ARTICLE OF FOOTWEAR HAVING A COMFORTABLE AND PROTECTIVE TOE CAP

Abstract

An article of footwear includes an upper having a toe box and a forefoot portion adjacent the toe box. The forefoot portion has a first region having a first stiffness. The article of footwear also includes a transition region including an elastomeric transition layer disposed on and partially covering the first region. The transition region has a second stiffness that is greater than the first stiffness. The article of footwear further includes a toe cap disposed on and partially covering the elastomeric transition layer at the toe box.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of and priority to U.S. Provisional Patent Application No. 62/776,542, filed on Dec. 7, 2018, which is incorporated herein by reference in its entirety.

TECHNICAL FIELD

The disclosure relates to an article of footwear including a toe cap.

BACKGROUND

Articles of footwear are generally configured to protect a foot from contact with a traveling surface and/or objects, and often include two primary elements: an upper and a sole structure. The upper may be formed from several material elements such as textiles, polymer sheet layers, foam layers, leather, synthetic leather, and the like that are stitched or adhesively bonded together. The upper may form a structure that extends over and protects an instep and toe area of the foot, medial and lateral sides of the foot, and a heel area of the foot.

The sole structure is generally attached to a lower portion of the upper and positioned between the foot and the traveling surface. In many articles of footwear, including athletic shoes, the sole structure may be a layered construction that generally incorporates a comfort-enhancing insole, an impact-mitigating midsole, and a surface-contacting outsole.

BRIEF DESCRIPTION OF THE DRAWINGS

The drawings described herein are for illustrative purposes only, are schematic in nature, and are intended to be exemplary rather than to limit the scope of the disclosure.

FIG. 1 is a schematic illustration of a perspective view of a lateral side of an article of footwear including an upper having a toe box and a forefoot portion adjacent the toe box.

FIG. 2 is a schematic illustration of a perspective view of a top side of the forefoot portion and toe box of FIG. 1.

FIG. 3 is a schematic illustration of a perspective view of a medial side of the article of footwear of FIG. 1.

FIG. 4 is a schematic illustration of a perspective view of a rear of a heel portion of the article of footwear of FIGS. 1-3.

FIG. 5 is a schematic illustration of a perspective view of a portion of an ankle collar that is at least partially connected to the heel portion of FIG. 4.

DESCRIPTION

The present disclosure generally relates to an article of footwear that includes a toe cap configured to comfortably protect a toe area of a foot. The article of footwear includes an upper having a forefoot portion adjacent a toe box, and the toe cap is disposed on an exterior of the article of footwear at the toe box. The toe cap is formed from a stiff, non-metal material. The article of footwear also includes a transition region that includes an elastomeric transition layer disposed between the upper and the toe cap. The elastomeric transition layer underlays an edge or boundary of the toe cap and therefore ensures a comfortable transition from the toe cap to the forefoot portion.

The article of footwear may also include a tape adhered to a bite line at an interface of the upper and a sole structure. The tape may be reflective and/or waterproof and therefore may enhance a visibility of the article of footwear and mitigate moisture transmission through the bite line.

Further, the article of footwear includes a heel portion and an ankle collar that together define a seam channel. An entirety of the ankle collar is spaced apart from the heel portion by the seam channel on the lateral side; a first portion of the ankle collar is spaced apart from the heel portion by the seam channel on the medial side; and a second portion of the ankle collar is connected to the heel portion on the medial side. As such, the specific configurations of the heel portion, seam channel, and ankle collar provide the user with excellent ankle support while allowing for fluid, flexible movement of the ankle.

In an example, an article of footwear may include an upper having a toe box and a forefoot portion adjacent the toe box. The forefoot portion may have a first region having a first stiffness. The article of footwear may also include a transition region including an elastomeric transition layer disposed on and partially covering the first region. The transition region may have a second stiffness that is greater than the first stiffness. In addition, the article of footwear may include a toe cap disposed on and partially covering the elastomeric transition layer at the toe box.

In an aspect, the toe cap may have a third stiffness that is greater than the second stiffness.

In a further aspect, the elastomeric transition layer may partially overlay the first region and partially underlay the toe cap.

In one or more configurations, the upper may have a heel portion spaced apart from the toe box such that the forefoot portion is disposed between the heel portion and the toe box. Further, the toe cap may have an arcuate edge facing the heel portion that does not contact the first region.

In a further aspect, the elastomeric transition layer may have a first thickness and the toe cap may have a second thickness that is greater than the first thickness.

In one or more configurations, the upper may have a medial side, a lateral side opposite the medial side, and a second region abutting the first region and disposed along at least one of the medial side and the lateral side. The second region may have a fourth stiffness that is less than the first stiffness.

In an aspect, the second region may have a stiffening pattern that includes a plurality of stiffened portions and a non-stiffened portion disposed between adjacent ones of the plurality of stiffened portions.

In a further aspect, the forefoot portion may be formed from a fusible yarn having a variable stiffness, and the first region and the plurality of stiffened portions may include a fused thermoplastic.

In one or more configurations, the upper may have an exterior, and the article of footwear may further include an ankle collar defining a foot-receiving cavity that is spaced apart from the exterior; a sole structure attached to the upper at a bite line disposed along the exterior; and a tape adhered to the sole structure and the upper and covering the bite line.

In an aspect, the tape may be adhered to an entirety of the bite line such that the tape encircles the sole structure at the bite line and covers a portion of the toe cap.

In a further aspect, the tape may be formed form at least one of a light-reflective material and a waterproof material configured to inhibit fluid transmission through the bite line to the foot-receiving cavity.

In an example, an article of footwear may include an upper having a medial side, a lateral side opposite the medial side, a toe box, a heel portion spaced apart from the toe box, and a forefoot portion disposed between the toe box and the heel portion. The forefoot portion may have a first region having a first stiffness. The article of footwear may also include a transition region including an elastomeric transition layer disposed on and partially covering the first region. The transition region may have a second stiffness that is greater than the first stiffness. The article of footwear may further include a toe cap disposed on and partially covering the elastomeric transition layer at the toe box, and an ankle collar defining a foot-receiving cavity. The ankle collar and the heel portion may define a seam channel therebetween such that an entirety of the ankle collar is spaced apart from the heel portion by the seam channel on the lateral side; a first portion of the ankle collar is spaced apart from the heel portion by the seam channel on the medial side; and a second portion of the ankle collar is connected to the heel portion on the medial side.

In an aspect, the ankle collar may be spaced apart from the forefoot portion by the seam channel on the lateral side and the medial side.

In a further aspect, the heel portion may be spaced apart from the forefoot portion by the seam channel on the lateral side and the medial side.

In yet another aspect, the seam channel may not completely encircle the ankle collar.

In one or more configurations, the ankle collar may be a unitary structure attached to the forefoot portion at the seam channel such that the article of footwear does not include a tongue connected to the forefoot portion.

In one aspect, the heel portion may include a padded heel cup having a contour, disposed within the foot-receiving cavity, and extending from the medial side to the lateral side.

In another aspect, the seam channel may abut the contour on the lateral side such that the seam channel completely divides the ankle collar from the heel portion on the lateral side. The seam channel may abut the contour on the medial side such that the ankle collar is partially attached to the heel portion on the medial side.

In yet another aspect, the upper may have an exterior spaced apart from the foot-receiving cavity. The toe cap may be formed from a non-metal and may be disposed on the exterior at the toe box.

In one or more configurations, the article of footwear may also include a sole structure attached to the upper at a bite line, and a tape adhered to the sole structure and the upper on the exterior. The tape may cover an entirety of the bite line such that the tape encircles the sole structure.

The above features and advantages and other features and advantages of the present teachings are readily apparent from the following detailed description of the modes for carrying out the present teachings when taken in connection with the accompanying drawings.

Referring to the Figures, wherein like reference numerals refer to like elements, an article of footwear 10 is shown generally in FIG. 1. The article of footwear 10 may be useful for applications requiring excellent protection for a toe area of a foot. In particular, the article of footwear 10 includes a toe cap 12 configured to enhance both toe protection and comfort for a user. As such, the article of footwear 10 may be useful for, by way of non-limiting examples, athletic footwear and industrial footwear configured for walking, running, and/or working in an environment in which objects or obstacles may otherwise contact the toe area of a user. The article of footwear 10 illustrated herein is generally depicted as athletic footwear configured for sports such as walking and running, but the article of footwear 10 and toe cap 12 are not limited to running shoes or other sports shoes. Rather, the toe cap 12 and other features of the article of footwear 10 may also be used for footwear for various other sports such as, but not limited to, tennis, football, soccer, basketball, or in other types of footwear, such as a protective shoe, a leisure shoe, a dress shoe, a work shoe, a sandal, a slipper, a boot, or any other category of footwear.

Referring again to FIG. 1, the article of footwear 10 includes an upper 14 having a toe box 16 and a forefoot portion 18 adjacent the toe box 16. The upper 14 may also have a heel portion 20 spaced apart from the toe box 16 such that the forefoot portion 18 is disposed between the heel portion 20 and the toe box 16. More specifically, the upper 14 may also include a midfoot portion 22 disposed between the heel portion 20 and the forefoot portion 18. In addition, the article of footwear 10 may include an ankle collar 24 defining a foot-receiving cavity 26. The upper 14 may have an exterior 28 spaced apart from the foot-receiving cavity 26, and may incorporate a lacing or fastening system 30 to adjust a fit of the article of footwear 10 on the foot.

In one embodiment, the article of footwear 10 may not include a sock liner. Instead, the article of footwear 10 may be formed using a strobel construction in which the upper 14 may be sewn to a padded surface. For example, the padded surface may be comparatively thicker than average, i.e., include a comparatively large amount of padding, may be formed from ethylene-vinyl acetate, and may be adhered to the midsole and stitched to the upper 14 to define an edge seam. Further, the edge seam may not be perceptible to the user (such as a stitch that may contact the foot within the foot-receiving cavity 26), but may instead be a smooth seam. For this construction, an upper surface of the midsole may also be contoured for comfort and support of the foot.

The forefoot portion 18, the midfoot portion 22, the heel portion 20, and the ankle collar 24 are not intended to demarcate precise areas of the article of footwear 10, but are instead intended to represent general areas of the article of footwear 10 to aid in the following discussion. That is, the toe box 16 may generally include portions of the article of footwear 10 corresponding with the toes. The forefoot portion 18 may generally include portions of the article of footwear 10 corresponding with the joints connecting the metatarsals with the phalanges. The midfoot portion 22 may generally include portions of the article of footwear 10 corresponding with an arch area and instep of the foot. An instep portion 32 of the upper 14, also referred to as a top portion, may extend over a top of the foot in the forefoot portion 18 and the midfoot portion 22. The heel portion 20 may correspond with a rear portion of the foot, including the calcaneus bone. The ankle collar 24 may corresponds with an ankle.

Accordingly, the article of footwear 10 and toe cap 12 provide both comfort and excellent protection of the toe area. In particular, a transition region 34 including an elastomeric transition layer 36 that may cooperate with the toe cap 12 may enhance a comfort and protection of the toes and/or foot of the user, as set forth in more detail below.

Referring now to FIG. 2, the forefoot portion 18 has a first region 38 having a first stiffness 40. In particular, the forefoot portion 18 and first region 38 may be formed from a fabric set or fused to the first stiffness 40. For example, the forefoot portion 18 may be formed from a fusible yarn having a variable stiffness, and the first region 38 may include a fused thermoplastic. That is, as used herein, the terminology fusible yarn may refer to a comparatively low-melt multi-filament yarn, formed from, for example, a comparatively low-melt thermoplastic, such as polyamide or polyester, that may be stitched into a textile or fabric, e.g., the forefoot portion 18. As heat is applied to specific areas of a textile or fabric formed from the fusible yarn, the specific areas may melt and stiffen or harden.

As such, as best shown in FIG. 2, the first region 38 of the forefoot portion 18 may include fused thermoplastic and may therefore be stiffer than other regions that have not been heated or melted or fused to the same degree as the first region 38. For example, as shown in FIGS. 1-3, the upper 14 may have a medial side 44, a lateral side 46 opposite the medial side 44, and a second region 48 abutting the first region 38 and disposed along at least one of the medial side 44 and the lateral side 46. The second region 48 may have a fourth stiffness 50 that is less than the first stiffness 40. That is, the first region 38 may be stiffer than the second region 48.

As described with reference to FIGS. 1 and 3, in one non-limiting example, the second region 48 may include a stiffening pattern 52 that includes a plurality of stiffened portions 54 and a non-stiffened portion 42 disposed between adjacent ones of the plurality of stiffened portions 54. That is, the stiffening pattern 52 may include areas or zones of a comparatively stiffer material, i.e., the plurality of stiffened portions 54, that may include the fused thermoplastic as set forth above. Although shown as extending along both the medial side 44 and lateral side 46 of the article of footwear 10, the stiffening pattern 52 may extend along only one of the medial side 44 and lateral side 46, may extend along an entirety of the medial side 44 and/or lateral side, and/or may extend along only a section of the medial side and/or lateral side 46.

The stiffening pattern 52 may be arranged in any configuration. For example, the non-stiffened portion 42 may extend between the plurality of stiffened portions 54 to form a web or matrix as best shown in FIGS. 1 and 3. Alternatively or additionally, the plurality of stiffened portions 54 may be configured as protrusions extending from the non-stiffened portions 42 as shown in the instep portion 32 of FIG. 2. In another configuration, although not shown, the stiffening pattern 52 may be arranged as a logo or brand indicia or other shape.

Referring again to FIG. 1, the article of footwear 10 also includes a transition region 34 including an elastomeric transition layer 36 disposed on and partially covering the first region 38. In particular, the transition region 34 has a second stiffness 56 that is greater than the first stiffness 40. That is, the elastomeric transition layer 36 may increase a stiffness of the transition region 34 such that the transition region 34 is stiffer than the first region 38.

In one example, the elastomeric transition layer 36 may be formed from a flexible, stretchable tape that may adhere to at least a part of the first region 38. For example, the elastomeric transition layer 36 may be formed from a thermoplastic polyurethane layer that may be shaped to adhere and extend from the medial side 44 to the lateral side 46 at the toe box 16. The elastomeric transition layer 36 may have a first thickness 58 that is sufficient to withstand creasing and wrinkling of the elastomeric transition layer 36 as the foot bends and a weight of the user pivots to the toes within the article of footwear 10.

Referring again to FIG. 2, the article of footwear 10 further includes a toe cap 12 disposed on and partially covering the elastomeric transition layer 36 at the toe box 16. That is, the elastomeric transition layer 36 may partially overlay the first region 38 and partially underlay the toe cap 12. The toe cap 12 may have a third stiffness 60 that is greater than the second stiffness 56. That is, the toe cap 12 may be stiffer than the transition region 34. Further, the toe cap 12 may have a second thickness 82 that is greater than the first thickness 58. That is, the toe cap 12 may be thicker than the elastomeric transition layer 36.

The toe cap 12 may be formed from a non-metal and may be disposed on the exterior 28 at the toe box 16. For example, the toe cap 12 may be formed from rubber, vinyl, leather, and the like and may be configured to protect the toe box 16 and toes of the user from impact with an object or obstacle. The toe cap 12 may be formed from an electrically-insulating material that may not conduct electrical energy to the article of footwear 10. In one example, the toe cap 12 may be formed from a rubber having a durometer of from 70 to 100 on the Shore A hardness scale, e.g., 75 or 80 or 85 or 90 or 95 on the Shore A hardness scale. Such hardness may protect the toes of the user from contact with an object or obstacle during walking or running, for example. Accordingly, the article of footwear 10 may be useful for urban or rugged or industrial applications requiring enhanced yet comfortable toe protection.

As best shown in FIGS. 1 and 3, the toe cap 12 may have an arcuate edge 62 facing the heel portion 20 that may not contact the first region 38. That is, the transition region 34 may soften a feel of the arcuate edge 62 as the user bends the foot at the toes. More specifically, the elastomeric transition layer 36 may cushion or soften the comparatively hard arcuate edge 62 as the toes abut the upper 14 at the toe box 16 within the foot-receiving cavity 26 during use. That is, since the transition region 34 is stiffer than the first region 38, the transition region 34 may protect the toes from contact with the arcuate edge 62. Although the toe cap 12 may be formed from a sufficiently hard material to protect the toes from contact with an object or obstacle, and therefore may include the comparatively hard arcuate edge 62, the article of footwear 10 may be comfortable for the user since the elastomeric transition layer 36 guards the toes and forefoot portion 18 from contact with the arcuate edge 62.

Referring again to FIGS. 1 and 3, the article of footwear 10 may also include a sole structure 64 attached to the upper 14 at a bite line 66 disposed along the exterior 28. The sole structure 64 may be configured to provide subjacent support for the foot. The sole structure 64 may be generally attached to a lower portion of the upper 14 at the bite line 66 and may be positioned between the foot and the ground. As such, the bite line 66 may be appear as a crease or boundary between the upper 14 and the sole structure 64 and may encircle the article of footwear 10.

Although not shown in detail, generally, the sole structure 64 may be a layered construction that may incorporate a comfort-enhancing insole, an impact-mitigating midsole, and a surface-contacting outsole. The insole (not shown) may be located partially or entirely within the upper 14 and may be a thin and compressible member that provides a contact surface for an underside of the foot. The midsole (not shown) may be mounted underneath the insole and may form a middle layer of the sole structure 64. In addition to attenuating ground reaction forces, the midsole may help to control foot motion and impart stability. The outsole (not shown) may form the ground-contacting portion of the article of footwear 10 and may be fabricated from a durable and wear-resistant material that includes features for improving traction.

As described with continued reference to FIGS. 1 and 3, the article of footwear 10 may further include a tape 68 adhered to the sole structure 64 and the upper 14 and covering the bite line 66. That is, the tape 68 may be adhered to an entirety of the bite line 66 such that the tape 68 encircles the sole structure 64 at the bite line 66 and covers a portion 70 of the toe cap 12. In other words, the tape 68 may be adhered to the sole structure 64 and the upper 14 on the exterior 28, and may cover the entirety of the bite line 66 such that the tape 68 encircles the sole structure 64. That is, the tape 68 may encircle the exterior 28 along the bite line 66.

The tape 68 may be formed from at least one of a light-reflective material and a waterproof material configured to inhibit fluid transmission through the bite line 66 to the foot-receiving cavity 26. That is, the tape 68 may be a reflective tape and/or a waterproof tape. In one example, the tape 68 may be a thermally fused tape. In another example, the tape 68 may be as a self-fusing silicone rubber tape or a self-vulcanizing silicone rubber tape. In yet another example, the tape 68 may be a self-fusing ethylene propylene rubber tape. Further, the tape 68 may include an additive such as iron-oxide and may have a comparatively high thermal conductivity. As such, the article of footwear 10 may be suitable for use in wet, dark, and/or high vehicular traffic areas, such as in urban or industrial environments.

Referring now to FIGS. 1, 3, and 4, in one example, the ankle collar 24 and the heel portion 20 may define a seam channel 72 therebetween. The specific configurations of the heel portion 20, seam channel 72, and ankle collar 24 set forth below may provide the user with excellent ankle support while allowing for fluid, flexible movement of the ankle.

The seam channel 72 may be an indentation or valley or depression defined between the heel portion 20 and the ankle collar 24. In particular, the ankle collar 24 and the heel portion 20 may define the seam channel 72 therebetween such that an entirety of the ankle collar 24 is spaced apart from the heel portion 20 by the seam channel 72 on the lateral side 46; a first portion 74 (FIG. 3) of the ankle collar 24 is spaced apart from the heel portion 20 by the seam channel 72 on the medial side 44; and a second portion 76 (FIG. 3) of the ankle collar 24 is connected to the heel portion 20 on the medial side 44.

That is, as described by comparing FIGS. 1, 3 and 4, the seam channel 72 may completely divide the ankle collar 24 from the heel portion 20 on the lateral side 46 as shown in FIGS. 1 and 4. However, as shown in FIGS. 3 and 4, the seam channel 72 may only extend along a portion of the medial side 44 such that the first portion 74 of the ankle collar 24 is separated from the heel portion 20 and the second portion 76 of the ankle collar 24 is connected to the heel portion 20.

Further, the ankle collar 24 may be spaced apart from the forefoot portion 18 by the seam channel 72 on the lateral side 46 and the medial side 44. Similarly, the heel portion 20 may be spaced apart from the forefoot portion 18 by the seam channel 72 on the lateral side 46 and the medial side 44. As such, as shown in FIG. 3, the seam channel 72 may not completely encircle the ankle collar 24. Further, as shown in FIG. 2, the ankle collar 24 may be a unitary structure attached to the forefoot portion 18 at the seam channel 72 such that the article of footwear 10 does not include a tongue connected to the forefoot portion 18. That is, the ankle collar 24 may form a complete, unbroken, generally circular or elongated entry point for the foot.

Referring now to FIG. 5, the heel portion 20 may also include a padded heel cup 78 having a contour 80. The padded heel cup 78 may be disposed within the foot-receiving cavity 26 and may extend from the medial side 44 to the lateral side 46. The padded heel cup 78 may support and cradle an ankle bone of the foot to enhance the comfort of the article of footwear 10 and provide the ankle bone with protection from side impact during use. In particular, the seam channel 72 may abut the contour 80 on the lateral side 46 such that the seam channel 72 completely divides the ankle collar 24 from the heel portion 20 on the lateral side 46. Further, the seam channel 72 may abut the contour 80 on the medial side 44 such that the ankle collar 24 is partially attached to the heel portion 20 on the medial side 44. As such, the padded heel cup 78 and ankle collar 24 may provide the article of footwear 10 with excellent flexibility and ease of movement on the medial side 44.

In addition, referring to the lacing or fastening system 30 shown generally in FIGS. 1-3, the lacing or fastening system 30 may include four or more lace loops spaced apart from one another along each of the medial side 44 and lateral side 46 of the article of footwear 10. For example, the lacing or fastening system 30 may include seven lace loops extending from the stiffened portion 54 of the midfoot portion 22 towards the instep portion 32 on each of the medial side 44 and the lateral side 46. A lace may extend through each of the lace loops that is configured to fasten the article of footwear 10 to the foot.

As described in greater detail with reference to FIGS. 1 and 3, a top lace loop may extend through the ankle collar 24, and a bottom lace loop may be disposed near a top edge of the tape 68 at a front of the article of footwear 10. More specifically, referring to the lateral side 46 of the article of footwear 10 shown in FIG. 1, a first end of the top lace loop may extend through the ankle collar 24 towards the heel portion 20, and a second end of the top lace loop may be fastened to the heel portion 20 on the lateral side 46. Similarly, referring to the medial side 44 shown in FIG. 3, the first end of the top lace loop may extend through the ankle collar 24 towards the heel portion 20, and the second end of the top lace loop may be fastened to the heel portion 20 on the medial side 44. That is, each top lace loop may form a continuous loop that extends from the heel portion 20 to and through the ankle collar 24. As such, as the lace is pulled taught, the top lace loop may pull down a tongue portion of the ankle collar 24 towards a top portion of the ankle while concurrently causing the padded heel cup 78 (FIG. 5) to cinch inward to opposing sides of an Achilles tendon of the user above the calcaneus bone of the user. Therefore, the top lace loops provide the article of footwear 10 with a customizable, secure fit while also allowing flexibility of movement.

Accordingly, the article of footwear 10 enhances comfort, protection for the toes, and flexibility of movement. That is, the article of footwear 10 enhances comfort via the transition region 34 and elastomeric transition layer 36, protects the foot via the toe cap 12 and padded heel cup 78, and provides for flexibility of movement via the heel portion 20 at least partially connected to the ankle collar 24 on the medial side 44. The article of footwear 10 may be especially suitable for urban environments in which a user may encounter a) objects or obstacles that may impact the toe cap 12, b) moisture that may otherwise enter the foot-receiving cavity 26 at the bite line 66 but-for the tape 68, and/or c) uneven surfaces requiring agile and nimble bending at the ankle.

To assist and clarify the description of various embodiments, various terms are defined herein. Unless otherwise indicated, the following definitions apply throughout this specification (including the claims).

An “article of footwear 10” and “footwear” may be considered to be both a machine and a manufacture. Assembled, ready-to-wear articles of footwear 10 (e.g., shoes, sandals, boots, etc.) and discrete components of articles of footwear 10 (such as a midsole, an outsole, an upper 14, etc.) prior to final assembly into ready-to-wear articles of footwear 10 are considered and alternatively referred to herein in either the singular or plural as “article(s) of footwear 10”.

“A”, “an”, “the”, “at least one”, and “one or more” are used interchangeably to indicate that at least one of the items is present. A plurality of such items may be present unless the context clearly indicates otherwise. All numerical values of parameters (e.g., of quantities or conditions) in this specification, unless otherwise indicated expressly or clearly in view of the context, including the appended claims, are to be understood as being modified in all instances by the term “about” whether or not “about” actually appears before the numerical value. “About” indicates that the stated numerical value allows some slight imprecision (with some approach to exactness in the value; approximately or reasonably close to the value; nearly). If the imprecision provided by “about” is not otherwise understood in the art with this ordinary meaning, then “about” as used herein indicates at least variations that may arise from ordinary methods of measuring and using such parameters. As used in the description and the accompanying claims, a value is considered to be “approximately” equal to a stated value if it is neither more than 5 percent greater than nor more than 5 percent less than the stated value. In addition, a disclosure of a range is to be understood as specifically disclosing all values and further divided ranges within the range.

The terms “comprising”, “including”, and “having” are inclusive and therefore specify the presence of stated features, steps, operations, elements, or components, but do not preclude the presence or addition of one or more other features, steps, operations, elements, or components. Orders of steps, processes, and operations may be altered when possible, and additional or alternative steps may be employed. As used in this specification, the term “or” includes any one and all combinations of the associated listed items. The term “any of” is understood to include any possible combination of referenced items, including “any one of” the referenced items. The term “any of” is understood to include any possible combination of referenced claims of the appended claims, including “any one of” the referenced claims.

For consistency and convenience, directional adjectives may be employed throughout this detailed description corresponding to the illustrated embodiments. Those having ordinary skill in the art will recognize that terms such as “above”, “below”, “upward”, “downward”, “top”, “bottom”, etc., may be used descriptively relative to the Figures, without representing limitations on the scope of the disclosure, as defined by the claims.

The term “longitudinal” refers to a direction extending a length of a component. For example, a longitudinal direction of a shoe extends between the forefoot portion 18 and the heel portion 20 of the shoe. The term “forward” or “anterior” is used to refer to the general direction from the heel portion 20 toward the forefoot portion 18, and the term “rearward” or “posterior” is used to refer to the opposite direction, i.e., the direction from the forefoot portion 18 toward the heel portion 20. In some cases, a component may be identified with a longitudinal axis as well as a forward and rearward longitudinal direction along that axis. The longitudinal direction or axis may also be referred to as an anterior-posterior direction or axis.

The term “transverse” refers to a direction extending a width of a component. For example, a transverse direction of a shoe extends between a lateral side 46 and a medial side 44 of the shoe. The transverse direction or axis may also be referred to as a lateral direction or axis or a mediolateral direction or axis.

The term “vertical” refers to a direction generally perpendicular to both the lateral and longitudinal directions. For example, in cases where the sole structure 64 is planted flat on a ground or traveling surface, the vertical direction may extend from the ground or traveling surface upward. It will be understood that each of these directional adjectives may be applied to individual components of the sole structure 64. The term “upward” or “upwards” refers to the vertical direction pointing towards a top of the component, which may include the instep portion 32, a fastening region and/or a throat of the upper 14. The term “downward” or “downwards” refers to the vertical direction pointing opposite the upwards direction, toward the bottom of a component and may generally point towards the bottom of the sole structure 64 of the article of footwear 10.

The “interior” of the article of footwear 10, such as a shoe, refers to portions at the space that is occupied by a wearer's foot when the shoe is worn. The “inner side” of a component refers to the side or surface of the component that is (or will be) oriented toward the interior of the component or article of footwear 10 in an assembled article of footwear 10. The “outer side” or “exterior” of a component refers to the side or surface of the component that is (or will be) oriented away from the interior of the shoe in an assembled shoe. In some cases, other components may be between the inner side of a component and the interior in the assembled article of footwear 10. Similarly, other components may be between an outer side of a component and the space external to the assembled article of footwear 10. Further, the terms “inward” and “inwardly” refer to the direction toward the interior of the component or article of footwear 10, such as a shoe, and the terms “outward” and “outwardly” refer to the direction toward the exterior 28 of the component or article of footwear 10, such as the shoe. In addition, the term “proximal” refers to a direction that is nearer a center of a footwear component, or is closer toward a foot when the foot is inserted in the article of footwear 10 as it is worn by a user. Likewise, the term “distal” refers to a relative position that is further away from a center of the footwear component or is further from a foot when the foot is inserted in the article of footwear 10 as it is worn by a user. Thus, the terms proximal and distal may be understood to provide generally opposing terms to describe relative spatial positions.

While various embodiments have been described, the description is intended to be exemplary, rather than limiting and it will be apparent to those of ordinary skill in the art that many more embodiments and implementations are possible that are within the scope of the embodiments. Any feature of any embodiment may be used in combination with or substituted for any other feature or element in any other embodiment unless specifically restricted. Accordingly, the embodiments are not to be restricted except in light of the attached claims and their equivalents. Also, various modifications and changes may be made within the scope of the attached claims.

While several modes for carrying out the many aspects of the present teachings have been described in detail, those familiar with the art to which these teachings relate will recognize various alternative aspects for practicing the present teachings that are within the scope of the appended claims. It is intended that all matter contained in the above description or shown in the accompanying drawings shall be interpreted as illustrative and exemplary of the entire range of alternative embodiments that an ordinarily skilled artisan would recognize as implied by, structurally and/or functionally equivalent to, or otherwise rendered obvious based upon the included content, and not as limited solely to those explicitly depicted and/or described embodiments.

Claims

1. An article of footwear comprising:

an upper having a toe box and a forefoot portion adjacent the toe box;

wherein the forefoot portion has a first region having a first stiffness;

a transition region including an elastomeric transition layer disposed on and partially covering the first region;

wherein the transition region has a second stiffness that is greater than the first stiffness; and

a toe cap disposed on and partially covering the elastomeric transition layer at the toe box.

2. The article of footwear of claim 1, wherein the toe cap has a third stiffness that is greater than the second stiffness.

3. The article of footwear of claim 1, wherein the elastomeric transition layer partially overlays the first region and partially underlays the toe cap.

4. The article of footwear of claim 1, wherein the upper has a heel portion spaced apart from the toe box such that the forefoot portion is disposed between the heel portion and the toe box, and further wherein the toe cap has an arcuate edge facing the heel portion that does not contact the first region.

5. The article of footwear of claim 1, wherein the elastomeric transition layer has a first thickness and the toe cap has a second thickness that is greater than the first thickness.

6. The article of footwear of claim 1, wherein the upper has a medial side, a lateral side opposite the medial side, and a second region abutting the first region and disposed along at least one of the medial side and the lateral side, and further wherein the second region has a fourth stiffness that is less than the first stiffness.

7. The article of footwear of claim 6, wherein the second region has a stiffening pattern that includes a plurality of stiffened portions and a non-stiffened portion disposed between adjacent ones of the plurality of stiffened portions.

8. The article of footwear of claim 7, wherein the forefoot portion is formed from a fusible yarn having a variable stiffness, and the first region and the plurality of stiffened portions include a fused thermoplastic.

9. The article of footwear of claim 1, wherein the upper has an exterior, and further including:

an ankle collar defining a foot-receiving cavity that is spaced apart from the exterior;

a sole structure attached to the upper at a bite line disposed along the exterior; and

a tape adhered to the sole structure and the upper and covering the bite line.

10. The article of footwear of claim 9, wherein the tape is adhered to an entirety of the bite line such that the tape encircles the sole structure at the bite line and covers a portion of the toe cap.

11. The article of footwear of claim 9, wherein the tape is formed from at least one of a light-reflective material and a waterproof material configured to inhibit fluid transmission through the bite line to the foot-receiving cavity.

12. An article of footwear comprising:

an upper having a medial side, a lateral side opposite the medial side, a toe box, a heel portion spaced apart from the toe box, and a forefoot portion disposed between the toe box and the heel portion;

wherein the forefoot portion has a first region having a first stiffness;

a transition region including an elastomeric transition layer disposed on and partially covering the first region;

wherein the transition region has a second stiffness that is greater than the first stiffness;

a toe cap disposed on and partially covering the elastomeric transition layer at the toe box; and

an ankle collar defining a foot-receiving cavity;

wherein the ankle collar and the heel portion define a seam channel therebetween such that: an entirety of the ankle collar is spaced apart from the heel portion by the seam channel on the lateral side; a first portion of the ankle collar is spaced apart from the heel portion by the seam channel on the medial side; and a second portion of the ankle collar is connected to the heel portion on the medial side.

13. The article of footwear of claim 12, wherein the ankle collar is spaced apart from the forefoot portion by the seam channel on the lateral side and the medial side.

14. The article of footwear of claim 13, wherein the heel portion is spaced apart from the forefoot portion by the seam channel on the lateral side and the medial side.

15. The article of footwear of claim 14, wherein the seam channel does not completely encircle the ankle collar.

16. The article of footwear of claim 12, wherein the ankle collar is a unitary structure attached to the forefoot portion at the seam channel such that the article of footwear does not include a tongue connected to the forefoot portion.

17. The article of footwear of claim 12, wherein the heel portion includes a padded heel cup having a contour, disposed within the foot-receiving cavity, and extending from the medial side to the lateral side.

18. The article of footwear of claim 17, wherein the seam channel abuts the contour on the lateral side such that the seam channel completely divides the ankle collar from the heel portion on the lateral side, and further wherein the seam channel abuts the contour on the medial side such that the ankle collar is partially attached to the heel portion on the medial side.

19. The article of footwear of claim 12, wherein the upper has an exterior spaced apart from the foot-receiving cavity, and further wherein the toe cap is formed from a non-metal and disposed on the exterior at the toe box.

20. The article of footwear of claim 19, further including:

a sole structure attached to the upper at a bite line; and

a tape adhered to the sole structure and the upper on the exterior and covering an entirety of the bite line such that the tape encircles the sole structure.