Seamless upper for footwear and method for making the same

Abstract

This invention relates generally to footwear and methods for making the same, more particularly to a seamless upper for footwear and methods for making a seamless upper. In one aspect of the invention, the upper is seamless and / or is of unitary construction that defines an interior void for comfortably receiving a foot.

Description

CROSS REFERENCE TO RELATED APPLICATIONS[0001]This application is a continuation of U.S. patent application Ser. No. 13 / 442,239, filed Apr. 9, 2012, which claims the benefit of U.S. Provisional Patent Application No. 61 / 473,473, entitled “SEAMLESS UPPER FOR FOOTWEAR AND METHOD FOR MAKING THE SAME” filed on Apr. 8, 2011, which applications are incorporated by reference herein.FIELD OF INVENTION[0002]This invention relates generally to an upper for footwear, more particularly to a seamless upper for footwear and method for making the same.BACKGROUND OF THE INVENTION[0003]The upper portion of footwear vary in composition and design based on several design parameters, to include function / performance, weight, cost, aesthetics, comfort and ease of manufacture. Athletic shoes, for example, typically emphasize performance as dictated by the sport. A running shoe is commonly of lighter-weight than a tennis shoe, for example, given a running shoe generally does not require the lateral support ...

AI Technical Summary

Benefits of technology

[0012]Certain embodiments of the present disclosure relate to an upper for footwear and methods for making the footwear upper. The invention involves application of a knitting process to the production of footwear uppers and entire footwear. In one preferred embodiment, a knitting process is disclosed to create a completely seamless upper portion of a shoe. The process can form the seamless footwear upper in a single step. In another embodiment, an entire seamless article of footwear, including the upper portion, is formed. Some benefits of this process include ease and efficiency of production, reduction of assembly time, maximum comfort through reduction of seams, and freedom of design. The methods can include weaving and / or knitting the upper. The knitting process typically includes forming upper by interconnecting a series of stitches or loops.

[0013]Although many of the embodiments are focused on athletic footwear, other applications are available. Such applications include activities in which one or more of increased footwear performance, decreased manufacturing complexity, time and cost, and greater freedom of design is desired. Further, the use of the disclosed seamless uppers for footwear have applications beyond footwear, to include clothing, protective wrappings or covers, medical care such as for use as wrappings for burn-victims, geriatric care, and any application where seamless covering is desired.

Problems solved by technology

Leather, synthetic leather, and rubber materials, however, may not exhibit the desired degree of flexibility and air-permeability.

However, the above-mentioned shoe upper having a plastic foam layer interposed therein is not necessarily satisfactory in air permeability.

Therefore, this causes problems such that the inside of the shoe becomes stuffy and hot because of abnormal temperature increase attributable to the sweating and generation of heat from feet during exercise, which brings about a discomfort.

However, the prior art use of fabrics and / or textiles in footwear uppers typically require seams.

Seams introduce difficulties and limitations, to include difficulties in manufacture and freedom of design, and unintended abrasion to the user causing, for example, blisters and thereby compromising athletic performance.

Fewer materials reduce costs and increase efficiency, given that shoe manufacture is a labor intensive process.

Modern footwear designs, particularly athletic shoe designs, require numerous upper pieces and complicated manufacturing steps, leading to high labor costs.

In addition, incorporating separate materials into an upper may involve multiple distinct manufacturing steps requiring multiple individuals.

Employing multiple materials, in addition to textiles, may also detract from the breathability of footwear.

However, this shoe manufacturing process does not greatly reduce the assembly time and costs associated with creating new patterns and retooling the manufacturing process for new designs, new styles and different shoe sizes.

From the perspective of manufacturing, utilizing multiple materials to impart different properties to an article of footwear may be an inefficient practice.

For example, the various materials utilized in a conventional upper are not generally obtained from a single supplier.

Employing multiple materials, in addition to textiles, may also detract from the breathability of footwear.

Accordingly, positioning leather, synthetic leather, or rubber on the exterior of the upper may inhibit air flow through the upper, thereby increasing the amount of perspiration, water vapor, and heat trapped within the upper and around the foot.

Thus, existing uppers result in reduced footwear performance, increased manufacturing complexity, time and cost, and limited freedom of design.

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