US20110308115A1

Movatterモバイル変換

Info

Publication number: US20110308115A1
Application number: US13/164,594
Authority: US
Inventors: Tuan Le; Aaron Azevedo; David A. Jewell
Original assignee: K2 Corp
Current assignee: K2 Corp
Priority date: 2010-06-18
Filing date: 2011-06-20
Publication date: 2011-12-22
Also published as: WO2011160131A2; WO2011160131A3

Abstract

A footwear and footwear construction method that creates the footwear upper sleeve (shoe upper) using at least two overlapping, layered panels of fabric oriented 90 degrees with respect to each other. A lacing system creates a support cage for the foot, which is independent from the footwear upper. The lacing support cage can be asymmetrical in several respects to accommodate the physically asymmetrical shape of the foot. The lacing system includes fingers independent from the footwear upper. The fingers then end in lace eyelets.

Description

CROSS-REFERENCE TO RELATED APPLICATION

This application claims the benefit of U.S. Provisional Application No. 61/356,460, filed Jun. 18, 2010, the entire disclosure of which is hereby incorporated by reference herein.

BACKGROUND

Seeking to provide every possible advantage to athletes, many footwear companies are trying to develop athletic footwear incorporating technological advances using new fabrics, new construction methods, and high strength, low weight materials to meet the demands of athletes. Nevertheless, there still remains a desire to improve on the existing footwear available in the market today.

SUMMARY

This summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This summary is not intended to identify key features of the claimed subject matter, nor is it intended to be used as an aid in determining the scope of the claimed subject matter.

In a first embodiment, a shoe is disclosed. The shoe includes a shoe upper having a forefoot area, a midfoot area, a medial quarter area, and a lateral quarter area, and a sole on the bottom of the shoe, wherein the upper is formed from one or more fabric laminates, each fabric laminate comprises two or more fabrics joined to each other, each fabric in the fabric laminate defines an orientation with respect to stretch, wherein the orientation of fabrics with respect to stretch in the fabric laminate do not coincide.

In the first embodiment, two or more fabrics may be joined to each other throughout the whole of their contact area. Fabrics can be joined by adhesives, for example.

In the first embodiment, each of the forefoot, midfoot, medial quarter, and lateral quarter area may include one or more fabric laminates.

In the first embodiment, the fabric laminate is on the exterior of the shoe upper.

In the first embodiment, fabric laminates may include a first and second woven fabric.

In the first embodiment, the fabric laminate may include a first fabric with warp and weft threads and a second fabric with warp and weft threads, wherein the warp threads of the first fabric are aligned with the weft threads of the second fabric.

In the first embodiment, the fabric laminate may include a similar first and second fabric.

In the first embodiment, the fabric laminate may include a dissimilar first and second fabric.

In the first embodiment, the fabric laminate may include fabrics made from nylon and spandex.

In the first embodiment, the fabric laminate may include breathable, lightweight fabrics.

In the first embodiment, the upper may omit a tongue that is free on the medial and lateral sides thereof.

In the first embodiment, the fabric laminate may include a first fabric having a first direction of highest stretch and a second fabric having a second direction of highest stretch, and the first and second directions do not coincide.

In the first embodiment, the fabric laminate may include a first fabric having a first direction of highest stretch and a second fabric having a second direction of highest stretch, and the first and second directions are perpendicular.

In the first embodiment, the fabric laminate may be formed by two or more fabrics joined at major surfaces to each other.

The features described above may all be present in the shoe of the first embodiment, or any combination of fewer than all features may be present in the shoe. Furthermore, the shoe with any, some, or all features described above may further include a lacing system, wherein the lacing system has a plurality of lacing fingers on the lateral side of the upper and a plurality of lacing fingers on the medial side of the upper, wherein the fingers comprise a lacing eyelet on one end thereof and are free to move with respect to the upper at least partly along their length. Furthermore, any, some, or all of the features of the shoe of the first embodiment may be combined with any, some, or all of the features of the shoe of the second embodiment.

In a second embodiment, a shoe is disclosed. The shoe according to a second embodiment includes a shoe upper, wherein the upper defines a centerline dividing the upper into a medial side and a lateral side; sole joined to the shoe upper; and a lacing system comprising a plurality of lacing fingers extending on the lateral side of the upper and a plurality of lacing fingers extending on the medial side of the upper, wherein the fingers comprise a lacing eyelet on one end thereof and are independent from the shoe upper at least partly along their length.

In the second embodiment, the length of one or more fingers on the medial side can be shorter than the length of one or more fingers on the lateral side.

In the second embodiment, one or more fingers on the lateral side may cross the centerline into the medial side.

In the second embodiment, a forwardmost finger on the lateral side may be placed further forward than a forwardmost finger on the medial side.

In the second embodiment, the shoe may further include a shoelace laced through the eyelets in a zigzag pattern, and the lace defines a loop.

In the second embodiment, the shoe may further include a shoelace laced through the eyelets in a zigzag pattern, and the lace includes a static end secured on the upper, and a free end passing through a locking mechanism.

In the second embodiment, two adjacent fingers may be joined to each other at an upper portion.

In the second embodiment, the finger to finger distance at the eyelets on the lateral side can be different to the finger to finger distance at the eyelets on the medial side.

In the second embodiment, a first finger to finger distance between any two fingers on a side can be different than a second finger to finger distance on the same side.

In the second embodiment, the lateral side may include the same number of fingers as the medial side, and a length of one or more fingers on the lateral side is greater than a length of a corresponding finger on medial side.

In the second embodiment, one or more fingers are not joined to the shoe upper.

In the second embodiment, the shoe may further include a shoe upper, wherein the upper is formed from one or more fabric laminates, each fabric laminate comprises two or more fabrics, and each fabric in the fabric laminate defines an orientation with respect to stretch, wherein the orientation of fabrics with respect to stretch in the fabric laminate do not coincide. Furthermore, any, some, or all of the features of the shoe of the first embodiment may be combined with any, some, or all of the features of the shoe of the second embodiment.

Shoe uppers and shoes of the first and second embodiments, having any, some, or all features, may be made by a process including obtaining a first fabric and a second fabric, each fabric having a direction with higher stretch in said direction, aligning the first fabric and the second fabric, wherein the direction of the second fabric with higher stretch does not coincide with the direction of higher stretch in the first fabric, joining the first and the second fabric together into a fabric laminate, cutting one or more patterns from the fabric laminate, and assembling one or more patterns cut from the fabric laminate into the shoe upper. The shoe upper may include at least one pattern cut from the fabric laminate being applied to a forefoot, a midfoot, a medial quarter, or a lateral quarter area of the upper. The shoe upper with a forefoot, a midfoot, a medial quarter, and a lateral quarter area may include at least one fabric laminate, in any, some, or all areas.

DESCRIPTION OF THE DRAWINGS

The foregoing aspects and many of the attendant advantages of this invention will become more readily appreciated as the same become better understood by reference to the following detailed description, when taken in conjunction with the accompanying drawings, wherein:

FIG. 1 is a flow diagram of a construction method for a shoe upper and shoe;

FIG. 2A is a diagrammatical illustration of a first and second fabric which are oriented different to one another with respect to their direction of stretch;

FIG. 2B is a diagrammatical illustration of a fabric laminate with a shoe upper pattern marked on the fabric laminate;

FIG. 3 is a top plan view illustration of a shoe according to one embodiment of the present invention;

FIG. 4 is a lateral view illustration of the shoe ofFIG. 3;

FIG. 5 is a medial view illustration of the shoe ofFIG. 3;

FIG. 6 is a top view illustration of a shoe according to one embodiment of the present invention;

FIG. 7 is a lateral view illustration of the shoe ofFIG. 6;

FIG. 8 is a top view illustration of a shoe according to one embodiment of the present invention;

FIG. 9 is a lateral view illustration of the shoe ofFIG. 8;

FIG. 10 is a medial view illustration of the shoe ofFIG. 8; and

FIG. 11 is an exploded view illustration of portions of a shoe in accordance with one embodiment of the present invention.

DETAILED DESCRIPTION

Disclosed is a footwear or shoe construction method to create a footwear upper sleeve (shoe upper) using fabric laminates made of two overlapping, layered panels of fabric oriented 90 degrees with respect to each other.

Also disclosed is a lacing system that creates a support cage for the foot which is independent from the footwear upper. The lacing support cage can be asymmetrical in several respects to accommodate the physically asymmetrical shape of the foot.

The disclosed shoe may eliminate the freely moving tongue portion of the shoe upper, thus making the shoe more comfortable. The disclosed shoe may allow for a wider range of feet to fit in the shoe while maintaining a secure fit. The lacing system support cage is advantageously asymmetrical in design to better work with the asymmetrical nature of the human foot. Freely moving fingers of the lacing support cage allow for accommodating bones and nerves typically irritated by conventional shoe portions. The shoe construction allows the shoe upper sleeve and the lacing system cage to function independently of one another as they are not fully connected.

Referring toFIG. 1, amethod1100 for making athletic shoes and shoe uppers is illustrated. While athletic shoes are mentioned as one representative example of the invention, the method of forming uppers can be applied to non-athletic shoes, such as shoes for casual use, and also for all footwear. In one embodiment, an athletic shoe is characterized as being lightweight and, thus, finds favor with athletes engaging in running or long endurance sports such as marathons and triathlons.

Block

1102 indicates the start of a method of making a shoe upper and shoe. Fromblock1102, the method entersblock1104. Inblock1104, two fabrics are obtained. The fabrics can be obtained in rolls or sheets. When unrolled and in sheets, the fabrics have major planar surfaces on both sides. At least two fabrics are joined at their major surfaces to one another to make a fabric laminate. In one embodiment, the fabrics can be breathable to allow the evaporation of moisture generated by the foot. Some fabrics are characterized as meshes, and these are acceptable breathable fabrics that can be used. In one embodiment, the fabrics can be lightweight fabrics, such that each fabric may have a fabric weight ranging from approximately 310 to 320 grams per yard with a width of 60 inches. While being representative of one embodiment, this range is not limiting as to other embodiments, and some embodiments may use even lighter fabrics, medium weight fabrics and heavy fabrics or any combination thereof. The fabrics include threads made from one or more of synthetic, semi-synthetic or natural fibers. Synthetic fibers include, but are not limited to, nylon fibers; polypropylene fibers; polystyrene fibers, polyurethane fibers, polyacrylic fibers, polyester fibers, spandex fibers (a polyurethane polyurea copolymer), or any combination thereof. Natural fibers include, but are not limited to, animal fibers, such as wool and silk; plant fibers, such as cotton, flax, and jute, or any combination thereof. Semi-synthetic fibers include, but are not limited to, rayon, lyocell, viscose rayon, or any combination thereof. In one embodiment, the fabrics can be a combination of various fibers, including synthetic fibers, natural fibers, or semi-synthetic fibers. In one embodiment, the threads are made from a combination of synthetic fibers. A suitable combination of fibers includes nylon and spandex fibers, and particularly approximately 79% by weight nylon and 21% by weight spandex. In one embodiment, two fabrics may be the same weight and material. In other embodiments, two fabrics may be different weight and the same material. In other embodiments, two fabrics may be the same weight and different material. In other embodiments, two fabrics may be different weight and material. One fabric may be dyed or include patterns, as one fabric will be the exterior of the shoe upper, and one fabric may not be dyed. Generally, the fabrics used inblock1104 are woven fabrics. In weaving, there is an orientation of threads named warp and weft threads. Generally, the threads regarded as the weft threads run across the fabric from side to side, whereas the threads which run lengthwise are referred to as the warp. Accordingly, for each fabric, there is an orientation in which stretching and/or deformation of the fabric in one direction is more than in the other direction. FromBlock1104, the method entersblock1106.

Inblock1106, the fabrics are oriented such that their direction of highest stretch do not coincide with each other. In one embodiment, the fabrics are oriented such that their direction of lowest stretch do not coincide with each other. In one embodiment, the fabrics are oriented 90° with respect to each other, meaning that the direction of highest stretch of one fabric is 90° with respect to the direction of highest stretch of the fabric next to it. For example, when the warp threads run lengthwise in one fabric, the second fabric that is overlaid on top of the first fabric is oriented such that the warp threads run from side to side. Inblock1106, one embodiment orients the at least two overlapping is fabrics at 90°. However, based on the fabric construction method, other fabrics may be oriented less than 90° depending on the direction of highest or lowest stretch direction of the fabrics. It is also possible that there can be more than two fabrics, in which case any fabric does not have an orientation that coincides with any other fabric directly juxtaposed next to it. Fromblock1106, the method entersblock1110

Inblock1110, the dissimilarly oriented first and second fabrics are joined with an adhesive compatible with the fabrics. As used herein a “fabric laminate” means any two or more fabrics joined together at the entire area in which they coincide. Suitable adhesives for synthetic, semi-synthetic and natural materials include, but are not limited to, silicone, latex, rubber, and the like. Fromblock1110, the method entersblock1112.

Inblock1112, the fabric laminate created inblock1110 is patterned and cut from the fabric laminate according to a shoe upper template. When the pattern is cut from the fabric laminate, the size of the first fabric naturally coincides with a size of the second fabric. A shoe upper is a portion of a shoe that surrounds and supports the foot, except generally the foot sole. The upper can generally be divided into four areas. These four areas include a forefoot portion to cover the toes, a midfoot portion to cover the foot instep, and medial and lateral quarters that cover the sides of the foot to the heel. The upper includes an opening that is bounded on the sides formed from midfoot portion, and the medial and lateral side quarters. The medial and lateral quarters extend from the midfoot back and join each other at the heel. Lateral, as used herein, means toward the outside of the body, whereas, medial means toward the inside of the body. For example, a foot arch is located on the medial side of both the right and left feet. The fabric laminate can be used in all areas of the shoe upper, or less than the whole of the shoe upper. The fabric laminate can be the exterior of the shoe upper, except where there are reinforcing materials, such as around the toes, heel, and arch. Such reinforcing materials can be leather, synthetic leather, canvas, heavyweight cloth, rubber, plasticized fabrics, reinforced fabrics, and the like. On the shoe upper and interior to the fabric laminate, there may be additional materials such as padding, foam, closed or open celled foam, additional moisture wicking fabrics, or moisture absorbing fabrics to draw moisture away from the skin. These additional fabrics to the interior of the fabric laminate are not part of the fabric laminate. In one embodiment, a fabric laminate mimics a tongue portion of a shoe upper, however, unlike conventional tongues that move freely at the sides, the is tongue portion of the upper disclosed herein is entirely stitched from the bottom of the tongue to the very top of the tongue on both sides, ending at the foot opening. This construction provides essentially a sleeve, or tube into which the foot is fitted, as there is no freely moving tongue portion. The entire shoe upper can be formed from one or more fabric laminates, and additionally include other layers. Also, various designs for tongues can be incorporated into the shoe upper. For example, the tongue can be a generally symmetrical tongue that extends from the forefoot portion of the upper to the foot opening. In this case, the tongue is secured on both sides to respective medial and lateral sides of the shoe upper, such that the tongue does not separate from the shoe upper, unlike the more conventional tongues that are stitched at the forefoot portion and are not stitched along the sides, the tongue disclosed herein is stitched at the forefoot portion and for the entirety of the sides from the forefoot to the foot opening. In one embodiment, the tongue can be a small V-shaped portion covering a small part of the midfoot area. In this embodiment, too, the tongue is also stitched or joined to the fabrics on both sides to prevent up and down movement. Other designs of a shoe tongue are also within the scope of the invention.

Fromblock1112, the method entersblock1114. Inblock1114, the shoe upper is constructed according to the templates for a particular style of shoe. Shoes, while functional are also fashionable, therefore, there can be an almost infinite number of patterns cut from the fabric laminate to form the show upper. Each pattern cut from the fabric laminate may cover an area of the forefoot, midfoot, medial quarter, or lateral quarter of the shoe upper. Each pattern cut from the fabric laminate may cover more than one portion of one of the forefoot, midfoot, medial quarter, or lateral quarter of the shoe upper. Each pattern cut from the fabric laminate may cover just one of the forefoot, midfoot, medial quarter, or lateral quarter of the shoe upper. Two or more patterns cut from the fabric laminate may cover any one or more of the forefoot, midfoot, medial quarter, or lateral quarter of the shoe upper. The many combinations of combining patterns to form the shoe upper may be decided upon purely for function and fashion. For examples, some patterns may be cut, such that the exterior stitching creates a pleasing appearance. Individual cut fabric laminate patterns may be joined to one another by stitching, adhesives, or by utilizing an intermediate material that joins the two fabric laminate pieces to one another.

Fromblock1114, the method entersblock1116. Inblock1116, the shoe is finished such as by joining the shoe upper to the shoe sole. Any one of various shoe construction methods may be used at this point, for example, an insole board may be stitched around the lower periphery of the shoe upper, and then the board is stitched or adhered to the sole, or an intermediate member that ultimately attaches to the sole. The sole can be a combination of closed cell foam rubber and solid flexible rubber parts to provide cushioning as well as durability. Furthermore, the upper can be reinforced by providing a leather or rubberized toe box extending over the forefoot of the upper. Additionally, a heel box may be created at the back of the shoe to provide for support. Cushioning materials may be provided on the insole of the shoe and also in the interior of the shoe upper. An arch support may also be added. Soft foam padding may be provided in areas, such the tongue, the heel, and around the foot opening. In one embodiment of a shoe, a lacing support cage is added for a lacing system. The lacing support cage is further described below.

The shape, seam work, material, and construction of the shoe upper can change as long as the shoe upper incorporates one or more fabric laminates in the shoe upper.

The shoe and shoe upper construction method described herein achieves a biaxially oriented fabric laminate from at least two layers of bonded or laminated fabric in a manner that allows full breathability. The construction method forms a high level of compression yet allows for a dynamic fit over a human foot. Dynamic refers to the ability to accommodate changes in foot structure of individuals who share the same size foot.

Referring toFIG. 2A, a simplified diagrammatical illustration of two fabrics is illustrated. Afirst fabric1201 is superimposed over asecond fabric1203. Thefirst fabric1201 includeswarp threads1202 running lengthwise andweft threads1200 running from side to side.

Threads

1200 and1202 can be the same or dissimilar fibers, such as nylon, polypropylene, polyurethane, spandex, and the like. Similarly, thesecond fabric1203 includeswarp fibers1204 running lengthwise andweft threads1206 running from side to side. Each of the

fabrics

1201 and1203 possess an orientation with respect to highest stretch (or lowest stretch). For example,fabric1201 may possess an orientation of highest stretch in the direction shown by double headedarrow1208. Similarly,fabric1203 includes an orientation of highest stretch (or lowest stretch) along is the direction denoted by double headedarrow1210.Fabric1201 includes a major planarsurface facing fabric1203. Similarly,fabric1203 includes a majorsurface facing fabric1201. An adhesive is applied to bond the entirety of surfaces of the

fabrics

1201 and1203 facing one another. The adhesive can be silicone, latex, or rubber, and the like. In one embodiment, the adhesive is applied such that the fabrics remain breathable, i.e., allow moisture to pass through from an exterior major side of one fabric to the exterior major side of the second fabric. The joined fabrics are call a fabric laminate.

As illustrated inFIG. 2A, the orientation offabric1201 does not coincide with the orientation offabric1203. In one particular embodiment, the fabrics are aligned such that the orientation in the direction of highest stretch offabric1201 is at 90° with respect to the orientation of highest stretch offabric1203. In such orientation, thefabric1201 is joined withfabric1203 to produce afabric laminate1212 diagrammatically illustrated inFIG. 2B. Once afabric laminate1212 is produced, thefabric laminate1212 may be used as materials for construction of a shoe upper. For example, any part of the shoe upper can be constructed from the fabric laminate. A shoe upper pattern, such aspattern1214 is cut from thefabric laminate1212. Clearly, more than one pattern can be cut from thefabric laminate1212 to make a shoe upper. Thefabric pattern1214 is then used as a component in fabricating shoe uppers, such as illustrated inFIGS. 3-10.

UsingFIG. 3 as an example, the shoe uppers ofFIGS. 3-10 include aforefoot area50, amidfoot area52, amedial side quarter56, and alateral side quarter54 on the opposite side to themedial side quarter56. These areas are present in all the shoe uppers of the embodiments disclosed herein. Theforefoot area50 generally covers the area of the toes. The midfoot area52 (as called the instep area) generally covers the arched part of the upper from the end of theforefoot portion50 to the top of the shoe upper down the center. Each of thelateral quarter area54 or themedial quarter area56 covers the side of the upper to the center of the back of the heel. Themidfoot area52, thelateral quarter area54 and the medial quarter area also define a periphery that is thefoot opening42. Any pattern cut from thefabric laminate212 may be used to cover theforefoot area50, themidfoot area52, or the medial56 or lateral54 quarter area. Anypattern1214 cut from thefabric laminate1212 may be used to cover only a portion of the is above-noted upper shoe areas. Alternatively, anypattern1214 cut from thefabric laminate1212 may be used to cover two or more of the general areas of the shoe upper.

It should be appreciated thatFIG. 2A is highly diagrammatical in nature. More complex weaving patterns are capable of being used for the fabrics used in the construction of thefabric laminate1212. In one embodiment, a weave known as “warp knit mesh” is used for weaving the fabrics of the fabric laminate. Fabrics may be woven by computer-controlled weaving machines that are able to create much more complex fabrics. Nevertheless, even more complex woven fabrics tend to possess an orientation of highest stretch. Therefore, the method disclosed herein may use fabrics wherein a fabric laminate is constructed such that the orientation of highest stretch of one fabric does not coincide with the orientation of highest stretch of a second fabric. This produces a fabric laminate that provides better support by combining two fabrics.

Furthermore, the fabrics need not be oriented with respect to the direction of highest stretch. In other embodiments, the orientation of the first and second fabrics in a fabric laminate may be oriented such that the direction of lowest stretch does not coincide with one another. Furthermore, while the embodiment illustrated inFIG. 2A shows a 90° orientation of thefirst fabric1201 with respect to thesecond fabric1203, other fabric laminates can be oriented more than or less than 90°.

Embodiments of lacing support cages are illustrated in any one ofFIGS. 3 to 11. In one embodiment, the lacing support cage includes a plurality of fingers on the medial side of the shoe upper and a plurality of fingers on the lateral side of the shoe upper. Each of the fingers may terminate at the upper end (shoe upper side) in an eyelet, whereas the lower end (the sole side) is anchored to the sole, the upper, or between the sole and upper. For example, the lacing support cage may include a connecting portion connecting the bottom of the medial fingers to the bottom of the lateral fingers. This connecting portion is then anchored between two components, such as between the sole and the insole board.

While the fingers are attached at the sole, or at a bottom portion of the shoe upper, the fingers remain free and independently move to take a position which best corresponds to the individual wearing the shoe. In some embodiments, each finger can be stitched to the upper any distance from an insole board up to, but not including, the eyelet area. The feature of the fingers is that some length remains free and unattached.

The fingers can be made of a durable hard plastic reinforced with high frequency welded thermoplastic polyurethane (TPU) or embossed synthetic leather. Each finger could be made with any material, textile, leather, or synthetic leather. A feature is that some level of independence and freedom of movement is retained in each of the lacing fingers. This advantageously provides an independent lacing support cage and allows reducing pressure on the foot while maintaining a secure fit.

For eyelets, any number of devices may be used. Eyelets may be loops formed from resilient fabrics or synthetic leather, metal hooks, sheaves, drums, or a combination of metal and fabric, or the simple punched eyelets.

The shoelace is provided in a zigzag pattern through the eyelets. A zigzag pattern denotes a lace that crosses the centerline of the shoe between a lateral eyelet to a medial eyelet and back to a lateral eyelet one or more times. In some embodiment, the shoelace can be threaded on both sides of the eyelet row. For example, a shoe lace is threaded through the bottom two eyelets, such that the center of the shoelace is approximately at the centerline of the shoe. This creates two portions of shoelace, and each portion is threaded alternately threaded through the eyelets on one side then the other. In this case, the two portions of shoelace crisscross one another. The lace can be a loop and tied at the ends as illustrated inFIG. 3, or the lace may have one end secured to a bottom eyelet and a freely moving end passing through a locking mechanism, as illustrated inFIG. 8. To tighten the lace, a user pulls the shoelace through the locking mechanism. A locking mechanism can a spring loaded lock. In one embodiment, a locking mechanism includes a cup-shaped body. The body has a slot through which one or both ends of the shoelace pass. The body includes a spring that presses a brake against the shoelace on one side thereof. The brake then presses the shoelace against one side of the slot, thus preventing the shoelace from slipping in or out of the locking mechanism. A user may simply pull on the shoelace and the shoelace is held by the brake. To release the brake, the cup-shaped body includes a button on the side of the slot opposite to the brake. When the button is depressed, it pushes the brake away from the shoelace and against the spring, thus, releasing the shoelace. Shoelaces may be elastic or inelastic cords, and the like.

In some embodiments, the lacing fingers are asymmetrical in one or more respects. Several ways in which the lacing support cage can by asymmetrical are is described below. Asymmetry of the lacing system is a function of the foot also not being symmetrical. The independent, freely moving fingers and eyelets accommodate each individual foot so that the fingers align to provide directional stability. These adjustments lead to an asymmetrical lacing system that is independent at least partly from the shoe upper.

Unlike conventional shoes that have medial and lateral eyelet rows being generally straight on a line when viewed from a top plan view, in one embodiment of a lacing system, an eyelet row defines a curve when view from a top plan view. The eyelet row does not define a line, but rather the eyelet row defines a curve, i.e., if a line were drawn between each eyelet at the end of a finger, the line would describe a curve when viewed from a top plan view.

In the embodiment shown inFIGS. 8-10, ashoelace220 is alternately threaded through a medial eyelet, then a lateral eyelet, and back toward a medial outlet, without a corresponding lace portion on the opposite side. In other words, the lace system shown inFIGS. 8-10 does not include lacing portions that crisscross one another as they pass from one eyelet on one side to an eyelet on the opposite side. Instead, asingle shoelace portion220 is fixed at one end to aneyelet210 at the forefoot area and zigzags alternately from medial to lateral eyelets, and the other end of the shoelace is attached to the shoe upper at the lateral quarter via alocking mechanism232 to allow tensioning of the shoelace.

As shown inFIG. 3, a shoe in accordance with one embodiment of the invention comprises a shoe upper formed from at least two or more patterns or panels of a

fabric laminate

2,4 and5 that omits the conventional freely moving tongue portion of the shoe upper. Thefabric laminate2 covers theforefoot area50, themidfoot area52, and thelateral quarter area54. Thefabric laminate4 covers themidfoot area52 and themedial quarter area56. The fabric laminate5 covers the midfoot area5. Thefabric laminate2 includes astitch line46 to connectfabric laminate2 withfabric laminates4, and5. The fabricatelaminate4 includes astitch line48 to connect thefabric laminate4 with the fabric laminate5. While one representative example of how fabric laminates can be used to form a shoe upper, it is to be appreciated that the fabric laminate panels can be cut into many different shapes other than the particular ones shown inFIG. 3. As described in detail above, the fabric laminates used in making the shoe upper may have two or more overlapping and adhered fabrics, such that the fabrics in the laminate have an orientation dissimilar to each other. For example, weaving methods result in a first set of threads in one direction and a second set of threads generally perpendicular to the first set of threads. When two fabrics are assembled into a fabric laminate, the threads of one fabric are placed perpendicular to the same threads on the second fabric. The fabric laminates can thus have different stretch properties than the individual fabrics owing to the bonding of two or more fabrics in a dissimilar orientation throughout the whole of their surfaces in contact with each other. Further, because the patterns are cut from the fabric laminate, the fabrics that make up the fabric laminate of a pattern are each of the same size of every other fabric in the pattern. In one embodiment, a shoe upper can include more than one panels of fabric laminates, wherein the fabric laminate includes two layered fabrics one on top of another one, and oriented 90 degrees to one another with respect to one set of threads. The fabrics may also be oriented with respect to a stretch property. For example, the highest (or lowest) stretch direction of one fabric is placed at 90° with respect to the corresponding highest (or lowest) stretch direction of a second fabric. The fabrics are then bonded and/or laminated together over the entire area of contact in a manner that allows full breathability between and across the two layers. In other embodiments, the orientation can be greater than 0 degrees and less than 90 degrees with respect to one another. The athletic shoe construction in the present invention aligns the fabric panels in such a manner to best take advantage of the stretch properties of the fabrics to further support the body part being clothed. This construction forms a high level of compression yet allows for a dynamic fit over the human foot.

Also shown inFIG. 3 is a lacingsupport cage6 incorporated with the shoe upper formed with the

fabric laminates

2,4, and5. The lacingsupport cage6 includes a lateral set of

fingers

8,10,12,14 (best seen inFIG. 4) and a medial set of

fingers

16,18,20, and22 (best seen inFIG. 5). As shown inFIG. 3, the shoe upper is defined by acenter line24 that runs from the back of the heel to the tip of the toe. Each one of the fingers extends from the shoe sole to an area that does not quite reach thecenter line24. The top end of each finger includes an eyelet for passing a lace therethrough.

Lateral fingers

8,10,12, and14 include

eyelets

24,26, and28. The

eyelets

24,26, and28 form an eyelet row on the lateral side of the upper.

Medial fingers

16,18,20, and22, include

eyelets

30,32, and34. The

eyelets

30,32 and34 form an eyelet row on the medial side of the upper. As can be seen inFIG. 3, the medial side fingers are asymmetrical with the lateral side fingers. More specifically, as can be noted, the medial side fingers34,32, and30 are placed further forward than the corresponding

lateral side fingers

28,26, and24 resulting in firstmedial eyelet30 being placed further forward than firstlateral eyelet24. The secondmedial eyelet32 is placed further forward as compared to the secondlateral eyelet26. The thirdmedial eyelet34 is placed further forward as compared to the thirdlateral eyelet28. However, the distance from eyelet to eyelet on the same side can stay approximately the same. A greater distance can separate the third pair of medial and

lateral eyelets

34,28 as compared to the distance between the first pair of medial and

lateral eyelets

30,24. Also, while the medial and lateral fingers number four each, the medial third20 and fourth22 finger is arranged into an “A-type” structure, meaning the third20 and fourth22 fingers are joined at the top in the proximity of the eyelet. This can be done to avoid putting a finger directly over a bony prominence of the foot. The lateral sidesecond finger10 andthird finger12 are also arranged into an “A-type” structure.

In other embodiments of the shoe, the eyelets can be placed nearer to or further from thecenter line24. Also, other embodiments may include an A-type structure using the first and second fingers, or one side may include two A-type structures arranged from the first and second fingers for one, and from the third and fourth fingers for the other. Alternatively, all fingers on the medial and lateral sides can use a single finger “I” structure. Asingle lace44 is generally centered through the two

eyelets

34 and28 creating two shoelace portions that are passed alternately from the medial side to the lateral side for one portion, and vice versa for the second portion as shown inFIG. 3. A lace system described above forms an asymmetrical support cage that can reduce the pressure on the foot while providing a secure fit.

A feature of the disclosed lacing system is that the fingers are independent of the shoe upper for at least a portion of the length of the fingers. In one embodiment, the fingers are not stitched to the shoe upper, providing up to 100% of the finger length above the sole board stitch-free and independent from the shoe upper. In other embodiments, up to 90% or greater, but less than 100%, of the length of each finger can be stitched or otherwise attached to the footwear upper to provide at least some independence. In the disclosed embodiments, at least some amount of independence for moving freely is allowed between the fingers of the lacing system and the shoe upper.

Also as seen inFIG. 8, some fingers, such as210 can be very short and essentially be an eyelet portion. In some embodiments, each of the fingers on both the lateral side and the medial side of the upper can be very short and basically only exists as eyelets. However, even with the very short finger andeyelet210 illustrated inFIG. 8, the finger (eyelet) remains independent and moves freely with respect to the shoe upper.

Each finger on the lacing system support cage can be, but is not required to be, supported further with high-frequency welded thermoplastic urethane (TPU) or embossed in synthetic leather. Each finger could be made with any material, textile, leather, or synthetic leather. Each finger can be stitched down any distance from the insole board up to, but not including, the eyelet area. In terms of length, this is approximately 60% to 70% of the finger length. Thus, some level of independence is retained in the lace system and the support shoe upper.

As illustrated inFIG. 3, an asymmetrical nature of the lacing system cage is seen wherein medial side fingers are further forward than the lateral side fingers. A further asymmetrical aspect may be added by having a different distance between the first 34 and second 32 eyelets on the same side as compared to the distance between the second 32 and third 30 eyelets on that side. Alternatively, the distance between the first and second fingers on both the medial and lateral side can be shorter or longer than the distance between the second and third fingers on the same side. Further, the independent nature of the fingers, allows the fingers to freely align in the direction of pull.

FIGS. 6, and7 show an embodiment of a shoe having a lacing system with four fingers on the medial side and the lateral side, where none of the fingers are joined into an “A-type” structure. As can be seen inFIG. 6, the lacing system achieves asymmetry by having the

lateral side fingers

102,104,106, and108 further forward than the corresponding

medial side fingers

110,112,114, and116, which is opposite from that of the embodiment ofFIGS. 3-5 that has the medial side fingers further forward than the lateral side fingers. The

lateral fingers

102,104,106, and108, and the

medial fingers

110,112,114, and116 in this embodiment also have some degree of independence from the shoe upper. Similar to the embodiment illustrated inFIGS. 3-5, the shoe ofFIGS. 6, and7 is formed form one or more fabric laminates for the forefoot area, the midfoot area, the lateral quarter area and the medial quarter area. Illustrated in this embodiment is a “tongue”120 formed from afabric laminate120. Thefabric laminate120 is joined to the corresponding sides of the upper on both the medial and the lateral sides and, thus, is not freely movable as a conventional tongue. Theshoelace122 crisscrosses thetongue120 with a lateral and medial shoelace portions that terminate at the upper ends128, and124 of the corresponding eyelet rows. Theshoelace122 may be elastic and joined to the

eyelets

128 and124 such that the need to tie and untie theshoelace122 is avoided.

Referring toFIGS. 8,9, and10, another embodiment of a shoe is illustrated. In the embodiment ofFIGS. 8-10, another example of asymmetry of the lacing system is shown. In this embodiment, the medial side includes five

fingers

202,204,206, and208, whereas the lateral side includes four

fingers

212,214,216, and218. Further, it is possible that one or more of the lateral side fingers extend to and even cross thecenter line224 along the longitudinal direction of the top portion of shoe. As seen inFIG. 8, the asymmetry of the eyelet rows is shown by the eyelet row curving in the direction toward the medial side of the shoe. The eyelet row on the medial side created by

fingers

202,204,206, and208 appears to be concave toward the center, wherein the eyelet row on the lateral side created by

fingers

212,214,216, and218 appears to be convex toward the center. However, both eyelet rows can be concave toward the center, or convex toward the center, or one concave, and one convex. As seen inFIG. 9, the

lateral side fingers

214,216, and218 extend to at least the top outline of the shoe, and inFIG. 10, the

lateral side fingers

218 and216 are seen in the medial side view illustration, and the

medial side fingers

202,204,206, and208 do not extend to the top outline of the shoe. The fingers in this embodiment also have some degree of independence from the shoe upper. Also, similar to the upper shown inFIG. 3, the upper shown inFIG. 8 includes afabric laminate222 extending over the forefoot area, the midfoot area, and the lateral quarter area. Thefabric laminate226 extends over the midfoot area, and the medial quarter area. Thefabric laminate230 extends over the midfoot area. The fabric laminates222,226, and230 also define thefoot opening228.

FIG. 11 shows a representative illustration of a construction of the shoe sole and lacingsupport cage300, with

fingers

302,304,306, and308. The

fingers

302,304,306, and308 can be made from a single piece ofthermoplastic rubber314, wherein a lower and center portion of thethermoplastic rubber314 is placed between a topsole portion310 and a bottomsole portion312. The sole312 is a compression molded sole with rubber outsole on the bottom thereof. It is to be appreciated that the

shoe sole

310 and312 is combinable with the shoe uppers and lacing support cages shown and described in association withFIGS. 3-10.

Several embodiments of a shoe in accordance with the above description are described.

In a first embodiment, a shoe includes a shoe upper having a forefoot area, a midfoot area, a medial quarter area, and a lateral quarter area, and a sole on the bottom of the shoe, wherein the upper is formed from one or more fabric laminates, each fabric laminate comprises two or more fabrics joined to each other, each fabric in the fabric laminate defines an orientation with respect to stretch, wherein the orientation of fabrics with respect to stretch in the fabric laminate do not coincide.

The features described above may all be present in the shoe of the first embodiment, or any combination of fewer than all features may be present in the shoe. Furthermore, the shoe with any, some, or all features described above, may further include a lacing system, wherein the lacing system has a plurality of lacing fingers on the lateral side of the upper and a plurality of lacing fingers on the medial side of the upper, wherein the fingers comprise a lacing eyelet on one end thereof and are free to move with respect to the upper at least partly along their length. Furthermore, any, some, or all of the features of the shoe of the first embodiment may be combined with any, some, or all of the features of the shoe of the second embodiment.

In the second embodiment, one or more fingers are not joined to the shoe upper.

While illustrative embodiments have been illustrated and described, it will be appreciated that various changes can be made therein without departing from the spirit and scope of the invention.

Claims

1. A shoe, comprising:

a shoe upper having a forefoot area, a midfoot area, a medial quarter area, and a lateral quarter area, and

a sole on the bottom of the shoe, wherein the upper is formed from one or more fabric laminates, each fabric laminate comprises two or more fabrics joined to each other, each fabric in the fabric laminate defines an orientation with respect to stretch, wherein the orientation of fabrics with respect to stretch in the fabric laminate do not coincide.

2. The show ofclaim 1, wherein the two or more fabrics are joined to each other throughout the whole of their contact area.

3. The shoe ofclaim 1, wherein each of the forefoot, midfoot, medial quarter, and lateral quarter area includes one or more fabric laminates.

4. The shoe ofclaim 1, wherein the fabric laminate is on the exterior of the shoe upper.

5. The shoe ofclaim 1, wherein the fabric laminates includes a first and second woven fabric.

6. The shoe ofclaim 1, wherein the fabric laminate includes a first fabric with warp and weft threads and a second fabric with warp and weft threads, wherein the warp threads of the first fabric are aligned with the weft threads of the second fabric.

7. The shoe ofclaim 1, wherein the fabric laminate includes a similar first and second fabric.

8. The shoe ofclaim 1, wherein the fabric laminate includes a dissimilar first and second fabric.

9. The shoe ofclaim 1, wherein the fabric laminate includes fabrics made from nylon and spandex.

10. The shoe ofclaim 1, wherein the fabric laminate includes breathable, lightweight fabrics.

11. The shoe ofclaim 1, wherein the upper does not include a tongue that is free on the medial and lateral sides thereof.

12. The shoe ofclaim 1, wherein the fabric laminate includes a first fabric having a first direction of highest stretch and a second fabric having a second direction of highest stretch, and the first and second directions do not coincide.

13. The shoe ofclaim 1, wherein the fabric laminate includes a first fabric having a first direction of highest stretch and a second fabric having a second direction of highest stretch, and the first and second directions are perpendicular.

14. The shoe ofclaim 1, wherein the fabric laminate is formed by two or more fabrics joined at major surfaces to each other.

15. The shoe ofclaim 1, further comprising a lacing system comprising a plurality of lacing fingers on the lateral side of the upper and a plurality of lacing fingers on the medial side of the upper, wherein the fingers comprise a lacing eyelet on one end thereof and are free to move with respect to the upper at least partly along their length.

16. A shoe, comprising:

a shoe upper, wherein the upper defines a centerline dividing the upper into a medial side and a lateral side;

a sole joined to the shoe upper; and

a lacing system comprising a plurality of lacing fingers extending on the lateral side of the upper and a plurality of lacing fingers extending on the medial side of the upper, wherein the fingers comprise a lacing eyelet on one end thereof and are independent from the shoe upper at least partly along their length.

17. The shoe ofclaim 16, wherein the length of one or more fingers on the medial side is shorter than the length of one or more fingers on the lateral side.

18. The shoe ofclaim 16, wherein one or more fingers on the lateral side cross the centerline into the medial side.

19. The shoe ofclaim 16, wherein a forwardmost finger on the lateral side is placed further forward than a forwardmost finger on the medial side.

20. The shoe ofclaim 16, further comprising a shoelace laced through the eyelets in a zigzag pattern, and the lace defines a loop.

21. The shoe ofclaim 16, further comprising a shoelace laced through the eyelets in a zigzag pattern, and the lace includes a static end secured on the upper, and a free end passing through a locking mechanism.

22. The shoe ofclaim 16, wherein two adjacent fingers are joined to each other at an upper portion.

23. The shoe ofclaim 16, wherein the finger to finger distance at the eyelets on the lateral side is different to the finger to finger distance at the eyelets on the medial side.

24. The shoe ofclaim 16, wherein a first finger to finger distance between any two fingers on a side is different than a second finger to finger distance on the same side.

25. The shoe ofclaim 16, wherein the lateral side includes the same number of fingers as the medial side, and a length of one or more fingers on the lateral side is greater than a length of a corresponding finger on medial side.

26. The shoe ofclaim 16, wherein one or more fingers are not joined to the shoe upper.

27. The shoe ofclaim 16, further comprising a shoe upper, wherein the upper is formed from one or more fabric laminates, each fabric laminate comprises two or more fabrics, and each fabric in the fabric laminate defines an orientation with respect to stretch, wherein the orientation of fabrics with respect to stretch in the fabric laminate do not coincide.

28. A shoe upper made by the process, comprising:

obtaining a first fabric and a second fabric, each fabric having a direction with higher stretch in said direction;

aligning the first fabric and the second fabric, wherein the direction of the second fabric with higher stretch does not coincide with the direction of higher stretch in the first fabric;

joining the first and the second fabric together into a fabric laminate;

cutting one or more patterns from the fabric laminate; and

assembling one or more patterns cut from the fabric laminate into the shoe upper.

29. The shoe upper ofclaim 28, wherein at least one pattern cut from the fabric laminate is applied to a forefoot, a midfoot, a medial quarter, or a lateral quarter area of the upper.

30. The shoe upper ofclaim 28, wherein the shoe upper includes a forefoot, a midfoot, a medial quarter, and a lateral quarter area including a fabric laminate.