RECONFIGURABLE ARTICLE OF FOOTWEAR

An article of footwear includes a sole, an upper connected to the sole, and an insole positioned within a foot cavity. The upper includes an outer shell extending from the heel region to the forefoot region, the outer shell including an outer heel wall defining an upper perimeter. A bootie is positioned within the outer shell and extends from the heel region to the forefoot region. The bootie is free floating relative to the outer shell within the heel region. The booting includes an inner heel cup configured to be moved between an upright position and a folded position. A posterior wall of the inner heel cup extends above the upper perimeter of the outer heel wall when the inner heel cup is in the upright position. The posterior wall of the inner heel cup is laid against the insole when the inner heel cup is in the folded position.

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Description
CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority from U.S. Provisional Patent Application No. 63/409,034, filed Sep. 22, 2022, the entire contents of which are incorporated by reference herein.

FIELD

This document relates to the field of footwear, and particularly to convertible heel members for footwear.

BACKGROUND

Articles of performance footwear, such as training shoes, are designed to assist the wearer in achieving a high level of athletic performance while also offering both comfort and durability. To provide these features, performance footwear is typically constructed from a combination of materials and components that together provide stability, cushioning, support, breathability, moisture resistance, and/or abrasion-resistance characteristics. These articles of footwear, may be configured in any of numerous forms such as cross-training shoes, turf shoes, court shoes, running shoes, walking shoes, casual shoes, work shoes, etc. Comfort and adaptability are important design considerations for each of these footwear configurations, as users often use one article of footwear for multiple purposes. For example, running shoes may serve as a workout shoe at one time (e.g., during a training session), while also serving as a casual comfort shoe at another time (e.g., when the wearer is relaxing at home or during leisure activities).

In view of the foregoing, it would be advantageous to provide an article of footwear that is adaptable for multiple uses. It would be of further advantage for the footwear to provide both comfort and performance features for the user, such as improved stability, cushioning, and reduced weight. It would also be advantageous if the footwear could be manufactured relatively easily and at a reasonable cost.

SUMMARY

In accordance with at least one embodiment of the disclosure, there is provided an article of footwear including a sole structure with a footbed and an upper including an outer shell and an inner shell or bootie coupled to the sole. The outer shell has an outer heel wall oriented generally orthogonal to the footbed. The upper further includes an inner shell coupled to the sole structure, the inner shell including an inner heel wall generally aligned with the outer heel wall, wherein the inner heel wall is pivotable away from the outer heel wall from a first position, in which the inner heel wall is oriented generally parallel to the outer heel wall to a second position, in which the inner heel wall is oriented generally orthogonal to the outer heel wall.

The above-described features and advantages, as well as others, will become more readily apparent to those of ordinary skill in the art by reference to the following detailed description and accompanying drawings. While it would be desirable to provide an article of footwear that provides one or more of these or other advantageous features, the teachings disclosed herein extend to those embodiments which fall within the scope of the appended claims, regardless of whether they accomplish one or more of the above-mentioned advantages.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows a front-medial perspective view of an article of footwear with a convertible heel member, wherein a heel cup of the article of footwear is in an upright position;

FIG. 2 shows a medial side view of the article of footwear of FIG. 1;

FIG. 3 shows a lateral side view of the article of footwear of FIG. 1;

FIG. 4 shows a top view of the article of footwear of FIG. 1;

FIG. 5 shows an exploded front-lateral perspective view of the article of footwear of FIG. 1;

FIGS. 6A-6E illustrate the footwear of FIG. 1 with the outer shell and lacing system removed for clarity.

FIG. 7A shows a front-lateral perspective view of an outer shell and sole structure of the article of footwear of FIG. 1 in isolation from an inner bootie;

FIG. 7B shows a rear-medial perspective view of the outer shell and sole structure of FIG. 6;

FIG. 8 shows a front-medial perspective view of the article of footwear of FIG. 1, wherein a heel cup of the article of footwear is in a folded position;

FIG. 9 shows a medial side view of the article of footwear of FIG. 8;

FIG. 10 shows a lateral side view of the article of footwear of FIG. 8;

FIG. 11 shows a top view of the article of footwear of FIG. 8;

FIG. 12A shows a lateral side view of the article of footwear of FIG. 1 having an alternative embodiment of the outer shell;

FIG. 12B shows a lateral perspective view of the article of footwear of FIG. 1 with the outer shell removed for clarity; and

FIG. 12C shows a medial perspective view of the article of footwear of FIG. 1 with the outer shell removed for clarity.

 DESCRIPTION

In the following detailed description, reference is made to the accompanying figures which form a part hereof wherein like numerals designate like parts throughout, and in which is shown, by way of illustration, embodiments that may be practiced. It is to be understood that other embodiments may be utilized, and structural or logical changes may be made without departing from the scope of the present disclosure. Therefore, the following detailed description is not to be taken in a limiting sense, and the scope of embodiments is defined by the appended claims and their equivalents.

Aspects of the disclosure are disclosed in the accompanying description. Alternate embodiments of the present disclosure and their equivalents may be devised without parting from the spirit or scope of the present disclosure. It should be noted that any discussion herein regarding “one embodiment”, “an embodiment”, “an exemplary embodiment”, and the like indicate that the embodiment described may include a particular feature, structure, or characteristic, and that such particular feature, structure, or characteristic may not necessarily be included in every embodiment. In addition, references to the foregoing do not necessarily comprise a reference to the same embodiment. Finally, irrespective of whether it is explicitly described, one of ordinary skill in the art would readily appreciate that each of the particular features, structures, or characteristics of the given embodiments may be utilized in connection or combination with those of any other embodiment discussed herein.

Various operations may be described as multiple discrete actions or operations in turn, in a manner that is most helpful in understanding the claimed subject matter. However, the order of description should not be construed as to imply that these operations are necessarily order dependent. In particular, these operations may not be performed in the order of presentation. Operations described may be performed in a different order than the described embodiment. Various additional operations may be performed and/or described operations may be omitted in additional embodiments.

For the purposes of the present disclosure, the phrase “A and/or B” means (A), (B), or (A and B). For the purposes of the present disclosure, the phrase “A, B, and/or C” means (A), (B), (C), (A and B), (A and C), (B and C), or (A, B and C).

The terms “comprising,” “including,” “having,” and the like, as used with respect to embodiments of the present disclosure, are synonymous.

As used herein, an “article of footwear” refers to an article of apparel designed and configured to be worn on a user's foot. Examples of articles of footwear include, but are not limited to: athletic shoes such as basketball shoes, running shoes, walking shoes, and tennis shoes; athletic cleated or spiked shoes such as golf shoes, football cleats, soccer cleats, baseball cleats, lacrosse cleats, and track spikes; and boots such as hiking boots. The illustrated embodiments depict athletic shoes, though the reader should appreciate that the embodiments described herein may be used with any desired article of footwear.

It will be recognized that although the article of footwear may be placed in any number of orientations during times of use and non-use by a wearer, terms of position used herein in association with the article of footwear are defined with reference to the sole of the article of footwear being positioned on level ground of the earth. Accordingly, “vertical” references a direction that is generally perpendicular to the sole, and “horizontal” references a direction that his generally parallel to the sole. Similarly, the term “above” references a relative position where one component is vertically higher than another component, and “below” references a relative position where one component is vertically lower than another component.

As shown in the figures, an article of footwear is disclosed herein in the form of an athletic shoe 10, and particularly a training shoe. The shoe includes an upper 20 connected to a sole structure 12. The sole structure 12 and the upper 20 together form a foot cavity 22 that is configured to receive the foot of a human wearer. The upper 20 is a two-part upper including an outer shell 30 and an inner bootie 50. Both the outer shell and the inner bootie extend from a heel region to a midfoot and/or forefoot region of the shoe. The inner bootie 50 is substantially free-floating relative to the outer shell 30 with the exception of connections made between the bootie 50 and the shell 30 along the sole structure 12 and the instep. As explained in detail herein, the inner bootie 50 includes a heel cup that is reconfigurable/moveable between an upright position/configuration (e.g., see FIGS. 1-4; which may also be referred to as an “upright configuration”) and a folded position/configuration (e.g., see FIGS. 8-11; which may also be referred to as a “folded configuration”). A lacing arrangement 100 is included on the shoe 10 to assist in stabilizing and supporting the foot of the wearer when the heel cup in either the upright position or the folded position. Further details and description of these and other components of the shoe 10 are provided in the following paragraphs.

Sole Structure

With reference to FIGS. 1-5, the sole structure 12 of the shoe 10 is a durable, wear-resistant component configured to attenuate forces under load by cushioning and stabilizing the foot during use, and by providing cushioning as the article footwear 10 impacts the ground. The sole structure 12 of the shoe 10 (which may also be referred to as simply the “sole”) may be similar to any of various conventional sole structures known to those of skill in the art. In the disclosed embodiment, the sole 12 includes an integrated midsole and outsole provided by a unitary/monolithic structure. However, in other embodiments, the sole structure 12 may include a midsole with a distinguished outsole.

As best illustrated in FIG. 5, the sole structure 12 includes a first, upper- or foot-facing side 14 (which may also be referred to as a “top side”) and a second, ground-facing side 16 (which may also be referred to as a “bottom side”). The top side 14 may possess a generally smooth and planum surface 28 that is surrounded by a gently curved rim or perimeter wall that defines an upper perimeter 26 for the sole structure 12. An insole 24 is configured to rest on the planum surface 28 along the top side 14 of the sole structure 12. As shown in FIG. 5, because the upper perimeter 26 of the sole structure 12 extends above the planum surface 28, it will be recognized that the top side 14 of the sole structure 12 defines a recess and the foot cavity 22 extends into the recess.

In an embodiment, as noted by the axis 23 in FIG. 5, the inner perimeter wall of the sole structure 12 is pitched slightly forward in the heel region of the foot cavity 22. Because of this forward pitch, the axis 23 is not 90° relative to horizontal, and is instead arranged at an acute angle, Θ, relative to horizontal (e.g., of 60°<Θ<85°). This forward pitch on the interior heel wall results in an additional cupping structure for foot cavity 22 that serves to hold the heel of the wearer in place within the foot cavity (note that this cupping structure is also represented in FIG. 9 by the dotted-dashed lines 15). As also shown in FIG. 5, in at least some embodiments, the top side 14 of the sole structure 12 includes a central cavity 29 that receives an additional midsole cushioning and/or support component 18 such as a resilient, generally rigid shank operable to control torsion.

The exterior surface of the sole structure 12 (including the bottom side 16) may be textured to provide a friction-enhancing surface to the sole. In the illustrated embodiment, the bottom side 16 of the sole structure 12 includes a plurality of friction-generating ridges or protrusions 17 disposed along the sole in a predetermined pattern. Additional information on the traction pattern is disclosed in US Application Publication No. 2022/0002495, incorporated herein by reference in its entirety.

The sole structure 12 may be formed of a single material or, in at least some embodiments, may be formed of a plurality of materials. By way of example, the sole structure may possess a unisole (one-piece) construction lacking an added outsole (e.g., a conventional outsole formed of rubber). The unisole may be formed of a foamed reaction product of an olefin block copolymer, a silicone polymer, a blowing agent, and a crosslinking agent. The unisole may have a plurality of ground-engaging protrusions have a length and recessed portions between the protrusions. The ground-engaging protrusions having a first total area, and the recessed portions having a second total area. The ratio of the first total area to the second total area is between about 45:55 to about 65:35.

The sole structure (unisole) is foam that provides improved abrasion resistance and coefficient of traction (CoT) properties. In embodiments of the disclosure, foam is an olefin block copolymer such as an ethylene/α-olefin block copolymer. Typically, about 50 mol % or more of the olefin block copolymer may include the ethylene-containing hard blocks. In some embodiments, the hard blocks may include at least about 95 wt percent ethylene, and may be 100 wt percent ethylene. The ethylene hard blocks may be highly crystalline. The remainder of the olefin block copolymer may be soft blocks of amorphous olefins. In some embodiments of the disclosure, suitable α-olefin fractions include straight-chain or branched α-olefin having between 3 and about 30 carbon atoms. Embodiments of the disclosure also may include cyclo-olefins having between 3 and about 30 carbon atoms and di- and polyolefins having at least 4 carbon atoms.

In embodiments of the disclosure, silicone rubber may be added to the foam composition. By way of example, the silicone may be present in about 25 phr in the composition. Silicone rubber typically has excellent resistance to compression set. Minor quantities of other polymers also may be included in this 25 phr of rubbers. Silicone rubber has the general formula [—Si(R1)(R2)-O]m[—Si(R3)(R4)-O]n, wherein m is between 1 and about 20,000 and n is between 1 and 20,000. Often, differences between silicone rubbers are found in the pendant groups, i.e., R1, R2, R3, and R4. In some embodiments, R1, R2, R3, and R4 each may be individually selected from the group consisting of methyl, phenyl, vinyl, trifluoropropyl, and blends thereof, wherein at least one of R1, R2, R3, and R4 is vinyl. In some embodiments, R1, R2, R3, and R4 each may be individually selected from the group consisting of an alkyl, and R1, R2, R3, and R4 may be the same alkyl. Other silicone rubber compositions also are available. In some embodiments, the silicone rubber may be a blend of silicone rubbers having different pendant groups.

A blowing agent typically may be present in an amount of between 0.25 phr and about 3.0 phr, and typically between about 1 phr and about 2 phr. Cross-linking agents may be present in an amount between about 0.5 and 3 phr, typically between about 1 and about 2 phr. Pigments in the form of fine particulates may be used in quantities up to about 5 phr.

Outer Shell

With continued reference to FIGS. 1-5 and additional reference to FIGS. 6 and 7, the outer shell 30 includes a forefoot portion or vamp 32, a midfoot portion 34 formed of medial quarter 34a and lateral quarter 34b, and a heel portion 36. The shell 30 further includes a shell opening 40 on the upper side of the shell that extends from the midfoot portion 34 to the heel portion 36.

The forefoot portion 32 of the outer shell 30 completely encloses a toe region of the shoe 10. Accordingly, the forefoot portion 32 forms a toe cage that extends from a medial side of the shoe, across an upper stretch on the dorsal side of the shoe, and then to a lateral side of the shoe.

The midfoot portion 34 of the outer shell 30 extends between the forefoot portion 32 and the heel portion 36, and includes a medial side wall 34a and a lateral side wall 34b. A U-shaped forward portion of the shell opening 40 separates the medial side wall 34a from the lateral side wall 34b. As shown in FIG. 2, the medial side wall 34a of the midfoot portion 34 extends upward from the sole structure 12 to an upper perimeter/collar 42 that extends along a medial side of the shell opening 40, a lateral side of the shell opening, and around a heel region at the posterior of the article of footwear. Similarly, as shown in FIG. 3, the lateral side wall 34b of the midfoot portion extends upward from the sole structure 12 to the collar 42 on a lateral side of the shell opening 40. In other words, the shell opening 40 defines a tongue opening running from the heel portion to the forefoot portion and defined by lateral 34b and medial 34a sides. Eyelets 44 are positioned along the collar 42 of the shell opening 40 on both the medial side wall 34a and the lateral side wall 34b. As explained in further detail below, webbing 102 for a lacing arrangement 100 extends through the eyelets 44.

The heel portion 36 of the outer shell 30 travels rearward from the midfoot portion 34, curving around the heel region of the shoe 10. This outer shell heel portion 36 extends distally from the sole structure to define a truncated flange/heel wall 38 terminating along the collar 42. With this configuration, the heel portion 36 of the outer shell 30 forms a heel wall 38 (which may also be referred to herein as a “truncated heel counter”) traveling from the medial quarter, around the back of the heel region, and to the lateral quarter. The height (h4) of the heel wall is selected to capture the bottom of a wearer's heel to prevent to foot from sliding off of the footbed when the shoe is in its folded down or recovery configuration (discussed in greater detail below). The height h4 of the heel wall 38 may be any suitable for its described purpose. By way of specific example, the wall height h4 (FIG. 3) is approximately 1.5-3.5 cm. In this manner, the heel wall 38 defines a flange member that curves around the heel region while also extending upward from the sole structure 12 and the stability bar 120, which is disposed along flange proximal end. Because the foot cavity 22 is somewhat recessed into the sole structure 12, it will be recognized that the internal height (h5) of the heel wall 38 is greater than the external height (h4) of the heel wall (note that h5 is shown in FIG. 6 and h4 is shown in FIG. 3).

As shown in FIGS. 2 and 3, the height of the heel wall 38 is significantly less than the height of the medial side wall 34a (medial quarter) and the lateral side wall 34b (lateral quarter). Therefore, a transition portion or zone 42a of the collar 42 slopes downward between the medial side wall 34a (proximate tongue opening) and the medial portion of the heel wall 38. Similarly, a transition portion 42b of the collar 42 slopes downward between the lateral side wall 34b (proximate the tongue opening) and the lateral portion of the heel wall 38. Accordingly, when the foot of a wearer is in the foot cavity 22 of the shoe, the collar 42 defining the upper perimeter of the outer shell 30 generally extends around the instep of the foot, downward to a position under the ankle, and then around the back of the heel along a stretch that is below or near the bottom of the Achilles tendon of the wearer.

As noted above, this truncated heel counter 38 is designed to engage a person's heel when the rear bootie flap is folded downward such that it is flat against the insole. With this configuration, the truncated heel 38 maintains the foot within the shoe, namely, the outer shell. This in contrast with conventional uppers having structures where any and all layers of the heel fold inward. This is further in contrast to the configuration in which the bootie flap is folded upward, where it is the internal bootie maintaining the foot within the shoe.

The outer shell 30 may be formed of a durable, self-supporting textile. In an example, any of various materials typically used in association with the upper of an article of footwear, such as nylon, polyester, leather, synthetic leather, or any of various other materials. In at least one embodiment, the outer shell 30 is provided by a synthetic woven fabric comprised of nylon, acetal, or similar materials that exhibit increased fatigue resistance and wear resistance. The synthetic fabric is generally inelastic and provides the upper with support and stability for the foot of the wearer when the shoe 10 is used for training or other athletic activity.

The outer shell 30 may include a plurality of apertures 48 that further provide for the flow of fluid (i.e., air or water) through the outer shell. This flow of fluid supports breathability for the article of footwear 10. In at least some embodiments, such as that shown in FIGS. 1-5, the apertures 48 are formed by perforations cut into the layer of material that forms the outer shell (e.g., a leather, synthetic leather, or other solid sheet of material). The apertures 48 may be dispersed widely across the entire outer shell 30, or only in certain portions of the outer shell 30, depending on the desired areas of breathability. In addition to providing breathability, the apertures 48 in the outer shell 30 also expose portions of the underlying inner bootie 50 that is mostly or substantially covered by the outer shell 30. In at least one embodiment, the outer shell 30 with the plurality of apertures 48 may be provided by a mesh material.

As mentioned above, the upper 20 further includes a stabilizer member 120 disposed within the heel region of the upper 20. The stabilizer 120, disposed on the exterior surface of the outer shell, provides support to the heel area of the upper 20 stabilizing the wearer's heel when inside the shoe. As shown in FIGS. 1-5, the stabilizer member 120 (which may also be referred to herein as a “stability bar”) is a generally arch-shaped bar member that includes a curved posterior portion 122, a relatively straight medial arm 124, and a relatively straight lateral arm 126. With this configuration, the stability bar 120 defines a generally C-shaped bar that curves around a heel portion 36 of the outer shell 30. The lateral arm 126 is significantly longer than the medial arm 124 and extends further forward to the midfoot region of the shoe 10. In particular, the lateral arm 126 extends forward to a position that reaches or is near (e.g., within 10 mm horizontally) the instep region 60 of the bootie 50. In contrast, the medial arm 124 terminates well short of the instep region 60 of the bootie 50. For example, the medial arm 124 terminates at or near a medial trough 84 defined along a mouth 80 of the bootie.

The stability bar 120 may be formed of any material suitable for its described purpose. By way of example, the stability bar 120 may be formed a generally rigid, flexible material such as plastic. By way of example the stability bar 120 may be formed of thermoplastic polyurethane, thermoplastic elastomers made up of rigid polyamide blocks and soft polyether blocks, or carbon fiber.

Inner Bootie

With reference to FIGS. 6A-6E, the inner bootie 50 is generally arranged within the outer shell 30 and defines the foot cavity 22 for the shoe 10. The inner bootie 50 includes a hindfoot portion 52 coupled to an forefoot portion 54 (which may also be referred to herein as a “dorsum portion”) including an instep section 54a, a tongue section 54b, and a peripheral section 54c with quarter and vamp areas. The bootie 50, including the hindfoot portion 52 and the forefoot portion 54, may be a textile laminate including a plurality of panels molded via heat and pressure. Each multi-layer panel includes a thin foam layer sandwiched between an exterior four-way stretch fabric and an interior four-way stretch fabric. The four-way stretch fabric may be a textile including elastomeric threads (e.g., elastance) and evaporative yarns that are knit together and configured to conform to the contours of the foot of the wearer. The evaporative yarns possess a special cross section that offers more skin contact to absorb heat and optionally minerals in the yarn that absorb heat from the skin and transfer it to the surrounding environment, outside the upper. One example of the evaporative yarn is AQUA-X by Hyonsong (Seoul, South Korea).

The intermediate foam layer is provided by a reticulated foam material that is positioned between the interior fabric layer and the exterior fabric layer. The foam layer is relatively thin, e.g., between about 1 mm and 3 mm in thickness, and specifically about 2 mm. Together, the two fabric layers and the foam layer combine to provide a thin lining for the foot cavity 22 that comfortable, bendable, and easily conformed to the foot of the wearer.

Specifically, each of the hindfoot portion 52 and the forefoot portion 54 may be formed/shaped via a compression molding process. Compression molding permits formation of a textile laminate having unique geometries. Although the textile laminate is comprised of multiple layers (i.e., a thin foam layer positioned between two layers of four-way stretch material), the overall thickness of the laminate may be relatively thin (e.g., between 2 mm and 5 mm). Compression molding (whether 2D or 3D) facilitates the unique geometries of various sections of the bootie 50, including the unique geometry of the interior heel wall 70.

The hindfoot portion 52 of the inner bootie 50 defines a interior heel wall 70 that generally extends around the heel of the wearer. The interior heel wall 70 is a self-supporting, compression-molded structure configured to surround at least the lateral side, posterior side, and medial side of the heel bone (i.e., the calcaneus of the wearer), and in some instances the heel wall is further configured to surround the bottom of the heel bone. Accordingly, it will be recognized that the interior heel wall 70 is curved and includes a medial portion, a lateral portion, and a central/posterior portion 72 (which may also be referred to herein as the “posterior heel wall” or the “central wall portion”).

The heel wall 70 is disposed internally of the truncated heel wall 38 of the outer shell 30, extending upward from the sole structure 12 such that its distal edge is significantly higher than outer heel wall 38 of the outer shell 30. For example, the height (h3) of the interior heel wall 70 above the sole structure 12 is two to four times greater than the height (h4) of the outer heel wall 38 above the sole structure 12.

As best shown in FIG. 1, a foam pad 74 is included on the interior heel wall 70 at the posterior portion 72. The foam pad 74 possesses a generally triangular shape with a rounded vertex 75 that points upward (toward distal edge of interior heel wall 70). The foam pad 74 further includes a base 76 along its lower edge oriented generally horizontally. The size of the foam pad is sufficient to provide a cushion structure for the Achilles when the heel wall is positioned in its train configuration but also attenuate ground forces along the heel bone of the wearer when the heel wall 70 is oriented in the recovery configuration. The thickness of the foam pad 74 makes the posterior heel wall 72 significantly thicker at the foam pad. For example, the foam pad 74 may be between 5 mm and 12 mm thick. In at least one embodiment, the foam pad tapers in thickness from the vertex 75 to the base 76. For example, the thickness of the foam pad 74 at the vertex 75 is about 10 mm, and the thickness of the foam pad 74 at the base 76 is about 6 mm. In at least some embodiments, the foam pad 74 is comprised of memory foam or other polyurethane foam with desirable density, compression and resilience properties commonly used in association with padding for footwear.

The forefoot section 54 of the bootie 50 is generally aligned with the forefoot portion 32 of the outer shell 30. The forefoot section 54 of the bootie 50 includes the toe cage, which covers/houses the toes of the wearer. Accordingly, the toe cage includes a generally horizontal top cover configured to span over the toes of the foot.

The hindfoot portion 52 is coupled or otherwise connected to the forefoot portion 54 to form the complete bootie 50. In at least some embodiments, the hindfoot portion 52 is connected to the forefoot portion 54. In an embodiment, seam is produced by sewing or stitching (such as via a zig-zag stitch), fusing techniques (e.g., using heat, pressure, ultrasonic radiation, laser radiation, radio frequency energy, etc.), mechanical connectors, adhesives, etc. If desired, the thread material used in making the sewn or stitched seam may be made from a material that can be softened or melted. For example, the thread material of one edge joint may be made from a thermoplastic polyurethane material that can be essentially melted into the material of the abutting edge joint (such as the seam support material) by application of one or more of heat, pressure, laser radiation, radio frequency energy, etc.

In an embodiment, the bootie portions are coupled utilizing seam support members 66. When utilized as a seam support member, the material may be a material that is capable of maintaining a stable edge and capable of supporting a sewn seam (e.g., without readily pulling the seam apart under normal usage forces). By way of example, the seam support material may be leather, synthetic leather, suede, synthetic suede materials, polyesters, other polymer-based fabrics and materials, thick fabric materials, etc., such as a non-woven fabric material known as Ecsaine® (Toray Industries, Inc.)

The seam support member, moreover, may be an adhesive film material (such as a thermoplastic polyurethane material) that will enable engagement of the seam support material to the upper member. An example of the adhesive film is Bemis tape available from Bemis Associates, Inc., such as Bemis's Sewfree® material.

As shown in FIGS. 1-6E, a coupling member 66 joins the instep portion 54 to the hindfoot portion 52. Specifically, the bootie 50 includes a medial coupling member 66a disposed along the medial side of the upper and a lateral coupling member 66b disposed along the lateral side of the upper. In the embodiment disclosed herein, the hindfoot portion 52 and forefoot portion 54 of the bootie 50 are connected via a fabric tape such as a thermal adhesive tape (e.g., BEMIS seam tape, available from Bemis Associates, Inc., Shirley, Mass.). In at least one alternative embodiment, the coupling member 66 comprises fabric similar to the fabric forming the upper (e.g., polyester, spandex, etc.). In other embodiments, adhesives or ultrasonic welding may be utilized to couple the different panels, and the adhesive and/or weld is covered by a strip of heat sealable film. With this taped or similar seamless configuration, the coupling member 66 provides a stitch-less connection that minimizes and/or eliminates the friction caused by conventional (exposed) stitched seams. That is, a seamless connection is provided between the hindfoot portion 52 and the forefoot portion 54 because the coupling member 66 creates a substantially smooth surface along the interior surface (and exterior surface) of the bootie 50 that is free of exposed stitching between the hindfoot portion 52 and the forefoot portion 54 (which, again, may also be referred to herein as a “dorsum portion”). Moreover, as explained in further detail below, the seam tape is advantageously located at a position that reinforces a hinge point between the hindfoot portion 52 and the dorsum portion 54 when the heel cup 70 is moved between an upward position (as shown in FIGS. 1-4) and a folded position (as shown in FIGS. 8-11).

While the connection between the hindfoot portion 52 and the instep portion 54 of the bootie 50 has been described as seamless, it will be recognized that in other embodiments, the connection is not truly seamless or without stitching. For example, in at least some embodiments, stitching or other fastening means many be used to connect the hindfoot portion 52 to the dorsum portion 54. In this case, a thermal adhesive tape (e.g., BEMIS seam tape) may be used to cover the fastening members along the seam and provide additional comfort to the foot of the wearer. Furthermore, in this embodiment the seam tape 64 may also serve to reinforce the hinge point between the hindfoot portion 52 and the instep portion 54 when the heel cup 70 is moved between an upward position and a folded position.

When the hindfoot portion 52 is coupled to the instep portion 54, the complete inner bootie 50 is formed. With particular reference now to FIGS. 1-3, the complete bootie 50 includes a mouth 80 that provides an opening to the foot cavity 22 in the posterior/heel region of the shoe 10. The mouth 80 is defined along a lip 82 that extends along a posterior perimeter of the instep region 60 and an upper perimeter of the hindfoot portion 52. As best shown in FIG. 3, the lip 82 of the mouth 80 extends continuously from a instep/forward crest or apex 68 (in the instep region 60), to a medial ankle trough or nadir 84 (in the region of the medial seam tape 64), to an Achilles/rearward crest or apex 78 (at the top of the posterior heel wall 72), to a lateral ankle trough or nadir 86 (in the region of the lateral seam tape 64), and back to the forward crest 68. The forward crest 68 is located at a highest vertical point on the lip 82 in the midfoot region, which may also be at or near a highest point of the instep portion 54. Similarly, the Achilles crest 78 is located at a highest vertical point on the lip 82 in the heel region. The medial ankle trough 84 is located at a lowest point on the medial side of the lip 82, and the lateral ankle trough 86 is located at a lowest point on the lateral side of the lip 82. The medial ankle trough 84 and the lateral ankle trough 86 are at the same or generally the same height above the sole structure 12 such that a line extending through the two points is a generally horizontal line (e.g., within ten degrees of horizontal).

As shown in FIG. 3, the forward crest 68 extends a first vertical height (h1) above the lateral ankle trough 86. The rearward crest 78 extends a second vertical height (h2) above the lateral ankle trough 86. The second vertical height (h2) is relatively close to that of the first vertical height, but is less than the first vertical height (h1). As a result, in many embodiments, including the embodiment disclosed herein, 1.0<(h1/h2)<2.0.

As also shown in FIG. 3, the lateral ankle trough 86 is generally positioned near a horizontal midpoint between the forward crest 68 and the Achilles crest 78. In particular, the lateral ankle trough 86 is positioned a first horizontal length (l1) from a dorsum crest 68 and a second horizontal length (l2) from the rearward crest, wherein 0.9<(l1/l2)<1.1.

FIG. 3 further shows that the rearward crest 78 extends another vertical height (h4) above the sole structure 12. This vertical height (h4) is significantly more than the height (h3) that the outer heel wall 38 extends above the sole structure. In at least one embodiment, h4 is about 7 cm, and/or 2.0<h4/h3<4.0.

As shown in FIGS. 1-4, the mouth 80 of the bootie is positioned completely outside of the outer shell 30 when the posterior heel wall 72 is in an upright position. Accordingly, no portion of the lip 82 is concealed within the outer shell 30 when the posterior heel wall 72 is configured in the upright position. Stated differently, for any vertical line extending through a point on the lip 82, the lip 82 is positioned above the collar 42 along that same vertical line. Thus, although some points on the lip 82 are below some points on the collar 42 (e.g., the lateral ankle trough 86 is below the collar in the instep region of the shoe), the entire mouth 80 of the bootie 50 is positioned outside of the outer shell when the posterior heel wall is in the upright position (i.e., as shown in FIGS. 1-4). This positioning of the mouth 80 outside of the collar 42 includes all points on the lip 82 that are posterior to the medial ankle trough 84 and the lateral ankle trough 86, including the entire posterior heel wall 72.

As noted previously, the hindfoot 52 and forefoot 54 portions of the bootie 50 are connected along lateral and medial joints (where forward edge of the heel portion abuts the rearward edge of the instep portion. The two lengths of seam tape 64 extend around the lip 82 at positions near the medial and lateral troughs 84, 86. As shown in FIGS. 1-4, a first piece of seam tape 66a on the outer medial side of the bootie extends upwardly and rearwardly relative to the sole structure 12 at an angle (e.g., 45°-70° relative to horizontal). The first piece of seam tape 66a then extends over and around the lip 82 at a location near the medial trough 84 (e.g., within 10 mm or the medial trough), wraps around lip edge and then returns back to the sole structure 12 along the same angle on the inner medial side of the bootie (i.e., the seam tape has the same pitch and extends along the same line on both the outer and inner medial sides of the bootie). In the same manner, a second piece of seam tape 66b on the outer lateral side of the bootie 50 extends upwardly and rearwardly from the sole structure 12 at an angle, wraps over and around the lip 82 at a location near the lateral trough 86, and then returns back to the sole structure 12 along the same angle on the inner lateral side of the bootie.

As noted previously, only a limited number of connections are made between the bootie 50 and the outer shell 30. Those limited connections include: (a) connections along the sole structure 12 wherein the lower perimeter portions of both the bootie 50 and the outer shell 30 are stitched and/or adhered or otherwise connected to the sole structure 12, and (b) connections along the instep region 60 of the bootie, wherein the bootie 50 is connected to the outer shell 30 along the eyelets 44 and the U-shaped forward portion of the shell opening 40. All other portions of the bootie 50 remain free and disconnected from the outer shell 30. Accordingly, it will be recognized that the bootie 50 is generally free-floating relative to the shell 30 within the shoe. Particularly, in the heel region of the shoe 10, the hindfoot portion 52 of the bootie 50 is completely free-floating relative to the outer shell 30, as the only connections between the bootie 50 and the outer shell 30 in the heel region of the shoe 10 are along the sole structure 12. This free-floating configuration results in a heel gap 90 being formed between the bootie 50 and the outer shell 30 in the heel region of the shoe 10. As described in further detail below, the heel gap 90 is adjustable in size such that the cavity defined by the heel gap 90 is diminished to a relatively small volume when the inner heel wall 70 of the bootie 50 is in an upright position (as shown in FIGS. 1-4) and is enlarged to a relatively large volume when the inner heel wall is in a folded position (as shown in FIGS. 8-11).

Foldable Heel Wall of Inner Bootie

FIGS. 1-4 show the shoe 10 with the interior heel wall 70 (i.e., the heel wall of the bootie 50) in an upright position such that the central wall portion 72 of the bootie 50 is substantially vertical and abuts the exterior heel wall 36 of the outer shell 30. In this position, the vertex 75 of the triangular foam pad 74 points in a generally vertical/upward direction (i.e., away from the sole structure 12). Also, the entire mouth 80 of the bootie 50 is positioned outside of the outer shell 30 when in the upright position.

In contrast to the upright position of FIGS. 1-4, FIGS. 6-9 show the shoe 10 with the interior heel wall 70 in a folded position such that the central wall portion 72 of the bootie is oriented substantially horizontally. In this position, the vertex 75 of the triangular foam pad 74 points in a generally horizontal/forward direction (i.e., towards the forefoot region of the shoe 10) and the central wall portion 72 of the interior heel wall 70 lays flat against the insole 24. Advantageously, when the central wall portion 72 is laid flat against the insole 24, the foam pad 74 of the central wall portion 72 is located directly below the heel bone (i.e., calcaneus) of a wearer. At the same time the Achilles crest 78 is located proximate the midtarsal joint (e.g., at a position generally forward of the heel bone and in the vicinity of (or to the rear of) the midtarsal joint). Furthermore, in the folded position, the central wall portion 72 and a posterior portion of the lip 82 of the bootie 50 are arranged below the collar 42 and within the outer shell 30.

Two folds lines 88 enable this reconfiguration from the upright, training mode of the shoe to the downward, recover mode of the shoe. Specifically, fold lines are formed in the lip 82 mouth 80 when the heel cup 70 is in the folded position. A first fold 88 is on the medial side of the mouth, and a second fold 88 is on the lateral side of the mouth 80. The fold 88 on the medial side of the mouth 80 occurs along a stretch of the lip 82 that includes the medial trough 84, and the fold 88 on the lateral side of the mouth occurs along a stretch of the lip 82 at the lateral trough 86. The position of the medial trough 84 and lateral trough 86 facilitate folding of the heel cup 70 at a location that tends to minimize bunching of the laminate material of the bootie 50 within the foot cavity, thus making the shoe more comfortable for the wearer when in the interior heel wall 70 is in the folded position.

The location of the folds may be controlled via thickness of the textile laminate forming the heel portion. For example, the fold may begin proximate joint. In a further embodiment, each fold 88 occurs along a stretch of the lip 82 on the posterior side of the membrane/seam tape 66a, 66b. The seam tape 66 advantageously reinforces the lip 82 at a forward portion of the fold 88, encouraging the fold 88 to form as a gradual inward twist that does not result in a hard crease in the lip 82. The seam tape 66a, 66b also serves as a forward buttress/support for the fold 88 and prevents deterioration of the lip over time that may otherwise result from repeated movement of the interior heel wall 70 between the upright position and the folded position.

A heel gap 90 is provided between the exterior heel wall of the outer shell 30 and the interior heel wall 70 of the bootie 50. The specific dimensions of the heel gap 90 may be defined in different ways, but in any event the gap defines a cavity between the outer shell 30 and the bootie 50, and the volume of that cavity changes when the interior heel wall 70 is moved from the upright position to the folded position (and vice-versa). In the embodiment disclosed herein, the heel gap 90 may be considered to include following borders: (1) a first arc 92 that extends along the collar 42 at the heel portion 36 of the outer shell 30, (2) a second arc 94 (noted in dotted lines in FIGS. 8 and 11) projected horizontally from the collar 42 onto the heel cup 70 of the bootie 50 when the heel cup 70 is in the upright position, (3) a third arc (or any point on such arc) defined along a base of the heel region where the outer shell 30 and the bootie 50 are joined at the sole structure 12, and (4) lines connecting points on such borders to form a cavity defining a volume of space (e.g., lines connecting the two ends of the first arc to the two ends of the second and third arcs). It will be recognized that when the interior heel wall 70 is in the upright position (as shown in FIG. 1), the cavity formed by the heel gap is diminished and is defined within a very thin curved space (e.g., a paper-thin curved cuboid). Accordingly, the cavity formed by the heel gap 90 is insufficient to receive the heel of the foot of the wearer when the interior heel wall 70 is in the upright position. However, when the interior heel wall 70 is in the folded position (as shown in FIGS. 8-11), the cavity formed by the heel gap 90 is enlarged and is defined within a significantly larger space (e.g., a curved prism-like or pyramid-like space) that is sufficient to receive the heel of the foot of the wearer.

During manufacture of the shoe, the interior heel wall 70 is compression molded in the upright position (of FIGS. 1-4). Therefore, the interior heel wall 70 is biased toward the upright position. However, because the material of the interior heel wall 70 is flexible (e.g., a compression molded laminate including a foam material positioned between two layers of elastomeric fabric), the interior heel wall 70 may be easily bent and moved to the folded position (FIGS. 6-9) by the wearer. Advantageously, this movement from the upright position to the folded position may be easily accomplished by the hand or foot of the wearer by simply applying a forward-directed force to the rear of the posterior heel wall 72.

When the wearer intends to use the shoes 10 for training, the interior heel wall 70 is placed in the upright position, and the wearer inserts the foot into the foot cavity 22 through the mouth 80 of the bootie 50. In this position, the plantar surface of the foot engages the insole 24. When the wearer intends to use the shoes 10 for recovery post workout, the interior heel wall is placed in the folded position, and the wearer inserts the foot into the foot cavity 22 through an opening formed along a combination of the collar 42 of the outer shell 30 and the unfolded portion of the bootie lip 82. In this position, the toes and midfoot surface of the foot engage the insole, but the heel pad of the foot engages the triangular pad on the folded down central portion of posterior heel wall 72 of the bootie 50. Advantageously, the exterior truncated heel wall 38 of the outer shell 30 extends a sufficient height above the folded interior heel wall 70 of the bootie 50 and the sole structure 12 to serve as truncated heel counter 38 that prevents movement off of the insole (stated another way, the exterior heel wall 38 serves as a catch for the heel of the foot when the interior heel wall 70 is in the folded position). Furthermore, the previously described back-pitch along the inner posterior of the foot cavity further encourages the heel of the foot into the cavity and maintains the heel in place when the foot is placed in the foot cavity with the heel cup in the folded position.

Lacing Arrangement System with Midfoot Lockdown

With reference again to FIGS. 1-4 and to FIGS. 12A-12C, a lacing arrangement is included on the shoe 10. The lacing arrangement 100 includes webbing 102, a lace 112, a locking dial 114, and a dial mount 116. As best shown in FIG. 12A, the webbing 102 is visible through the outer shell 30 which is comprised of a mesh material. The various apertures 48 in the mesh material of the outer shell 30 allows for convenient visual appreciation of the arrangement and configuration of the webbing 102. The webbing 102 is comprised of a relatively strong material such as nylon or similar fibers that are woven or knit together to provide strong tether members for the lace 112. The webbing 102 includes a plurality of webbing sections. A total of six webbing sections are included in the embodiment of the shoe disclosed herein, including three webbing sections 102a, 102b, 102c on the lateral side of the shoe, and three identical webbing sections on the medial side of the shoe. Each webbing section 102a, 102b, 102c is positioned between the outer shell 30 and the inner bootie 50 and includes two ends that are secured to the sole structure 12 along with the other portions of the upper.

Each webbing section 102a, 102b, 102c includes a middle portion 104 where the webbing section is folded and extends through one of the eyelets 44 in the outer shell 30. The webbing 102 may be further secured to the upper 20 along the eyelets 44 using stitching, adhesives, welding, or other connection means. A proximal portion 106 of each webbing section angles backward and downward from the middle portion 104 toward the sole structure 12. A distal portion 108 of the webbing section angles forward and downward from the middle portion 104. A fold 110 in the middle portion 104 serves as a coupling for a length of the lace 112 of the lacing arrangement 100 (i.e., the lace 112 extends through the fold 110 in the webbing).

The webbing 102 advantageously serves to add stability and containment for the midfoot of the wearer. Furthermore, the proximal portion 106 of the proximal-most webbing section 102a extends all the way to the heel portion 36 of the outer shell 30. As best shown in FIG. 12, the proximal portion 106 of the webbing section 102a on the lateral side of the shoe 10 extends all the way to the stability bar 120 (i.e., the webbing section 102a is connected to the sole structure 12 at a location that overlaps the lateral arm 126 of the stability bar 120). The proximal portion of the webbing section 102a on the medial side of the shoe does not extend to the stability bar 120, but is connected to the sole structure 12 at a position near the medial arm 124 of the stability bar 120 (e.g., within 3 cm of the stability bar). With this cooperation between the webbing 102, the stability bar 120, and the exterior heel wall 36 of the outer shell, additional support and containment of the foot of the wearer is provided. This additional support and containment is particularly advantageous when the heel cup 70 of the bootie 50 is in the folded position (see FIGS. 8-11).

The lacing system includes a ratcheting system with a base member, a ratchet member, a tensile member or line, a spool, and an actuator. The base member is coupled to the bootie 50 and the ratchet member is rotatably coupled to the base member. The spool is coupled to the ratchet member and rotates with the ratchet member. The line is wound on the spool and extends through at least one web channel. The actuator is coupled to the ratchet member and may be selectively rotatable in a first direction and a second direction without activation of any release mechanism. The ratchet member and spool rotate along with the actuator. Thus, when a first force is applied to rotate the actuator in the first direction, the line is incrementally wound upon the spool, tightening the lace. When a second force is applied to rotate the actuator in the second direction, moreover, the line is incrementally unwound from the spool, loosening the lace. The ratchet member and the spool are blocked from rotation when neither the first force nor the second force is applied to the actuator.

In a further embodiment, the actuator or is rotatable only in the first direction to tighten incrementally increase tension (i.e., tighten the lace). A release mechanism may be engaged to release the spool. The spool may be released by pulling the actuator outward, permitting loosening of the lace. Dial-type wire lacing systems have been developed by Boa Technology Inc. Additional details regarding exemplary Boa lacing systems may be found in U.S. Pat. Nos. 5,934,599; 6,202,953; and 6,689,558, all of which are incorporated herein by reference.

The lace 112 is provided by an elongated length of wire, cable, yarn, string, cording or similar structure that is interlaced through the webbing 102 and used to lock down the mid-foot of the wearer within the shoe when tightened. Each webbing section 102a, 102b, 102c serves as a tether that retains the lace in position on the upper 20. The lace 112 is generally comprised of a relatively strong material that resists wear and breaking, including any of various natural or synthetic materials as will be recognized by those of ordinary skill in the art. The lace 112 extends through the middle fold 110 of each webbing section and across the instep region 54b of the bootie 50.

The ends of the lace 112 are retained by a ratcheted spool 62 that is connected to the locking dial 114. The dial 114 may be similar to any of various ratcheted dials known for use in association with footwear, including the Boa® dial sold by BOA Technology Inc. of Denver, Colorado. The dial 114 is both rotatable and is moveable between a locking position and a release position. When the dial is pushed inwardly, it is moved to the locking position. When in the locking position, rotation of the dial 114 in the clockwise direction serves to shorten the effective length of lace 112 that engages the webbing 102, thus tightening the shoe 10 on the foot of the wearer. When the dial 114 is pulled outward to a release position, the spool is released and allowed to rotate in the counter-clockwise direction such that the effective length of lace 112 that engages the webbing 102 is increased, thus loosening the shoe 10 on the foot of the wearer.

The dial mount 116 (which may also be referred to herein as a “mounting base”) serves as a base for the locking dial 114. The dial mount 116 includes an upper cylinder portion connected to a lower bayonet fitting. The upper cylinder portion of the dial mount 116 is visible on the instep 60 of the bootie 50. The locking dial 114 is positioned above the upper cylinder portion of the mounting base 116. The ratcheted spool that is coupled to the dial 114 is positioned within the upper cylinder portion of the mounting base 116. The bayonet fitting of the dial mount 116 is configured for insertion into a socket 118 of the bootie 50, and is hidden from view on the instep 60 of the bootie 50. The bayonet fitting of the dial mount 116 may be, for example, a circular plate-like structure having a diameter that is greater than that of the upper cylinder portion and the dial 114.

The socket 118 is a pocket that is formed on the instep region 60 of the bootie 50 proximate the dorsum crest 68 (e.g., within 5 cm of the dorsum crest). An opening to the instep socket 118 is formed on the upper side of the instep 60 of the bootie 50. No opening to the instep socket 118 is provided on the lower side of the instep 60. Accordingly, the bayonet fitting of the dial mount 116 is inserted into the instep socket 118 via the opening on the upper side of the bootie instep 60. The opening has a diameter that is approximately equal to the diameter of the dial 114 and upper cylinder of the dial mount 116, but is significantly less than the diameter of the bayonet portion of the dial mount 116. However, because the material that forms the bootie 50 is elastic, the opening to the instep socket 118 may be stretched to a sufficient extent to receive the bayonet fitting of the dial mount 116, and then resiliently close to fit snugly against the upper cylinder of the dial mount 116. Stitching, adhesives, or other fastening means may be used to secure the bayonet fitting of the dial mount 116 in place within the instep socket 118. The laminate material that forms the bootie 50, including a layer of comfort fabric and foam, is positioned behind the instep socket 118 and the dial mount 116. This arrangement advantageously provides comfort and cushioning for the wearer such that the dial mount 116 is essentially imperceptible to a foot placed in the foot cavity 22.

ALTERNATIVE EMBODIMENTS

While an embodiment of an article of footwear has been described herein as a shoe 10 having various components and associated features, it will be recognized that other embodiments of the article of footwear are possible, including the article of footwear provided in a different form and/or with different components. The term “bootie” as used throughout this detailed description and in the claims refers to any component that is generally configured to receive a foot configured for use with an article of footwear. A bootie is positioned within an upper in order to receive the foot and provide an additional layer of cushioning, support, structure, protection as well as any other user needs. In some cases, booties can be provided with various structures such as tongues, fastening systems, cushioning, and supporting systems. The material forming the bootie may be a thermoformable, textile laminate (also referred to herein as a fabric laminate) comprising a plurality of layers including one or more fabric (textile) layers, one or more foam layers, and optionally a structural support layer disposed internally within the upper (i.e., located between two or more layers within the plurality of layers forming the upper), where the fabric laminate is capable of being shaped via compression molding. The one or more fabric layers provided in the fabric laminate can comprise any suitable textile, herein defined as fabrics and other manufactured products made from strands such as fibers, filaments, and yarns. By way of example, the textiles include knit, woven, nonwoven, embroidered, and braided constructions. The strands forming the fabric may include hard yarns or resilient yarns possessing stretch and recovery characteristics. Specifically, the hard yarns may include any one or combination of compounds selected from the group consisting of polyurethanes, polyesters (e.g., polyethylene terephthalate), polyolefins (e.g., polyethylene and polypropylene), polyamides (e.g., aliphatic or aromatic polyamide materials, such as nylon), and any suitable combinations or copolymers thereof. Regarding elastic yarns, the strands include elastomeric materials such as a polyester-polyurethane copolymer commercially available under the names elastane, LYCRA and SPANDEX. A fabric layer can further be formed of synthetic or natural leather or may even further comprise a plurality of layers (e.g., a plurality of layers comprising waterproof and breathable properties, such as fabric layers commercially available under the name GORETEX). The fabric layers can include elastomers that provide any suitable degree of stretch (e.g., two-way stretch or four-way stretch) at any one or more locations of the upper.

The fabric layers may possess any thickness suitable for its described purpose. In example embodiments, the fabric layers can have thicknesses in the range of about 0.25 mm to about 4 mm, e.g., about 0.50 mm to about 3 mm.

The one or more foam layers provided in the fabric laminate can comprise any suitable one or more type(s) of open and/or closed cell foam materials that provide adequate cushioning and comfort for the intended purpose. In particular, an open-celled, thermoplastic foam may be utilized. Some examples of types of foam materials suitable for use in forming the upper include, without limitation, polyolefins (e.g., polyethylene or polypropylene) foam materials, ethylene vinyl acetate (EVA) foam materials and polyurethane (PU) foam materials. The foam materials can have a thickness that is greater than the fabric materials. In example embodiments, the foam materials can have thicknesses in the range of about 1 mm to about 10 mm, e.g., about 2 mm to about 8 mm (e.g., about 3 mm to about 6 mm). Foam layers can vary in thickness depending upon where such foam layers are located along the upper.

The one or more internal structural support members provided within the fabric laminate that forms the upper can be formed of any suitable type(s) materials that deform during the compression molding process and provide structural support for the upper at the location(s) in which the support members are provided once the material cools. In particular, the materials used to form the internal structural support members can be formed so as to have a hardness value (e.g., as measured on a Shore A hardness scale, a Shore A hardness) that is greater than the hardness value (e.g., Shore A hardness) of the materials used to form the foam and fabric layers of the fabric laminate. Some examples of materials that can be used to form the internal structural support members include, without limitation, polyurethanes, polyolefins, polyamides (e.g., nylon), ethylene vinyl acetate (EVA), etc. In example embodiments, one or more internal structural support members are formed from a thermoplastic polyurethane (TPU) material, such as a TPU material commercially available from Chemex Company Ltd. During the formation of the fabric laminate, the internal structural support member can be formed from a flat sheet that is contoured during the compression molding process. Alternatively, the internal structural support member can be formed from starting materials comprising a powder composition that is fused and hardened into a single, unitary member either prior to or during the compression molding process. The internal structural support member can have a thickness in the range of about 0.2 mm to about 2.0 mm (e.g., a thickness of about 1.0 mm).

As noted herein, the fabric laminate that forms the upper comprises a plurality of layers and can include any selected number of layers, where different fabric laminates including different types and/or numbers of layers can be provided at different locations of the upper. For example, some locations of the upper may include one or more internal structural support members while other locations do not, thus changing the structural configuration of the fabric laminate at different locations of the upper.

Accordingly, it will be appreciated that variants of the above-described shoe 10 and other features and functions, or alternatives thereof, may be desirably combined into many other different systems, applications or methods. Various presently unforeseen or unanticipated alternatives, modifications, variations or improvements may be subsequently made by those skilled in the art that are also intended to be encompassed by the foregoing disclosure.

Claims

1. An article of footwear comprising:

a sole structure including a footbed; and
an upper including: an outer shell coupled to the sole, the outer shell including an outer heel wall oriented generally orthogonal to the footbed; and an inner shell coupled to the sole structure, the inner shell including an inner heel wall generally aligned with the outer heel wall;
wherein the inner heel wall is pivotable away from the outer heel wall from a first position in which the inner heel wall is oriented generally parallel to the outer heel wall, to a second position in which the inner heel wall is oriented generally orthogonal to the outer heel wall.

2. The article of footwear of claim 1, wherein the outer heel wall extends a first height above the footbed and the inner heel wall extends a second height above the footbed, wherein the second height is greater than the first height.

3. The article of footwear of claim 2 wherein the second height is at least two times the first height.

4. The article of footwear of claim 1 further comprising a stabilization bar coupled to an exterior surface of the outer heel wall.

5. The article of footwear of claim 1 wherein the outer shell is comprised of a perforated material and the inner shell is comprised of a foam layer positioned between an inner layer of four-way stretch material and an outer layer of four-way stretch material.

6. The article of footwear of claim 5 wherein the perforated material is an inelastic fabric.

7. The article of footwear of claim 1 wherein the inner shell is a bootie including a hindfoot portion seamlessly coupled to a forefoot portion.

8. The article of footwear of claim 7 wherein the bootie includes a mouth providing an opening into a foot cavity, wherein a lip extends around the mouth, wherein the second position is an upright position, and wherein an entirety of the mouth is outside of the shell when the inner heel wall is in the upright position.

9. The article of footwear of claim 8 wherein, when the inner heel wall is in the upright position, the lip of the mouth extends continuously from a dorsum crest, to a lateral trough, to a heel apex, to a medial trough, and back to the dorsum crest, wherein the dorsum crest extends a first vertical height (h1) above the lateral trough, and wherein the heel apex extends a second vertical height (h2) above the lateral trough.

10. The article of footwear of claim 9 wherein 1.0<(h1/h2)<2.0.

11. The article of footwear of claim 10 wherein the lateral trough is a first horizontal length (l1) from the dorsum crest, wherein the lateral trough is a second horizontal length (l2) from the heel apex, and wherein 0.9<(l1/l2)<1.1.

12. The article of footwear of claim 8 wherein a first length of tape provides a coupling between the hindfoot portion and a forefoot portion on a medial side of the bootie, and wherein a second length of tape provides a coupling between the hindfoot portion and the forefoot portion on a lateral side of the bootie.

13. The article of footwear of claim 12 wherein:

the first length of tape extends upward from an inner bottom position on the medial side of the bootie, around the lip, and downward to an outer bottom position on the medial side of the bootie; and
the second length of tape extends upward from an inner bottom position on the lateral side of the bootie, around the lip, and downward to an outer bottom position on the lateral side of the bootie.

14. The article of footwear of claim 8 wherein the article of footwear is a shoe, wherein the bootie comprises a textile laminate comprising an interior layer facing the foot cavity, wherein an exterior layer facing the outer shell and forming a portion of exterior of the shoe, and wherein an intermediate layer disposed between interior and exterior layers.

15. The article of footwear of claim 14 further comprising a lacing arrangement wherein:

the lacing arrangement includes a plurality of tethers positioned between the bootie and the outer shell, each of the plurality of tethers including a first end extending from a bottom portion of the bootie, a second end extending from the bottom portion of the bootie, and a middle fold extending through one of a plurality of openings in the outer shell; and
a lace engages the middle fold of each of the plurality of tethers.

16. The article of footwear of claim 15 wherein:

the plurality of tethers includes six tethers; and
the plurality of openings includes six openings.

17. The article of footwear of claim 15 wherein a portion of the lace is wound around a ratcheted spool, wherein the lace is tightened on the article of footwear when the spool is moved in a clockwise direction and the lace is loosened on the article of footwear when the spool is moved in a counter-clockwise direction.

18. The article of footwear of claim 17 wherein the spool is retained on the forefoot portion within a mounting base, the mounting base including an enlarged fitting that is retained within an instep socket on the bootie, and wherein the spool is connected to a dial that is rotatably positioned on the mounting base.

19. The article of footwear of claim 1 further comprising a triangular foam pad positioned on the inner heel wall, wherein a vertex of the triangular foam pad points upward when the inner heel wall is in the first position, and wherein the vertex of the triangular foam pad points to the forefoot of the article of footwear when the inner heel wall is in the second position.

20. An article of footwear including a heel region, a midfoot region and a forefoot region, the article of footwear comprising:

a sole;
an upper connected to the sole, the upper and the sole forming a foot cavity; and
an insole positioned within the foot cavity;
wherein, the upper comprises an outer shell extending from the heel region to the forefoot region, the outer shell including an outer heel wall defining an upper perimeter, and a bootie positioned within the outer shell and extending from the heel region to the forefoot region, the bootie including an inner heel cup configured to be moved between an upright position and a folded position, wherein a posterior wall of the inner heel cup extends above the upper perimeter of the outer heel wall when the inner heel cup is in the upright position, and wherein the posterior wall of the inner heel cup is laid against the insole when the inner heel cup is in the folded position.

21. The article of footwear of claim 20 wherein the posterior wall of the inner heel cup is further positioned below the upper perimeter of the outer heel wall when the inner heel cup is in the folded position.

22. An article of footwear including a heel region, a midfoot region and a forefoot region, the article of footwear comprising:

a sole; and
an upper connected to the sole, the upper and the sole forming a foot cavity, the upper comprising: an outer shell extending from the heel region to the forefoot region, the outer shell including an outer heel wall, and a bootie positioned within the outer shell and extending from the heel region to the forefoot region, the bootie free-floating relative to the outer shell within the heel region of the article of footwear, the bootie including a hindfoot portion and a midfoot portion with at least one seam formed between the hindfoot portion and the midfoot portion, the bootie further including a heel cup in the hindfoot portion, the heel cup configured to be moved between an upright position and a folded position, wherein at least one fold is formed in the heel cup on a posterior side of the seam when the heel cup is in the folded position.

23. The article of footwear of claim 22 wherein a length of tape covers the seam and provides a coupling between the hindfoot portion and the midfoot portion of the bootie.

Patent History
Publication number: 20240099424
Type: Application
Filed: Sep 22, 2023
Publication Date: Mar 28, 2024
Inventors: Kevin Plank (Baltimore, MD), John Humphrey (Baltimore, MD), Marcus Cheatham (Baltimore, MD), Ryan Drew (Baltimore, MD)
Application Number: 18/472,564
Classifications
International Classification: A43B 23/02 (20060101); A43C 11/16 (20060101);