BRAIDED UPPER FOR FOOTWEAR WITH FINISHED HEEL AXIS
A system for forming a braided footwear upper is provided. The upper has a medial side and a lateral side, and a toe end and a heel end. The braided footwear is made from a number of yarns that are braided together. The heel-axis finishing system includes an alignment mechanism that orients the medial side and the lateral side at the heel end. The lateral side and the medial side come together at the heel to form a heel axis. A joining mechanism is associated with the alignment mechanism. The joining mechanism couples at least one braided yarn from the medial side to at least one braided yarn from the lateral side along the heel axis. By joining the aligned yarns as they are severed, the heel area transitions from the medial side to the lateral side with an appearance of seamlessness.
This application is a non-provisional application which claims the benefit of U.S. Provisional Application 62/512,449 filed on May 30, 2017 and entitled Braided Upper for Footwear with Finished Heel Axis. The entirety of the aforementioned application is incorporated by reference herein.
TECHNICAL FIELDAspects herein relate to a braided structure that forms a footwear upper. In further aspects, a braided footwear upper is constructed on a circular braiding machine and finished to have a heel axis with a closed seam that appears to be continuously braided.
BACKGROUNDTraditional shoes are often made from textiles or materials that have uppers that are cut to a desired shape and stitched together. Newer methods also now include forming shoe uppers from a knitted textile. Still newer methods involve braiding a tubular textile for use as the shoe upper. Aspects herein relate to braiding tubular structures that in some aspects are used in articles of footwear.
BRIEF SUMMARYThis Summary provides a high-level overview of the disclosure and introduces a selection of concepts that are further described in the Detailed Description below. 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 isolation to determine the scope of the claimed subject matter.
Aspects herein generally relate to a system for forming a braided footwear upper having at least a medial side and a lateral side, and a toe end and a heel end. The braided footwear is made from a number of yarns that are braided together. The heel axis finishing system includes an alignment mechanism that orients the medial side of the upper and the lateral side of the braided upper at the heel end. The lateral side and the medial side come together at the heel and form a heel axis. A joining mechanism is associated with the alignment mechanism. The joining mechanism couples at least one braided yarn from the medial side to at least one braided yarn from the lateral side along the heel axis. In some aspects, the alignment mechanism includes a jig that aligns the medial side and the lateral side at the heel axis. In some aspects, the joining mechanism is a sonic welding apparatus that severs and joins the yarns along the heel axis to present a finished seam. By joining the yarns as they are severed, when they are properly aligned, the heel area transitions from the medial side to the lateral side with an appearance of seamlessness.
In one aspect, an article of footwear is provided that has a unitary, braided upper. The upper has a medial side, a lateral side, a toe end, and a heel end opposite the toe end. The braided upper has a joined heel axis along a joinder line where the lateral side and the medial side meet at the heel end. The joinder line forms a heel axis that, in one aspect, has at least one braided yarn from the medial side coupled to at least one braided yarn from the lateral side. In some aspects, the heel axis presents a smooth and appealing transition from the medial side to the lateral side.
Aspects herein are described in detail below with reference to the attached drawing figures, wherein:
Aspects herein provide a system for forming a braided footwear upper having at least a medial side and a lateral side, and a toe end and a heel end. The braided footwear is made from a number of yarns that are braided together. The heel axis finishing system includes an alignment mechanism that orients the medial side of the upper and the lateral side of the braided upper at the heel end. The lateral side and the medial side come together at the heel and form a heel axis. A joining mechanism is associated with the alignment mechanism. The joining mechanism couples at least one braided yarn from the medial side to at least one braided yarn from the lateral side along the heel axis. In some aspects, the alignment mechanism includes a jig that aligns the medial side and the lateral side at the heel axis. In some aspects, the joining mechanism is a sonic welding apparatus that severs and fuses the yarns along the heel axis to present a finished seam. By fusing the yarns as they are severed, when they are properly aligned, the heel area transitions from the medial side to the lateral side with an appearance of seamlessness.
In one aspect, an article of footwear is provided that has a unitary, braided upper. The upper has a medial side, a lateral side, a toe end, and a heel end opposite the toe end. The braided upper has a joined heel axis along a joinder line where the lateral side and the medial side meet at the heel end. The joinder line forms a heel axis that, in one aspect, has at least one braided yarn from the medial side coupled to at least one braided yarn from the lateral side. In some aspects, the heel axis presents a transition from the medial side to the lateral side.
Braiding is a process of interlacing or interweaving three or more yarns diagonally to a product axis in order to obtain a thicker, wider, or stronger product or in order to cover (overbraid) some profile. Interlacing diagonally means that the yarns make an angle with the product axis, which can be between 1° and 89° but is 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, two, or three-dimensional textiles) with constant or variable cross-sections, and of closed or open appearance.
As used herein, the yarns used for braiding may be formed of different materials having different properties. The properties that a particular yarn will impart to an area of a braided component partially depend upon the materials that form the yarn. Cotton, for example, provides a softer product, natural aesthetics, and biodegradability. Elastane and stretch polyester each provide substantial stretch and recovery, with stretch polyester also providing recyclability. Rayon provides high luster and moisture absorption. Wool also provides high moisture absorption, in addition to insulating properties and biodegradability. Nylon is a durable and abrasion-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 formation of a braided component may affect the properties of the braided component. For example, a yarn may be a monofilament or a multifilament. The yarn may also include separate filaments that are each formed of different materials. In addition, the yarn may include filaments that are each formed of two or more different materials, such as a bicomponent yarn with filaments having a sheath-core configuration or two halves formed of different materials.
As stated above, braided structures can be formed as tubular braids on a braiding machine, such as a radial, axial, or lace braiding machine. One example of a lace braiding machine can be found in Ichikawa, EP 1 486 601, granted May 9, 2007, entitled “Torchon Lace Machine,” and EP No. 2 657 384, published Oct. 30, 2013, entitled “Torchon Lace Machine,” the entireties of which are hereby incorporated by reference. The upper portion of an exemplary braiding machine 10 is shown in
As best seen in
In some aspects, the size of braiding machine 10 may be varied. It should be understood that the braiding machine 10 shown and described is for illustrative purposes only. In some aspects, braiding machine 10 may be able to accept 144 carriages, although other sizes of braiding machines, carrying different numbers of carriages and spools, is possible and is within the scope of this disclosure. By varying the number of carriages and spools within a braiding machine, the density of the braided structure as well as the size of the braided component may be altered.
Turning now to
With continued reference to
However, other orientations of the first plane of braiding 106 and second plane of braiding 108 are considered to be within the scope of this disclosure. For example, the first plane of braiding 106 may be placed in an X-Z orientation, while the second plane of braiding 108 may be placed in a Y-Z orientation or an X-Y orientation. Regardless of the exact planes of braiding selected, the important aspect of the planes of braiding is that the first plane of braiding 106 and the second plane of braiding 108 are perpendicular to each other, such that a “Mobius twist” is performed to rotate from the first plane of braiding 106 to the second plane of braiding 108. However, aspects in which the first plane of braiding 106 and the second plane of braiding 108 are not perpendicular are considered to be within the scope of this disclosure. For example, the first plane of braiding 106 and the second plane of braiding 108 may be offset 45 degrees from one another, or may be offset any other amount between 0 and 90 degrees from each other. Generally, the article of footwear will have the greatest resistance to stretch in a direction that aligns to the plane of braiding used to manufacture that portion of the article of footwear. In other words, the amount of “Mobius twist” performed changes the functional characteristics of the article of footwear created by the methods described herein.
In accordance with aspects herein, the “Mobius twist” is generally performed at a transition point 110 of the article of footwear, which generally refers to a point of the article of footwear in which the first plane of braiding 106 and second plane of braiding 108 intersect. In some aspects, the first plane of braiding 106 may transition to the second plane of braiding 108 instantaneously at the transition point 110. The transition point 110 may be located between 2 and 6 inches from the first end 102 of the article of footwear. However, in some aspects, the first plane of braiding 106 may gradually morph into the second plane of braiding 108. In this aspect, the transition point 110 may be more accurately referred to as a transition section 112, wherein the transition section 112 has a beginning transition point 114a and an ending transition point 114b. Similar to the transition point 110, the beginning transition point 114a may be located between 2 and 6 inches from the first end 102 of the article of footwear.
Thus far in this disclosure, the discussion with respect to
Turning now to
For example, the lead spool can be tracked from the first set of positions 210 as shown in
Turning now to
An exemplary article of footwear 100 is shown in
The article of footwear 100 of
A method 400 for manufacturing a braided upper for an article of footwear is shown in
From the foregoing, it will be seen that this invention is one well adapted to attain all the ends and objects hereinabove set forth together with other advantages which are obvious and which are inherent to the structure.
It will be understood that certain features and sub-combinations are of utility and may be employed without reference to other features and sub-combinations. This is contemplated by and is within the scope of the claims.
Since many possible embodiments may be made of the invention without departing from the scope thereof, it is to be understood that all matter herein set forth or shown in the accompanying drawings is to be interpreted as illustrative and not in a limiting sense.
Claims
1. A heel-axis finishing system for forming a braided footwear upper comprising:
- an alignment mechanism configured to orient a medial side of a braided upper with a lateral side of the braided upper at a heel end of the braided upper; and
- a joining mechanism associated with the alignment mechanism, said joining mechanism configured to couple a first braided yarn of the medial side to a first braided yarn of the lateral side along a heel axis.
2. The heel-axis finishing system of claim 1, wherein the joining mechanism is a sonic welder.
3. The heel-axis finishing system of claim 2, wherein the alignment mechanism comprises a base and a pair of back plates coupled to the base in spaced apart relation to define a slot.
4. The heel-axis finishing system of claim 3, wherein at least one of the pair of back plates is slidingly coupled to the base.
5. The heel-axis finishing system of claim 4, wherein both of the back plates are slidingly coupled to the base.
6. The heel-axis finishing system of claim 5, wherein the sonic welder comprises a sonic welding anvil housed within one of the pair of back plates, and a sonic welding horn housed within the other of the pair of back plates, the sonic anvil and sonic horn extending into the defined slot.
7. An upper for an article of footwear comprising:
- a braided upper comprising a unitary, braided structure having a lateral side opposite a medial side and a heel end opposite a toe end,
- wherein the braided upper comprises a joined heel axis between the lateral side and the medial side proximate the heel end of the braided upper, said joined heel axis comprising at least a first braided yarn of the lateral side coupled to at least a first braided yarn of the medial side at the joined heel axis.
8. The upper for an article of footwear of claim 7, wherein the joined heel axis presents a vertical transition seam from the lateral side to the medial side.
9. The upper for an article of footwear of claim 8, wherein the braided structure of the medial side and the braided structure of the lateral side are configured to mate with one another at the heel axis.
10. The upper for an article of footwear of claim 9, wherein the joined heel axis comprises yarns from the medial side sonically welded to yarns from the lateral side.
11. The upper for an article of footwear of claim 7, wherein the toe end presents a seam oriented orthogonally to the joined heel axis.
12. A method for forming a heel axis on a braided footwear upper, comprising:
- placing a braided upper on an alignment mechanism configured to orient a medial side of a braided upper with a lateral side of the braided upper at a heel end of the braided upper; and
- joining at least a first braided yarn of the medial side to a first braided yarn of the lateral side along a heel axis.
13. The method of forming a heel axis on a braided footwear upper of claim 12, wherein the joining step comprises activating a sonic welder along the heel axis.
14. The method of forming a heel axis on a braided footwear upper of claim 13, further comprising removing at least a portion of the braided upper along the heel axis.
15. The method of forming a heel axis on a braided footwear upper of claim 14, wherein the removing step includes activating a sonic welding apparatus along the length of the heel axis.
Type: Application
Filed: May 29, 2018
Publication Date: Dec 6, 2018
Inventors: Robert M. Bruce (Portland, OR), Eun Kyung Lee (Beaverton, OR), James Y. Yoo (Portland, OR), Chikao Ichikawa (Gunma), Michihiro Ichikawa (Gunma)
Application Number: 15/991,844