Footwear Upper With Ribbed Panels

Abstract

An improved article of footwear is disclosed herein. The upper of the footwear is disposed on the sole, where the upper may be constructed from a first layer and a second layer disposed on the exterior surface of the first layer. The second layer may be constructed from a less flexible material than the first layer. The second layer may include a plurality of panels disposed adjacent to one another, where each panel may include a plurality of equally spaced parallel ribs. The dimensions and spacing of the ribs of each of the panels may vary, which gives each panel a designed degree of flexibility and support. Panels having similar performance characteristics may be grouped together into zones, where the number, shape, size, and layout of both the panels and the ribs gives each zone a specific degree of flexibility, support, and comfort.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority under 35 U.S.C. 119(e) to U.S. Provisional Patent Application Ser. No. 62/301,698, entitled “Footwear Upper With Ribbed Panels”, filed Mar. 1, 2016, the disclosure of which is incorporated herein by reference in its entirety for all purposes.

FIELD OF THE INVENTION

The present invention relates to articles of footwear, and, in particular, footwear including an upper designed with a polymer layer disposed over a fabric base layer, the polymer layer defining zonal support area that provide varying levels of support.

BACKGROUND OF THE INVENTION

Articles of footwear typically include an upper affixed upon a sole structure, where the upper is configured to wrap around and contour to the foot of a user while simultaneously securing the footwear to the foot. Uppers in athletic footwear are usually formed from one or more pieces of fabric, leather, and/or plastic that are stitched, adhesively bonded, or otherwise attached together. Other materials, such as synthetic leather, polymers, rubber and/or other components can also be incorporated into the upper to form an upper having desirable aesthetic and functional features that incorporate durability, flexibility, air permeability and/or other types of desirable properties to the upper. Providing such features in an upper, however, can also increase the undesirable features in an upper. For example, the incorporation of materials such as leather or rubber into the upper to increase the strength and durability of the upper may reduce air permeability of the upper, which results in moisture (e.g., perspiration) being trapped within the upper during use. In addition, providing desired features in an upper through added materials can also decrease the other desirable features in an upper. For example, the incorporation of materials such as plastic and rubber into the upper to increase the stiffness and support of the upper for athletic use may decrease the comfortability of the footwear, which can reduce the usability of the footwear. Accordingly, it would be desirable to provide an article of footwear (e.g., for athletic activities) having an upper with zonal areas that vary in the amount of support and flexibility provided, where the zonal areas may be created by a series of interconnected panels that contain a plurality of ribs or fins that vary in size and spacing.

SUMMARY OF THE INVENTION

An article of footwear includes an upper constructed from two layers, a fabric base layer and a polymer skin layer disposed on the fabric base layer. The polymer skin layer may include a plurality of interconnected panels, where each panel contains a plurality of ribs or fins. The number of ribs, the dimensions of the ribs, and the spacing between the ribs may determine the level of support provided by each panel. Each panel may be specifically designed to provide a specific level of support or a specific degree of flexibility to the upper at the location of that panel on the upper. The panels may each represent a micro zone of the upper, while groups of panels having similar performance characteristics may together form zones of the upper. The plurality of panels may be disposed along the upper to form zones and micro-zones in a specific layout that enables the upper to provide structure, support, flexibility, and comfort to the article of footwear in desired locations. With this configuration and construction of an upper, the desired performance characteristics of an upper of an article of footwear can be more easily implemented into an article of footwear without decreasing other desired performance characteristics or increasing undesired performance characteristics.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates a side view of the lateral side an embodiment of an article of footwear according to the present invention.

FIG. 2 illustrates a side view of the medial side of the embodiment of the article of footwear of FIG. 1.

FIG. 3 illustrates a rear view of the embodiment of the article of footwear of FIG. 1.

FIG. 4 illustrates a front view of the embodiment of the article of footwear of FIG. 1.

FIG. 5 illustrates a top view of the upper of the embodiment of the article of footwear of FIG. 1 before the upper is fastened to the article of footwear.

FIG. 6 illustrates a detailed view of the upper of FIG. 5.

FIG. 7A illustrates a cross sectional view of a pair of ribs of a first type of panel of the upper of FIG. 5.

FIG. 7B illustrates a cross sectional view of a pair of ribs of a second type of panel of the upper of FIG. 5.

FIG. 7C illustrates a cross sectional view of a pair of ribs of a third type of panel of the upper of FIG. 5.

FIG. 7D illustrates a cross sectional view of a pair of ribs of a fourth type of panel of the upper of FIG. 5.

Like reference numerals have been used to identify like elements throughout this disclosure.

DETAILED DESCRIPTION OF THE INVENTION

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 described herein with reference to the example embodiment of FIGS. 1-5, an article of footwear 100 in accordance with the invention includes an upper 200 coupled to a sole structure 300. The article of footwear 100, also referred to herein as a shoe, can be in the form of a basketball shoe or other type of athletic shoe. The article of footwear, or shoe, 100 includes a medial side 110 that is oriented along the medial or big toe side of the user's foot, a lateral side 120 that is oriented along the lateral or little toe side of the user's foot, a toe (i.e., front) end 130 that corresponds with the toe end of the user's foot and a heel (i.e., rear) end 140 that corresponds with the heel of the user's foot. The shoe 100 further includes a top side 150 that is oriented between the medial side 110, the lateral side 120, the toe end 130, and the heel end 140. While many of the example embodiments depicted in the figures (including FIGS. 1-4) show an article of footwear (shoe) configured for a left foot, it is noted that the same or similar features can also be provided for an article of footwear (shoe) configured for a right foot (where such features of the right footed shoe are reflection or “mirror image” symmetrical in relation to the left footed shoe, e.g., the embodiment depicted in FIGS. 1-4).

The upper 200 defines an envelope or pocket that, when secured to a portion of the sole structure 300 as described herein, covers and protects the foot of the wearer. The upper 200 may include a forefoot region 202 that generally aligns with the ball and toes of a user's foot (i.e., when a user is wearing the shoe), a midfoot region 204 that generally aligns with the arch and instep areas of the user's foot, and a hindfoot region 206 that generally aligns with the heel and ankle areas of the user's foot. The upper may further include an opening 208 formed in the hindfoot region 206 and the midfoot region 204, where the opening 208 provides access to the interior of the upper 200. The upper 200 may possess any dimensions (size/shape) suitable for its described purpose. For example, the upper 200 may possess a “high top” configuration (as illustrated in FIGS. 1-4), in which a hindfoot region 206 of the upper extends over and/or above at least a portion of a user's ankle. Alternatively, other embodiments, the upper 200 may possess a “mid top” configuration (in which the upper extends to slightly below or at the user's ankle), a low top configuration, or any other suitable configuration. The upper 200 is coupled to the sole structure 300 via any conventional and/or other suitable manner (e.g., via any form of adhesion or bonding, via a woven connection, via one or more types of fasteners, etc.).

The sole structure 300 may include a midsole structure 310 and an outsole structure 320 that provide features of suitable cushioning and comfort while maintaining adequate flexibility to a user during use of the shoe 100. The midsole structure 310 may be constructed from a thermoplastic or thermoset material, such as an ethylene-vinyl acetate (EVA) foam material, that is configured to compress on impact and provide cushion and support to the foot as the article of footwear 100 impacts a support surface. The outsole 320 may be constructed from a material that is durable and contains a durometer value greater than the midsole 310. As illustrated in FIGS. 1-4, the outsole 320 is configured to cover the entire bottom surface of the midsole 310. In another embodiment, the outsole 320 may be separated into multiple regions that are positioned on the midsole 310 at locations that receive the most wear on the bottom surface of the midsole 300.

As illustrated in FIGS. 1-4, the upper 200 contains a ribbed portion 210 and a fabric portion 270. The ribbed portion 210 and the fabric portion 270 are coupled to one another to form the upper 200 of the shoe 100. As illustrated, the ribbed portion 210 is disposed on the lateral side 120 of the shoe 100, over forefoot region 202, around the hindfoot region 206, and is at least partially disposed on the medial side 110 of the shoe 100. Thus, the ribbed portion 210 spans along the entire length of, and essentially defines, the upper portion along lateral side 120 of the shoe 100. The ribbed portion 210 further extends over the toe end 130 and vamp of the shoe 100, and around the heel end 140 of the shoe 100.

The ribbed portion 210 includes a first sloped edge 212, a second sloped edge 214, a top edge 216, and a bottom edge 224. The first sloped edge 212 extends from the top side 150 of the shoe 100 in the forefoot region 202 rearward toward the medial side 110 of the shoe 100 in the midfoot region 204. The second sloped edge 214 extends from the top side 150 of the shoe 100 in the hindfoot region 206 proximate to the opening 208, around the heel end 140, and forward toward the medial side 110 of the shoe 100 in the midfoot region 204. The top edge 216 spans along the top side 150 of the shoe 100 from the forefoot region 202 to the hindfoot region 206. The first sloped edge 212, the second sloped edge 214, and the top edge 216 are coupled to the fabric portion 270. The bottom edge 224 of the ribbed portion 210 is disposed along the lateral side 120, around the toe end 130, around the heel end 140, and at least partially disposed along the medial side 110 (e.g., primarily in the forefoot 202 and hindfoot 206 regions). The bottom edge 224 of the ribbed portion 210 is coupled to the sole structure 300 via any conventional and/or other suitable manner (e.g., via any form of adhesion or bonding, via a woven connection, via one or more types of fasteners, etc.).

The fabric portion 270 is oriented on the shoe 100 generally in the midfoot region 204 on the top side 150 of the shoe 100 and the medial side 110 of the shoe 100. The fabric portion 270 is also at least partially oriented in the hindfoot region 206 and the forefoot region 202 of the shoe 100. The fabric portion 270 includes a tongue section 272 and a side section 274. As best illustrated in FIGS. 2 and 4, the tongue section 272 is disposed on the top side 150 of the shoe 100 extending from the forefoot region 202, through the midfoot region 204, and to the hindfoot region 206. The side section 274, as best illustrated in FIG. 2, is disposed on the medial side 110 of the shoe 100 and spans from the midfoot region 204 to the hindfoot region 206. The side section 274 is coupled to the tongue section 272, where the side section 274 and the tongue section 272 may be uniformly formed together (e.g., as a single piece or single section) to form the fabric portion 270. In another embodiment, the tongue section 272 and side section 274 may be formed separately and combined or coupled together in any suitable manner.

The fabric portion 270 includes a top edge 276 disposed proximate to the opening 208 in the hindfoot region 206 of the shoe 100. The top edge 276 serves as part of tongue section 272 and the side section 274. As illustrated in FIGS. 1, 2, and 4, the opening 208 of the upper 200 is at least partially formed from the combination of the top edge 216 of the ribbed portion 210 and the top edge 276 of the fabric portion 270. The fabric portion 270 further includes a first side edge 278, which also serves as one side of the tongue section 272, disposed proximate to the top edge 216 of the ribbed portion 210. The top edge 216 of the ribbed portion 210 and the first side edge 278 of the fabric portion 270 are not coupled to one another, such that the first side edge 278 may be disposed under the top edge 216 of the ribbed portion 210. The fabric portion 270 may further include a second side edge 280 that extends forwardly from the hindfoot region 206 toward midfoot region 204, and from the top side 150 of the shoe 100 proximate to the opening 208 towards the medial side 110 of the shoe 100. The second side edge 280 is coupled to the second sloped edge 214 of the ribbed portion 210. In addition, the fabric portion 270 may include a third side edge 282 that extends rearwardly from the forefoot region 202 toward the midfoot region 206, and from the top side 150 of the shoe 100 to the medial side 110 of the shoe 100. The third side edge 282 is coupled to the first sloped edge 212 of the ribbed portion 210. The fabric portion 270 further includes a bottom edge 284 extending from the second side edge 280 to the third side edge 282. The bottom edge 284 may be coupled to the support structure 300 via any conventional and/or other suitable manner (e.g., via any form of adhesion or bonding, via a woven connection, via one or more types of fasteners, etc.). As illustrated in FIGS. 1, 2, and 4, the opening 208 of the upper 200 is formed from the combination of the top edge 216 of the ribbed portion 210 and the top edge 276 of the fabric portion 270.

As best illustrated in FIGS. 5 and 6, which are views of the ribbed portion 210 of the upper 200 prior to the construction of the upper 200 of the shoe 100, the ribbed portion 210 includes a skin layer 226 disposed on a fabric base layer 228. The skin layer 226 may be formed from a plurality of interconnected panels 230, 240, 250, 260. As illustrated in FIGS. 1-6, the skin layer 226 of the ribbed portion 210 may include four different types of panels 230, 240, 250, 260, where each of the panels 230, 240, 250, 260 are polygonal (e.g., pentagonal) in shape and comprise a set of ribs or fins 232, 242, 252, 262, respectively. Each of the panel types 230, 240, 250, 260 provide a predetermined level of support and flexibility, determined by the dimensions and spacing of the sets of ribs 232, 242, 252, 262 of the panel types 230, 240, 250, 260, respectively. While the embodiment of the ribbed portion 210 illustrated in FIGS. 1-6 is formed from a plurality of four different types of panels 230, 240, 250, 260 that are interconnected to one another, other embodiments of the ribbed portion 210 of a shoe 100 may contain fewer or greater than four types of panels. In addition, in another embodiment of the ribbed portion 210, each of the panel types 230, 240, 250, 260 may be shaped differently (e.g., having other polygonal shapes, such as triangular, rectangular, hexagonal, octagonal, etc.). In other embodiments of the ribbed portion 210, each individual panel may be shaped differently, rather than all of the panels of a panel type being of the same or similar shape (e.g., as illustrated in the embodiment of FIGS. 1-6).

The differences in the size and spacing of the ribs 232, 242, 252, 262 of the panels 230, 240, 250, 260 may be seen in FIG. 6. As illustrated, each of the panels 230, 240, 250, 260 may include the same number of ribs 232, 242, 252, 262 (e.g., twelve). In other embodiments of the ribbed portion 210, different types of panels 230, 240, 250, 260 may each include a different number of ribs. In addition, as illustrated in FIGS. 5 and 6, the ribs 232, 242, 252, 262 of the panel types 230, 240, 250, 260 are parallel to one another (e.g., where one or more ribs may extend continuously along the same linear progression between two or more adjacent panel types). In other embodiments, the ribs 232, 242, 252, 262 may traverse the ribbed portion 210 such that the ribs 232, 242, 252, 262 of one panel 230, 240, 250, 260 are not parallel to the ribs 232, 242, 252, 262 of another panel 230, 240, 250, 260. In yet another embodiment, the ribs 232, 242, 252, 262 of a specific the panel type 230, 240, 250, 260 may not be parallel with one another.

Ribs of different panel types may further have different width dimensions (i.e., different dimensions that are transverse the longitudinal or lengthwise dimensions of the ribs) and/or spaced at different distances from immediate neighboring ribs. For example, as illustrated in FIG. 6, the ribs 232 of the first panel type 230 may be the smallest in size and may be spaced furthest apart from one another, when comparing the first panel type 230 to the other panel types 240, 250, 260. As further illustrated, the underlying fabric base layer 228 is more easily viewed through the first panel type 230 because of the dimensions and the spacing (i.e., greatest spacing) of the ribs 232. As further illustrated in FIG. 6, the ribs 242 of the second panel type 240 are thicker than that of the ribs 232 of the first panel type 230. Because the ribs 242 are thicker than the ribs 232 of the first panel type 230, the spacing between the ribs 242 of the second panel type 240 is smaller than that of the first panel type 230. Thus, as illustrated, less of the fabric base layer 228 is visible through the second panel type 240 than the first panel type 230.

FIG. 6 further illustrates that the ribs 252 of the third panel type 250 are thicker than that of both the ribs 232 of the first panel type 230 and the ribs 242 of the second panel type 240. Because the ribs 252 are thicker than the both ribs 232 and ribs 242, the spacing between the ribs 252 of the third panel type 250 is even smaller than that of the second panel type 240. As illustrated in FIG. 6, the fabric base layer 228 is less visible through the third panel type 250 than both the first panel type 230 and the second panel type 240. In addition, the ribs 262 of the fourth panel type 260 are the thickest of the ribs 232, 242, 252, 262 of the panel types 230, 240, 250, 260, respectively. As illustrated in FIG. 6, the ribs 262 of the fourth panel type 260 are of a thickness that the ribs 262 may be adjacent to one another such that space between ribs 262 may be substantially smaller than the spacing between the other ribs 232, 242, 252, or may not be present (e.g., neighboring ribs may be adjacent or border upon each other). Thus, the fabric base layer 228 may not be visible through the fourth panel type 260.

The panels 230, 240, 250, 260 may be constructed from a polymer material, such as, but not limited to, polyurethane. The material of the panels 230, 240, 250, 260 may be stiffer or harder (e.g., having a greater Shore durometer value) than the fabric base layer 228 and the fabric portion 270. Furthermore, the material of the panels 230, 240, 250, 260 may be less flexible and/or less elastic (i.e., not be as stretchable) as the fabric base layer 228 and the fabric portion 270. The panels 230, 240, 250, 260 may be applied to the fabric base layer 228 via casting, bonding, an adhesive, or may be applied by the polymer material being infused into the fabric base layer 228. The fabric base layer 228 of the ribbed portion 210 may be constructed from a fabric material that may have desirable aesthetic and functional features that incorporate durability, flexibility, air permeability and/or other types of desirable properties to the upper 200. Similar to the fabric base layer 228, the fabric portion 270 of the upper 200 may also be constructed from a fabric material that may have desirable aesthetic and functional features that incorporate durability, flexibility, air permeability and/or other types of desirable properties to the upper 200. In another embodiment, the fabric portion 270 of the upper 200 may be constructed from a fabric material that further contains elastomeric properties, where the fabric portion 270 is configured to stretch and conform to the arch of a user's foot. The fabric base layer 228 and the fabric portion 270 may be constructed from the same or different types of fabric.

Turning back to FIGS. 1, 2, and 5, the skin layer 226 of the ribbed portion 210 of the upper 200 includes a series of eyelets 220 disposed proximate to, and along, the top edge 216 of the upper 200 in the midfoot region 204. In one embodiment, the eyelets 220 may be formed from the same polymer material as the panels 230, 240, 250, 260 and extend from the fabric base layer 228 at suitable distance (e.g., approximately 0.3 mm). Furthermore, the fabric portion 270 includes a plurality of eyelets 286 disposed along the coupling of the tongue section 272 and the side section 274. In the embodiment illustrated in FIG. 2, the eyelets 286 of the fabric portion 270 may be slits or elongated openings in the fabric portion 270. A fastening element or fastener 222 (e.g., a lace, cord, string, etc.) may be threaded through the eyelets 216 of the ribbed portion 210 and the eyelets 286 of the fabric portion 270, such that the fastener 222 may be used to tighten and secure the upper 200 around a foot placed within the shoe 100.

As illustrated in FIGS. 7A-7D, cross sectional views are shown of the ribs 232, 242, 252, 262 of the panels 230, 240, 250, 260, respectively, where each view in FIGS. 7A-7D is shown to scale with respect to every other view. FIGS. 7A-7D further illustrate differences in the dimensions and spacing of the ribs 232, 242, 252, 262 of the panels 230, 240, 250, 260, respectively. The ribs 232 of the first panel type 230, as illustrated in FIG. 7A, include a base portion 234, a middle portion 236, and a top portion 238. The ribs 232 are disposed on and extend upwardly from the fabric base layer 228. More specifically, the base portion 234 is disposed on the fabric base layer 228 and contains the widest width, but the smallest height, of the portions 234, 236, 238 of the ribs 232. The middle portion 236 of each of the ribs 232 is formed on the base portion 234, where the middle portion 236 tapers from its maximum width proximate to the base portion 234 to its minimum width proximate to the top portion 238. The middle portion 236 may be rectangular. The top portion 238 is formed on top of the middle portion 236, where the top portion 238 may be triangular such that the top portion 238 tapers to a central point or edge. As further illustrated in FIG. 7A, neighboring ribs 232 are separated by spacing 239.

In one embodiment of the first panel type 230, the total height of the ribs 232 may be approximately 0.8 mm. In addition, the bottom portion 234 may extend upwardly from the fabric base layer 228 by 0.1 mm, while the top portion 238 may extend upwardly from the top of the middle portion 236 by 0.2 mm. Thus, the middle portion 236 may have a height of 0.5 mm. Furthermore, the middle portion 236 may have a width of 1 mm proximate to the bottom portion 234, and may taper to a width of 0.75 mm proximate to the top portion 238. In addition, the bottom portion 234 may extend 0.3 mm beyond the each side of the bottom of the middle portion 236. Finally, each of the ribs 232 of the first panel type 232 may be spaced 2.2 mm from one another.

Turning to FIG. 7B, the ribs 242 of the second panel type 240 include a base portion 244, a middle portion 246, and a top portion 248, similar to that of the first panel type 230. As illustrated, the ribs 242 are disposed on and extend upwardly from the fabric base layer 228. More specifically, the base portion 244 is disposed on the fabric base layer 228 and contains the widest width of the portions 244, 246, 248 of the ribs 242, but the smallest height of the portions 244, 246, 248 of the ribs 242. The middle portion 246 of each of the ribs 242 is formed on the base portion 244, where the middle portion 246 tapers from its maximum width proximate to the base portion 244 to its minimum width proximate to the top portion 248. Similar to the ribs 232 of the first panel type 230, the middle portion 246 of the ribs 242 of the second panel type 240 may be rectangular. As illustrated in FIG. 7B, the top portion 248 is formed on top of the middle portion 246, where the top portion 248 may be triangular such that the top portion 248 tapers to a central point or edge. As further illustrated in FIG. 7B, neighboring ribs 242 are separated by spacing 249. When comparing the ribs 242 illustrated in FIG. 7B to the ribs 232 illustrated in FIG. 7A, the differences in the dimensions and spacings between the ribs 232, 242 of the first and second panel types 230, 240 are evident.

In one embodiment of the ribs 242 of the second panel type 240, the total height of the ribs 242 may be 1.1 mm. Thus, the ribs 242 of second panel type 240 are taller than the ribs 232 of the first panel type 230. As further illustrated, the height of the bottom portion 244 from the fabric base layer 228 may be 0.1 mm, which is similar to that of the ribs 232 of the first panel type 230. In addition, the height of the top portion 248 from the top of the middle portion 246 may be 0.3 mm, which is greater than that of the top portion 236 of the ribs 232 of the first panel type 230. It then follows that the middle portion 246 of ribs 242 may have a height of 0.7 mm. As further illustrated in FIG. 7B, the middle portion 246 of ribs 242 may have a width of 1.5 mm proximate to the bottom portion 244, and may taper to a width of 1.25 mm proximate to the top portion 248. Thus, the middle portion 246 of the ribs 242 of the second panel type 240 may be taller and wider than that of the middle portion 236 of the ribs 232 of the first panel type 230. In addition, similar to the ribs 232 of the first panel type 230, the bottom portion 244 of the ribs 242 of the second panel type 240 may extend 0.3 mm beyond the bottom of each side of the middle portion 246. Finally, each of the ribs 242 of the second panel type 242 may be spaced 1.7 mm from one another. Thus, the ribs 242 of the second panel type 242 are taller and wider than the ribs 232 of the first panel type 230, while the ribs 242 of the second panel type 242 are spaced closer to one another than the ribs 232 of the first panel type 230.

Similar to ribs 232, 242, as illustrated in FIG. 7C, the ribs 252 of the third panel type 250 include a base portion 254, a middle portion 256, and a top portion 258. As illustrated, the ribs 252 are disposed on and extend upwardly from the fabric base layer 228. More specifically, the base portion 254 is disposed on the fabric base layer 228 and contains the widest width, but the smallest height, of the portions 254, 256, 258 of the ribs 252. The middle portion 256 of each of the ribs 252 is formed on the base portion 254, where the middle portion 256 tapers from its maximum width proximate to the base portion 254 to its minimum width proximate to the top portion 258. Similar to the ribs 232 of the first panel type 230 and the ribs 242 of the second panel type 240, the middle portion 256 of the ribs 252 of the third panel type 250 may be rectangular. In addition, the top portion 258 is formed on top of the middle portion 256, where the top portion 258 may be triangular such that the top portion 258 tapers to a central point or edge. As further illustrated in FIG. 7C, neighboring ribs 252 are separated by spacing 259. When comparing the ribs 252 illustrated in FIG. 7C to the ribs 232 illustrated in FIG. 7A and the ribs 242 illustrated in FIG. 7B, the differences of the dimensions and spacings of the ribs 252 of the third panel type 250 with the ribs 232, 242 of the first and second panel types 230, 240 are evident.

In one embodiment of the ribs 252 of the third panel type 250, the total height of the ribs 252 may be 1.4 mm, which is taller than both the ribs 242 of the second panel type 240 and the ribs 232 of the first panel type 230. As further illustrated, the bottom portion 254 may extend upward from the fabric base layer 228 by 0.1 mm, which is similar both the ribs 232 of the first panel type 230 and the ribs 242 of the second panel type 240. In addition, the top portion 258 may extend upwardly from the top of the middle portion 256 by 0.4 mm. Thus, the top portions 258 of the ribs 252 are taller than the top portions 236, 246 of the ribs 232, 242, respectively. Accordingly, the middle portion 256 of ribs 252 may have a height of 0.9 mm. As further illustrated in FIG. 7C, the middle portion 256 of ribs 252 may have a width of 2.0 mm proximate to the bottom portion 254, and may taper to a width of 1.75 mm proximate to the top portion 258. Thus, the middle portion 256 of the ribs 252 of the third panel type 250 may be both taller and wider than that of the middle portion 236 of the ribs 232 of the first panel type 230 and the middle portion 246 of the ribs 242 of the second panel type 240. Similar to both the ribs 232 of the first panel type 230 and the ribs 242 of the second panel type 240, the bottom portion 254 of the ribs 252 of the third panel type 250 may extend 0.3 mm beyond the bottom of each side of the middle portion 256. In addition, each of the ribs 252 of the third panel type 252 may be spaced only 1.2 mm from one another. Thus, the ribs 252 of the third panel type 250 are taller and wider than the both ribs 232 of the first panel type 230 and ribs 242 of the second panel type 240. Additionally, the ribs 232 of the first panel type 230 and the ribs 242 of the second panel type 242 are both spaced farther apart than that of the ribs 252 of the third panel type 252.

Turning to FIG. 7D, illustrated is a set or ribs 262 of the fourth panel type 260, where the ribs 262 include a base portion 264, a middle portion 266, and a top portion 268, that are shaped similarly to that of the ribs 232, 242, 252 of the first, second, and third panel types 230, 240, 250, respectively. The ribs 262 are disposed on and extend upwardly from the fabric base layer 228. More specifically, the base portion 264 is disposed on the fabric base layer 228 and contains the widest width, but the smallest height, of the portions 264, 266, 268 of the ribs 262. The middle portion 266 of the ribs 262 extends upwardly from the base portion 264, where the middle portion 266 tapers from its maximum width proximate to the base portion 264 to its minimum width proximate to the top portion 268. Similar to the ribs 232, 242, 252 of the first, second, and third panel types 230, 240, 250, the middle portion 266 of the ribs 262 of the fourth panel type 260 may be rectangular. As further illustrated in 7D, the top portion 268 of the ribs 262 extends upwardly from the top of the middle portion 266, where the top portion 268 may be triangular such that the top portion 268 tapers to a central point or edge. In addition, neighboring ribs 262 are separated by spacing 269. When comparing the ribs 262 illustrated in FIG. 7D to the ribs 232, 242, 252 illustrated in FIGS. 7A-7C, it is apparent that the ribs 262 of the fourth panel type 260 are larger, wider, and more closely spaced to one another than the ribs 232 of the first panel type 230, the ribs 242 of the second panel type 240, and the ribs 252 of the third panel type 250.

In one embodiment of the ribs 262 of the fourth panel type 260, the total height of the ribs 262 may be 1.7 mm. Thus, the ribs 262 of the fourth panel type 260 may be taller than any of the ribs 232, 242, 252 of the other panel types 230, 240, 250. As further illustrated, the height of the bottom portion 264 from the fabric base layer 228 may be approximately 0.3 mm to 0.4 mm, which is greater than ribs 232 of the first panel type 230, the ribs 242 of the second panel type 240, and the ribs 252 of the third panel type 250. In addition, the height of the top portion 268 from the top of the middle portion 266 may be 0.5 mm. Thus, the top portions 268 of the ribs 262 are taller than the top portions 236, 246, 256 of the ribs 232, 242, 252, respectively. It further follows that the middle portion 266 of ribs 262 may have a height of approximately 0.8 mm to 0.9 mm. As further illustrated in FIG. 7D, the middle portion 266 of ribs 262 may have a width of 2.5 mm proximate to the bottom portion 264, and may taper to a width of 2.25 mm proximate to the top portion 268. Thus, the middle portion 266 of the ribs 262 of the fourth panel type 260 may be taller and wider compared to the middle portion 236 of the ribs 232 of the first panel type 230, the middle portion 246 of the ribs 242 of the second panel type 240, and the middle portion 256 of the ribs 252 of the third panel type 250. Similar to the ribs 232, 242, 252 of the other panel types 230, 240, 250, the bottom portion 264 of the ribs 262 of the fourth panel type 260 may extend 0.3 mm beyond the bottom of each side of the middle portion 266. In addition, each of the ribs 262 of the fourth panel type 262 may be spaced only 0.75 mm from one another. Thus, the ribs 262 of the fourth panel type 260 are taller and wider than the ribs 232 of the first panel type 230, ribs 242 of the second panel type 240, and the ribs 252 of the third panel type 250. Additionally, the ribs 232 of the first panel type 230, the ribs 242 of the second panel type 242, and the ribs 252 of the third panel type 250 are all spaced farther apart than that of the ribs 262 of the fourth panel type 262.

With the ribs 232, 242, 252, 262 of each of the types of panels 230, 240, 250, 260 having different dimensions and being spaced differently, each of the panel types 230, 240, 250, 260 provides a different amount or degree of support and also enables a different degree of flexibility. Because the ribs 232 of the first panel type 230 are smaller in height and width in relation to the other ribs 242, 252, 262, the first panel type 230 is constructed from (and thus includes) the smallest amount of polymer material of the panel types 230, 240, 250, 260. Because the first panel type 230 contains the least amount of polymer material of the panel types 230, 240, 250, 260, and further because the ribs 232 of the first panel type 230 are spaced the farthest apart when compared to the other ribs 242, 252, 262, the first panel type 230 provides the smallest amount of support of the panel types 230, 240, 250, 260. Furthermore, the first panel type 230 enables a greater degree of flexibility when compared to the second, third and fourth panel types 240, 250, 260.

Conversely, because the ribs 262 of the fourth panel type 260 are larger in height and width than ribs 232, 242, 252, the fourth panel type 260 is constructed from (and thus includes) the largest amount of polymer material of all of the panel types 230, 240, 250, 260. Because the fourth panel type contains the largest amount of polymer material, and because the spacing between the ribs 262 of the fourth panel type 260 is the smallest of the ribs 232, 242, 252, the fourth panel type 260 provides the greatest amount of support of the panel types 230, 240, 250, 260. Furthermore, the fourth panel type 260 has the smallest degree of flexibility of the panel types 230, 240, 250, 260. Thus, the fourth panel type 260 is the stiffest of the panel types 230, 240, 250, 260, while the first panel type 230 is least stiff of the panel types 230, 240, 250, 260. It then follows that the second panel type 240 is stiffer than the first panel type 230, but more flexible than the third panel type 250 and the fourth panel type 260. The third panel type is stiffer than the first panel type 230 and the second panel type 240, but more flexible than the fourth panel type 260.

As illustrated in FIGS. 1-6, the ribbed portion 210 of the upper can be configured with discrete micro zones or larger areas/zones of varying stiffness and flexibility. The discrete micro zones may formed from a single panel type 230, 240, 250, 260, while larger areas/zones may be formed from a grouping of panel types 230, 240, 250, 260 that have the same or similar amount of support. As illustrated, the ribbed portion 210 disposed in the forefoot region 202 contains the stiffer panel types 250, 260 disposed proximate to the bottom edge 224, while the more flexible panel types 230, 240 are disposed proximate to the top edge 216 and the first sloped edge 212. This construction and placement of each of the panel types 230, 240, 250, 260 of the ribbed portion 210 enables the forefoot region 202 of the upper 200 to bend and conform to the movements of a foot placed within the upper 200 of the shoe 100, while still providing structure and protection to the toes of the foot at the toe end 130 of the shoe 100. The more flexible panel types 230, 240 may be disposed or aligned approximately where the phalanges or toes are coupled to the metatarsal bones of a foot disposed within the shoe 100. Thus, the more flexible panel types 230, 240 enable the vamp and toebox of the shoe 100 to bend as the toes of the foot are bent backward during movements (e.g., walking, running, jumping, etc.). The less flexible and more supportive panels 250, 260 may be disposed or aligned over the ends of the toes of the foot disposed within the shoe 100 to provide additional protection to the ends of the toes.

As further illustrated, the ribbed portion 210 disposed in the hindfoot region 206 of the shoe 100 contains mostly the stiffer panel types 250, 260 disposed proximate to the bottom edge 224, and mostly flexible panel types 230, 240 disposed proximate to the top edge 216 and the second sloped edge 214. This construction and placement of the panel types 230, 240, 250, 260 of the ribbed portion 210 in the hindfoot region 206 of the upper 200 enables the hindfoot region 206 of the upper 200 in this section to bend and conform to the movement of the foot about the ankle (e.g., inversion, eversion, dorsiflexion, plantarflexion, etc.), while still providing structure and support to the foot and ankle disposed within the upper 200 of the shoe 100.

In addition, FIGS. 1-6 illustrates that the section of the ribbed portion 210 in the midfoot region 204 includes stiffer panel types 250, 260 disposed proximate to the bottom edge 224 and the top edge 216, while more flexible panel types 230, 240 are disposed between the two sets of stiffer panel types 250, 260. As further illustrated, the eyelets 220 are disposed in the ribbed portion 210 proximate to the top edge 216 in the midfoot region 204, and are mostly disposed on the stiffer panel types 250, 260. This construction of the ribbed portion 210 in the midfoot region 204 enables the upper 200 to provide adequate support to the instep of the foot disposed within the shoe 100 when the fastener 222 is pulled through the eyelets 220 to tighten the upper 200 around the foot placed within the shoe 100. This construction of the ribbed portion 210 in the midfoot region 204 further enables the upper to conform to the foot disposed within the shoe 100 as the upper 200 is tightened around the foot, while also providing some degree of flexibility to enable the foot and the arch of the foot to flex and move.

The present invention enables performance customization of a shoe 100, where the shoe 100 contains specific zones and sub-zones of support and/or flexibility. The panels 230, 240, 250, 260 may be selected and disposed on the ribbed portion 210 of the upper 200 to form a different zones of support, flexibility, and comfort based on the location of the groups of similar panels 230, 240, 250, 260. As previously explained, each of the panels 230, 240, 250, 260 may individually serve as a sub-zone with a unique level of support, flexibility and comfort based on the dimensions and spacing of the ribs 232, 242, 252, 262. Each of the zones and/or sub-zones together provide unique performance characteristics for the shoe 100. These zones and sub-zones can vary from shoe to shoe depending on the designed purpose and intended use of each shoe. The combination of the different types of panels 230, 240, 250, 260 enables a shoe manufacturer to more easily customize performance characteristics of a shoe for a given situation, environment and/or user activity. For example, by grouping the panel types 250, 260 to define zones or sub-zones of the upper 200 that have greater support in relation to zones or sub-zones formed from panel types 230, 240, the shoe 100 may provide a greater degree of support but reduced flexibility and cushioning at such zones/sub-zones of the upper 200. In addition, the shoe 100 may provide a greater degree of flexibility and comfort but reduced support at the zones or sub-zones formed from the panel types 230, 240.

It is to be understood that terms such as “left,” “right,” “top,” “bottom,” “front,” “rear,” “side,” “height,” “length,” “width,” “upper,” “lower,” “interior,” “exterior,” “inner,” “outer” and the like as may be used herein, merely describe points or portions of reference and do not limit the present invention to any particular orientation or configuration. Further, the term “exemplary” is used herein to describe an example or illustration. Any embodiment described herein as exemplary is not to be construed as a preferred or advantageous embodiment, but rather as one example or illustration of a possible embodiment of the invention.

Although the disclosed inventions are illustrated and described herein as embodied in one or more specific examples, it is nevertheless not intended to be limited to the details shown, since various modifications and structural changes may be made therein without departing from the scope of the inventions and within the scope and range of equivalents of the claims. In addition, various features from one of the embodiments may be incorporated into another of the embodiments. Accordingly, it is appropriate that the appended claims be construed broadly and in a manner consistent with the scope of the disclosure as set forth in the following claims.

Claims

1. An article of footwear comprising:

a sole structure; and

an upper disposed on the sole structure, the upper comprising: a first layer having an interior surface and an exterior surface, and a second layer disposed on the exterior surface of the first layer, the second layer including a plurality of panels.

2. The article of footwear of claim 1, wherein each of the plurality of panels includes a plurality of equally spaced parallel ribs.

3. The article of footwear of claim 2, wherein the first layer is at least partially visible through the second layer.

4. The article of footwear of claim 2, wherein the plurality of panels include at least a first panel and a second panel.

5. The article of footwear of claim 4, wherein ribs of the first panel have a first width and a first height, and ribs of the second panel have a second width and a second height, the first width being different than the second width, and the first height being different than the second height.

6. The article of footwear of claim 4, where the ribs of the first panel are equally spaced a first distance and the ribs of the second panel are equally spaced a second distance, the first distance being different than the second distance.

7. The article of footwear of claim 6, wherein the first panel has a first degree of flexibility and the second panel has a second degree of flexibility, the first degree of flexibility being different than the second degree of flexibility.

8. The article of footwear of claim 4, wherein the ribs of the first panel are parallel to the ribs of the second panel.

9. The article of footwear of claim 1, wherein the first layer is constructed from a woven textile, and the second layer is constructed from polyurethane.

10. An article of footwear comprising:

a sole structure; and

an upper disposed on the sole structure, the upper comprising: a first layer having an interior surface and an exterior surface, and a second layer disposed on the exterior surface of the first layer, the second layer including a plurality of parallel ribs.

11. The article of footwear of claim 10, wherein the plurality of parallel ribs are oriented in a direction that is transverse to a longitudinal direction of the article of footwear, the longitudinal direction extending from a toe end of the article of footwear to a heel end of the article of footwear.

12. The article of footwear of claim 10, wherein the plurality parallel ribs are disposed within a plurality of panels such that each panel of the plurality of panels includes a subset of the plurality of parallel ribs.

13. The article of footwear of claim 12, wherein the plurality of panels include at least a first panel and a second panel, the first panel including a first subset of the plurality of parallel ribs and the second panel including a second subset of the plurality of parallel ribs.

14. The article of footwear of claim 13, wherein the first subset of the plurality of ribs have a first width and a first height, and second subset of the plurality of ribs have a second width and a second height, the first width being different than the second width, and the first height being different than the second height.

15. An article of footwear comprising:

a sole structure; and

an upper disposed on the sole structure, the upper comprising: a first layer, and a second layer disposed on the first layer, the second layer including a plurality of panels, wherein the plurality of panels collectively define a plurality of support zones, each support zone being formed by a subset of the plurality of panels that are disposed adjacent to one another.

16. The article of footwear of claim 15, wherein the plurality of panels include at least a first panel type, a second panel type, a third panel type, and a fourth panel type, the first panel type includes a first set of equally spaced parallel ribs, the second panel type includes a second set of equally spaced parallel ribs, the third panel includes a third set of equally spaced parallel ribs, and the fourth panel includes a fourth set of equally spaced parallel ribs.

17. The article of footwear of claim 16, wherein first set of ribs have a first width and a first height, the second set of ribs have a second width and a second height, the third set of ribs have a third width and a third height, and the fourth set of ribs have a fourth width and a fourth height, the fourth width being greater than the third width, the second width, and the first width, the third width being greater than the second width and the first width, and the second width being greater than the first width, and the fourth height being greater than the third height, the second height, and the first height, the third height being greater than the second height and the first height, and the second height being greater than the first height.

18. The article of footwear of claim 17, wherein the first panel type has a first degree of flexibility, the second panel type has a second degree of flexibility, the third panel type has a third degree of flexibility, and the fourth panel type has a third degree of flexibility, the first degree of flexibility being greater than the second degree of flexibility, the third degree of flexibility, and the fourth degree of flexibility, the second degree of flexibility type being greater than the third degree of flexibility and the fourth degree of flexibility, and the third degree of flexibility being greater than the fourth degree of flexibility.

19. The article of footwear of claim 18, wherein a first support zone formed by a plurality of panels of the third panel type and the fourth panel type is configured to provide more support to a foot disposed within the article of footwear than a second support zone formed by a plurality of panels of the first panel type and the second panel type.

20. The article of footwear of claim 18, wherein a first support zone formed by a plurality of panels of the first panel type and the second panel type is configured to be more flexible than a second support zone formed by a plurality of panels of the third panel type and the fourth panel type.