Mechanical locking sole structure for knitted footwear

Abstract

The present application relates to a mechanical locking sole structure for braided footwear. The present invention relates to a braided footwear article (126, 300, 406) including a mechanical locking structure. A braided upper (104, 302, 400) includes a tubular braided structure (114, 304, 408) having a plurality of holes (106, 306, 403). In some embodiments, a midsole (100, 402) includes a plurality of protruding spikes (102, 404) configured to receive the plurality of holes. The midsole receives the braided upper, and the plurality of protruding spikes extend below the bottom surface of the braided upper via the plurality of holes, locking or fixing the braided upper and the midsole together, thereby creating a mechanical locking structure.

Description

[0001] This application is a divisional application of an application with an application date of May 30, 2018, application number 201880035150.2, and invention name “Mechanical locking sole structure for knitted footwear”. Field of the Invention

[0002] The present invention relates to articles of footwear, and in particular to mechanical locking sole structures for knitted articles of footwear. Background of the Invention

[0003] Conventional shoes are typically made of textiles or materials with uppers that are cut into desired shapes and sewn together. Newer methods now also include forming the uppers of shoes from knitted textiles. Still newer methods involve braiding tubular textiles for use as uppers of shoes. Aspects of this article relate to braided tubular structures for use in footwear articles in some aspects. SUMMARY OF THE INVENTION

[0004] Provided is a kind of footwear article with a mechanical locking sole structure and a braided upper.Some aspects generally include a braided upper and a one-piece sole structure that mechanically engages at least a portion of the braided upper, such as a locking midsole, which has a bottom surface keyed to a surface feature portion, and the surface feature portion interacts with the sole and / or side surface of the braided upper. The one-piece midsole can engage at least a portion of the braided upper and contact the ground surface by extending through a plurality of mesh braided holes of the braided upper, thereby providing outsole functionality in addition to midsole support. In addition, based on engaging the perimeter of each sole surface feature portion with the corresponding and surrounding braided holes, in some aspects, the sole and braided upper that are interlocked in a fixed / keyed position in the braided upper can become stable.

[0005] This Summary is provided to introduce the essence of the concepts that are further described below in the Detailed Description in a simplified form. This Summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used as an aid in determining the scope of the claimed subject matter. BRIEF DESCRIPTION OF THE DRAWINGS

[0006] Illustrative aspects of the invention are described in detail below with reference to the accompanying drawings, which are incorporated herein by reference, and in which:

[0007] Figure 1 depicts a schematic diagram of an exemplary braiding machine according to aspects herein;

[0008] Figure 2 depicts a schematic top view of an exemplary braiding machine according to aspects herein, illustrating a carriage and rotor metalwork;

[0009] Figure 3 Depicts a device similar to Figure 2 's view, but in which the rotor metal piece moves the bracket;

[0010] Figure 4 Depicts a device similar to Figure 3 view, but shows Figure 3 Completion of exemplary movement;

[0011] Figure 5 depicts a perspective view of an exemplary midsole according to aspects herein;

[0012] Figure 6 depicts a side perspective view of an exemplary knitted upper including a tubular knitted structure and a plurality of apertures according to aspects herein;

[0013] Figure 7 depicts a side perspective view of an exemplary knitted article of footwear according to aspects herein;

[0014] Figure 8 Describes aspects of this invention Figure 7 a bottom view of an exemplary knitted article of footwear;

[0015] Fig.9A Describes aspects of this invention Figure 7 A rear view of an exemplary braided article of footwear at a heel end;

[0016] Fig. 9B Describes aspects of this invention Fig.9A A cross-sectional view of

[0017] Fig.10 Describes aspects of this invention Figure 7 a close-up view of a portion of an exemplary knitted article of footwear;

[0018] Fig.11A Describes aspects of this invention Figure 7 A perspective view of an exemplary knitted article of footwear wherein a sprayed outsole covers a portion of a midsole and a bottom surface of a knitted upper;

[0019] Fig. 11B Depicted is a view taken at cut line 11B-11B according to aspects of the present invention. Fig.11A A cross-sectional view of

[0020] Fig. 12A depicts a side view of an exemplary knitted article of footwear according to aspects herein;

[0021] Fig. 12B Describes aspects of this invention Fig. 12A A perspective view of an exemplary knitted article of footwear;

[0022] Fig.13 Describes aspects of this invention Fig. 12A a bottom view of an exemplary knitted article of footwear;

[0023] Fig.14A and Fig. 14B Describes aspects of this invention Fig.13 A cross-sectional view of

[0024] Fig.15 depicts a side view of an exemplary knitted article of footwear according to aspects herein; and

[0025] Fig.16 Describes aspects of this invention Fig.15 A bottom view of a braided article of footwear. DETAILED DESCRIPTION OF THE INVENTION

[0026] The subject matter of the present invention is described herein with specificity to meet statutory requirements. However, the description itself is not intended to limit the scope of this patent.

[0027] Typically, footwear articles have two main components: an upper that provides an enclosure for receiving the foot and a sole that is secured to the upper. The upper may be adjustable using laces, hook-and-loop fasteners, or other devices to secure the shoe to the foot. The upper may also be designed to provide the appropriate type of protection to the foot and maximize the comfort of the wearer. The sole may include a midsole and an outsole. The outsole portion is typically primarily in contact with the ground and may be designed to absorb vibrations when the footwear contacts the ground or other surface.

[0028] In aspects discussed herein, the articles of footwear are in the form of different athletic shoes. However, in some other aspects, the arrangements discussed herein for the knitted articles of footwear may be incorporated into various other types of footwear, including, but not limited to, basketball shoes, hiking boots, soccer shoes, rugby shoes, sneakers, running shoes, cross-training shoes, and other types of footwear. Furthermore, in some aspects, the arrangements discussed herein for the articles of footwear may be incorporated into various other types of non-sports related footwear, including, but not limited to, slippers, sandals, high-heeled footwear, loafers, and other types of footwear.

[0029] In summary, aspects of this paper relate to a kind of braided footwear articles, and the braided footwear articles include the sole of the flexible shoe fixed to the braided upper.The braided upper is defined as the overall braided structure made using the braiding technology.Braiding is to interlace (interlacing) or interweave (interweaving) three or more yarns diagonally to the product axis, so as to obtain a thicker, wider or stronger product, or in order to cover (overbraid) a certain profile (profile) process.Diagonally interlaced means that the yarn is at a certain angle to the product axis, and the angle can be between 1 ° and 89 °, but usually in the range of 30 °-80 °.This angle is called the braiding angle.Braids can be linear products (ropes), hollow tubular shells or solid structures (one-dimensional textiles, two-dimensional textiles or three-dimensional textiles) with constant or variable cross-sections and closed or open appearances.

[0030] As used herein, the yarn for braiding can be formed by different materials with different properties. The properties of the area of ​​the braided parts given by a specific yarn depend in part on the material forming the yarn. For example, cotton provides softer products, natural beauty and biodegradability. Elastic fiber (elastane) and stretch polyester each provide considerable stretchability and recovery, wherein stretch polyester also provides reusability. Rayon provides high luster (luster) and hygroscopicity. Wool also provides high hygroscopicity in addition to providing thermal insulation properties and biodegradability. Nylon is a durable and wear-resistant material with relatively high strength. Polyester is a hydrophobic material that also provides relatively high durability. In addition to materials, other aspects of the yarn selected for forming the braided parts can affect the properties of the braided parts. For example, the yarn can be a monofilament or a multifilament. The yarn can also include a separate silk formed by different materials. In addition, the yarn can include a silk formed by two or more different materials, such as a bicomponent yarn, wherein the silk has a sheath-core configuration (sheath-core configuration) or two halves formed by different materials.

[0031] By using braiding technology, footwear articles can be designed to have specific features customized for specific sports activities or recreational activities, and characterized by tight constraints on the wearer's foot. Different areas of braided shoe uppers can have different braiding structures. For example, higher braiding density can be used in the specific area of ​​footwear to provide additional structural support or compression. Different braiding densities are combined with each other to form seamless braided shoe uppers. The term braiding density refers to the number and / or concentration of specific yarns used for braiding different areas, and is measured by the number of yarns interlaced per unit area. In addition, the yarn of different materials can be incorporated into the different areas of the braided shoe upper to provide specific properties to footwear in those areas. For example, the yarn made of material with larger tensile strength can be used in the section of footwear that experiences higher stress during a specific activity. Softer and more flexible yarn can be used in the section of footwear that does not withstand high stress, to provide a more comfortable and tightly fitting upper in those sections. Furthermore, different braid densities may vary in structural properties such as the number of yarns in the braid, the diameter of one or more yarns of the braid, the density of the yarns, and material properties of the yarns such as elasticity, stiffness, tensile strength, compressibility, and other material properties.

[0032] The braided upper formed using the braiding technique is fixed to a sole structure that extends between the foot and the ground when the article is worn. In different aspects, the sole structure may include different components. For example, the sole structure may include only a midsole or include a midsole and an outer sole. The sole structure may also provide one or more functions for the article. For example, the sole structure may be configured to provide traction friction for the article when worn. In addition, the midsole may include a polymer foam material that weakens ground reaction forces when compressed between the foot and the ground during walking, running or other ambulatory activities. The midsole may also be made of relatively soft materials to provide cushioning. The outer sole is usually made of harder, more wear-resistant materials such as rubber or EVA. The outer sole is fixed to the lower surface of the midsole and provides the part of the sole structure that engages the ground, which is formed by a durable and wear-resistant material such as rubber.

[0033] The accompanying drawings depict a footwear article with a braided upper, the footwear article comprising a braided tubular structure having a plurality of holes on the bottom surface of the braided upper. The braided upper extends below the foot of the wearer, thereby providing a 360-degree containment around the bottom of the foot. The midsole comprises a plurality of protruding studs, which are keyed to receive the plurality of holes of the braided upper. In other words, the plurality of holes of the braided upper and the plurality of protruding studs are configured so that the plurality of protruding studs fit through the plurality of holes and extend below the bottom surface of the plurality of holes of the braided upper. When the plurality of studs of the midsole receive the plurality of holes of the braided upper, at least one of the plurality of holes surrounds at least one of the plurality of protruding studs to provide a 360-degree containment. In addition, each of the plurality of studs comprises at least one ground contact outer surface, which extends below the bottom surface of the braided upper. The at least one ground-engaging outer surface comprises an incompressible material that maintains a primary configuration when grounded.In addition, the plurality of protruding spikes of the midsole may constitute all or a portion of the midsole.

[0034] In some aspects, the mechanical locking sole structure may include an interlocking midsole having one or more surface features keyed to the sole portion of the braided upper. For example, the midsole may include a plurality of protruding spikes along the bottom surface of the midsole. In other aspects, the midsole material may include various materials that provide cushioning, such as polyurethane foam, compression molded EVA, leather, or polyurethane.

[0035] In one aspect, uniform size, spacing, height and / or size can be associated with a plurality of prominent spikes on the midsole. In other aspects, depending on the type of footwear, a plurality of prominent spikes can change in size, spacing, height, size, position and / or configuration on the midsole. For example, in some sports shoes, a plurality of prominent spikes can be positioned with a specific pattern to help directional movement when wearing, and can be composed of one or more shapes. A plurality of holes in the braided upper structure are keyed to match a plurality of prominent spikes, and can correspond to the periphery of a specific prominent spike. For example, a hexagonal prominent spike extending from the bottom surface of the midsole can correspond to a hexagonal hole in the braided structure.

[0036] In one aspect, the midsole can be pre-molded with a plurality of prominent spikes before a plurality of prominent spikes are received by a plurality of holes of the braided upper. In other aspects, the midsole includes a co-molded midsole associated with the braided upper during the three-dimensional assembly process, wherein the co-molded midsole includes a flexible joining (flexible joining) with the braided upper. In another aspect, the braided footwear article includes a sprayed outsole. The sprayed outsole includes a spray component, which is applied to a plurality of spikes extending below the bottom surface of the braided upper and the bottom surface of the braided upper. In this respect, after the midsole and the bottom surface of the braided upper are "locked" together, the outsole is sprayed on the bottom surface of a plurality of spikes and the braided upper. The applied spray component can for example include a sprayed polyurethane, which provides an additional covering to the footwear article, and strengthens the flexible joining of the midsole and the braided upper.

[0037] In yet another aspect, the braided upper includes a tubular braided structure and a plurality of holes, and the midsole includes a flat surface including a plurality of braid receiving features that fit into the plurality of holes. The braided upper and midsole are secured together based on the plurality of holes being coupled to the plurality of braid receiving features. In some aspects, an outsole may also be coupled to the braided upper and midsole.

[0038] In yet another aspect, a braided article of footwear includes a braided upper and a midsole. The braided upper includes a tubular braided structure and a plurality of holes. When secured together, the plurality of holes are keyed to surround a plurality of protruding spikes of the midsole to provide 360-degree restraint of the protruding spikes.

[0039] As stated above, the braided structure can be formed into a tubular braid on a braiding machine, such as a radial braiding machine, an axial braiding machine, or a lace braiding machine. An example of a lace braiding machine can be found in EP 1 486 601 entitled "Torchon Lace Machine" issued on May 9, 2007 to Ichikawa and EP No. 2 657 384 entitled "Torchon Lace Machine" issued on October 30, 2013, the entire contents of which are hereby incorporated by reference. Figure 11 shows an upper portion of an exemplary braiding machine 10. The braiding machine 10 includes a plurality of spools 12. In some aspects, the spools 12 carry yarns 14 selected for braiding. The yarns 14 from the individual spools 12 are selectively intertwined or entangled with each other by the braiding machine 10. This intertwining or entanglement of the strands forms a braided structure 16, as further described below. Each of the spools 12 is supported and constrained by a track 18 around the perimeter of the braiding machine 10. Each spool 12 has a tensioner 20 (at Figure 1 2 ), the tensioner 20 operates with the roller 22 to maintain the desired tension in the yarns 14 and the braided structure 16. As the yarns 14 extend upward, they pass through a braiding loop 24, which is generally considered a braiding point. The braiding point is defined as the point or area where the yarns 14 merge to form the braided structure 16. At or near the loop 24, the distance between the yarns 14 from different spools 12 is reduced. As the distance between the yarns 14 decreases, the yarns 14 are intertwined or braided with each other in a tighter manner and are pulled linearly by the roller 22.

[0040] like Figure 2 and Figure 3 As best seen in the drawings, each bobbin 12 is carried and supported by a carriage 26. Each bobbin 12 is movable around the periphery of the track 18 by a rotor metal piece 28. As described for the Torchon Lace Machine previously referenced and disclosed in EP 1 486 601, each of the rotor metal pieces 28 can be moved clockwise or counterclockwise. In contrast to radial braiding machines or completely non-jacquard machines, in a lace braiding machine, each rotor metal piece is not intertwined with an adjacent rotor metal piece. Instead, each rotor metal piece 28 can be selectively independently movable. As shown by comparison Figure 3 and Figure 4As can be seen, as the rotor metal part 28 rotates, the rotor metal part 28 moves the carriage 26, and thereby moves the bobbin 12 around the periphery of the track 18 by making the bobbin 12 supported on the carriage 26 move. The braiding machine 10 is programmable so that the independent rotor metal part 28 rotates the carriage 26, and therefore rotates the bobbin 12, so that the bobbin 12 moves around the periphery of the track 18. When the independent bobbin 12 moves relative to the adjacent bobbin 12, the yarn 14 carried on the bobbin 12 is interwoven to produce the desired braiding pattern. The movement of the bobbin 12 can be pre-programmed to form a part of a specific shape, design and line density or a braiding component of the braiding component. By changing the rotation and position of the independent bobbin 12, various braiding patterns can be formed. Such an exemplary braiding machine can form a complicated braiding pattern, including a braiding pattern or geometric shapes of jacquard and non-jacquard. Such a configuration and geometric shape provide a design possibility that transcends the design possibility provided by other textiles such as knitted fabrics.

[0041] In some aspects, the size of the braiding machine 10 can vary. It should be understood that the braiding machine 10 shown and described is for illustrative purposes only. In some aspects, the braiding machine 10 can receive 144 carriages, but braiding machines of other sizes carrying different numbers of carriages and spools are possible and within the scope of the present disclosure. By changing the number of carriages and spools in the braiding machine, the density of the braided structure and the size of the braided components can be changed.

[0042] Now go to Figure 5-10 , aspects of the mechanical locking sole structure of the knitted article of footwear include a knitted upper 104 ( Figure 6 ) and midsole 100( Figure 5 ), which are coupled together to form a knitted article of footwear 126 ( Figure 7 ).like Figure 5 As seen in FIG. 1 , midsole 100 includes a plurality of spaced apart protruding spikes 102 extending from bottom surface 101 of midsole 100. Depending on the article of footwear, spikes 102 may vary in position, spacing, shape, height, and width. For example, as shown in FIG. Figure 5 As shown in the figure, the protruding spikes 102 have a generally part-spherical shape extending from the bottom surface 101. However, in alternative aspects such as soccer cleats, the geometry of the protruding spikes 102 on the midsole 100 can alternatively be tapered to facilitate multi-directional movement. In addition, the midsole 100 can include protruding spikes 102 of more than one geometry. For example, the bottom surface 101 of the midsole 100 for a soccer cleat can include protruding spikes 102 of a cone, a chevron (inverted V-shape), and other geometric shapes.

[0043] Depending on the location of the spike, the shape of the spike, and the type of footwear, protruding spikes 102 extend a certain distance 103 below midsole 100. In some aspects, each protruding spike 102 has at least one ground-engaging outer surface 132. It is also contemplated that protruding spikes 102 may cover all or a portion of bottom surface 101 of midsole 100. Figure 5 In some embodiments, protruding spikes 102 are evenly positioned across bottom surface 101 of midsole 100. However, protruding spikes 102 may be positioned in any position or configuration across all or a portion of bottom surface 101 of midsole 100. In some aspects, protruding spikes 102 are pre-molded or co-molded with midsole 100.

[0044] Figure 6 A side perspective view of a knitted upper 104 of a knitted article of footwear 126 is depicted. The knitted upper 104 includes a tubular knitted structure 114 having an ankle opening 112, a toe end 108 opposite a heel end 110, an interior cavity 116, and a bottom surface 118. The tubular knitted structure 114 has a knit pattern in at least one area defining a plurality of apertures 106 that correspond in position, size, and shape to the bottom surface 118 of the footwear. Figure 5 The protruding spike-like members 102 of the midsole 100 are depicted in FIG.

[0045] The tubular braided structure 114 is an integral braided structure when formed as a one-piece element by a braiding process that forms various features and structures of the braided component without requiring a large number of additional manufacturing steps or manufacturing processes. The density and composition of the braiding of the braided upper 104 can vary from the top portion 120 of the braided upper 104 to the bottom surface 118 of the braided upper 104, which produces a zonal braiding, wherein the density of the braiding varies in different areas of the braided upper or varies from zone to zone. Figure 6 The braided upper 104 depicted in FIG. 1 is merely one example of a braided pattern. However, it is contemplated that the braided upper may include a variety of braided patterns based on the type of footwear. For example, in Figure 6 , the braid pattern includes a dense braid on the top portion of the braided upper at 120. The braid then transitions to a slightly wider braid 122 on the sides of the braided upper, and further transitions to an even wider braid 124 on the bottom surface 118 of the braided upper 104, where a plurality of holes 106 are located. Although the density of the braid may vary in different areas of the braided upper, the braided upper 104 is as follows: Figure 6A continuous braided tubular structure 114 is depicted in FIG. The varying density of the tubular braided structure 114 can be designed to provide appropriate levels of structural stability, support, durability, and comfort.

[0046] Figure 7 and Figure 8 The combination of midsole 100 and knitted upper 104 is shown to form a knitted article of footwear 126. Figure 7-10 As shown in Figure 5 The midsole 100 is made of Figure 6 In this case, the spikes 102 of the midsole 100 extend through the defined holes 106 of the knitted upper 104. When the midsole 100 is engaged with the knitted upper 104, the yarns of the knitted pattern defining the holes 106 provide 360-degree restraint around the corresponding protruding spikes 102, such as Fig.10 This constraint “locks” the knitted upper 104 into the midsole 100.

[0047] Figure 8 Pictured Figure 7 A bottom perspective view of a knitted article of footwear 126. Figure 8 As seen in FIG. 1 , in some aspects, the knitted upper 104 has a tighter, more dense knitting pattern at 122 and a less dense knitting pattern at 124. The wider knitting present at the bottom surface 118 of the knitted upper 104 at least partially creates the apertures 106 through which the protruding spikes 102 extend to provide 360 ​​degree restraint.

[0048] Fig.9A A rear view of knitted article of footwear 126 at heel end 110 is depicted. Fig. 9B yes Fig.9A , showing the midsole 100 and the protruding spikes 102 extending through the bottom surface 118 of the knitted upper 104. Fig.9A and Fig. 9B , in some aspects, at least a portion of the knitted upper 104 defined by the apertures 106 abuts the perimeter of each of the plurality of protruding spikes 102, as seen at 140 and 146. The relationship between the apertures 106 of the knitted upper 104 and the protruding spikes 102 of the midsole 100 is also shown in FIG. Fig.10 is shown in an enlarged view.

[0049] Figures 11A-11BAdditional aspects are illustrated in which outsole 200 is applied to bottom surface 118 of knitted upper 104 and protruding spikes 102 of midsole 100. In one aspect, outsole 200 includes component 150, which is applied to both protruding spikes 102 extending below bottom surface 118 of knitted upper 104 and bottom surface 118 of knitted upper 104. In an exemplary aspect, component 150 can be applied as a spray. As described above, component 150 can include a polyurethane material or any other suitable component for an outsole. Fig. 11B yes Fig.11A , and depicts outsole 200 having been applied to both protruding spikes 102 extending from bottom surface 101 of midsole 100 and bottom surface 118 of knitted upper 104.

[0050] Figures 12A-14B Additional aspects of a mechanical locking sole structure of a knitted article of footwear are illustrated. Fig. 12A A side perspective view of a knitted article of footwear 300 is illustrated, shown without an outsole. In this configuration, a knitted upper 302 includes a tubular knitted structure 304 that defines a plurality of holes 306. For clarity, the knitting pattern of the knitted upper 302 is schematically illustrated. It should be understood that any number of knitting patterns may be used. At least a portion of the knitted upper 302 has a knitting pattern that defines holes 306. The holes 306 are illustrated as being generally diamond-shaped, but may be any of a number of other shapes. The knitted upper 302 may be knitted in a manner similar to that of a conventional knitted upper. Fig. 12A is shown as being engaged with the midsole 320, which will be referred to as Fig. 12B Further description. Fig. 12B As best seen in FIG. 3 , midsole 320 extends from top 305 to bottom surface 307, with top 305 and bottom surface 307 separated from each other by sidewall 309. Midsole 320 includes a plurality of spaced-apart braid receiving features 312. In one aspect, braid receiving features 312 are formed as grooves extending into midsole 320. Fig. 12A and Fig. 12B As shown in FIG. 3 , the braid receiving feature 312 may be formed on the bottom surface 307 as well as the sidewall 309 .

[0051] Fig.13 Picture shows Fig. 12A A bottom view of a knitted article of footwear. Fig. 12A and Fig.13306 of the knitted upper 302 are positioned to correspond with the knitted receiving features 312 on the midsole 320. When the midsole 320 is placed within the knitted upper 302, the knitted receiving features 312 receive the yarns of the knitted upper 302 in at least some locations such that the holes 306 cooperate with the knitted receiving features 312. In this configuration, the knitted upper 302 is keyed into the midsole 320.

[0052] Fig. 14B Picture shows Fig.13 The cross-section of the braided upper 302 extends around the midsole 320. In addition, portions of the braided upper 302, namely the braided structure around the hole 306, fit within at least some of the braided receiving features 312. This may include, for example, the braided receiving features 312 on the bottom surface 307 or on the sidewall 309 or both. Fig. 14B Also depicted is outsole 322 , which in some aspects can be coupled to combined knitted upper 302 and midsole 320 . Fig.14A Picture shows Fig. 14B structure, wherein the outsole 322 is connected to the midsole 320 and the knitted upper 302.

[0053] Figure 15-16 Another aspect of the mechanical lock structure of the knitted article of footwear 406 is shown. Figures 12A-14B As in the discussed aspects, the knitted article of footwear 406 includes a knitted upper 400 and a midsole 402. In this aspect, the midsole 402 has a plurality of protruding spikes 404 that are similar to those of the reference numerals. Figure 5-10 The spikes in question are somewhat similar. Fig.15 A side view of a knitted article of footwear 406 is depicted. Knitted upper 400 includes a tubular knitted structure 408 that receives a midsole 402 and corresponding spikes 404. Figures 12A-14B Likewise, knitted upper 400 may be knitted with apertures 403 that interact with knitted receiving features 405 .

[0054] Fig.16 Picture shows Fig.154. The bottom surface 410 of the braided shoe upper 400 has a braided design, which is configured to engage the protruding nail-shaped member 404 to provide a 360-degree constraint. For example, the yarns 412, 414, 416, 418 and 420 on the bottom surface 410 of the braided shoe upper 400 are configured to surround the protruding nail-shaped member 422 and provide a 360-degree constraint of the protruding nail-shaped member 422. In this aspect, the depicted multiple protruding nail-shaped members 404 are herringbone-shaped and are configured for the illustrated footwear type with a specific pattern. However, the multiple protruding nail-shaped members 404 can vary in shape and height, wherein each protruding nail-shaped member 404 maintains a ground contact surface.

[0055] From the foregoing, it will be seen that the present invention is well adapted to attain all of the ends and purposes set forth above, together with other advantages which are obvious and inherent to the structure. It will be appreciated that certain features and subcombinations are of utility and may be employed without reference to other features and subcombinations. This is encompassed by and within the scope of the claims.

[0056] Although specific elements are discussed in conjunction with each other, it should be understood that any element provided herein is contemplated to be combinable with any other element, whether or not the element is explicitly provided, while still being within the scope provided herein. Since many possible aspects can be formed from the present disclosure without departing from the scope of the present disclosure, it should be understood that all content stated herein or shown in the drawings is to be interpreted as illustrative and non-limiting.

[0057] This application also involves the following:

[0058] 1) A footwear article including a braided structure, comprising: a braided upper, the braided upper comprising a tubular braided structure having an inner surface and an outer surface, wherein a plurality of holes extend from the inner surface to the outer surface; and a midsole, the midsole comprising a toe tip portion opposite to a heel end portion and a top flat surface opposite to a bottom flat surface, and a plurality of protruding spike-like members, the bottom flat surface being adjacent to the inner surface of the braided upper, the plurality of protruding spike-like members extending below the bottom flat surface on at least a portion of the midsole, wherein at least one of the plurality of holes surrounds at least one of the plurality of protruding spike-like members on the bottom flat surface to securely position the midsole relative to the braided upper, and further, wherein each of the plurality of protruding spike-like members comprises at least one ground-contacting outer surface, the at least one ground-contacting outer surface extending below the outer surface of the braided upper via the plurality of holes.

[0059] 2) The article of footwear of 1), wherein the at least a portion of the midsole is pre-molded with the plurality of protruding spikes before the plurality of protruding spikes are received by the plurality of holes of the knitted upper.

[0060] 3) The article of footwear as described in 1), wherein the plurality of protruding spike-like members extending below the bottom flat surface are positioned on one or more of the toe end of the bottom of the midsole, the heel end of the bottom of the midsole, and are evenly spaced across the entire bottom flat surface of the midsole.

[0061] 4) The article of footwear of 1), wherein the midsole comprises a co-molded midsole associated with the knitted upper during three-dimensional assembly of the article of footwear, wherein the co-molded midsole comprises a flexible connection to the knitted upper.

[0062] 5) An article of footwear as described in 1), wherein the plurality of protruding nail-like members are keyed so that at least a portion of each of the plurality of protruding nail-like members intersects with the knitted upper at a corresponding hole proximate to a horizontal plane of the knitted upper, wherein each corresponding hole surrounds each intersecting, protruding nail-like member.

[0063] 6) The article of footwear as described in 1) further includes a sprayed outsole, wherein the sprayed outsole includes a spray component, and the spray component is applied to both the plurality of protruding spikes extending below the bottom flat surface and the bottom surface of the knitted upper.

[0064] 7) The article of footwear as described in 1), wherein the midsole includes one or more of a rubber material and an ethylene vinyl acetate (EVA) material.

[0065] 8) The article of footwear as described in 1), wherein the knitted upper is formed from one or more of nylon, carbon, polyurethane, polyester, cotton, aramid, polyethylene and polypropylene fibers.

[0066] 9) The article of footwear of 1), wherein the at least one ground-contacting outer surface comprises an incompressible material that maintains a primary configuration when grounded.

[0067] 10) The article of footwear of 1), wherein providing 360 degree restraint includes at least a portion of the tubular braided structure abutting a perimeter of each of the plurality of protruding spikes.

[0068] 11) The article of footwear of 1), wherein the plurality of protruding spikes comprise at least one of a uniform shape, a uniform height, and a uniform width.

[0069] 12) An interlocking braided upper and midsole system, comprising: a midsole insert, the midsole insert including a top flat surface opposite to the bottom flat surface, and a plurality of protruding spikes extending below the bottom flat surface on at least a portion of the midsole insert, the midsole insert having a perimeter corresponding to the bottom of the shoe; and a braided upper, the braided upper having an ankle opening opposite to the toe portion, a tubular braided structure with an inner cavity, an inner surface and an outer surface, and a first area having a first braiding density including a plurality of holes and a second area having a second braiding density including a plurality of holes, wherein the plurality of holes of the first braiding density and the plurality of holes of the second braiding density correspond to the plurality of protruding spikes, so that the plurality of protruding spikes extend below the outer surface of the braided upper through the plurality of holes of the first braiding density and the plurality of holes of the second braiding density, thereby connecting the bottom flat surface of the midsole insert to the braided upper and providing a grounded external sole.

[0070] 13) The system of 12) wherein said plurality of protruding spikes are positioned within said perimeter of said midsole insert in one or more configurations.

[0071] 14) The system of 12) wherein the interior cavity surrounds at least a portion of the midsole insert.

[0072] 15) The system of 14) wherein said interior cavity includes said plurality of holes contacting at least a portion of said bottom planar surface of said midsole insert.

[0073] 16) The system of 12) wherein each of said plurality of protruding spikes extends a threshold distance below said bottom planar surface of said midsole insert.

[0074] 17) The system of 12), wherein the first braiding density and the second braiding density are composed of yarns of at least one or more materials.

[0075] 18) A braided footwear article, comprising: a braided upper, the braided upper including a tubular braided structure and a plurality of holes in a sole portion proximate to the braided upper, wherein at least a portion of the tubular braided structure surrounds a perimeter of each of the plurality of holes; and a midsole, the midsole having a perimeter corresponding to the sole portion of the braided upper, wherein the midsole includes a flat surface, the flat surface including a plurality of braided receiving features on at least a portion of the flat surface, the plurality of braided receiving features being positioned to cooperate with the plurality of holes, wherein when the plurality of holes cooperate with the plurality of braided receiving features, the braided upper and the midsole are positioned relative to each other.

[0076] 19) The knitted article of footwear as described in 18), further comprising an external sole connected to the knitted upper and the midsole.

[0077] 20) The knitted article of footwear as described in 19), wherein at least a portion of the outer sole includes a ground-contacting surface.

[0078] 21) A knitted footwear article as described in 18), wherein the sole portion of the knitted upper is fixed between the midsole and the external sole, and the foot portion of the knitted upper extends along the perimeter of the sole portion and across the top portion of the knitted footwear article to form the tubular knitted structure.

[0079] 22) The knitted article of footwear of 18), wherein at least a portion of one or more of the midsole and the knitted upper includes at least one ground-contacting surface.

[0080] 23) The knitted article of footwear of 18) wherein the knit receiving feature is configured to couple to at least a portion of the tubular knit structure surrounding the perimeter of each of the plurality of apertures.

Claims

1. An article of footwear comprising a knitted structure, comprising: a braided upper, the braided upper comprising a tubular braided structure having an ankle opening, a toe end, a heel end opposite the toe end, an interior cavity, a bottom surface, and a braided pattern defining a plurality of apertures, the plurality of apertures being positioned on the bottom surface of the braided upper, wherein at least a portion of the tubular braided structure is braided around a perimeter of each of the plurality of apertures, the braided upper having an inner surface and an outer surface, wherein the plurality of apertures extend from the inner surface to the outer surface; as well as a midsole comprising a toe tip portion opposite the heel end and a top planar surface opposite the bottom planar surface and a plurality of protruding spikes, the bottom planar surface abutting the inner surface of the knitted upper, the plurality of protruding spikes extending below the bottom planar surface over at least a portion of the midsole and having more than one geometric shape, wherein at least one of the plurality of holes surrounds at least one of the plurality of protruding spikes on the bottom planar surface to securely position the midsole relative to the knitted upper, the plurality of holes having shapes corresponding to the geometric shapes of the plurality of protruding spikes so that the plurality of holes are keyed to mate with the plurality of protruding spikes, wherein the plurality of holes correspond in position, size and shape to the plurality of protruding spikes, and further wherein each of the plurality of protruding spikes comprises at least one ground-engaging outer surface extending below the outer surface of the knitted upper via the plurality of holes, wherein different areas of the knitted upper have varying knitting densities, The braided structure of the braided upper includes a wider braided portion on the bottom surface of the braided upper, wherein the plurality of holes are located at the wider braided portion, and the protruding spikes extend through the wider braided portion.

2. The article of footwear according to claim 1, wherein the at least a portion of the midsole is pre-molded with the plurality of protruding spikes before the plurality of protruding spikes are received by the plurality of holes of the knitted upper.

3. The article of footwear according to claim 1, wherein the plurality of protruding spike-like members extending below the bottom flat surface are positioned on one or more of the toe end of the bottom of the midsole, the heel end of the bottom of the midsole, and are evenly spaced across the entire bottom flat surface of the midsole.

4. The article of footwear according to claim 1, wherein the midsole comprises a co-molded midsole associated with the knitted upper during three-dimensional assembly of the article of footwear, wherein the co-molded midsole includes a flexible connection to the knitted upper.

5. The article of footwear according to claim 1, wherein the plurality of protruding spikes are keyed such that at least a portion of each of the plurality of protruding spikes intersects the knitted upper at a corresponding hole proximate to a horizontal plane of the knitted upper, wherein each corresponding hole surrounds each intersecting, protruding spike.

6. The article of footwear according to claim 1, further comprising a painted outsole, the painted outsole comprising a painted component applied to both the plurality of protruding spikes extending below the bottom planar surface and the bottom surface of the knitted upper.

7. The article of footwear according to claim 1, wherein the midsole comprises one or more of a rubber material and an ethylene vinyl acetate (EVA) material.

8. The article of footwear according to claim 1, wherein the knitted upper is formed from one or more of nylon, carbon, polyurethane, polyester, cotton, aramid, polyethylene, and polypropylene fibers.

9. The article of footwear according to claim 1, wherein the at least one ground-engaging exterior surface comprises an incompressible material that retains a primary configuration when grounded.

10. The article of footwear according to claim 1, wherein at least a portion of the tubular braided structure abuts a perimeter of each of the plurality of protruding spikes.

11. The article of footwear according to claim 1 , wherein the plurality of protruding spikes comprise at least one of a uniform height and a uniform width.

12. The article of footwear according to any one of claims 1-11, wherein the plurality of protruding spikes have one or more geometric shapes of a cone, a herringbone, and a generally partial spherical shape extending from the bottom planar surface.

13. An interlocking braided upper and midsole system comprising: a midsole insert including a top planar surface opposite a bottom planar surface, and a plurality of protruding spikes extending below the bottom planar surface on at least a portion of the midsole insert, the plurality of protruding spikes having more than one geometric shape, the midsole insert having a perimeter corresponding to a bottom portion of a shoe; as well as a braided upper having an ankle opening opposite a toe portion and a tubular braided structure having an inner cavity and a braiding pattern, the braiding pattern defining a plurality of holes, the plurality of holes being located on a bottom surface of the braided upper, the plurality of holes having a shape corresponding to a geometry of the plurality of protruding spikes so that the plurality of holes are keyed to fit the plurality of protruding spikes, wherein the plurality of holes correspond in position, size and shape to the plurality of protruding spikes, wherein at least a portion of the tubular braided structure is braided to surround a perimeter of each of the plurality of holes, the braided upper also having an inner surface and an outer surface, wherein the plurality of holes correspond to the plurality of protruding spikes so that the plurality of protruding spikes extend through the plurality of holes below the outer surface of the braided upper, thereby coupling the bottom flat surface of the midsole insert to the braided upper and providing an outer sole that is grounded, wherein different areas of the knitted upper have varying knitting densities, The braided structure of the braided upper includes a wider braided portion on the bottom surface of the braided upper, wherein the plurality of holes are located at the wider braided portion, and the protruding spikes extend through the wider braided portion.

14. The system of claim 13, wherein the plurality of protruding spikes are positioned within the perimeter of the midsole insert in one or more configurations.

15. The system of claim 13, wherein the interior cavity surrounds at least a portion of the midsole insert.

16. The system of claim 15, wherein the interior cavity includes the plurality of holes contacting at least a portion of the bottom planar surface of the midsole insert.

17. The system of claim 13, wherein each of the plurality of protruding spikes extends a threshold distance below the bottom planar surface of the midsole insert.

18. The system of any one of claims 13-17, wherein the plurality of protruding spikes have one or more geometric shapes of a cone, a chevron, and a generally partial spherical shape extending from the bottom planar surface.

19. A knitted article of footwear comprising: a braided upper, the braided upper comprising a tubular braided structure having an inner surface, an outer surface, and a braiding pattern, the braiding pattern defining a plurality of apertures proximate a sole portion of the braided upper, the plurality of apertures having more than one shape, wherein at least a portion of the tubular braided structure is braided around a perimeter of each of the plurality of apertures; as well as a midsole having a perimeter corresponding to the sole portion of the knitted upper, wherein the midsole includes a planar surface including a plurality of knit receiving features on at least a portion of the planar surface, the plurality of knit receiving features being positioned to cooperate with the plurality of holes to key to the knitted upper, wherein the midsole has a plurality of protruding spikes, wherein a bottom surface of the knitted upper has a knitting pattern configured to engage the protruding spikes, wherein different areas of the knitted upper have varying knitting densities, The braided structure of the braided upper includes a wider braided portion on the bottom surface of the braided upper, wherein the plurality of holes are located at the wider braided portion, and the protruding spikes extend through the wider braided portion.

20. The knitted article of footwear according to claim 19, further comprising an external sole coupled to the knitted upper and the midsole.

21. The knitted article of footwear according to claim 20, wherein at least a portion of the outer sole includes a ground-engaging surface.

22. A knitted footwear article according to claim 19, wherein the sole portion of the knitted upper is secured between the midsole and the external sole, and a foot portion of the knitted upper extends along the perimeter of the sole portion and across a top portion of the knitted footwear article to form the tubular knitted structure.

23. The knitted article of footwear according to claim 19, wherein at least a portion of one or more of the midsole and the knitted upper includes at least one ground-contacting surface.

24. The knitted article of footwear according to claim 19, wherein the knit receiving feature is configured to couple to at least a portion of the tubular knit structure surrounding the perimeter of each of the plurality of apertures.

25. The knitted article of footwear according to claim 19, wherein the knit receiving feature is formed as a groove extending into the midsole.

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