US20160345675A1 - Hybrid Braided Article - Google Patents

Abstract

An upper for an article of footwear is formed by incorporating different braided portions. The upper may be formed by incorporating a first braided portion with a second braided portion. The top portion of the upper may have the first braided portion. The lower portion of the upper may have the second braided portion.

Description

BACKGROUND OF THE INVENTION
• The present embodiments relate generally to articles of footwear, and in particular to articles of footwear with uppers.
• Articles of footwear generally include an upper and one or more sole structures. The upper may be formed from a variety of materials that are stitched or adhesively bonded together to form a void within the footwear for comfortably and securely receiving a foot. The sole structures may include midsole structures that provide cushioning and shock absorption.
SUMMARY OF THE INVENTION
• In one aspect, the invention provides a sole and an upper attached to the sole. The upper includes a first portion and a second portion. The first portion has a Jacquard braid pattern. The second portion has a Non-Jacquard braid pattern.
• In another aspect, the invention provides a sole and an upper attached to the sole. The upper includes a seamless braided structure. The seamless braided structure includes a top portion and a lower portion. The top portion has a Jacquard braid pattern. The lower portion has a Non-Jacquard braid pattern.
• In another aspect, the invention provides a method of making an article of footwear. The method comprises providing a set of spools to configure with a set of tensile elements. Providing a braiding machine configured with the set of spools. Passing a last through a braiding point, where the tensile elements converge thereby forming a seamless braided structure on the last. Moving the set of spools through a first section to form a first braid portion of the braided structure. Moving the set of spools through a second section to form a second braid portion of the braided structure. Wherein a set of rotor gears move the set of spools in a Jacquard motion in the first section. Wherein the set of rotor gears move the set of spools in a Non-Jacquard motion in the second section.
• Other systems, methods, features, and advantages of the invention will be, or will become, apparent to one of ordinary skill in the art upon examination of the following figures and detailed description. It is intended that all such additional systems, methods, features, and advantages be included within this description and this summary, be within the scope of the invention, and be protected by the following claims.
BRIEF DESCRIPTION OF THE DRAWINGS
• The invention can be better understood with reference to the following drawings and description. The components in the figures are not necessarily to scale, emphasis instead being placed upon illustrating the principles of the invention. Moreover, in the figures, like reference numerals designate corresponding parts throughout the different views.
• FIG. 1 is an isometric view of an embodiment of an article of footwear with a first braided portion and a second braided portion;
• FIG. 2 is a schematic close-up view of a first braided portion ofFIG. 1;
• FIG. 3 is a schematic close-up view of a second braided portion ofFIG. 1;
• FIG. 4 is a side view of an embodiment of an article of footwear with an upper having a first braided portion and a second braided portion;
• FIG. 5 is an isometric view of an embodiment of an article of footwear with an upper having a first braided portion and a second braided portion;
• FIG. 6 is a schematic enlarged isometric view of a forefoot portion of the article of footwear ofFIG. 5.
• FIG. 7 is a schematic view of an embodiment of an article of footwear with an upper having a first braided portion and a second braided portion;
• FIG. 8 is a schematic cross-sectional view of a forefoot portion of the article of footwear ofFIG. 7;
• FIG. 9 is a schematic view of an embodiment of an article of footwear with an upper having a first braided portion and a second braided portion;
• FIG. 10 is a schematic view of an enlarged cross-sectional view of a forefoot portion of the article of footwear ofFIG. 9;
• FIG. 11 is a schematic view of an embodiment of an article of footwear with a first braided portion and a second braided portion;
• FIG. 12 is a schematic view of an embodiment of a braiding machine;
• FIG. 13 is a schematic view of an embodiment of a braiding machine with an enlarged view of a section of the braiding machine;
• FIG. 14 is a schematic view of an embodiment of a braiding machine with enlarged views of a first section and a second section;
• FIG. 15 is top down schematic view of an embodiment of a braiding machine with a first section and a second section;
• FIG. 16 is top down schematic view of an embodiment of a braiding machine depicting spool paths of a first section and a second section of the braiding machine;
• FIG. 17 is top down schematic view of an embodiment of a braiding machine with a first section and a second section; and
• FIG. 18 is top down schematic view of an embodiment of a braiding machine depicting spool paths of a first section and a second section of the braiding machine.
DETAILED DESCRIPTION
• FIG. 1 illustrates an isometric view of an embodiment of an article of footwear. In some embodiments, article offootwear100, also referred to simply asarticle100, is in the form of an athletic shoe. In some other embodiments, the provisions discussed herein forarticle100 could be incorporated into various other kinds of footwear including, but not limited to, basketball shoes, hiking boots, soccer shoes, football shoes, sneakers, running shoes, cross-training shoes, rugby shoes, baseball shoes as well as other kinds of shoes. Moreover, in some embodiments, the provisions discussed herein for article offootwear100 could be incorporated into various other kinds of non-sports related footwear, including, but not limited to, slippers, sandals, high-heeled footwear, loafers, as well as other kinds of footwear.
• In some embodiments,article100 may be characterized by various directional adjectives and reference portions. These directions and reference portions may facilitate in describing the portions of an article of footwear. Moreover, these directions and reference portions may also be used in describing subcomponents of an article of footwear, for example, directions and/or portions of a midsole structure, an outer sole structure, an upper, or any other components.
• For consistency and convenience, directional adjectives are employed throughout this detailed description corresponding to the illustrated embodiments. The term “longitudinal” as used throughout this detailed description and in the claims may refer to a direction extending the length ofarticle100. In some cases, the longitudinal direction may extend from a forefoot region to a heel region ofarticle100. Also, the term “lateral” as used throughout this detailed description and in the claims may refer to a direction extending along the width ofarticle100. In other words, the lateral direction may extend between a lateral side and a medial side ofarticle100. Furthermore, the term “vertical” as used throughout this detailed description and in the claims may refer to a direction generally perpendicular to a lateral and longitudinal direction. For example, in some cases wherearticle100 is planted flat on a ground surface, the vertical direction may extend from the ground surface upward. In addition, the term “proximal” may refer to a portion ofarticle100 that is closer to portions of a foot, for example, whenarticle100 is worn. Similarly, the term “distal” may refer to a portion ofarticle100 that is further from a portion of a foot whenarticle100 is worn. It will be understood that each of these directional adjectives may be used in describing individual components ofarticle100, such as an upper, outsole member, midsole member, as well as other components of an article of footwear.
• As shown inFIG. 1,article100 may be associated with the right foot; however, it should be understood that the following discussion may equally apply to a mirror image ofarticle100 that is intended for use with a left foot. In some embodiments, an article may include upper102. Likewise,article100 may includesole structure103 secured to upper102. For purposes of reference,article100 may be divided intoforefoot portion104,midfoot portion106, andheel portion108.Forefoot portion104 may be generally associated with the toes and joints connecting the metatarsals with the phalanges.Midfoot portion106 may be generally associated with the arch of a foot. Likewise,heel portion108 may be generally associated with the heel of a foot, including the calcaneus bone.Article100 may also include ankle portion110 (which may also be referred to as a cuff portion). In addition,article100 may includelateral side112 andmedial side114. In particular,lateral side112 andmedial side114 may be opposing sides ofarticle100. In general,lateral side112 may be associated with the outside parts of a foot whilemedial side114 may be associated with the inside part of a foot. Furthermore,lateral side112 andmedial side114 may extend throughforefoot portion104,midfoot portion106, andheel portion108.
• It will be understood thatforefoot portion104,midfoot portion106, andheel portion108 are only intended for purposes of description and are not intended to demarcate precise regions ofarticle100. Likewise,lateral side112 andmedial side114 are intended to represent generally two sides rather than precisely demarcatingarticle100 into two halves.
• In some embodiments,article100 may be configured with upper102.Upper102 may includeankle opening118 to provide access tointerior cavity120.Upper102 may also include throat opening119 to further facilitate access tointerior cavity120. In some embodiments, upper102 may incorporate a plurality of material elements (for example, textiles, polymer sheets, form layers, leather, synthetic leather) that are stitched or bonded together to form an interior void for securely and comfortably receiving a foot. In some cases, the material elements may be selected to impart properties of durability, air permeability, wear resistance, flexibility, and comfort, for example, to specific areas of upper102.
• Some embodiments may include provisions for providing different physical characteristics and properties for an upper. In some embodiments,article100 may have upper102 formed withbraided structure130. In some embodiments, upper102 may have more than one braided structure. In an exemplary embodiment, upper102 may have top part orfirst portion132 formed withfirst braided structure134, and lower part orsecond portion136 formed withsecond braided structure138. In some embodiments,first braided structure134 may have different characteristics than secondbraided structure138 even though both structures are formed from the same tensile elements.
• In some embodiments,first portion132 withfirst braided structure134 may extend along the length ofarticle100 along a longitudinal direction fromforefoot portion104 throughmidfoot portion106 toheel portion108. In some cases,first portion132 may also includeankle opening118 andthroat opening119.
• Likewise, in some embodiments,second portion136 withsecond braided structure138 may extend along the length ofarticle100 along a longitudinal direction fromforefoot portion104 throughmidfoot portion106 toheel portion108.Second portion136 may also extend along the width of the article along a lateral direction fromlateral side112 tomedial side114. Further,second portion136 may be in direct contact withsole structure103.
• As shownFIGS. 2 and 3,first braided structure134 may have components that are arranged in a braid pattern that is different fromsecond braided structure138. In some embodiments, the components or tensile elements may be arranged in a braid pattern where tensile elements are more or less dense. In one embodiment,tensile elements140 forsecond braided structure138 are braided to have a greater density thantensile elements140 braided forfirst braided structure134. Furthermore, as arranged,tensile elements140 insecond braided structure138 substantially form arhombiform mesh pattern122 having twoacute angles124 and twoobtuse angles126. In some other embodiments,tensile elements140 insecond braided structure138 may form a mesh pattern where the angles are substantially the same. In some embodiments, the different types of braided structures may impart different physical properties for an upper. The different properties associated with different braided structures will be explained further in detail below.
• The detailed description and the claims may make reference to various kinds of tensile elements, braided structures, braided configurations, braided patterns, and braiding machines. As used herein, the term “tensile element” refers to any kinds of threads, yarns, strings, filaments, fibers, wires, cables as well as possibly other kinds of tensile elements described below or known in the art. As used herein, tensile elements may describe generally elongated materials with lengths much greater than corresponding diameters. In some embodiments, tensile elements may be approximately one-dimensional elements. In some other embodiments, tensile elements may be approximately two dimensional, that is, with thicknesses much less than their lengths and widths. Tensile elements may be joined to form braided structures. A “braided structure” may be any structure formed intertwining three or more tensile elements together. Braided structures could take the form of braided cords, ropes, or strands. Alternatively, braided structures may be configured as two-dimensional structures, for example, flat braids, or three-dimensional structures, for example, braided tubes, such as with lengths and widths (or diameters) significantly greater than their thicknesses.
• A braided structure may be formed in a variety of different configurations. Examples of braided configurations include, but are not limited to, the braiding density of the braided structure, the braid tension(s), the geometry of the structure, for example, formed as a tube, or an article; the properties of individual tensile elements, for example, materials, cross-sectional geometry, elasticity, tensile strength; as well as other features of the braided structure. One specific feature of a braided configuration may be the braid geometry, or braid pattern, formed throughout the entirety of the braided configuration or within one or more regions of the braided structure. As used herein, the term “braid pattern” refers to the local arrangement of tensile elements in a region of the braided structure. Braid patterns can vary widely and may differ in one or more of the following characteristics: the orientations of one or more groups of tensile elements (or strands), the geometry of spaces or openings formed between braided tensile elements, the crossing patterns between various strands as well as possibly other characteristics. Some braided patterns include lace-braided or Jacquard patterns, such as Chantilly, Bucks Point, and Torchon. Other patterns include biaxial diamond braids, biaxial regular braids, as well as various kinds of triaxial braids.
• Braided articles or braided structures can be formed with various kinds of braid patterns, as described above. The present embodiments may be characterized as having braid patterns than are “jacquard braid patterns” or “non-jacquard braid patterns”. Jacquard braid patterns and non-jacquard braid patterns may refer to distinct classes of braid patterns. Thus jacquard braid patterns may comprise a variety of different braid patterns that share common features, and non-jacquard braid patterns may comprise a variety of different braid patterns that share common features. One type of jacquard braid pattern may be a lace braid pattern. Another type of jacquard braid pattern may be a Torchon braid pattern, or Torchon lace braid pattern. In contrast, non-jacquard braid patterns may be associated with bi-axial, tri-axial, diamond, or other kinds of regular braid patterns. In some cases, a non-jacquard braid pattern may be referred to as a radial braid pattern, as non-jacquard braid patterns can be easily formed using a radial braiding machine. However, it may be appreciated that in some cases non-jacquard braid patterns can also be formed from machines that may not be radial braiding machines. Thus, it should be appreciated that the terms “jacquard braid pattern” and “non-jacquard braid pattern” refer to the configuration of a braided structure, and may be independent of the type of machine, or method, used to make the braided structure.
• Generally, jacquard braid patterns and non-jacquard braid patterns may have different characteristics. For example, jacquard braid patterns may be characterized as more open, with spacing between adjacent tensile strands varying in a non-uniform manner. In contrast, non-jacquard braid patterns may generally be uniform. In some cases, non-jacquard braid patterns may be grid or lattice like. Jacquard and non-jacquard braid patterns can also be characterized by the presence or absence of ornamental designs. Specifically, jacquard braid patterns may feature one or more ornamental designs whereas non-jacquard braid patterns lack such ornamental designs due to the nature in which they are formed (by moving spools around on a constant path of the braiding machine). Further, the density of tensile strands (e.g., the average number of strands in a given area) may be highly variable in a jacquard braid pattern and may change along multiple directions of the braided structure. In contrast, the density of tensile strands in a non-jacquard braid pattern may generally be constant, or change only along a single axial direction dictated by the method of forming a braided structure. Thus, while some non-jacquard braid patterns could have densities that vary along one axis of the structure, they may generally not very in density along multiple different directions of the structure.
• In some embodiments, different braid patterns may be selected for different portions of an upper. For example, as seen inFIG. 1,first portion132 has braidedtensile elements140 arranged in a first pattern that is different in appearance than a second pattern shown insecond portion136.
• Referring toFIG. 4, a side view ofarticle100 having an upper102 attached tosole structure103 is shown. In some embodiments, upper102 includes a top part withfirst portion132 having first braidedstructure134, and a lower part withsecond portion136 having secondbraided structure138 is shown.
• In some embodiments, first braided structure134 may havefirst braid pattern150 and second braid pattern152 (shown also inFIG. 1).First braid pattern150 may be may be associated with a Jacquard braid pattern.Second braid pattern152 may be associated with a Non-Jacquard braid pattern. With this arrangement,article100 may have physical properties that vary with different portions of upper102. For example, in some embodiments, a braided structure with a Jacquard braid pattern may have a lower density or greater elasticity than a braided structure with a Non-Jacquard braid pattern. In still some cases, a braided structure with a Jacquard braid pattern may further include intricate patterns and designs that may be absent from a braided structure with a Non-Jacquard braid pattern. In some other cases, a braided structure with a Non-Jacquard braid patterns may have a greater density and greater abrasion resistance than a braided structure with a Jacquard braid pattern.
• In some embodiments,first braid pattern150 may includefinished edge160. As used in this detailed description and in the claims, finishededge160 and its variants thereof may refer to an aperture or opening that may eliminate a need for cutting, sewing, or skinning to create a structure for eyelets, laces, or other components facilitating the adjustment ofarticle100 to a user's foot. As shown inFIG. 1, in some embodiments,first braid pattern150 withfinished edge160 eliminates the need for eyelets forlaces162. Alternatively,first braid pattern150 could be formed with explicitly defined eyelet regions adjacentfinished edge160. Moreover, this feature allows further reduction of the overall weight ofarticle100 while still enabling the adjustment ofarticle100 on a user's foot.
• FIGS. 5 and 6 illustrate an isometric view of upper102 withbraided structure130 comprisingfirst portion132 andsecond portion136, including an enlarged isometric view of a portion ofbraided structure130. In particular, an isometric cross-sectional view offorefoot portion104 ofbraided structure130 is shown. For purposes of illustration, upper102 and braidedstructure130 are shown isolated fromsole structure103.
• As seen inFIG. 6,forefoot portion104 hascross-sectional area170 where first braidedstructure134 is incorporated withsecond braided structure138 to formseamless braided structure172. It is to be noted that the sametensile elements140 are used infirst braided structure134, which has a first braid pattern, andsecond braided structure138, which has a second braid pattern.
• Referring toFIGS. 5 and 6, in some embodiments,first surface area190 offirst braided structure134 may encompass 50 percent or more oftotal surface area194 ofseamless braided structure172. In some embodiments,second surface area192 ofsecond braided structure138 may encompass 50 percent or more oftotal surface area194 ofseamless braided structure172. In one embodiment,seamless braided structure172 may have half of itstotal surface area194 with a Jacquard braid pattern, and the other half with a Non-Jacquard braid pattern.
• In some cases, totalcross-sectional area196 of upper102 withseamless braided structure172 may also be divided between Jacquard and Non-Jacquard braid patterns. In one embodiment, totalcross-sectional area196 may be divided equally between firstcross-sectional area197 with a Jacquard braid pattern and secondcross-sectional area198 with a Non-Jacquard braid pattern.
• Some embodiments may provide different zones or portions of an upper with varying degrees of different physical properties. In some embodiments, a degree of relative thickness between a first portion and a second portion may vary. In some other embodiments, a degree of relative tensile strength may vary between a first portion and a second portion. In still some other embodiments, a degree of relative flexibility may vary between a first portion and a second portion. In different embodiments, a degree of relative abrasion resistance may vary between a first portion and a second portion. In other embodiments, other physical properties within the upper may vary between different portions.
• In some embodiments, an upper may have a degree of relative thickness between different braided structures. In some embodiments, the thickness offirst portion132 withfirst braided structure134 may be substantially the same as the thickness ofsecond portion136 withsecond braided structure138. In an exemplary embodiment,first braided structure134 with first braid pattern150 (i.e., Jacquard braid pattern) may havefirst thickness174 that is substantially the same assecond thickness176 ofsecond braided structure138 with second braid pattern152 (i.e., Non-Jacquard braid pattern). In some other embodiments, the thicknesses may be substantially different. With this capability, the thickness of a braided structure for a portion of an upper may be tuned to provide a desired customized fit or comfort to the wearer.
• In some embodiments, a degree of relative tensile strength between firstbraided structure134 andsecond braided structure138 may vary. In some embodiments,first portion132 withfirst braided structure134 may exhibit a higher tensile strength thansecond portion136. Therefore,first braided structure134 may provide greater stretch resistance in locations where desired. In some other embodiments, those skilled in the art may providesecond braided structure138 with a higher tensile strength than firstbraided structure134.
• In some embodiments, a degree of relative flexibility between firstbraided structure134 andsecond braided structure138 may vary. In some embodiments,first portion132 withfirst braided structure134 may be more flexible because offirst braid pattern150. In some embodiments,tensile elements140 arranged in first braid pattern150 (i.e., a Jacquard braid pattern) provides greater flexibility than tensile elements arranged in second braid pattern152 (i.e., a Non-Jacquard braid pattern). In some other embodiments, upper102 may have different portions with greater degrees of flexibility.
• In some embodiments, a degree of relative wear or abrasion resistance between firstbraided structure134 andsecond braided structure138 may vary. In one embodiment,second portion136 withsecond braided structure138 may be more wear resistant because ofsecond braid pattern152. In certain embodiments, the relative density oftensile elements140 arranged in a Non-Jacquard braid pattern may exhibit greater abrasion resistance than other portions with other braided structures and braid patterns. Therefore, portions of upper102 proximal to a ground surface may be formed to be sufficiently durable and complement the wear resistance of a sole structure attached to upper102.
• Some braided portions may encompass a greater area of an upper than other braided portions. In some embodiments, an upper may have a first braided structure with a Jacquard braid pattern covering more of an upper's surface area than a second braided structure with a Non-Jacquard braid pattern.FIGS. 7-10 illustrate several variations of an upper with different braided structures having different braid patterns encompassing more or less of an upper's surface area. For purposes of illustration, the figures show an upper for an article of footwear without a sole structure.
• The exemplary embodiment shown inFIGS. 7 and 8 illustrate the relative surface area of upper202 covered byfirst portion204 withfirst braided structure206 andsecond portion208 withsecond braided structure210. In particular,FIG. 7 shows an isometric view of upper202 having first braidedstructure206 withfirst braid pattern212, (i.e., Jacquard braid pattern), encompassing more of a surface area than secondbraided structure210 with second braid pattern214 (i.e., Non-Jacquard braid pattern).
• FIG. 8 illustrates an enlarged cross-sectional view offirst portion204 andsecond portion208. As shown,second portion208 covers only the lower part of upper202. Moreover, as shown in the enlarged cross-sectional view, firstcross-sectional area216 offirst portion204 is greater than secondcross-sectional area218 ofsecond portion208. In some embodiments, with this arrangement, upper202, having its surface area covered by a majority offirst braided structure206, may result in upper202 being lighter thereby reducing the overall weight of an article of footwear. In some cases, with this arrangement, becausefirst portion204 has a more open structure,first portion204 is more breathable thansecond portion208 and allows moisture to be transmitted through the material more readily.
• In contrast to the embodiment shown inFIGS. 7 and 8, in other embodiments, a first braided structure may encompass less of a surface area than a second braided structure. Referring toFIGS. 9 and 10, in one embodiment,second portion308, having second braidedstructure310 with second braid pattern314 (i.e., Non-Jacquard braid pattern), may cover a greater surface area of upper302 thanfirst portion304 having first braidedstructure306 with first braid pattern312 (i.e., Jacquard braid pattern). Further,FIG. 10 illustrates an enlarged view of secondcross-sectional area318 that is greater than firstcross-sectional area316.
• In some embodiments, upper302 with a surface area covered by a majority ofsecond braided structure310 may vary the physical properties of upper302. In one embodiment, upper302, having a majority of its surface area covered bysecond braided structure310, may be resistant to abrasion and water than firstbraided structure306. In still some other embodiments,second braided structure310, having axial tensile elements, may improve the overall stability of the article.
• Referring toFIG. 11, another variation of an article with an upper is illustrated. In some embodiments,first portion404 withfirst braided structure406 may comprise offirst braid pattern408. In some embodiments,first braid pattern408 may be a Jacquard braid pattern. Further,second portion410 withsecond braided structure412 may comprise ofsecond braid pattern414 or a Non-Jacquard braid pattern. In certain embodiments,first braid pattern408 may include several intricate or ornamental designs, referred to hereafter astextures420.Textures420 may be formed by the intersection oftensile elements422 during the braiding process. The intersection oftensile elements422 to formtextures420 may be referred to hereafter as a stitch. In some embodiments,first texture424 may be formed byfirst stitch426. In some cases,first stitch426 providesfirst texture424 withtensile elements422 spaced apart to resemble netting or a lattice-like structure. In some embodiments,first braid pattern408 may include asecond texture428 formed bysecond stitch430.Second texture428 may be characterized as having a less open texture thanfirst texture424 but still associated with a Jacquard braid pattern. Moreover, as already discussed above, the different textures forfirst portion404 may impart different physical properties such as flexibility. In some other embodiments, those skilled in the art may use other stitches to formother textures420 thereby providing other distinct ornamental designs or physical properties to a braided structure with a Jacquard braid pattern.
• Braided structures may be formed using braided machines. As used herein, a “braiding machine” is any machine capable of automatically intertwining three or more tensile elements to form a braided structure. Braiding machines may generally include spools, or bobbins, that are moved or passed along various paths on the machine. As the spools are passed around, tensile strands extending from the spools toward a center of the machine may converge at a “braiding point” or braiding area. Braiding machines may be characterized according to various features including spool control and spool orientation. In some braiding machines, spools may be independently controlled so that each spool can travel on a variable path throughout the braiding process, hereafter referred to as “independent spool control.” Other braiding machines, however, may lack independent spool control, so that each spool is constrained to travel along a fixed path around the machine. Additionally, in some braiding machines, the central axes of each spool point in a common direction so that the spool axes are all parallel, hereby referred to as an “axial configuration.” In other braiding machines, the central axis of each spool is oriented toward the braiding point, for example, radially inward from the perimeter of the machine toward the braiding point, hereby referred to as a “radial configuration.”
• One type of braiding machine that may be utilized is a radial braiding machine or radial braider. A radial braiding machine may lack independent spool control and may therefore be configured with spools that pass in fixed paths around the perimeter of the machine. In some cases, a radial braiding machine may include spools arranged in a radial configuration. For purposes of clarity, the detailed description and the claims may use the term “radial braiding machine” to refer to any braiding machine that lacks independent spool control. The present embodiments could make use of any of the machines, devices, components, parts, mechanisms, and/or processes related to a radial braiding machine as disclosed in Dow et al., U.S. Pat. No. 7,908,956, issued Mar. 22, 2011, and titled “Machine for Alternating Tubular and Flat Braid Sections,” and as disclosed in Richardson, U.S. Pat. No. 5,257,571, issued Nov. 2, 1993, and titled “Maypole Braider Having a Three Under and Three Over Braiding path,” the entirety of each application being herein incorporated by reference in its entirety. These applications may be hereafter referred to as the “Radial Braiding Machine” applications.
• Another type of braiding machine that may be utilized is a lace braiding machine, also known as a Jacquard or Torchon braiding machine. In a lace braiding machine, the spools may have independent spool control. Some lace braiding machines may also have axially arranged spools. The use of independent spool control may allow for the creation of braided structures, such as lace braids, that have an open and complex topology, and may include various kinds of stitches used in forming intricate braiding patterns. For purposes of clarity, the detailed description and the claims may use the term “lace braiding machine” to refer to any braiding machine that has independent spool control. The present embodiments could make use of any of the machines, devices, components, parts, mechanisms, and/or processes related to a lace braiding machine as disclosed in Ichikawa, EP Patent Number 1486601, published on Dec. 15, 2004, and titled “Torchon Lace Machine,” and as disclosed in Malhere, U.S. Pat. No. 165,941, issued Jul. 27, 1875, and titled “Lace-Machine,” the entirety of each application being herein incorporated by reference in its entirety. These applications may be hereafter referred to as the “Lace Braiding Machine” applications.
• Spools may move in different ways according to the operation of a braiding machine. In operation, spools that are moved along a constant path of a braiding machine may be said to undergo “Non-Jacquard motions,” while spools that move along variable paths of a braiding machine are said to undergo “Jacquard motions.” Thus, as used herein, a lace braiding machine provides means for moving spools in Jacquard motions, while a radial braiding machine can only move spools in Non-Jacquard motions.
• FIGS. 12 through 18 illustrate schematically a single braiding machine that may be used to form different braided portions with different braided patterns on a last. In some embodiments, the braiding machine may be similar to the braiding machine disclosed in Bruce et al., U.S. patent Publication Ser. No. ______, published on ______, and titled, “BRAIDING MACHINE AND METHOD OF FORMING AN ARTICLE INCORPORATING A MOVING OBJECT” (now U.S. patent application Ser. No. ______, filed on May 26, 2015) (currently Attorney Docket Number 51-4506), the disclosure of which is herein incorporated by reference in its entirety. In other embodiments, the braiding machine may include a fixed last as disclosed in Bruce et al., U.S. patent Publication Number, ______, published on ______, and titled, “BRAIDING MACHINE AND METHOD OF FORMING AN ARTICLE INCORPORATING BRAIDING MACHINE” (now U.S. patent application Ser. No. ______, filed on May 26, 2015) (currently Attorney Docket Number 51-4260), the disclosure of which is herein incorporated by reference in its entirety.
• In some embodiments, braidingmachine500 may includeouter frame portion502, as shown inFIG. 12.Outer frame portion502 may house a set of spool components or spools504.Spools504 may havetensile elements506, extending fromspools504, that converge towardcentral braiding point508. In some embodiments, mold or last510 may be conveyed throughcentral braiding point508. In some embodiments, as last510 is fed throughcentral braiding point508,tensile elements506 may form braidedstructure512 on the surface of last510.
• Referring toFIG. 13, in some embodiments, braidingmachine500 may generally includespools504 that follow various trajectories or paths alongouter frame portion502 on braidingmachine500. As shown schematically in the enlarged view ofFIG. 13, in some embodiments, spools504 may be held byspindle runners520. During operation,spindle runners520 may be rotated and conveyed to different positions by rotor gears522. During operation, rotor gears522 may rotate in either a clockwise or counterclockwise direction so thatspindle runners520 withspools504 pass alone each other thus intertwiningtensile elements506 extending fromspools504. The intertwining oftensile elements506 results in the forming ofbraided structure512 on last510.
• Some embodiments of a braiding machine may have different sections where the set of spools follow different trajectories. In other words, in some embodiments, braidingmachine500 may have sections where there is independent spool control. In some embodiments, the braiding machine may have sections that lack independent spool control. Referring toFIG. 14, in an exemplary embodiment, braidingmachine500 may havefirst section530 wherespools504 follow a variable path. Accordingly, spools504 infirst section530 may undergo a Jacquard motion. Further, braidingmachine500 may havesecond section532 wherespools504 follow a constant path. With this arrangement, spools504 may undergo a Non-Jacquard motion. It is understood thatfirst section530 andsecond section532 are not meant to convey any specific location on braidingmachine500. Moreover,first section530 may be any location alongouter frame portion502 of the braiding machine where spools follow a variable path with independent spool control, whereassecond section532 may be any location alongouter frame portion502 where spools follow a constant path.
• The enlarged views ofFIG. 14 illustrate an exemplary embodiment ofbraiding machine500 wherespools504 follow variable and constant paths. In some embodiments, spools504 infirst section530 of the braiding machine may exhibit independent spool control via rotor gears522. During operation,first spool540 andsecond spool542 are rotated byfirst rotor gear550. In contrast,third spool544 andfourth spool546 remain in place assecond rotor gear552 andthird rotor gear554 remain stationary. Thus,first spool540 andsecond spool542 are said to undergo a Jacquard motion. Asfirst spool540 andsecond spool542 rotate, their respectivetensile elements506 are intertwined forming first braid portion580 on last510. In some embodiments, first braid portion580 has a Jacquard braid pattern.
• In different embodiments, spools504 infirst section530 that undergo a Jacquard motion may form additional features previously mentioned on first braid portion580. As discussed above, becausespools504 infirst section530 possess independent spool control thereby allowingspools504 to follow variable paths, first braid portion580 may include different textures. In addition, asspools504 undergo a Jacquard motion infirst section530, a finished edge may be formed on first braid portion580.
• In some embodiments, braidingmachine500 may havesecond section532 in which spools504 follow a constant path during operation. In some embodiments, spools504 insecond section532 may follow a constant path simultaneously asspools504 infirst section530 follow a variable path. As shown, during operation, fifth spool560 and sixth spool562 are rotated byfourth rotor gear570. At the same time,seventh spool564 andeighth spool566 are rotated bysixth rotor gear574. Further,fifth rotor gear572 remains stationary so as not to interfere and contact fifth spool560, sixth spool562,seventh spool564, andeighth spool566 as they are rotated. As fifth spool560, sixth spool562,seventh spool564, andeighth spool566 are rotated, their respectivetensile elements506 are intertwined formingsecond braid portion582 on last510. In some embodiments,second braid portion582 has a Non-Jacquard braid pattern. Therefore, in an exemplary embodiment, asspools504 infirst section530 form first braid portion580 simultaneously asspools504 insecond section532 formsecond braid portion582 on last510, a seamless braided structure may be formed. With this arrangement, the seamless braided structure incorporates first braid portion580 having a Jacquard braid pattern withsecond braid portion582 having a Non-Jacquard braid pattern.
• FIGS. 15-18 schematically illustrate another embodiment of how a first section and a second section of a braiding machine may form a braided structure on an upper with different and distinct braid patterns.
• Referring toFIG. 15, in an initial orfirst configuration601, spools605 are configured onspindle runners606 disposed onouter portion608 of braidingmachine600. Asspools605 are rotated by rotor gears610,tensile elements612 are intertwined forming braidedstructures614 on a last atcentral braiding point609. During operation,first spool620,second spool621,third spool622,fourth spool623,fifth spool624,sixth spool625,seventh spool626, andeighth spool627, may be traveling infirst section618.Spools605 disposed infirst section618 may exhibit independent spool control. Accordingly, spools605 infirst section618 may be associated with following independent or variable paths. Simultaneously during operation, spools605 disposed insecond section628 may lack independent spool control. Accordingly,ninth spool630,tenth spool631,eleventh spool632,twelfth spool633,thirteenth spool634,fourteenth spool635,fifteenth spool636, andsixteenth spool637 may each follow a constant path. For purposes of illustration,first section618 andsecond section628 are distinguished by the shading or non-shading of rotor gears610. Further, for purposes of illustration, spools605 may be shaded either black or white to show their initial and subsequent relative positions on braiding machine during operation.
• Referring toFIG. 16, in forming a braided structure with a Jacquard braid pattern, spools605 infirst section618, because they have independent spool control, may, individually, travel in either a clockwise or counterclockwise direction around the center of braidingmachine600. Additionally,other spools605 infirst section618 may remain static and not rotate. Therefore, as shown, insecond configuration602,first spool620 andsecond spool621 are rotated bysecond rotor gear642 in a clockwise direction, andthird spool622 andfourth spool623 are rotated byfifth rotor gear648 in a counterclockwise direction.Sixth spool625 andseventh spool626 are rotated in a counterclockwise direction byninth rotor gear656. Further,fifth spool624 andeighth spool627 may remain static.
• In some embodiments, asspools605 infirst section618 follow variable paths, at the same time, spools605 insecond section628 each follow a constant path. Therefore, insecond configuration602,ninth spool630 andtenth spool631 are rotated bythirteenth rotor gear664,eleventh spool632 andtwelfth spool633 are rotated byfifteenth rotor gear668,thirteenth spool634 andfourteenth spool635 are rotated byseventeenth rotor gear672, andfifteenth spool636 andsixteenth spool637 are rotated bynineteenth rotor gear676.
• It is to be noted that insecond configuration602, spools605 insecond section628 are all rotated only in a clockwise direction around the respective rotor gears610. However, each spool insecond section628 is forced to go either in a clockwise or counterclockwise direction around the center of braidingmachine600. For example,tenth spool631,twelfth spool633,fourteenth spool635, andsixteenth spool637 may all travel in a generally clockwise direction around the center of braidingmachine600, whileninth spool630,eleventh spool632,thirteenth spool634, andfifteenth spool636 may travel in a generally counterclockwise direction around the center of braidingmachine600. In contrast, spools605 infirst section618 may rotate, individually, in either a clockwise or counterclockwise direction around rotor gears610, and around the center of braidingmachine600.
• FIG. 17 further illustrates schematically the independent spool control offirst section618, and the lack of independent spool control insecond section628. In some embodiments, after completing rotations in second configuration602 (as shown inFIG. 16), spools605 infirst section618, because of their ability to move independently without restrictions, may be positioned anywhere alongfirst section618. For example,third spool622, after being rotated counterclockwise around the center of braidingmachine600 insecond configuration602, is positioned proximal tofifth spool624 inthird configuration603. However in some other embodiments,third spool622 could be rotated clockwise around the center of braidingmachine600, and therefore could be positioned proximal tofirst spool620 andsecond spool621 after rotation. In contrast, every other spool (e.g., shading or non-shading) insecond section628 is restricted in moving in the same direction, clockwise or counterclockwise, around the center of braidingmachine600.
• Referring toFIG. 18, because of the independent spool control infirst section618, spools605 have different options regarding their path of travel. In some embodiments, after rotating, spools605 infirst section618 may remain in place, may be further rotated by a different rotor gear, or may be rotated again with the same rotor gear. Therefore, infourth configuration604,third spool622 after being rotated byfifth rotor gear648, may be rotated again, this time bysixth rotor gear650, or may remain static. In one embodiment,third spool622 andfifth spool624 are rotated in a counterclockwise direction bysixth rotor gear650. In some embodiments,third spool622 may eventually traverse the entireouter portion608 of the braiding machine so thatthird spool622 may entersecond section628 and undergo a Non-Jacquard motion. In other words, spools605 can enterfirst section618 and follow a variable path, and subsequently entersecond section628 and follow a constant path.
• In contrast, duringfourth configuration604, spools605 insecond section628, because they do not have independent spool control, continue on their constant paths in either a clockwise or counterclockwise direction around the center of braidingmachine600. In one embodiment, spools605 insecond section628 will undergo rotation by the next adjacent rotor gear. For example,ninth spool630 andtwelfth spool633 will be rotated byfourteenth rotor gear666,eleventh spool632 andfourteenth spool635 will be rotated bysixteenth rotor gear670,thirteenth spool634 andsixteenth spool637 will be rotated byeighteenth rotor gear674. In some embodiments, spools605 insecond section628 may eventually enterfirst section618 and accordingly undergo a Jacquard motion. In other words, spools605 can entersecond section628 and follow a constant path, and subsequently enterfirst section618 and follow a variable path.
• While the embodiments of the figures depict articles having low collars (e.g., low-top configurations), other embodiments could have other configurations. In particular, the methods and systems described herein may be utilized to make a variety of different article configurations, including articles with higher cuff or ankle portions. For example, in another embodiment, the systems and methods discussed herein can be used to form a braided upper with a cuff that extends up a wearer's leg (i.e., above the ankle). In another embodiment, the systems and methods discussed herein can be used to form a braided upper with a cuff that extends to the knee. In still another embodiment, the systems and methods discussed herein can be used to form a braided upper with a cuff that extends above the knee. Thus, such provisions may allow for the manufacturing of boots comprised of braided structures. In some cases, articles with long cuffs could be formed by using lasts with long cuff portions (or leg portions) with a braiding machine (e.g., by using a boot last). In such cases, the last could be rotated as it is moved relative to a braiding point so that a generally round and narrow cross-section of the last is always presented at the braiding point.
• While various embodiments of the invention have been described, the description is intended to be exemplary, rather than limiting, and it will be apparent to those of ordinary skill in the art that many more embodiments and implementations are possible that are within the scope of the invention. Accordingly, the invention is not to be restricted except in light of the attached claims and their equivalents. Also, various modifications and changes may be made within the scope of the attached claims.

Claims (20)

What is claimed is:

1. An article of footwear comprising:

a sole;

an upper attached to the sole;

wherein the upper includes a first portion and a second portion;

wherein the first portion has a Jacquard braid pattern; and

wherein the second portion has a Non-Jacquard braid pattern.

2. The article ofclaim 1, wherein the first portion includes at least a first stitch, and a second stitch, and wherein the first stitch is different than the second stitch.

3. The article ofclaim 2, wherein the first stitch forms a first texture, and the second stitch forms a second texture, and wherein the first texture is different than the second texture.

4. The article ofclaim 1, wherein the first portion has a first flexibility, and the second portion has a second flexibility, and wherein the first flexibility is different than the second flexibility.

5. The article ofclaim 1, wherein the first portion has a first abrasion resistance, and the second portion has a second abrasion resistance, and wherein the first abrasion resistance is different than the second abrasion resistance.

6. The article ofclaim 1, wherein the first portion has a first tensile strength, and the second portion has a second tensile strength, and wherein the first tensile strength is different than the second tensile strength.

7. The article ofclaim 1, wherein the first portion includes a finished edge.

8. An article of footwear comprising:

a sole;

an upper attached to the sole;

wherein the upper comprises a seamless braided structure;

wherein the seamless braided structure includes a top portion and a lower portion;

wherein the top portion has a Jacquard braid pattern; and

wherein the lower portion has a Non-Jacquard braid pattern.

9. The article ofclaim 8, wherein the top portion includes a finished edge.

10. The article ofclaim 8, wherein the top portion has a surface area substantially encompassing 50 percent of a total surface area of the seamless braided structure.

11. The article ofclaim 8, wherein the top portion includes a first stitch, and a second stitch, and wherein the first stitch is different than the second stitch.

12. The article ofclaim 8, wherein the top portion has a surface area substantially greater than the lower portion.

13. The article ofclaim 8, wherein the lower portion has a surface area substantially greater than the top portion.

14. The article ofclaim 8, wherein the top portion includes a throat opening.

15. The article ofclaim 8, wherein the lower portion is substantially in contact with the sole.

16. A method of making an article of footwear, comprising:

providing a set of spools configured with a set of tensile elements;

providing a braiding machine having a first section and a second section;

wherein the braiding machine is configured with the set of spools;

passing a last through a braiding point, the braiding point being a region where the set of tensile elements converge, thereby forming a seamless braided structure on the last;

moving the set of spools through the first section to form a first braid portion of the seamless braided structure;

moving the set of spools through the second section to form a second braid portion of the seamless braided structure;

wherein a set of rotor gears move the set of spools in a Jacquard motion in the first section; and

wherein the set of rotor gears move the set of spools in a Non-Jacquard motion in the second section.

17. The method ofclaim 16, further including forming a Jacquard braid pattern in the first braid portion.

18. The method ofclaim 17, further including forming a Non-Jacquard braid pattern in the second braid portion.

19. The method ofclaim 17, further including forming the first braid portion with a first texture and a second texture, and wherein the first texture is different than the second texture.

20. The method ofclaim 16, further including forming a finished edge in the first braid portion.

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