. a diagonal direction). This anisotropic flexibility in the rear section 14 may also be achieved by using an appropriate material. For example, materials having such anisotropic properties, which are known as 4-way-stretch materials, may be used. Further, certain weft-knitted fabrics or warp-knitted fabrics that also have such properties due to a specific loop structure may be used.
In the embodiments of FIGS. 1A, 1B, and 1C, a film 17 of thermoplastic polyurethane is applied to specific regions of the front section 15. The film 17 reduces the flexibility of the front section 15 at those regions where the film is applied. The film 17 may be applied to the front section 15 by welding mechanisms (e.g. infrared welding, high-frequency welding, laser welding). Instead of thermoplastic polyurethane, different materials may be applied which reduce flexibility, such as non-flexible rubber. In the embodiments of FIGS. 1A, 1B, and 1C, the film 17 is applied in the front toe portion and in the portion of the transition region of the metatarsal to the toe bones. In general, however, other arrangements are also possible.
In the embodiments of FIGS. 1A, 1B, and 1C, the shoe upper 11 further comprises an inner lining 18, which extends below the rear section 14 and the front section 15 of the shoe upper 11. The flexibility of the material of the inner lining 18 is at least as high as the flexibility of the material of the front section 15 to not restrict the flexibility of the front section 15. For example, a polyurethane-coated inner lining may be used as a material for the inner lining 18.
In the following, further examples are described to facilitate the understanding of the invention:
1. A shoe upper (11) for a shoe, in particular, a sports shoe, comprising:
a rear section (14); and

- a front section (15), wherein the front section (15) is smaller graded than the rear section (14), and wherein the front section (15) is more flexible than the rear section (14).

2. The shoe upper according to the preceding example, wherein the front section is smaller graded than the rear section by at least a full shoe size.
3. The shoe upper according to any one of the preceding examples, wherein the front section is smaller graded than the rear section at least with respect to width.
4. The shoe upper according to any one of the preceding examples, wherein the front section is more flexible in one direction than in another direction.
5. The shoe upper according to the preceding example, wherein the front section is more flexible in one direction being perpendicular to the longitudinal axis of the shoe upper than in another direction being parallel to the longitudinal axis of the shoe upper.
6. The shoe upper according to any one of the preceding examples, wherein the rear section is more flexible in at least two directions than in a third direction being different thereof.
7. The shoe upper according to the preceding example, wherein the rear more flexible in a direction being perpendicular to and a direction being parallel to the longitudinal axis of the shoe upper than in a third direction being different thereof.
8. The shoe upper according to any one of the preceding examples, wherein the rear section and the front section are sewn together.
9. The shoe upper according to any one of the preceding examples, wherein the rear section and the front section further comprise a synthetic polyurethane material.
10. The shoe upper according to the preceding example, wherein the synthetic polyurethane material is applied onto a carrier material.
11. The shoe upper according to any one of the preceding examples, wherein a layer that reduces flexibility is applied onto at least a portion of the front section,
12. The shoe upper according to the preceding example, wherein the layer is a film of thermoplastic polyurethane.
13. The shoe upper according to the preceding example, wherein the film is applied onto the front section by welding.
14. The shoe upper according to any one of the proceedings examples, wherein the front section is adapted to cover a front portion of a foot during wear and the rear section is adapted to cover a rear portion of the foot during wear
15. A shop: (10) comprising:
a sole (12); and

- a shoe upper (11) according to any one of the preceding examples.

16. The shoe according to the preceding example, wherein the sole is graded simultaneously with the rear section of the shoe upper.
17. A method for manufacturing a shoe upper (11) for a shoe, in particular, a sports shoe, comprising the steps of:

- providing a rear section (14) of the shoe upper (11);
- providing a front section (15) of the shoe upper (11), wherein the front section (15) is smaller graded than the rear section (14), and wherein the front section (15) is more flexible than the rear section (14); and
- connecting the rear section (14) and the front section (15).

18. The method according to the preceding example, wherein the front section is smaller graded than the rear section by at least a full shoe size.
19. The method according to any one of examples 17 or 18, wherein the step of providing the rear section comprises punching out the rear section from a first material layer.
20. The method according to any one of the examples 17 to 19, wherein the step of providing the front section comprises punching out the front section from a second material layer.
21. The method according to examples 19 and 20, wherein the first material layer is different from the second material layer.
22. The method according to the preceding example, wherein the second material layer is more flexible than the first material layer.
23. The method according to any one of examples 19 to 22, wherein the second material layer is more flexible in one direction than in another direction.
24. The method according to any one of examples 19 to 23, wherein the first material layer is more flexible in at least two directions than in a third direction being different thereof.
25. The method according to any one of examples 17 to 24, wherein the step of connecting the rear section and the front section comprises sewing the rear section together with the front section.
26. The method according to any one of examples 17 to 25, further comprising the step of applying a layer that reduces flexibility to at least one portion of the front section.
27. The method according to the preceding example, wherein the step of applying the layer comprises welding the layer.
28. The method according to any one of examples 17 to 27, wherein the steps of providing the rear section and the front section comprise applying thermoplastic polyurethane onto a carrier material.
29. The method according to any one of examples 17 to 28, wherein the shoe upper is a shoe upper according to any one of examples 1 to 14.
Different arrangements of the components depicted in the drawings or described above, as well as components and steps not shown or described are possible. Similarly, some features and sub-combinations are useful and may be employed without reference to other features and sub-combinations. Embodiments of the invention have been described for illustrative and not restrictive purposes, and alternative embodiments will become apparent to readers of this patent. Accordingly, the present invention is not limited to the embodiments described above or depicted in the drawings, and various embodiments and modifications may be made without departing from the scope of the claims below.

Claims

That which is claimed is:

1. A shoe upper for a shoe comprising:

a rear section; and

a front section,

wherein the front section is smaller graded than the rear section, and wherein the front section is more flexible than the rear section.

2. The shoe upper of claim 1, wherein the front section is smaller graded than the rear section by at least about a full shoe size.

3. The shoe upper of claim 1, wherein the front section is smaller graded than the rear section least with respect to width.

4. The shoe upper of claim 1, wherein the front section is more flexible in one direction than in any other direction being different thereof.

5. The shoe upper of claim 4, wherein the front section is more flexible in the one direction perpendicular to a longitudinal axis of the shoe upper than in another direction parallel to the longitudinal axis of the shoe upper.

6. The shoe upper of claim 1, wherein the rear section is more flexible in at least two directions than in any other direction being different thereof.

7. The shoe upper of claim 6, wherein the rear section is more flexible in the at least two directions being perpendicular to and parallel to a longitudinal axis of the shoe upper than in another direction being different from said at least two directions.

8. The shoe upper of claim 1, wherein the rear section and the front section are sewn together.

9. The shoe upper according to claim 1, wherein the rear section and the front section further comprise a synthetic polyurethane material.

10. The shoe upper of claim 9, wherein the synthetic polyurethane material is applied onto a carrier material.

11. The shoe upper of claim 1, wherein a layer that reduces flexibility is applied onto at least a portion of the front section.

12. The shoe upper of claim 11, wherein the layer is a film of thermoplastic polyurethane.

13. The shoe upper of claim 12, wherein the film is applied onto the front section by welding.

14. The shoe upper of claim 1, wherein the front section is adapted to cover a front portion of a foot during wear and the rear section is adapted to cover a rear portion of the foot during wear.

15. A shoe comprising:

a sole; and

a shoe upper comprising a rear section and a front section, wherein the front section is smaller graded than the rear section.

16. The shoe according to claim 15, wherein the front section is more flexible than the rear section.

17. The shoe according to claim 15, wherein the sole is graded simultaneously with the rear section of the shoe upper.

18. A method for manufacturing a shoe upper for a shoe comprising:

providing a rear section of the shoe upper;

providing a front section of the shoe upper, wherein the front section is smaller graded than the rear section, and wherein the front section is more flexible than the rear section; and

connecting the rear section and the front section.

19. The method of claim 18, wherein the front section is smaller graded than the rear section by at least a full shoe size.

20. The method of claim 18, further comprising punching out the rear section from a first material layer.

21. The method of claim 20, further comprising punching out the front section from a second material layer.

22. The method of claim 21, wherein the first material layer is different from the second material layer.

23. The method of claim 22, wherein the second material layer is more flexible than the first material layer.

24. The method of claim 21, wherein the second material layer is more flexible in one direction than in another direction.

25. The method of claim 20, wherein the first material layer is more flexible in at least two directions than in any other direction being different thereof.

26. The method of claim 18, further comprising sewing the rear section together with the front section.

27. The method of claim 18, further comprising applying a layer that reduces flexibility to at least one portion of the front section.

28. The method of claim 27, wherein the layer is welded to the at least one portion of the front section.

29. The method of claim 18, further comprising applying thermoplastic polyurethane onto a carrier material.