Footwear with embroidered transitions between materials

Abstract

The present application relates to footwear having an embroidered transition between materials. The article of footwear includes a sole structure and an upper. The upper is connected to the sole structure to form an enclosure to at least partially receive a foot. The upper includes: a first piece of material that forms a first portion of the upper and has a first texture; a second piece of material that forms a second portion of the upper and has a second texture; and an embroidered area that extends across portions of the first and second pieces and has an appearance that the first texture extends into the second texture.

Description

[0001] This application is a divisional application of an application filed on January 18, 2017, with application number 201780012654.8 and invention name “Footwear with embroidered transition portions between materials”.

[0002] Priority claim

[0003] This application claims the benefit of priority to U.S. Provisional Patent Application Serial No. 62 / 280,547, filed on January 19, 2016, which is incorporated herein by reference in its entirety.

[0004] Cross-references to related patent documents

[0005] This patent application is also related to application No. 62 / 280,554 filed on January 19, 2016. Technical Field

[0006] The present disclosure relates to seams or joints for connecting pieces of material that may be used in apparel, footwear, and the like. In an exemplary application, the present disclosure relates to structures for uppers of shoes. background

[0007] Shoe uppers are often made of a variety of different materials to provide different performance characteristics at different locations on the shoe. For example, a shoe may be desired to be breathable near the toe to allow perspiration, but may be desired to be harder at the heel to keep the shoe attached to the foot during use. Thus, a shoe may incorporate a fabric mesh sheet near the toe cap and a reinforced polymer sheet near the heel cap. Other materials used in footwear may be relatively flexible and tough, such as those used near the metatarsophalangeal (MTP) joint between the metatarsal bones of the foot and the proximal phalanges of the toes, where repeated bending occurs. Thus, a shoe may incorporate a sheet made of leather, vinyl, or the like at the vamp.

[0008] In order to accommodate the different sizes, shapes and materials used in the sheet materials of the shoe upper, various stitching and joining methods are generally used. As described in U.S. Pat. No. 2,235,694 of Wolfhard et al., overlapping joints and butt joints are conventionally used. Recently, footwear has been combined with smooth seams, such as those seams using thermoplastic seam strips as described in U.S. Pat. No. 8,544,191 of Marvin et al., or seamless joints, such as those joints using a knitting process, which includes forming the upper by interconnecting a series of sutures or loops, as described in U.S. Publication No. 2012 / 0255201 of Little. In addition, other uppers have been made of integral textile materials with different stitched or woven portions to produce different performance characteristics or different aesthetic qualities at different parts of the upper, as described in U.S. Pat. No. 7,347,011 of Dua et al.

[0009] Horton's U.S. Patent No. 5,537,939 describes an edge embroidery process. Bell et al.'s U.S. Patent Application Publication No. 2015 / 0157084 generally describes the use of embroidery stitches in footwear. Hutchinson's U.S. Patent No. 6,237,174 describes embroidery on slippers.

[0010] Overview

[0011] The inventor has recognized that, among other things, the problem to be solved may include a sheet material joined at a seam in a footwear upper, the seam being uncomfortable on the inner side of the footwear and being aesthetically unpleasant on the outer side of the footwear. The present subject matter can help provide a solution to this problem, such as by using an embroidery stitch pattern that is flatter and less obtrusive than a conventional joint to join the sheet material. For example, the embroidery stitch pattern can be more comfortable due to, for example, having a flatter seam than a traditional overlap joint. As another example, the embroidery stitch pattern can be more aesthetically pleasing due to, for example, having a less prominent seam than a traditional butt joint. In particular, the embroidery described herein can provide a joint that appears to seamlessly blend the upper sheet materials of different materials, colors, and textures with each other.

[0012] In an example, an article of footwear includes a sole structure and an upper. The upper is connected to the sole structure to form an enclosure that at least partially receives a foot. The upper includes: a first piece of material that forms a first portion of the upper and has a first texture; a second piece of material that forms a second portion of the upper and has a second texture; and an embroidery area that extends across portions of the first and second pieces and has an appearance that the first texture extends into the second texture.

[0013] In an example, the embroidery area has an irregular edge along the second panel and a uniform edge along the first panel, and the embroidery area simulates the first panel bleeding into the second panel. In another example, the first panel includes a matrix of features arranged on a surface of the first panel, and the embroidery represents those features on the second panel, wherein the embroidery includes a first pattern representing the surface and a second pattern representing the matrix of features.

[0014] Aspects of the present application may be implemented in one or more of the following embodiments.

[0015] 1) An article of footwear, comprising: a sole structure; and an upper connected to the sole structure to form an enclosure for at least partially receiving a foot, the upper comprising: a first piece of material, the first piece of material forming a first portion of the upper and having a first texture; a second piece of material, the second piece of material forming a second portion of the upper and having a second texture; and an embroidery area, the embroidery area extending across portions of the first piece of material and the second piece of material and having an appearance of the first texture extending into the second texture.

[0016] 2) The article of footwear according to 1), wherein the first panel and the second panel are structurally joined by embroidered thread included in the embroidery area.

[0017] 3) The article of footwear according to 1), wherein the embroidery area has an irregular edge along the second panel.

[0018] 4) The article of footwear according to 3), wherein the embroidery area has a uniform edge along the first panel.

[0019] 5) The article of footwear according to 4), wherein the embroidered area simulates a fragmented transition of the first panel into the second panel.

[0020] 6) The article of footwear of 5), wherein the uniform edge is linear and the irregular edge has a plurality of peaks and valleys.

[0021] 7) The article of footwear according to 1), wherein the first piece of material includes a first material having a first roughness, and the second piece of material includes a second material having a second roughness less than the first roughness.

[0022] 8) The article of footwear according to 7), wherein the first material is a textile and the second material is a non-woven material.

[0023] 9) The article of footwear according to 8), wherein the first material is textile and the second material is leather.

[0024] 10) The article of footwear of 1), wherein the first panel includes a matrix of features arranged on a surface of the first panel, and the embroidered area represents these features on the second panel.

[0025] 11) The article of footwear according to 10), wherein the embroidered area includes a first pattern representing the surface and a second pattern representing the matrix of features.

[0026] 12) The article of footwear according to 11), wherein the first pattern is a first color and the second pattern is a second color different from the first color.

[0027] 13) The article of footwear according to 1), wherein the first piece and the second piece are butted against each other along respective edges of the first piece and the second piece.

[0028] 14) The article of footwear according to 1), wherein the first piece and the second piece overlap along respective edges of the first piece and the second piece.

[0029] 15) The article of footwear according to 1), further comprising a lining layer extending along the interior of the upper and along the embroidery area.

[0030] 16) The article of footwear according to 1), further comprising a stitch joining the first panel and the second panel.

[0031] 17) The article of footwear according to 1), further comprising an adhesive layer arranged between the first sheet and the second sheet.

[0032] 18) The article of footwear according to 1), wherein the embroidered area is positioned along a lateral side of an upper rear portion of the MTP joint.

[0033] 19) An upper for an article of footwear, the upper comprising: a first panel made of a first material; a second panel made of a second material; and an embroidery area joining the first panel and the second panel, the embroidery area having an appearance simulating the first material extending into the second material.

[0034] 20) The upper according to 19), wherein the embroidery area simulates the texture of the first material.

[0035] 21) The shoe upper according to 19), wherein the embroidery area extends unevenly into the first panel relative to the second panel.

[0036] 22. The upper according to 21), wherein the embroidery area extends into the first panel with a larger surface area than into the second panel.

[0037] 23) The upper of 19), wherein the embroidery area extends along the first panel at a uniform linear edge and along the second panel along an irregular edge having a plurality of peaks and valleys.

[0038] 24) The shoe upper according to 19) further includes: a stitching line, wherein the stitching line joins the first panel and the second panel; and an adhesive, wherein the adhesive is arranged along the interior of the shoe upper and along the embroidery area.

[0039] 25) The upper according to 19), wherein the first sheet and the second sheet are butted against each other at an edge of each sheet.

[0040] 26) An upper according to 19), wherein the first piece and the second piece form at least a part of an enclosure for receiving a foot, wherein the embroidery area is located in front of the MTP joint of the foot on the vamp of the upper.

[0041] This summary is intended to provide an overview of the subject matter of this patent application. It is not intended to provide an exclusive or exhaustive explanation of the invention. The detailed description is included to provide further information about this patent application. BRIEF DESCRIPTION OF THE DRAWINGS

[0042] Figure 1A is a perspective view of a lateral side of an article of footwear having an upper with two panels joined by an embroidery stitch of the present disclosure.

[0043] Figure 1B yes Figure 1A A top view of an article of footwear showing a medial side and a lateral side of an upper, each side having an embroidered transition pattern created by embroidery stitching.

[0044] Figure 1C yes Figure 1A 2 is a lateral side view of an article of footwear illustrating different areas of the article of footwear.

[0045] Figure 2A yes Figure 1B A cross-sectional view of an article of footwear taken along a toe to heel plane to illustrate the interior foot space.

[0046] Figure 2B yes Figure 1B A cross-sectional view of an article of footwear taken along a medial-lateral section to illustrate an insole and lining layer.

[0047] Figure 3 is a schematic illustration of a first panel and a second panel for an upper of an article of footwear joined by an embroidery stitch.

[0048] Figure 4 yes Figure 3 A cross-sectional view of an embroidery stitch illustrating an embodiment in which two different embroidery patterns are provided to produce an aesthetically appealing mechanical joint that simulates the texture and appearance of one of a first panel and a second panel.

[0049] Figure 5 yes Figure 3 A cross-sectional view of an embroidery stitch of FIG. 1 showing an embodiment having an adhesive layer positioned on the embroidery stitch within an upper of a footwear.

[0050] Figure 6 yes Figure 3 A cross-sectional view of an embroidery stitch of FIG. 1 showing an embodiment in which the first panel includes skiving to reduce its thickness at the embroidery stitch.

[0051] Figure 7 yes Figure 3 A cross-sectional view of an embroidery stitch showing an embodiment in which a first panel and a second panel overlap one another.

[0052] Figure 8 is a front schematic illustration of a first panel and a second panel for an upper of an article of footwear joined by an embroidery stitch, wherein the embroidery simulates surface features on both the first panel and the second panel.

[0053] In the accompanying drawings, which are not necessarily drawn to scale, the same number may describe similar components in different views. The same number with different letter suffixes may represent different instances of similar components. The accompanying drawings generally illustrate various embodiments discussed in this document by way of example and not limitation. Detailed Description

[0054] Figure 1A is a perspective view of an article of footwear 10 having an embroidery area 12A on an upper 14 connected to a sole structure 16 . Figure 1B is a top view of article of footwear 10 illustrating lateral side 18 and medial side 20 having embroidered areas 12A and 12B, respectively. Figure 1C A lateral side 18 of article of footwear 10 is shown, illustrating forefoot region 22, midfoot region 24, and heel region 26. Sole structure 16 may include outsole 28 and midsole 30. Upper 14 may include lace 32, tongue 34, and collar element 36. Upper 14 may be composed of multiple panels of different or same materials, such as toe panel 38 and heel panel 40. The multiple panels of upper 14 may be connected to each other via embroidery area 12A.

[0055] In the example shown, the upper 14 includes a toe piece 38 and a heel piece 40 that at least partially surround the foot. Each of the toe piece 38 and the heel piece 40 can at least partially wrap around the medial and lateral sides of the upper 14. For example, the toe piece 38 can form a vamp of the footwear 10, which extends from the lateral MTP joint area of ​​the foot around the toe cap of the footwear 10 and extends to the medial MTP joint area of ​​the foot. Similarly, the heel piece 40 can form a heel stabilizer for the footwear 10, which extends from the lateral midfoot area of ​​the foot around the heel cap of the footwear 10 and extends to the medial midfoot area of ​​the foot. The pieces 38 and 40, together with other portions of the footwear 10, form a shell when joined to the sole structure 16 for at least partially surrounding the foot. The upper 14 may include an aperture 42, an insole 44, a lining 46, and a foot void 48. The components of upper 14, including tongue 34, collar element 36, toe panel 38, and heel panel 40, may be formed from a variety of materials, such as knitted materials, woven materials, natural materials, or synthetic materials. Figure 1A In the example of the footwear 10, the toe panel 38 is made of a textile having a texture 50, and the heel panel 40 is smooth relative to the texture 50. For example, the texture 50 may have a low portion 52 and a high portion 54. The toe panel 38 and the heel panel 40 may be composed of one or more sub-panels. Each panel 38 and panel 40 and sub-panels of the footwear 10 may be joined together using conventional stitching structures and sewing structures and methods. In addition, as described herein, multiple panels and sub-panels may be joined using embroidery stitching that creates a pattern that visually and structurally connects the panels together.

[0056] Embroidery region 12A extends across the ends or edges of toe panel 38 and heel panel 40 and forms a bond therebetween to mechanically interlock panels 38 and 40, thereby reducing or eliminating the need for separate stitching to directly join panels 38 and 40. In addition, embroidery region 12A may be shaped to provide an aesthetic appearance to footwear 10. In particular, embroidery region 12A may have a pattern to provide a transition between colors, textures, and materials of panels 38 and 40, and combinations thereof. Embroidery region 12A may have a variety of appearances or patterns made from a plurality of different threads to match the appearance, color, and shape of texture 50. For example, embroidery region 12A may include thread 56A and thread 58A.

[0057] Forefoot region 22 generally includes portions of footwear 10 corresponding to the toe and the joint connecting the metatarsal bones to the phalanges (MTP joint). Midfoot region 24 generally includes portions of footwear 10 corresponding to the arch area of ​​the foot. Heel region 26 generally corresponds to the heel area of ​​the foot, which includes the calcaneus. Lateral side 18 and medial side 20 extend through each of regions 22 to 26 in a front-to-back direction. Regions 22 to 26 and sides 18 and 20 are not intended to demarcate precise regions of footwear 10. Rather, regions 22 to 26 and sides 18 and 20 are intended to represent general regions of footwear 10 to facilitate discussion of footwear 10.

[0058] The embroidery of the present disclosure, such as embroidery area 12A and embroidery area 12B, can be located in multiple locations in each of the areas and sides of the footwear 10 and in multiple orientations. However, it may be desirable to position the embroidery away from high stress points of the footwear 10. For example, it may be desirable to position the embroidery away from the MTP joint to avoid stressing the embroidery thread due to repeated flexing of the foot. In the example described herein, embroidery area 12A is positioned posterior to the MTP joint along the tarsal bones, and embroidery area 12B is positioned posterior to the MTP joint along the instep of the foot. Additionally or alternatively, the embroidery can be located on the distal upper surface of the toe panel 38, on the rear surface of the heel panel 40, on the tongue 34, and at other locations throughout the footwear 10.

[0059] The tongue 34 can be connected to the toe piece 38 and extend under the lace 32 to enhance the comfort or adjustability of the footwear 10. The tongue 34 can extend between the opposite portion of the toe piece 38 and the opposite portion of the heel piece 40. The opposite portion of the heel piece 40 can be equipped with a collar element 36. The collar element 36 is located in at least the heel area 26. The collar element 36 and the tongue 34 form an opening for providing an access point (access point) for the foot to enter the interior of the upper 14. The lace 32 extends through a plurality of lace holes 42 and extends across the throat area 49 of the upper 14 to allow the wearer of the footwear 10 to change the size of the upper 14 and adapt to the size of the foot. The lace 32 can be operated in a generally conventional manner to tighten the upper 14 around the foot when the lace 32 is tied, thereby reducing the size of the foot space 48 of the shell formed by the sheet 38 and the sheet 40. When lace 32 is loosened, upper 14 also loosens to expand the size of shell footwell 48. Footwear 10 may alternatively be provided with other types of fastening systems, such as elastic bands, hook-and-loop fasteners, and the like.

[0060] The foot of a wearer of footwear 10 may be placed on insole 44 within sole structure 16, while upper 14 surrounds the foot to retain the foot inserted into footwear 10. Sole structure 16 is secured to upper 14 and extends between the foot and the ground when footwear 10 is worn. Midsole 30 may be secured to a lower portion of upper 14 and may be secured to upper 14 by adhesive, stitching, or other suitable means.

[0061] Suitable materials for midsole 30 include polymer foam materials such as ethylene vinyl acetate or polyurethane, or any other resiliently compressible material to attenuate ground reaction forces (i.e., provide cushioning) when compressed between the foot and the ground during walking, running, or other ambulatory or athletic activities associated with a person's gait or movement of the foot.

[0062] Insole 44( Figure 1B ) may generally include a removable insert disposed on midsole 30 and may provide additional cushioning or ventilation (eg, by including perforations). Insole 44 may be located within upper 14 and positioned to extend below the lower surface of the foot.

[0063] Outsole 28 is secured to the lower surface of midsole 30 and may be formed of a wear-resistant rubber material that is textured to impart traction. Outsole 28 may be attached to the lower surface of midsole 30 by adhesive or other suitable means. Suitable materials for outsole 28 include polymers such as polyether-block copolyamide polymers (sold by ATOFINA Chemicals of Philadelphia, Pennsylvania). ), and nylon resins such as those sold by Dupont Other suitable materials for outsole 28 and midsole 30 may also be used, as is known in the art. Outsole 28 may include various features for providing traction, such as projections and ribs.

[0064] The midsole 30 may include a filling chamber, a plate, an adjuster or other element that further reduces the force, enhances stability or affects the movement of the foot, or the midsole 30 may be mainly formed by a fluid-filled chamber. The air bag may include two polymer film layers, as described in U.S. Pat. No. 5,802,739 of Potter et al. In another example, a four-layer air bag may be used, as described in U.S. Pat. No. 6,402,879 of Tawney et al. In another example, a fabric cushioning element may be used, as described in U.S. Pat. No. 8,764,931 of Turner. For various purposes, the entire contents of U.S. Pat. Nos. 5,802,739, 6,402,879 and 8,764,931 are hereby incorporated by reference in their entirety. In yet other examples, the capsule may be filled with other gases, such as nitrogen, helium or so-called dense gases (such as sulfur hexafluoride), liquids or gels.

[0065] The upper 14 and the sole structure 16 can be configured to enhance the comfort, appearance and performance of footwear during various activities. Although this description is written with reference to general athletic shoes, the disclosure of the present application can also be applied to other types of footwear, such as but not limited to dress shoes, running shoes, casual shoes, fashion shoes, golf shoes, football cleats, English soccer shoes, baseball cleats, tennis shoes, sandals, boots, slippers and the like. In addition, the disclosure of the present application can be used for other manufactured articles, including textiles, clothing articles and clothing articles.

[0066] Figure 2A yes Figure 1B 1 is a cross-sectional view of an article of footwear 10 taken along a toe to heel section to illustrate interior foot void 48. Figure 2B yes Figure 1B 4 is a cross-sectional view of an article of footwear 10 taken along a medial-lateral plane to illustrate an insole 44 and a lining layer 46. A portion of the lining layer 46 is shown at Figure 2A The figure is cut away to show the embroidery area 12B on the inner side of the toe panel 38 and the heel panel 40.

[0067] Upper 14 is formed of a plurality of layers, including a layer formed of toe panel 38 and heel panel 40, that combine to provide a structure for securely and comfortably receiving a foot. Although the configuration of upper 14 may vary significantly, the various elements generally define a void within footwear 10 for receiving and securing a foot relative to sole structure 16 within foot void 48. Additionally, upper 14 may include an interior layer, such as lining layer 46. Panels 38 and 40 form at least a portion of an exterior surface of upper 14. Lining layer 46 forms at least a portion of an interior surface of upper 14, i.e., a surface that defines foot void 48.

[0068] The sheets 38 and 40 and the lining layer 46 can be formed of various materials (e.g., textiles, fabrics, polymer foams, leather, synthetic materials) that can be stitched, bonded, or embroidered together. As an example, the heel sheet 40 can be formed of a smooth material such as leather or a synthetic material, while the toe sheet 38 can be formed of a breathable material such as a mesh material, a woven material, or a knitted material. In many conventional shoes, the sheets formed of sharply contrasting materials are butted at the edges that form distinct lines. These lines can be covered by a variety of side strips, strips, welts, or webbing, but these items themselves can leave clearly visible edge lines and add potentially undesirable thickness and hardness to the shoe.

[0069] The embroidery area 12A may be configured to provide a comfortable, aesthetically pleasing joint between the toe panel 38 and the heel panel 40. Figure 1A As shown in FIG, embroidery area 12A may include threads 56A and 58A that may extend from exterior E of upper 14 to interior I of upper 14 in foot space 48. Threads 56A and 58A loop back and forth between interior I and exterior E of upper 14 to interlock each of toe panel 38 and heel panel 40 with one another.

[0070] Figure 3 is a schematic diagram of toe panel 38 and heel panel 40 for upper 14 of article of footwear 10 joined by embroidery region 12A. Embroidery region 12A includes threads 56A and 58A extending through toe panel 38 and heel panel 40 to interlock the panels of upper 14 with one another. Toe panel 38 may include a texture that creates low portion 50 and high portion 52. Threads 56A and 58A of embroidery region 12A may be arranged or patterned to represent or mimic the texture of low portion 50 and high portion 52. Thread 56A may extend from first edge 60 to second edge 62, and thread 58A may also extend from first edge 64 to second edge 66.

[0071] exist Figure 3In the example of FIG. 5 , the toe panel 38 and the heel panel 40 are positioned in a butted relationship so that the rear edge 68 of the toe panel 38 butts against the front edge 70 of the heel panel 40, as shown in FIG. Figure 4 . The rear edge 68 and the front edge 70 can be joined by a stitch 72. The stitch 72 constitutes the initial connection between the toe piece 38 and the heel piece 40, which provides fixation between the two pieces to allow the embroidery process to occur. In other examples, the stitch 72 is omitted. The stitch 72 may include a single strand or fiber with a zigzag shape. In yet other examples, stitches with different shapes or different numbers of strands may be used. For example, a smoothly curved stitch or a stitch of two or three strands may be used. However, the fastening provided by the stitch 72 or its alternatives does not need to provide the main fixing force between the piece 38 and the piece 40, because the main fixing force can be provided by the embroidery area 12A.

[0072] Embroidered area 12A provides both a mechanical coupling between panels 38 and 40 and a customizable, aesthetically variable appearance on upper 14. Figure 3 In the example of , embroidery area 12A includes thread 56A and thread 58A that simulate different aspects of toe panel 38. Thread 56A can be patterned to simulate low area 52 of toe panel 38, and thread 58A can be patterned to simulate high area 54 of toe panel 38. Thus, embroidery area 12A can provide a transition between panel 38 and panel 40 that softens the hard edge formed at the junction of rear edge 68 and front edge 70. Embroidery area 12A can also be used to provide an aesthetically pleasing transition between toe panel 38 and heel panel 40. For example, thread 58A can stop at irregular edge 66 before the edge of thread 56A, and thread 56A can continue into heel panel 40 to form irregular edge 62. In this way, embroidery area 12A can appear to simulate a fading or tattering transition of heel panel 40 into toe panel 38.

[0073] Figure 4 yes Figure 31, which shows an embodiment in which threads 56A and 58A are positioned between the inner I and outer E of the toe piece 38 and the heel piece 40. The strand 74 of the thread 56A is schematically shown as extending between the outer E and the inner I of the upper 14. Similarly, the strand 76 is schematically shown as extending between the outer E and the inner I of the upper 14. The strands 74 and 76 represent a plurality of threads or cords that constitute each of the threads 56A and 58A, respectively. The strands 74 and 76 can be laid using any conventional embroidery process. Unless otherwise specified, the dimensions (e.g., thickness) of the sheets 38 and 40 and the strands 74 and 76 are not drawn to scale and are exaggerated for illustrative purposes.

[0074] In the example shown, thread 56A is positioned directly against the major surfaces of toe panel 38 and heel panel 40, extending through edge 68 and edge 70. Strand 74 of thread 56A extends through toe panel 38 and heel panel 40 (although this is not the case in the examples shown). Figure 4 40). The strands 74 provide a first light embroidery layer that does not protrude very far from the surface of the panels 38 and 40. Thus, the strands 74 do not substantially thicken the upper 14 to help create a more comfortable fit. The strands 74 may substantially continuously cover the surface of the panels 38 and 40 to provide a high level of mechanical interlocking between the panels 38 and 40, as well as to provide a first texture for the embroidery area 12A. For example, the strands 74 may have the same color as the lower portion 52 of the toe panel 38 so as to extend the color of the toe panel 38 into the heel panel 40. The strands 74 may form a base surface for the embroidery area 12A.

[0075] In the example shown, line 58A is positioned directly against line 56A along the major surfaces of toe panel 38 and heel panel 40, and also extends across edge 68 and edge 70. Strand 76 of line 58A extends through line 56A, panel 38 and panel 40. Strand 76 provides a second shallow embroidery layer that does not protrude far from the surface of line 56A. Therefore, strand 76 does not generally thicken upper 14 to help produce a more comfortable fit. Strand 76 may only partially or intermittently cover the surface of line 56A to provide a three-dimensional texture, thereby providing a second level of mechanical interface, and providing a second texture for embroidery area 12A. For example, strand 76 may have the same color as high portion 54 of toe panel 38, which may be different from the color of low portion 52, so as to appear to extend the texture of toe panel 38 into heel panel 40. Strand 76 may form a plurality of ridges or ribs along the base surface of strand 74. The ridges or ribs may be arranged in a regular pattern such as in Figure 3 The grid pattern depicted in FIG. 1 is formed.

[0076] The strands 74 and 76 extend beyond the exterior E of the toe panel 38 and the heel panel 40 to provide a visible and tangible finish to the panels 38 and 40. In particular, the strands 74 and 76 create a three-dimensional contour that simulates the texture 50 of the toe panel 38. The strands 74 and 76 may be made of any material suitable for embroidery, such as cotton, nylon, polyester, or the like.

[0077] In various examples, embroidery area 12A may be configured to have a higher density of strands 74 and 76 in toe panel 38 than in heel panel 40. Thus, in region Z1 (at Figure 3 4), strands 74 may be evenly or regularly distributed across panels 38 and 40. Likewise, in zone Z1, strands 76 may be evenly or regularly distributed across panels 38 and 40. Thus, zone Z1 not only provides a pattern that simulates texture 50 of toe panel 38, but also provides a high level of mechanical interlocking, particularly as compared to zone Z2.

[0078] In zone Z2, which may extend only in heel panel 40, the appearance of strands 74 and 76 may become uneven or irregular. Because a substantial mechanical interlock has been provided in zone Z1, the density of strands 74 and 76 may be reduced in heel panel 40. Strands 74 and 76 may be constructed to be visually similar to toe panel 38 from a color and texture perspective, becoming thinner and fragmented, and ultimately dissipating at the terminal edges. For example, the ribs or ridges formed by strand 76 may become only partially formed. Each of strands 74 and 76 may form a plurality of peaks and valleys along edge 62 and edge 66 to form an irregular shape. Thus, in zone Z2, strands 74 and 76 may be formed to be substantially uniform and irregular in appearance. Figure 3 and Figure 4 In the example of embroidery area 12A, embroidery area 12A simulates a transition similar to the gradual blending or infiltration of panels 38 and 40 into each other. In other examples, embroidery area 12A can follow other gradually disappearing patterns and transitions.

[0079] As mentioned above, the materials, textures, and colors of toe panel 38 and heel panel 40 can be different to provide different aesthetic effects. In one example, toe panel 38 can be formed of a smooth non-woven material, such as leather (e.g., natural or synthetic leather), while heel panel 40 is formed of a rough textile material (such as fabric). In one example, panel 38 and panel 40 can have the same color, and embroidery area 12A can provide a transition in texture. In another example, panel 38 and panel 40 can have the same texture with different colors, and embroidery area 12A can provide a transition in color.

[0080] Figure 5 yes Figure 3 1, which shows an embodiment with an adhesive layer 78 positioned along the inner portion I of the embroidery area 12A. In addition to providing an adhesive layer 78 to form an initial bond between the toe piece 38 and the heel piece 40, Figure 4 The embroidery area is similarly constructed Figure 5 embroidery area 12A. Additionally or alternatively, adhesive layer 78 can be used for suture 72. Adhesive layer 78 can promote embroidery process, for example, by promoting to push strand 74 and strand 76 through sheet 38 and sheet 40 in a uniform manner during embroidery process to promote embroidery process. That is, adhesive layer 78 can prevent sheet 38 and sheet 40 from wrinkling or pleating to promote the proper orientation, alignment and insertion of the needle used in the embroidery process. Any suitable adhesive can be used. For example, hot melt adhesive, such as ethylene-vinyl acetate (EVA) copolymer can be used. In other examples, solvent-based adhesive or polymer dispersion adhesive can be used. In one example, adhesive layer 78 can be applied after forming suture 72, and then line 56A and line 58A are formed on the adhesive layer. In multiple examples, the placement and insertion of line 56A and line 58A can be performed after the adhesive layer is set, for example, dried or hardened. In other examples, after the embroidery process, an adhesive layer may be applied to strands 74 and 76 on the inner sides of panels 38 and 40 within interior I of upper 14 to secure the joint.

[0081] Figure 6 yes Figure 3 1, which shows an embodiment in which the heel panel 40 includes a thinning portion 80 to reduce its thickness at the embroidery area 12A. In addition to providing the thinning portion 80 on the heel panel 40 to facilitate the strands 74 and 76 of the thread 56A and the thread 58A to pass through the heel panel 40, Figure 4 The embroidery area is similarly constructed Figure 6The thinned portion 80 may extend along the length L to reduce the initial thickness T1 of the heel panel 40 along the embroidery area 12A. The thinned portion length L may also be selected to extend beyond the length of the embroidery area 12A. For example, the thinned portion 80 may be Figure 6 12A. The skived portion 80 can reduce the initial thickness T1 to a reduced thickness T2 at least along the length of the heel panel 40 that joins the embroidery area 12A. The thickness T2 can be selected to match the thickness of the toe panel 38. In another example, the thickness T2 can be selected based on the embroidery process (such as the length of the embroidery needle). The stitching 72 and the adhesive layer 78 can be used in conjunction with the skived portion 80. The skived portion 80 can be provided on the heel panel 40 before the embroidery process occurs, but after the heel panel 40 is cut into the shape desired or required to manufacture the upper 14.

[0082] Figure 7 yes Figure 3 , which shows an embodiment in which the toe panel 38 and the heel panel 40 overlap each other along the overlap 82. In addition to providing the overlap 82 between the toe panel 38 and the heel panel 40 to facilitate the threading of the strands 74 and 76 of the thread 56A and the thread 58A therethrough and to facilitate the construction of the embroidery area 12A, Figure 4 The embroidery area is similarly constructed Figure 7 In some examples, particularly those examples where one or both of toe panel 38 and heel panel 40 are thin relative to, for example, the length of an embroidery needle used to create embroidery region 12A, toe panel 38 and heel panel 40 may overlap to facilitate the manufacture of embroidery region 12A. For example, it may be easier to provide stitching 72 and adhesive layer 78 while panels 38 and 40 overlap rather than butt joint. Overlap 82 may be as shown in FIG. Figure 7 1A, in order to allow for maximum mechanical interlocking. In other examples, overlap 82 may extend a portion of the length of embroidery region 12A, which may be used to manipulate the texture or appearance of embroidery region 12A. For example, an irregularly shaped edge of toe panel 38 may overlap the top of heel panel 38 to provide another degree of variation in the texture and appearance of embroidery region 12A.

[0083] Figure 81 is a front schematic diagram of a toe panel 38 and a heel panel 40 for an upper 14 of an article of footwear 10 joined by an embroidery portion 84, wherein the embroidery portion 84 simulates surface features 86 and surface features 88 on each of the toe panel 38 and the heel panel 40. The toe panel 38 may include decorative surface features 86, such as embossed or printed shape patterns. Similarly, the heel panel 40 may include decorative surface features 88, such as embossed or printed shape patterns. In one example, the surface features 86 and the surface features 88 include geometric shapes, such as diamonds, squares, or circles. The embroidery portion 84 may be provided to join the toe panel 38 and the heel panel 40 using a stitch pattern that exhibits the surface features 86 and the surface features 88. The embroidery portion 84 may include a single layer of embroidery thread, or may include multiple layers of embroidery thread. In one particular example, heel panel 40 includes a synthetic polymer material having surface features 88 including an embossed diamond pattern, toe panel 38 includes a synthetic neoprene material having surface features 86 including a printed diamond pattern, and embroidery portion 84 includes a single layer of embroidered diamond pattern formed on overlapping portions of toe panel 38 and heel panel 40 to join the panels together. Edge 90 of toe panel 38 may be positioned so as not to intersect any of surface features 86, and edge 92 of heel panel 40 may be positioned so as not to intersect any of surface features 88. Embroidery portion 84 may only create a fully formed shape that matches surface features 86 and surface features 88. Thus, the entire upper of the footwear does not include any aesthetically unappealing changes that are easily noticeable.

[0084] Multiple notes and examples

[0085] Example 1 may include or use a subject matter such as an article of footwear comprising: a sole structure; and an upper connected to the sole structure to form an enclosure for at least partially receiving a foot, the upper comprising: a first piece of material forming a first portion of the upper and having a first texture; a second piece of material forming a second portion of the upper and having a second texture; and an embroidery area extending across portions of the first piece and the second piece and having the appearance of the first texture extending into the second texture.

[0086] Example 2 may include the subject matter of Example 1 or may optionally be combined with the subject matter of Example 1 to optionally include a first panel and a second panel structurally joined by embroidery thread included in an embroidery area.

[0087] Example 3 may include or may optionally be combined with the subject matter of one or any combination of Examples 1 or 2 to optionally include an embroidery area having an irregular edge along the second panel.

[0088] Example 4 can include or can optionally be combined with the subject matter of one or any combination of Examples 1-3 to optionally include an embroidery area having a uniform edge along the first panel.

[0089] Example 5 may include or may optionally be combined with the subject matter of one or any combination of Examples 1-4 to optionally include an embroidery area that simulates a fragmented transition of the first panel into the second panel.

[0090] Example 6 may include or may optionally be combined with the subject matter of one or any combination of Examples 3-5 to optionally include a linear uniform edge and an irregular edge having multiple peaks and valleys.

[0091] Example 7 may include the subject matter of one or any combination of Examples 1-6 or may optionally be combined with the subject matter of one or any combination of Examples 1-6 to optionally include a first sheet of material and a second sheet of material, the first sheet of material including a first material having a first roughness, and the second sheet of material including a second material having a second roughness less than the first roughness.

[0092] Example 8 can include or can optionally be combined with the subject matter of one or any combination of Examples 1-7 to optionally include a first material that is a textile material and a second material that is a non-woven material.

[0093] Example 9 can include or can optionally be combined with the subject matter of one or any combination of Examples 1-8 to optionally include a first material that is a fabric and a second material that is a leather product.

[0094] Example 10 may include or may optionally be combined with the subject matter of one or any combination of Examples 1-9 to optionally include: a first piece of material comprising a matrix of features arranged on a surface of the first piece of material; and an embroidery area representing the features on a second piece of material.

[0095] Example 11 can include or can optionally be combined with the subject matter of one or any combination of Examples 1-10 to optionally include an embroidery area that includes a first pattern of a representational surface and a second pattern of a matrix of representational features.

[0096] Example 12 may include or may optionally be combined with the subject matter of one or any combination of Examples 1-11 to optionally include a first pattern of a first color and a second pattern of a second color different from the first color.

[0097] Example 13 may include or may optionally be combined with the subject matter of one or any combination of Examples 1-12 to optionally include the first and second sheets being butted together along their respective edges.

[0098] Example 14 may include or may optionally be combined with the subject matter of one or any combination of Examples 1-12 to optionally include the first and second sheets overlapping along respective edges of the first and second sheets.

[0099] Example 15 may include or may optionally be combined with the subject matter of one or any combination of Examples 1-14 to optionally include a lining layer extending along an interior of the upper and along the embroidery area.

[0100] Example 16 can include or can optionally be combined with the subject matter of one or any combination of Examples 1-5 to optionally include a seam joining the first panel and the second panel.

[0101] Example 17 may include or may optionally be combined with the subject matter of one or any combination of Examples 1-16 to optionally include an adhesive layer disposed between the first sheet and the second sheet.

[0102] Example 18 may include or may optionally be combined with the subject matter of one or any combination of Examples 1-17 to optionally include an embroidery area positioned along the lateral aspect of the superior posterior portion of the MTP joint.

[0103] Example 19 may include or use a theme, such as an upper for an article of footwear, the upper comprising: a first panel made of a first material; a second panel made of a second material; and an embroidery area that joins the first panel and the second panel, the embroidery area having an appearance that simulates the first material extending into the second material.

[0104] Example 20 may include or may optionally be combined with the subject matter of Example 19 to optionally include an embroidered area simulating the texture of the first material.

[0105] Example 21 may include or may optionally be combined with the subject matter of one or any combination of Examples 19 or 20 to optionally include an embroidery area that extends unequally into the first panel relative to the second panel.

[0106] Example 22 may include or may optionally be combined with the subject matter of one or any combination of Examples 19-21 to optionally include an embroidery area that extends into the first panel with a larger surface area than into the second panel.

[0107] Example 23 may include or may optionally be combined with the subject matter of one or any combination of Examples 19-22 to optionally include an embroidery area extending along a first piece of material at a uniform linear edge and along a second piece of material along an irregular edge having multiple peaks and valleys.

[0108] Example 24 may include or may optionally be combined with the subject matter of one or any combination of Examples 19-23 to optionally include stitching joining the first panel and the second panel and an adhesive arranged along the interior of the upper and along the embroidery area.

[0109] Example 25 may include or may optionally be combined with the subject matter of one or any combination of Examples 19-24 to optionally include the first and second panels butted at an edge of each panel.

[0110] Example 26 may include or may optionally be combined with the subject matter of one or any combination of Examples 19-25 to optionally include a first piece and a second piece that form at least a portion of an enclosure for accommodating a foot, wherein the embroidery is located in front of the MTP joint of the foot on the vamp of the upper.

[0111] Each of these non-limiting examples may stand alone or may be combined with one or more of the other examples in various permutations or combinations.

[0112] The above detailed description includes reference to the accompanying drawings, which form a part of the detailed description. The accompanying drawings show specific embodiments in which the present invention can be implemented by way of illustration. These embodiments are also referred to as "examples" in this article. Such examples may include elements other than the elements shown or described. However, the inventors also contemplate examples that only provide those elements shown or described. In addition, the inventors also contemplate examples of any combination or arrangement of those elements (or one or more aspects thereof) shown or described with reference to specific examples (or one or more aspects thereof) shown or described in this article or with reference to other examples (or one or more aspects thereof) shown or described in this article.

[0113] In the event of an inconsistency in usage between this document and any document incorporated by reference, the usage in this document controls.

[0114] In this document, as is common in patent documents, the terms "a" or "an" are used to include one or more than one, regardless of any other instance or usage of "at least one" or "one or more". In this document, unless otherwise indicated, the term "or" is used to refer to a non-exclusive or such that: "A or B" includes "A without B", "B without A", and "A and B". In this document, the terms "including" and "in which" are used as the plain English equivalents of the corresponding terms "comprising" and "wherein". Moreover, in the appended claims, the terms "including" and "comprising" are open-ended, that is, systems, devices, articles, compositions, formulations, or processes that also include elements other than those listed after such terms in the claims are still considered to fall within the scope of the claim. In addition, in the appended claims, the terms "first", "second", and "third", etc. are used only as labels and are not intended to impose numerical requirements on their objects.

[0115] The above description is intended to be illustrative and not restrictive. For example, the examples described above (or one or more aspects thereof) can be used in combination with each other. Other embodiments can be used, such as other embodiments that can be used by those of ordinary skill in the art when consulting the above description. An abstract is provided to allow the reader to quickly determine the nature of the technical disclosure. It is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims. Moreover, in the above detailed description, multiple features can be grouped together to simplify the disclosure. This should not be interpreted as intending that the disclosed features that are not claimed for protection are essential to any claim. Instead, the subject matter of the present invention may be less than all the features of a specific disclosed embodiment. Therefore, the attached claims are hereby incorporated into the detailed description as examples or embodiments, each claim independently as a separate embodiment, and it is envisioned that such embodiments can be combined with each other in various combinations or arrangements. The scope of the present invention should be determined with reference to the attached claims and the full scope of the equivalents of the rights granted by these claims.

Claims

1. An article of footwear comprising: Sole structure; and An upper connected to the sole structure to form an enclosure for at least partially receiving a foot, the upper comprising: a first piece of material, the first piece of material forming a first portion of the upper and having a first texture, the first texture having a low portion and a high portion; a second panel forming a second portion of the upper and having a second texture; and an embroidery area extending across portions of the first panel and the second panel and having a three-dimensional texture representing the first texture extending into the second texture; wherein the first panel and the second panel are structurally joined by first and second threads of embroidery included in the embroidery area, wherein the first line is positioned directly against major surfaces of the first sheet and the second sheet, and wherein the strands of the first thread extend through the first panel and the second panel and provide a first shallow embroidery layer protruding beyond the major surfaces of the first panel and the second panel, wherein the second line is positioned directly against the first line along the major surfaces of the first and second sheets, and wherein strands of the second thread extend through the first thread, the first panel and the second panel and provide a second shallow embroidery layer that protrudes beyond the surface of the first thread, wherein the strands of the second thread partially cover the surface of the first thread to provide the three-dimensional texture, and The first line and the second line are patterned to represent the texture of the low portion and the high portion of the first texture.

2. The article of footwear according to claim 1, wherein: The embroidery area has an irregular edge along the second panel, wherein the irregular edge has a plurality of peaks and valleys; and The embroidery area has a uniform edge along the first panel, wherein the uniform edge is linear.

3. The article of footwear according to claim 1, wherein: The first sheet stock includes a first material having a first roughness, and the second sheet stock includes a second material having a second roughness less than the first roughness.

4. The article of footwear according to claim 3, wherein: The first material is a woven material and the second material is a non-woven material.

5. The article of footwear according to claim 3, wherein: The first material is fabric and the second material is leather.

6. The article of footwear according to claim 1, wherein: The first panel includes a matrix of features comprising an embossed or printed pattern arranged on a surface of the first panel, and the embroidery area represents these features on the second panel.

7. The article of footwear according to claim 6, wherein: The embroidery area includes a first pattern representing the surface of the first panel and a second pattern representing the matrix of features.

8. The article of footwear according to claim 7, wherein: The first pattern includes a first color and the second pattern includes a second color different from the first color.

9. The article of footwear according to claim 1, wherein: The first sheet material and the second sheet material are butted against each other along respective edges of the first sheet material and the second sheet material.

10. The article of footwear according to claim 1, wherein: The first panel and the second panel overlap along respective edges of the first panel and the second panel.

11. The article of footwear according to claim 1, further comprising a lining layer extending along an interior of the upper and along the embroidered area.

12. The article of footwear according to claim 1, further comprising a stitch joining the first panel and the second panel.

13. The article of footwear according to claim 1, further comprising an adhesive layer disposed between the first panel and the second panel.

14. The article of footwear according to claim 1, wherein: The embroidery area is positioned along the lateral side of the upper rear portion of the location where the MTP joint of the foot will be positioned within the enclosure.

15. An upper for an article of footwear, the upper comprising: a first sheet of a first material, the first sheet having a first texture, the first texture having a low portion and a high portion; a second sheet made of a second material, the second sheet having a second texture; as well as an embroidery area, the embroidery area joining the first panel and the second panel, the embroidery area having a three-dimensional texture representing that the first texture extends into the second texture; wherein the first panel and the second panel are structurally joined by first and second threads of embroidery included in the embroidery area; wherein the first line is positioned directly against major surfaces of the first sheet and the second sheet; and wherein the strands of the first thread extend through the first panel and the second panel and provide a first light embroidery layer; wherein the second line is positioned directly against the first line along the major surfaces of the first and second sheets, and wherein the strands of the second thread extend through the first thread, the first panel and the second panel and provide a second light embroidery layer; wherein the strands of the second thread partially cover the surface of the first thread to provide the three-dimensional texture; and The first line and the second line are patterned to represent the texture of the low portion and the high portion of the first texture.

16. The shoe upper according to claim 15, wherein: The embroidery area extends unevenly into the first panel relative to the second panel.

17. The shoe upper according to claim 15, wherein: The embroidery area extends into the first panel over a greater surface area than into the second panel.

18. An upper for an article of footwear, the upper comprising: a first sheet made of a first material, the first sheet having a first texture; a second sheet made of a second material, the second sheet having a second texture; as well as an embroidery area having a three-dimensional texture representing the first texture extending into the second texture, the embroidery area including first and second threads of embroidery structurally joining the first panel and the second panel; wherein the strands of the first thread extend through the first panel and the second panel and provide a first shallow embroidery layer protruding from the surface of the first panel and the second panel; wherein the strands of the second thread extend through the first thread, the first panel and the second panel and provide a second shallow embroidery layer protruding from the surface of the first thread; wherein the strands of the second thread partially cover the surface of the first thread to provide the three-dimensional texture.

19. The upper according to claim 18, wherein: The first texture includes a low portion and a high portion; and The first lines and the second lines are patterned to express textures of the low portion and the high portion of the first texture.

Images