WO2011056853A2 - Article of footwear with integral upper and sole - Google Patents

Article of footwear with integral upper and sole Download PDF

Info

Publication number
WO2011056853A2
WO2011056853A2 PCT/US2010/055277 US2010055277W WO2011056853A2 WO 2011056853 A2 WO2011056853 A2 WO 2011056853A2 US 2010055277 W US2010055277 W US 2010055277W WO 2011056853 A2 WO2011056853 A2 WO 2011056853A2
Authority
WO
WIPO (PCT)
Prior art keywords
article
footwear
lateral edge
sole
integral upper
Prior art date
Application number
PCT/US2010/055277
Other languages
French (fr)
Other versions
WO2011056853A3 (en
Inventor
Thomas G. Bell
Michael R. Friton
Original Assignee
Nike International Ltd.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Nike International Ltd. filed Critical Nike International Ltd.
Priority to EP10800793.1A priority Critical patent/EP2498640B1/en
Priority to CN201080060970.0A priority patent/CN102711541B/en
Priority to EP16192532.6A priority patent/EP3158887B1/en
Publication of WO2011056853A2 publication Critical patent/WO2011056853A2/en
Publication of WO2011056853A3 publication Critical patent/WO2011056853A3/en

Links

Classifications

    • AHUMAN NECESSITIES
    • A43FOOTWEAR
    • A43BCHARACTERISTIC FEATURES OF FOOTWEAR; PARTS OF FOOTWEAR
    • A43B9/00Footwear characterised by the assembling of the individual parts
    • A43B9/02Footwear stitched or nailed through
    • AHUMAN NECESSITIES
    • A43FOOTWEAR
    • A43BCHARACTERISTIC FEATURES OF FOOTWEAR; PARTS OF FOOTWEAR
    • A43B1/00Footwear characterised by the material
    • A43B1/0081Footwear characterised by the material made at least partially of hook-and-loop type material 
    • AHUMAN NECESSITIES
    • A43FOOTWEAR
    • A43BCHARACTERISTIC FEATURES OF FOOTWEAR; PARTS OF FOOTWEAR
    • A43B13/00Soles; Sole-and-heel integral units
    • A43B13/14Soles; Sole-and-heel integral units characterised by the constructive form
    • A43B13/22Soles made slip-preventing or wear-resisting, e.g. by impregnation or spreading a wear-resisting layer
    • AHUMAN NECESSITIES
    • A43FOOTWEAR
    • A43BCHARACTERISTIC FEATURES OF FOOTWEAR; PARTS OF FOOTWEAR
    • A43B23/00Uppers; Boot legs; Stiffeners; Other single parts of footwear
    • A43B23/02Uppers; Boot legs
    • A43B23/0245Uppers; Boot legs characterised by the constructive form
    • A43B23/025Uppers; Boot legs characterised by the constructive form assembled by stitching
    • AHUMAN NECESSITIES
    • A43FOOTWEAR
    • A43BCHARACTERISTIC FEATURES OF FOOTWEAR; PARTS OF FOOTWEAR
    • A43B23/00Uppers; Boot legs; Stiffeners; Other single parts of footwear
    • A43B23/02Uppers; Boot legs
    • A43B23/0245Uppers; Boot legs characterised by the constructive form
    • A43B23/026Laminated layers
    • AHUMAN NECESSITIES
    • A43FOOTWEAR
    • A43BCHARACTERISTIC FEATURES OF FOOTWEAR; PARTS OF FOOTWEAR
    • A43B23/00Uppers; Boot legs; Stiffeners; Other single parts of footwear
    • A43B23/02Uppers; Boot legs
    • A43B23/04Uppers made of one piece; Uppers with inserted gussets
    • A43B23/042Uppers made of one piece
    • AHUMAN NECESSITIES
    • A43FOOTWEAR
    • A43BCHARACTERISTIC FEATURES OF FOOTWEAR; PARTS OF FOOTWEAR
    • A43B3/00Footwear characterised by the shape or the use
    • AHUMAN NECESSITIES
    • A43FOOTWEAR
    • A43BCHARACTERISTIC FEATURES OF FOOTWEAR; PARTS OF FOOTWEAR
    • A43B3/00Footwear characterised by the shape or the use
    • A43B3/24Collapsible or convertible
    • AHUMAN NECESSITIES
    • A43FOOTWEAR
    • A43BCHARACTERISTIC FEATURES OF FOOTWEAR; PARTS OF FOOTWEAR
    • A43B9/00Footwear characterised by the assembling of the individual parts
    • AHUMAN NECESSITIES
    • A43FOOTWEAR
    • A43BCHARACTERISTIC FEATURES OF FOOTWEAR; PARTS OF FOOTWEAR
    • A43B9/00Footwear characterised by the assembling of the individual parts
    • A43B9/12Stuck or cemented footwear
    • AHUMAN NECESSITIES
    • A43FOOTWEAR
    • A43CFASTENINGS OR ATTACHMENTS OF FOOTWEAR; LACES IN GENERAL
    • A43C15/00Non-skid devices or attachments
    • AHUMAN NECESSITIES
    • A43FOOTWEAR
    • A43DMACHINES, TOOLS, EQUIPMENT OR METHODS FOR MANUFACTURING OR REPAIRING FOOTWEAR
    • A43D111/00Shoe machines with conveyors for jacked shoes or for shoes or shoe parts
    • AHUMAN NECESSITIES
    • A43FOOTWEAR
    • A43DMACHINES, TOOLS, EQUIPMENT OR METHODS FOR MANUFACTURING OR REPAIRING FOOTWEAR
    • A43D999/00Subject matter not provided for in other groups of this subclass

Definitions

  • the present invention relates generally to an article of footwear with an integral upper and sole and, in particular, to a method of assembling an article of footwear with an integral upper and sole.
  • articles of footwear have been previously disclosed that are manufactured in a one-piece configuration and that can be assembled at home by a customer.
  • these articles of footwear are formed around a wearer's foot to assemble the article of footwear.
  • these articles of footwear include laces or other tightening mechanisms disposed down the center portion of the article of footwear for securing the article of footwear to the wearer's foot.
  • the invention provides an article of footwear comprising: an interior layer, an exterior layer connected to the interior layer, and wherein the interior layer and the exterior layer are cut in a pattern forming an integral upper portion and sole portion.
  • the invention provides a method of assembling an article of footwear comprising an integral upper portion and sole portion, the method comprising: folding the article of footwear along a midline between the upper portion and the sole portion, and attaching a top lateral edge of the upper portion to a bottom lateral edge of the sole portion.
  • the invention provides a kit of parts, comprising: an article of footwear cut in a pattern forming an integral upper portion and sole portion, a set of instructions, and wherein a top lateral edge of the upper portion may be attached to a bottom lateral edge of the sole portion to form an assembled article of footwear.
  • FIG. 1 is an isometric view of an embodiment of an article of footwear with an integral upper and sole in various stages of assembly
  • FIG. 2 is a schematic view of an embodiment of a method for assembling an article of footwear with an integral upper and sole;
  • FIG. 3 is an isometric view of an exemplary embodiment of an interior layer of an article of footwear
  • FIG. 4 is an isometric view of an exemplary embodiment of an exterior layer of an article of footwear
  • FIG. 5 is an isometric view of an embodiment of an exterior layer of an article of footwear aligned over an interior layer of an article of footwear;
  • FIG. 6 is an isometric view of an embodiment of an exterior layer and an interior layer of an article of footwear in the process of being attached;
  • FIG. 7 is an isometric view of an embodiment of an unassembled article of footwear with an integral upper and sole;
  • FIG. 8 is an isometric view of an embodiment of a method of assembly for an article of footwear with an integral upper and sole;
  • FIG. 9 is an isometric view of an embodiment of an article of footwear with an integral upper and sole in the process of assembly
  • FIG. 10 is an isometric view of an embodiment of an article of footwear with an integral upper and sole that has been folded along a midline;
  • FIG. 1 1 is an isometric view of an embodiment of an article of footwear with an integral upper and sole that has been attached along a lateral edge
  • FIG. 12 is an isometric view of an embodiment of an article of footwear with an integral upper and sole in the process of assembly;
  • FIG. 13 is an isometric view of an embodiment of an article of footwear with an integral upper and sole with a raised heel portion;
  • FIG. 14 is an isometric view of a close up of an embodiment of a heel portion that is being attached to a sole;
  • FIG. 15 is an isometric view of an embodiment of an article of footwear with an integral upper and sole with an attached heel portion;
  • FIG. 16 is an isometric view of an embodiment of an article of footwear with an integral upper and sole in the process of assembly
  • FIG. 17 is an isometric view of a close up of an embodiment of a heel portion of an article of footwear with an integral upper and sole;
  • FIG. 18 is an isometric view of an embodiment of an assembled article of footwear with an integral upper and sole;
  • FIG. 19 is an isometric view of an embodiment of the underside of an article of footwear with an integral upper and sole;
  • FIG. 20 is an isometric view of an exemplary embodiment of an unassembled article of footwear with an integral upper and sole;
  • FIG. 21 is an isometric view of a close up of an embodiment of alternating channels on an article of footwear with an integral upper and sole;
  • FIG. 22 is an isometric view of a close up of an embodiment of folded over alternating channels on an article of footwear with an integral upper and sole;
  • FIG. 23 is an isometric cut away view of an embodiment of alternating channels on an article of footwear with an integral upper and sole;
  • FIG. 24 is an isometric view of a close up of an embodiment of a cord passing through alternating channels on an article of footwear with an integral upper and sole;
  • FIG. 25 is an isometric view of an embodiment of a partially attached lateral side of an article of footwear with an integral upper and sole;
  • FIG. 26 is an isometric view of an exemplary embodiment of an unassembled article of footwear with an integral upper and sole;
  • FIG. 27 is an isometric cut away view of an embodiment of interlocking fasteners on an article of footwear with an integral upper and sole;
  • FIG. 28 is an isometric view of a close up of an embodiment of interlocking fasteners on an article of footwear with an integral upper and sole;
  • FIG. 29 is an isometric view of an embodiment of a partially attached lateral side of an article of footwear with an integral upper and sole;
  • FIG. 30 is an isometric view of an exemplary embodiment of a kit of parts for self-assembly of an article of footwear with an integral upper and sole;
  • FIG. 31 is an isometric view of an exemplary embodiment of a customer assembling an article of footwear with an integral upper and sole.
  • an article of footwear with an integral upper and sole may be provided in a flat configuration that can be assembled into a finished article of footwear.
  • a method of assembling an article of footwear with an integral upper and sole may be provided using various methods for joining together the article of footwear into a finished article of footwear.
  • FIG. 1 is an overview of an embodiment of the process 100 for assembling an article of footwear.
  • the article of footwear may be assembled by a customer.
  • an article of footwear may be provided in a flat configuration in a first step 102.
  • the article of footwear may be folded in a second step 104.
  • the article of footwear may be joined together in a final step 106 to complete the finished article of footwear.
  • article of footwear may be a bootie.
  • article of footwear may be a shoe for a baby, child or adult.
  • article of footwear could be any type of footwear, including, but not limited to: a running shoe, a dance shoe, a basketball shoe, a high heel shoe, a boot, a slip-on shoe, a low top shoe, as well as other types of footwear.
  • additional provisions may be made to increase support for the article of footwear.
  • FIG. 2 illustrates an exemplary process 200 for the manufacture of an article of footwear with an integral upper and sole.
  • the order of the steps illustrated in FIG. 2 is exemplary and not required.
  • portions of an article of footwear may be printed, including an interior layer and an exterior layer.
  • the portions may be provided with printed designs.
  • a customer may custom design portions of the article of footwear, including, but not limited to portions of the interior layer and exterior layer.
  • a customer may customize portions of the article of footwear using the system and method disclosed in copending and commonly owned U.S. Patent , currently U.S. Patent
  • the article of footwear may be cut in a pattern forming an integral upper and sole.
  • an interior layer and an exterior layer may be cut using a pattern forming an integral upper and sole.
  • the interior and exterior layers may be cut using reverse patterns such that the interior and exterior layers can be aligned in a back-to-back configuration.
  • portions of the article of footwear may be laser cut.
  • portions of the article of footwear may be stamped or die-cut.
  • portions of the article of footwear may be cut using different methods depending on the material used for the article of footwear.
  • the interior layer and the exterior layer may be connected.
  • the interior layer may be provided with an adhesive backing for connecting the exterior and interior layers.
  • the interior and exterior layers may be connected to one another in various ways, including, but not limited to: adhesive, heat, pressure, stitching and any other method of attachment.
  • the article of footwear may be assembled to form a finished article of footwear.
  • the article of footwear may be assembled by joining the article of footwear as described in more detail below with reference to the exemplary embodiments.
  • the article of footwear may be assembled by a customer.
  • the article of footwear may be assembled by a retailer or a manufacturer.
  • a retailer may be anyone configured to make and/or sell articles of footwear.
  • a retailer may be associated with a retail store.
  • a retailer may be associated with a kiosk in a mall.
  • a retailer may be associated with one or more manufacturing locations.
  • FIG. 3 illustrates an exemplary embodiment of an exterior layer 300 of an article of footwear.
  • exterior layer 300 may form the outside of an article of footwear.
  • the exemplary embodiments of the exterior layers and interior layers shown in the figures are shown with printed designs to allow the layers to be clearly
  • interior and exterior layers may include different designs, including, but not limited to: various patterns, solids, graphics, colors and custom designs.
  • exterior layer 300 includes an outer material 304 and a structural overlay 302.
  • outer material 304 may be made from different materials, including, but not limited to: fabric, mesh, canvas, leather, rubber, plastic and any other natural or synthetic material.
  • structural overlay 302 may be disposed over outer material 304.
  • structural overlay 302 may include a ground engaging portion.
  • structural overlay 302 may reinforce the article of footwear.
  • structural overlay 302 may form various portions of the article of footwear, including, but not limited to: the toe cap, heel, eyelets and ground engaging portion of the article of footwear.
  • portions of the structural overlay 302 may be laser cut.
  • portions of the structural overlay 302 may be customized.
  • portions of the structural overlay 302 may be made of various materials, including, but not limited to: escane, rubber, polyurethane and other natural and synthetic materials.
  • the structural overlay 302 may include more than one material.
  • portions of the structural overlay 302 may include materials with different levels of durability.
  • FIG. 4 illustrates an exemplary embodiment of an interior layer 400.
  • interior layer 400 may form the inside of an article of footwear.
  • interior layer 400 includes an inner material 402.
  • Inner material 402 may be cut in a pattern forming an integral upper and sole that includes a heel portion 406 and heel tabs 404.
  • Heel tabs 404 may include fasteners 408 disposed on inner material 402.
  • fasteners 408 may include hook and loop fasteners.
  • fasteners 408 may include various attachment mechanisms, including, but not limited to: zippers, buttons, snaps as well as other types of fasteners.
  • FIGS. 5-7 illustrate an exemplary embodiment of the method of connecting the exterior and interior layers to form an article of footwear with an integral upper and sole.
  • exterior layer 300 may be connected with interior layer 400.
  • inner material 402 is configured so that the back of inner material 402 can connect with the back of exterior layer 300.
  • the back of inner material may include adhesive for connecting the interior layer 400 to the exterior layer 300.
  • exterior layer 300 may be aligned with interior layer 400 so that interior heel portion 406 can be aligned with exterior heel portion 502 and heel tabs 404 can be aligned with exterior heel tabs 504.
  • exterior layer 300 includes a ground engaging portion 500.
  • FIG. 6 illustrates an exemplary embodiment of exterior layer 300 being connected to interior layer 400.
  • exterior layer 300 and interior layer 400 may be connected using adhesive.
  • heat and pressure may be applied to adhere exterior layer 300 and interior layer 400 together.
  • exterior layer 300 and interior layer 400 may be connected to one another in various ways, including, but not limited to: adhesive, heat, pressure, stitching and any other method of attachment.
  • FIG. 7 illustrates an exemplary embodiment of an article of footwear 700 with an integral upper and sole.
  • the outside of article of footwear 700 may include structural overlay 302 and outer material 304.
  • the inside of article of footwear 700 may include inner material 402.
  • article of footwear 700 may include an upper portion with heel tabs 702 and a sole portion with a heel portion 704 and a ground engaging portion 500.
  • the upper portion includes a top lateral edge 706 and the sole portion includes a bottom lateral edge 708.
  • article of footwear 700 may be assembled by joining together top lateral edge 706 and bottom lateral edge 708.
  • FIGS. 8-17 illustrate an exemplary embodiment of a method of assembling an article of footwear with an integral upper and sole.
  • FIG. 8 shows an embodiment of an article of footwear in the process of assembly.
  • a midline 800 divides the upper portion of the article of footwear from the sole portion.
  • top lateral edge 706 of the upper portion may be moved towards bottom lateral edge 708 of the sole portion by folding the article of footwear along midline 800.
  • FIG. 9 illustrates an embodiment of the article of footwear in the process of assembly where top lateral edge 706 may be brought in proximity to bottom lateral edge 708.
  • the top lateral edge and bottom lateral edge of the article of footwear have been brought together.
  • the outer material 304 and structural overlay 302 form the outside of the upper portion of the article of footwear.
  • FIG. 1 1 illustrates an exemplary embodiment of a method of assembling an article of footwear where the article of footwear has been attached by stitching 1 100 along the top lateral edge and bottom lateral edge.
  • stitching 1 100 may be used to accomplish the attachment of the top lateral edge and bottom lateral edge of the article of footwear.
  • simple stitches may be used.
  • more complex stitches may be used.
  • top and bottom lateral edges may be provided with pre-configured holes. This alternative arrangement may allow for increased ease of manual stitching, which may appeal to some customers.
  • FIGS. 12-17 illustrate an exemplary embodiment of the process for attaching a heel portion of an article of footwear with an integral upper and sole.
  • FIG. 12 illustrates an embodiment of the article of footwear in the process of assembly where a heel portion 704 may be moved towards an upright position. In FIG. 13, the heel portion 704 may be brought to an upright position.
  • heel portion 704 may include a back plate 1300 for engaging with fasteners 408 to removably attach heel tabs 702.
  • FIG. 14 illustrates an exemplary embodiment of a method of assembling an article of footwear where the heel portion 704 has been attached to the sole by stitching 1400.
  • stitching 1400 may include various types of stitches disclosed above.
  • heel portion 704 may be provided with pre- configured holes.
  • FIG. 16 illustrates an exemplary embodiment of a process of closing heel tabs 702.
  • fasteners 408 may be provided on heel tabs 702 for engaging with back plate 1300 to removably attach heel tabs 702.
  • FIG. 17 is a close up view of the embodiment of FIG. 16 showing fasteners 408 in proximity to back plate 1300.
  • heel tabs 702 may include a buckle.
  • heel tabs 702 may fasten the upper portion of the article of footwear from an open position to a closed position around a foot.
  • open position refers to a loosened position of an article of footwear in which a foot may be easily slipped into the article of footwear.
  • closed position refers to a tightened position of an article of footwear in which the article of footwear is tightly wrapped around the foot and cannot be generally removed.
  • FIGS. 18 and 19 illustrate an exemplary embodiment of a finished article of footwear 1800 assembled according to the process described in FIGS. 8- 17.
  • finished article of footwear 1800 includes outer material 304 and structural overlay 302 on the outside of article of footwear 1800 and inner material 402 on the inside of article of footwear 1800.
  • stitching 1100 has been used to attach the top lateral edge and bottom lateral edge of the article of footwear and stitching 1400 has been used to attach heel portion 704 to the sole.
  • FIG. 19 illustrates the underside of finished article of footwear 1800.
  • ground engaging portion 500 of the structural overlay is visible.
  • ground engaging portion 500 may include a traction tread.
  • the ground engaging portion 500 may be made of various materials, including, but not limited to: escane, rubber,
  • ground engaging portion 500 may include a material with a different level of durability than the rest of the structural overlay. In some cases, ground engaging portion 500 may include more than one material.
  • FIGS. 20-29 illustrate different exemplary embodiments of an article of footwear with an integral upper and sole.
  • an article of footwear 2000 with an integral upper and sole may be provided with alternating channels.
  • the alternating channels are shown in an
  • Alternating channels may include top lateral edge channels 2002, bottom lateral edge channels 2004 and heel portion channels 2006.
  • FIGS. 21 -22 illustrate an exemplary embodiment of a method of forming the top lateral edge channels 2002 of article of footwear 2000.
  • the unfinished top lateral edge channels 2002 are shown in the process of being folded over to form the channels.
  • top lateral edge channels 2002 may be formed by attaching the ends of the unfinished channels to the back side of the flat article of footwear.
  • top lateral edge channels 2002 may be attached using adhesive.
  • top lateral edge channels 2002 may be attached using stitching.
  • top lateral edge channels 2002 may be attached using any attachment
  • FIG. 23 illustrates an exemplary embodiment of an article of footwear with alternating channels.
  • top lateral edge channels 2002 may be brought together with bottom lateral edge channels 2004 to form alternating channels.
  • a cord 2300 may be passed through the alternating channels formed by top lateral edge channels 2002 and bottom lateral edge channels 2004.
  • FIG. 24 illustrates a close up view of cord 2300 passing through the alternating channels formed by top lateral edge channels 2002 and bottom lateral edge channels 2004.
  • cord 2300 is used to attach the top lateral edge and the bottom lateral edge to form the article of footwear.
  • cord 2300 also may be passed through heel portion channels 2006 to attach the heel portion to the sole of the article of footwear.
  • FIG. 25 is a cut away view of an exemplary embodiment of an article of footwear 2500 with an integral upper and sole that has been assembled by passing a cord through alternating channels.
  • FIG. 26 illustrates an alternative exemplary embodiment of an article of footwear 2600 with an integral upper and sole.
  • article of footwear 2600 may be provided with interlocking fasteners.
  • the interlocking fasteners may include top lateral edge fasteners 2602, bottom lateral edge fasteners 2604 and heel portion fasteners 2606.
  • FIG. 27 illustrates an exemplary embodiment of an article of footwear with interlocking fasteners. Referring to FIG. 27, top lateral edge fasteners 2602 may be alternatively interlaced with bottom lateral edge fasteners 2604 to form an interlocking seam.
  • top lateral edge fasteners 2602 engage with the inner material on the inside of the sole portion and bottom lateral edge fasteners 2604 engage with the inner material on the inside of the upper portion of the article of footwear.
  • heel portion fasteners 2606 engage with the inner material on the inside of the sole portion.
  • FIG. 28 illustrates a close up view of the interlocking fasteners engaging with the inner material of the article of footwear.
  • top lateral edge fasteners 2602 may engage with the inner material on the inside of the sole portion of the article of footwear.
  • Bottom lateral edge fasteners 2604 may engage with the inner material on the inside of the upper portion of the article of footwear.
  • FIG. 29 illustrates a cut away view of an exemplary embodiment of an article of footwear 2900 with an integral upper and sole that has been assembled using interlocking fasteners.
  • the interlocking fasteners form a releasable attachment for the top lateral edge and the bottom lateral edge to form the article of footwear 2900.
  • FIG. 30 illustrates an exemplary embodiment of a kit of parts 3000.
  • kit of parts 3000 may include an article of footwear 3004 with an integral upper and sole in an unassembled configuration.
  • kit of parts 3000 may include a cord 3002 for assembling article of footwear 3004.
  • article of footwear 3004 is provided with alternating channels for passage of cord 3002 as described in the exemplary embodiments discussed above.
  • article of footwear 3004 may be provided with different mechanisms for assembly as described in the exemplary
  • Examples of the mechanisms for assembly of the article of footwear 3004 may include, but are not limited to, one or more of: stitching, interlocking fasteners, alternating channels, and pre-configured holes.
  • Kit of parts 3000 may include a set of instructions 3006.
  • set of instructions 3006 may include a list of directions for assembling article of footwear 3004.
  • set of instructions 3006 may include step by step directions.
  • set of instructions 3006 may include diagrams as well.
  • the components comprising kit of parts 3000 may be gathered together for a customer.
  • the components comprising kit of parts 3000 may be packaged together so a customer can carry kit of parts 3000 home.
  • article of footwear 3004, cord 3002 and set of instructions 3006 may be packaged into container 3008.
  • the components comprising kit of parts 3000 could be packaged in a retail bag. Using this arrangement, a customer may easily carry home kit of parts 3000 or receive kit of parts 3000 in the mail.
  • FIG. 31 is an exemplary embodiment of customer 3100
  • customer 3100 has removed unassembled article of footwear 3004, cord 3002 and set of instructions 3006 from container 3008. Using set of instructions 3006, customer 3100 may assemble article of footwear 3004 together using cord 3002.

Abstract

An article of footwear with an integral upper and sole and a method of assembling the article of footwear are disclosed. The method includes folding the article of footwear from a flat configuration and attaching top and bottom lateral edges to form the article of footwear. A kit of parts containing an article of footwear with an integral upper and sole and a set of instructions is also disclosed.

Description

ARTICLE OF FOOTWEAR WITH INTEGRAL UPPER AND SOLE
BACKGROUND
[0001] The present invention relates generally to an article of footwear with an integral upper and sole and, in particular, to a method of assembling an article of footwear with an integral upper and sole.
[0002] Generally, articles of footwear have been previously disclosed that are manufactured in a one-piece configuration and that can be assembled at home by a customer. Typically, these articles of footwear are formed around a wearer's foot to assemble the article of footwear. Often, these articles of footwear include laces or other tightening mechanisms disposed down the center portion of the article of footwear for securing the article of footwear to the wearer's foot.
[0003] Other articles of footwear also have been disclosed that are manufactured in multi-piece configurations and can be assembled at home by a customer. Typically, these articles of footwear require more effort to assemble than those made with a one-piece configuration.
[0004] Articles of footwear that have been disclosed are limited in their methods of manufacture and in their ease of assembly.
[0005] Therefore, there exists a need in the art for an article of footwear that can be manufactured with an integral upper and sole portion. There is also a need in the art for an article of footwear that can be easily assembled. SUMMARY
[0006] In one aspect, the invention provides an article of footwear comprising: an interior layer, an exterior layer connected to the interior layer, and wherein the interior layer and the exterior layer are cut in a pattern forming an integral upper portion and sole portion.
[0007] In another aspect, the invention provides a method of assembling an article of footwear comprising an integral upper portion and sole portion, the method comprising: folding the article of footwear along a midline between the upper portion and the sole portion, and attaching a top lateral edge of the upper portion to a bottom lateral edge of the sole portion.
[0008] In another aspect, the invention provides a kit of parts, comprising: an article of footwear cut in a pattern forming an integral upper portion and sole portion, a set of instructions, and wherein a top lateral edge of the upper portion may be attached to a bottom lateral edge of the sole portion to form an assembled article of footwear.
[0009] Other systems, methods, features and advantages of the invention will be, or will become, apparent to one of ordinary skill in the art upon examination of the following figures and detailed description. It is intended that all such additional systems, methods, features and advantages be included within this description and this summary, be within the scope of the invention, and be protected by the following claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] The invention can be better understood with reference to the following drawings and description. The components in the figures are not necessarily to scale, emphasis instead being placed upon illustrating the principles of the invention. Moreover, in the figures, like reference numerals designate corresponding parts throughout the different views.
[0011] FIG. 1 is an isometric view of an embodiment of an article of footwear with an integral upper and sole in various stages of assembly;
[0012] FIG. 2 is a schematic view of an embodiment of a method for assembling an article of footwear with an integral upper and sole;
[0013] FIG. 3 is an isometric view of an exemplary embodiment of an interior layer of an article of footwear;
[0014] FIG. 4 is an isometric view of an exemplary embodiment of an exterior layer of an article of footwear;
[0015] FIG. 5 is an isometric view of an embodiment of an exterior layer of an article of footwear aligned over an interior layer of an article of footwear;
[0016] FIG. 6 is an isometric view of an embodiment of an exterior layer and an interior layer of an article of footwear in the process of being attached;
[0017] FIG. 7 is an isometric view of an embodiment of an unassembled article of footwear with an integral upper and sole;
[0018] FIG. 8 is an isometric view of an embodiment of a method of assembly for an article of footwear with an integral upper and sole;
[0019] FIG. 9 is an isometric view of an embodiment of an article of footwear with an integral upper and sole in the process of assembly;
[0020] FIG. 10 is an isometric view of an embodiment of an article of footwear with an integral upper and sole that has been folded along a midline;
[0021] FIG. 1 1 is an isometric view of an embodiment of an article of footwear with an integral upper and sole that has been attached along a lateral edge; [0022] FIG. 12 is an isometric view of an embodiment of an article of footwear with an integral upper and sole in the process of assembly;
[0023] FIG. 13 is an isometric view of an embodiment of an article of footwear with an integral upper and sole with a raised heel portion;
[0024] FIG. 14 is an isometric view of a close up of an embodiment of a heel portion that is being attached to a sole;
[0025] FIG. 15 is an isometric view of an embodiment of an article of footwear with an integral upper and sole with an attached heel portion;
[0026] FIG. 16 is an isometric view of an embodiment of an article of footwear with an integral upper and sole in the process of assembly;
[0027] FIG. 17 is an isometric view of a close up of an embodiment of a heel portion of an article of footwear with an integral upper and sole;
[0028] FIG. 18 is an isometric view of an embodiment of an assembled article of footwear with an integral upper and sole;
[0029] FIG. 19 is an isometric view of an embodiment of the underside of an article of footwear with an integral upper and sole;
[0030] FIG. 20 is an isometric view of an exemplary embodiment of an unassembled article of footwear with an integral upper and sole;
[0031] FIG. 21 is an isometric view of a close up of an embodiment of alternating channels on an article of footwear with an integral upper and sole;
[0032] FIG. 22 is an isometric view of a close up of an embodiment of folded over alternating channels on an article of footwear with an integral upper and sole;
[0033] FIG. 23 is an isometric cut away view of an embodiment of alternating channels on an article of footwear with an integral upper and sole;
[0034] FIG. 24 is an isometric view of a close up of an embodiment of a cord passing through alternating channels on an article of footwear with an integral upper and sole;
[0035] FIG. 25 is an isometric view of an embodiment of a partially attached lateral side of an article of footwear with an integral upper and sole; [0036] FIG. 26 is an isometric view of an exemplary embodiment of an unassembled article of footwear with an integral upper and sole;
[0037] FIG. 27 is an isometric cut away view of an embodiment of interlocking fasteners on an article of footwear with an integral upper and sole;
[0038] FIG. 28 is an isometric view of a close up of an embodiment of interlocking fasteners on an article of footwear with an integral upper and sole;
[0039] FIG. 29 is an isometric view of an embodiment of a partially attached lateral side of an article of footwear with an integral upper and sole;
[0040] FIG. 30 is an isometric view of an exemplary embodiment of a kit of parts for self-assembly of an article of footwear with an integral upper and sole;
[0041] FIG. 31 is an isometric view of an exemplary embodiment of a customer assembling an article of footwear with an integral upper and sole.
DETAILED DESCRIPTION
[0042] Generally, an article of footwear with an integral upper and sole may be provided in a flat configuration that can be assembled into a finished article of footwear. A method of assembling an article of footwear with an integral upper and sole may be provided using various methods for joining together the article of footwear into a finished article of footwear.
[0043] FIG. 1 is an overview of an embodiment of the process 100 for assembling an article of footwear. In one exemplary embodiment, the article of footwear may be assembled by a customer. As shown in FIG. 1 , an article of footwear may be provided in a flat configuration in a first step 102. The article of footwear may be folded in a second step 104. The article of footwear may be joined together in a final step 106 to complete the finished article of footwear.
[0044] In one exemplary embodiment, article of footwear may be a bootie. In another exemplary embodiment, article of footwear may be a shoe for a baby, child or adult. In other embodiments, article of footwear could be any type of footwear, including, but not limited to: a running shoe, a dance shoe, a basketball shoe, a high heel shoe, a boot, a slip-on shoe, a low top shoe, as well as other types of footwear. In some cases, additional provisions may be made to increase support for the article of footwear.
[0045] Additionally, while a single article of footwear is shown in the current embodiments, the same principles taught in this detailed description could be applied to a second, complementary article of footwear.
[0046] FIG. 2 illustrates an exemplary process 200 for the manufacture of an article of footwear with an integral upper and sole. The order of the steps illustrated in FIG. 2 is exemplary and not required. As shown in FIG. 2, in a first step 202, portions of an article of footwear may be printed, including an interior layer and an exterior layer. In an exemplary embodiment, the portions may be provided with printed designs. In some embodiments, a customer may custom design portions of the article of footwear, including, but not limited to portions of the interior layer and exterior layer. In some cases, a customer may customize portions of the article of footwear using the system and method disclosed in copending and commonly owned U.S. Patent , currently U.S. Patent
Application Serial No. 11/612,320, entitled "Method of Making an Article of
Footwear", and filed on December 18, 2006, which is incorporated herein by reference.
[0047] Referring to FIG. 2, at a second step 204, the article of footwear may be cut in a pattern forming an integral upper and sole. In some embodiments, an interior layer and an exterior layer may be cut using a pattern forming an integral upper and sole. In some embodiments, the interior and exterior layers may be cut using reverse patterns such that the interior and exterior layers can be aligned in a back-to-back configuration. In some cases, portions of the article of footwear may be laser cut. In other cases, portions of the article of footwear may be stamped or die-cut. In other cases, portions of the article of footwear may be cut using different methods depending on the material used for the article of footwear.
[0048] Referring to FIG. 2, in a third step 206, the interior layer and the exterior layer may be connected. In one embodiment, the interior layer may be provided with an adhesive backing for connecting the exterior and interior layers. In different embodiments, the interior and exterior layers may be connected to one another in various ways, including, but not limited to: adhesive, heat, pressure, stitching and any other method of attachment.
[0049] As shown in FIG. 2, in a fourth step 208, the article of footwear may be assembled to form a finished article of footwear. The article of footwear may be assembled by joining the article of footwear as described in more detail below with reference to the exemplary embodiments. In some cases, the article of footwear may be assembled by a customer. In other cases, the article of footwear may be assembled by a retailer or a manufacturer. Generally, a retailer may be anyone configured to make and/or sell articles of footwear. In some cases, a retailer may be associated with a retail store. In other cases, a retailer may be associated with a kiosk in a mall. In still other cases, a retailer may be associated with one or more manufacturing locations.
[0050] FIG. 3 illustrates an exemplary embodiment of an exterior layer 300 of an article of footwear. In some embodiments, exterior layer 300 may form the outside of an article of footwear. For the purposes of illustration, the exemplary embodiments of the exterior layers and interior layers shown in the figures are shown with printed designs to allow the layers to be clearly
distinguished. In other embodiments, the interior and exterior layers may include different designs, including, but not limited to: various patterns, solids, graphics, colors and custom designs. Referring to FIG. 3, in this embodiment, exterior layer 300 includes an outer material 304 and a structural overlay 302. In different embodiments, outer material 304 may be made from different materials, including, but not limited to: fabric, mesh, canvas, leather, rubber, plastic and any other natural or synthetic material.
[0051] Referring to FIG. 3, structural overlay 302 may be disposed over outer material 304. In one embodiment, structural overlay 302 may include a ground engaging portion. In some embodiments, structural overlay 302 may reinforce the article of footwear. In other embodiments, structural overlay 302 may form various portions of the article of footwear, including, but not limited to: the toe cap, heel, eyelets and ground engaging portion of the article of footwear. In some embodiments, portions of the structural overlay 302 may be laser cut. In other embodiments, portions of the structural overlay 302 may be customized. In different embodiments, portions of the structural overlay 302 may be made of various materials, including, but not limited to: escane, rubber, polyurethane and other natural and synthetic materials. In some cases, the structural overlay 302 may include more than one material. In some embodiments, portions of the structural overlay 302 may include materials with different levels of durability.
[0052] FIG. 4 illustrates an exemplary embodiment of an interior layer 400. In some embodiments, interior layer 400 may form the inside of an article of footwear. In this embodiment, interior layer 400 includes an inner material 402. Inner material 402 may be cut in a pattern forming an integral upper and sole that includes a heel portion 406 and heel tabs 404. Heel tabs 404 may include fasteners 408 disposed on inner material 402. In some cases, fasteners 408 may include hook and loop fasteners. In other cases, fasteners 408 may include various attachment mechanisms, including, but not limited to: zippers, buttons, snaps as well as other types of fasteners.
[0053] FIGS. 5-7 illustrate an exemplary embodiment of the method of connecting the exterior and interior layers to form an article of footwear with an integral upper and sole. Referring to FIG. 5, exterior layer 300 may be connected with interior layer 400. In this embodiment, inner material 402 is configured so that the back of inner material 402 can connect with the back of exterior layer 300. In some embodiments, the back of inner material may include adhesive for connecting the interior layer 400 to the exterior layer 300. As shown in FIG. 5, exterior layer 300 may be aligned with interior layer 400 so that interior heel portion 406 can be aligned with exterior heel portion 502 and heel tabs 404 can be aligned with exterior heel tabs 504. In this embodiment, exterior layer 300 includes a ground engaging portion 500.
[0054] FIG. 6 illustrates an exemplary embodiment of exterior layer 300 being connected to interior layer 400. In some embodiments, exterior layer 300 and interior layer 400 may be connected using adhesive. In one exemplary embodiment, heat and pressure may be applied to adhere exterior layer 300 and interior layer 400 together. In different embodiments, exterior layer 300 and interior layer 400 may be connected to one another in various ways, including, but not limited to: adhesive, heat, pressure, stitching and any other method of attachment.
[0055] FIG. 7 illustrates an exemplary embodiment of an article of footwear 700 with an integral upper and sole. Referring to FIG. 7, the outside of article of footwear 700 may include structural overlay 302 and outer material 304. The inside of article of footwear 700 may include inner material 402. In some embodiments, article of footwear 700 may include an upper portion with heel tabs 702 and a sole portion with a heel portion 704 and a ground engaging portion 500. In this embodiment, the upper portion includes a top lateral edge 706 and the sole portion includes a bottom lateral edge 708. As more fully explained below, article of footwear 700 may be assembled by joining together top lateral edge 706 and bottom lateral edge 708.
[0056] FIGS. 8-17 illustrate an exemplary embodiment of a method of assembling an article of footwear with an integral upper and sole. FIG. 8 shows an embodiment of an article of footwear in the process of assembly. In this embodiment, a midline 800 divides the upper portion of the article of footwear from the sole portion. Referring to FIG. 8, top lateral edge 706 of the upper portion may be moved towards bottom lateral edge 708 of the sole portion by folding the article of footwear along midline 800. FIG. 9 illustrates an embodiment of the article of footwear in the process of assembly where top lateral edge 706 may be brought in proximity to bottom lateral edge 708. In FIG. 10, the top lateral edge and bottom lateral edge of the article of footwear have been brought together. As shown in FIG. 10, the outer material 304 and structural overlay 302 form the outside of the upper portion of the article of footwear.
[0057] FIG. 1 1 illustrates an exemplary embodiment of a method of assembling an article of footwear where the article of footwear has been attached by stitching 1 100 along the top lateral edge and bottom lateral edge. Generally, any kind of stitching may be used to accomplish the attachment of the top lateral edge and bottom lateral edge of the article of footwear. In some cases, simple stitches may be used. In other cases, more complex stitches may be used.
Examples of various stitches that may be used include, but are not limited to: backstitches, basting stitches, blind stitches, buttonhole stitches, chain stitches, cross-stitches, embroidery stitches, feather stitches, hemming stitches, lock stitches, padding stitches, running stitches, slip stitches, stretch stitches, top stitches, whip stitches, zigzag stitches as well as any other types of machine or manual stitches. [0058] In other embodiments, the top and bottom lateral edges may be provided with pre-configured holes. This alternative arrangement may allow for increased ease of manual stitching, which may appeal to some customers.
[0059] FIGS. 12-17 illustrate an exemplary embodiment of the process for attaching a heel portion of an article of footwear with an integral upper and sole. FIG. 12 illustrates an embodiment of the article of footwear in the process of assembly where a heel portion 704 may be moved towards an upright position. In FIG. 13, the heel portion 704 may be brought to an upright position. In some embodiments, heel portion 704 may include a back plate 1300 for engaging with fasteners 408 to removably attach heel tabs 702.
[0060] FIG. 14 illustrates an exemplary embodiment of a method of assembling an article of footwear where the heel portion 704 has been attached to the sole by stitching 1400. Generally, any kind of stitching may be used to accomplish the attachment of the heel portion 704 to the sole. In different embodiments, the stitching 1400 may include various types of stitches disclosed above. In other embodiments, heel portion 704 may be provided with pre- configured holes.
[0061] As shown in FIG. 15, heel portion 704 has been attached to the sole of the article of footwear using stitching 1400. In this embodiment, stitching 1400 may hold heel portion 704 in an upright position. FIG. 16 illustrates an exemplary embodiment of a process of closing heel tabs 702. In this embodiment, fasteners 408 may be provided on heel tabs 702 for engaging with back plate 1300 to removably attach heel tabs 702. FIG. 17 is a close up view of the embodiment of FIG. 16 showing fasteners 408 in proximity to back plate 1300. In other embodiments, heel tabs 702 may include a buckle.
[0062] In some embodiments, heel tabs 702 may fasten the upper portion of the article of footwear from an open position to a closed position around a foot. The term "open position," as used in this detailed description and in the claims, refers to a loosened position of an article of footwear in which a foot may be easily slipped into the article of footwear. The term "closed position," as used in this detailed description and in the claims, refers to a tightened position of an article of footwear in which the article of footwear is tightly wrapped around the foot and cannot be generally removed.
[0063] FIGS. 18 and 19 illustrate an exemplary embodiment of a finished article of footwear 1800 assembled according to the process described in FIGS. 8- 17. Referring to FIG. 18, in this embodiment, finished article of footwear 1800 includes outer material 304 and structural overlay 302 on the outside of article of footwear 1800 and inner material 402 on the inside of article of footwear 1800. In this embodiment, stitching 1100 has been used to attach the top lateral edge and bottom lateral edge of the article of footwear and stitching 1400 has been used to attach heel portion 704 to the sole.
[0064] FIG. 19 illustrates the underside of finished article of footwear 1800. In this embodiment, ground engaging portion 500 of the structural overlay is visible. In some embodiments, ground engaging portion 500 may include a traction tread. In different embodiments, the ground engaging portion 500 may be made of various materials, including, but not limited to: escane, rubber,
polyurethane and other natural and synthetic materials. In some embodiments, ground engaging portion 500 may include a material with a different level of durability than the rest of the structural overlay. In some cases, ground engaging portion 500 may include more than one material.
[0065] FIGS. 20-29 illustrate different exemplary embodiments of an article of footwear with an integral upper and sole. Referring to FIG. 20, an article of footwear 2000 with an integral upper and sole may be provided with alternating channels. In this embodiment, the alternating channels are shown in an
unfinished configuration. Alternating channels may include top lateral edge channels 2002, bottom lateral edge channels 2004 and heel portion channels 2006.
[0066] FIGS. 21 -22 illustrate an exemplary embodiment of a method of forming the top lateral edge channels 2002 of article of footwear 2000. In FIG. 21 , the unfinished top lateral edge channels 2002 are shown in the process of being folded over to form the channels. Referring to FIG. 22, top lateral edge channels 2002 may be formed by attaching the ends of the unfinished channels to the back side of the flat article of footwear. In some embodiments, top lateral edge channels 2002 may be attached using adhesive. In other embodiments, top lateral edge channels 2002 may be attached using stitching. In different embodiments, top lateral edge channels 2002 may be attached using any attachment
mechanism. The process illustrated in FIGS. 21 -22 and described above also may be performed with bottom lateral edge channels 2004 and heel portion channels 2006.
[0067] FIG. 23 illustrates an exemplary embodiment of an article of footwear with alternating channels. Referring to FIG. 23, top lateral edge channels 2002 may be brought together with bottom lateral edge channels 2004 to form alternating channels. In this embodiment, a cord 2300 may be passed through the alternating channels formed by top lateral edge channels 2002 and bottom lateral edge channels 2004.
[0068] FIG. 24 illustrates a close up view of cord 2300 passing through the alternating channels formed by top lateral edge channels 2002 and bottom lateral edge channels 2004. In this embodiment, cord 2300 is used to attach the top lateral edge and the bottom lateral edge to form the article of footwear. In some embodiments, cord 2300 also may be passed through heel portion channels 2006 to attach the heel portion to the sole of the article of footwear.
[0069] FIG. 25 is a cut away view of an exemplary embodiment of an article of footwear 2500 with an integral upper and sole that has been assembled by passing a cord through alternating channels.
[0070] FIG. 26 illustrates an alternative exemplary embodiment of an article of footwear 2600 with an integral upper and sole. In this embodiment, article of footwear 2600 may be provided with interlocking fasteners. In this embodiment, the interlocking fasteners may include top lateral edge fasteners 2602, bottom lateral edge fasteners 2604 and heel portion fasteners 2606. [0071] FIG. 27 illustrates an exemplary embodiment of an article of footwear with interlocking fasteners. Referring to FIG. 27, top lateral edge fasteners 2602 may be alternatively interlaced with bottom lateral edge fasteners 2604 to form an interlocking seam. In this embodiment, top lateral edge fasteners 2602 engage with the inner material on the inside of the sole portion and bottom lateral edge fasteners 2604 engage with the inner material on the inside of the upper portion of the article of footwear. In some embodiments, heel portion fasteners 2606 engage with the inner material on the inside of the sole portion.
[0072] FIG. 28 illustrates a close up view of the interlocking fasteners engaging with the inner material of the article of footwear. In this embodiment, top lateral edge fasteners 2602 may engage with the inner material on the inside of the sole portion of the article of footwear. Bottom lateral edge fasteners 2604 may engage with the inner material on the inside of the upper portion of the article of footwear.
[0073] FIG. 29 illustrates a cut away view of an exemplary embodiment of an article of footwear 2900 with an integral upper and sole that has been assembled using interlocking fasteners. In this embodiment, the interlocking fasteners form a releasable attachment for the top lateral edge and the bottom lateral edge to form the article of footwear 2900.
[0074] FIG. 30 illustrates an exemplary embodiment of a kit of parts 3000. In this embodiment, kit of parts 3000 may include an article of footwear 3004 with an integral upper and sole in an unassembled configuration. In some embodiments, kit of parts 3000 may include a cord 3002 for assembling article of footwear 3004. In one embodiment, article of footwear 3004 is provided with alternating channels for passage of cord 3002 as described in the exemplary embodiments discussed above.
[0075] In other embodiments, article of footwear 3004 may be provided with different mechanisms for assembly as described in the exemplary
embodiments. Examples of the mechanisms for assembly of the article of footwear 3004 may include, but are not limited to, one or more of: stitching, interlocking fasteners, alternating channels, and pre-configured holes.
[0076] Kit of parts 3000 may include a set of instructions 3006. In some embodiments, set of instructions 3006 may include a list of directions for assembling article of footwear 3004. In some cases, set of instructions 3006 may include step by step directions. In other cases, set of instructions 3006 may include diagrams as well.
[0077] In some embodiments, the components comprising kit of parts 3000 may be gathered together for a customer. In some embodiments, the components comprising kit of parts 3000 may be packaged together so a customer can carry kit of parts 3000 home. In some cases, article of footwear 3004, cord 3002 and set of instructions 3006 may be packaged into container 3008. In other embodiments, the components comprising kit of parts 3000 could be packaged in a retail bag. Using this arrangement, a customer may easily carry home kit of parts 3000 or receive kit of parts 3000 in the mail.
[0078] For illustrative purposes, only the components needed to assemble a single article of footwear are shown in the present embodiments. However, it should be understood that a second article of footwear with an integral upper and sole as well as a second cord can be provided in a kit of parts to allow for the assembly of a pair of footwear, rather than just a single article of footwear.
[0079] FIG. 31 is an exemplary embodiment of customer 3100
assembling an article of footwear 3004 using cord 3002. In this embodiment, customer 3100 has removed unassembled article of footwear 3004, cord 3002 and set of instructions 3006 from container 3008. Using set of instructions 3006, customer 3100 may assemble article of footwear 3004 together using cord 3002.
[0080] While various embodiments of the invention 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 invention.
Accordingly, the invention is 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.

Claims

WHAT IS CLAIMED IS:
1 . An article of footwear comprising:
an interior layer;
an exterior layer connected to the interior layer; and
wherein the interior layer and the exterior layer are cut in a pattern forming an integral upper portion and sole portion.
2. The article of footwear according to claim 1 , wherein the exterior layer comprises:
an outer material; and
a structural overlay disposed over the outer material.
3. The article of footwear according to claim 2, wherein the structural overlay comprises at least a first material and a second material, wherein the first material and second material have different levels of durability.
4. The article of footwear according to claim 3, wherein the first material comprises a ground engaging portion.
5. The article of footwear according to claim 2, wherein the interior layer comprises an inner material and wherein at least one of the inner material and outer material are customizable.
6. The article of footwear according to claim 1 , wherein the integral upper portion comprises a top lateral edge and the sole portion comprises a bottom lateral edge, and wherein the top lateral edge and bottom lateral edge are attached to form the article of footwear.
7. The article of footwear according to claim 6, wherein the top lateral edge and bottom lateral edge comprise at least one of: interlocking fasteners, alternating channels, and pre-configured holes.
8. A method of assembling an article of footwear comprising an integral upper portion and sole portion, the method comprising:
folding the article of footwear along a midline between the upper portion and the sole portion; and
attaching a top lateral edge of the upper portion to a bottom lateral edge of the sole portion.
9. The method of assembling an article of footwear according to claim 8, further comprising:
folding a heel portion to an upright position; and
attaching the heel portion to the sole portion of the article of footwear.
10. The method of assembling an article of footwear according to claim 8, wherein the article of footwear comprises:
an interior layer;
an exterior layer connected to the interior layer; and
wherein the interior layer and the exterior layer are cut in a pattern forming an integral upper portion and sole portion.
1 1 . The method of assembling an article of footwear according to claim 10, wherein the exterior layer comprises:
an outer material; and
a structural overlay disposed over the outer material.
12. The method of assembling an article of footwear according to claim 1 1 , wherein the structural overlay comprises at least a first material and a second material, wherein the first material and second material have different levels of durability.
13. The method of assembling an article of footwear according to claim 1 1 , wherein the interior layer comprises an inner material and the method further comprises the step of customizing at least one of the outer material and the inner material.
14. The method of assembling an article of footwear according to claim 8, wherein the step of attaching the top lateral edge of the upper portion to the bottom lateral edge of the sole portion further includes at least one of:
stitching;
lacing a thread through pre-configured holes;
passing a cord through alternating channels; and
engaging interlocking fasteners.
15. A kit of parts, comprising:
an article of footwear cut in a pattern forming an integral upper portion and sole portion;
a set of instructions; and
wherein a top lateral edge of the upper portion may be attached to a bottom lateral edge of the sole portion to form an assembled article of footwear.
16. The kit of parts according to claim 15, wherein the kit of parts further comprises a cord for attaching the top lateral edge and the bottom lateral edge.
17. The kit of parts according to claim 15, wherein the top lateral edge and bottom lateral edge comprise at least one of: interlocking fasteners, alternating channels, and pre-configured holes.
18. The kit of parts according to claim 15, wherein the article of footwear comprises:
an interior layer; and
an exterior layer connected to the interior layer.
19. The kit of parts according to claim 18, wherein the exterior layer comprises: an outer material; and
a structural overlay disposed over the outer material.
20. The kit of parts according to claim 18, wherein at least one of the interior layer and the exterior layer are customizable.
PCT/US2010/055277 2009-11-09 2010-11-03 Article of footwear with integral upper and sole WO2011056853A2 (en)

Priority Applications (3)

Application Number Priority Date Filing Date Title
EP10800793.1A EP2498640B1 (en) 2009-11-09 2010-11-03 Article of footwear with integral upper and sole
CN201080060970.0A CN102711541B (en) 2009-11-09 2010-11-03 There is the upper of a shoe of one and the article of footwear of sole
EP16192532.6A EP3158887B1 (en) 2009-11-09 2010-11-03 Article of footwear with integral upper and sole

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US12/615,111 2009-11-09
US12/615,111 US8434245B2 (en) 2009-11-09 2009-11-09 Article of footwear with integral upper and sole

Publications (2)

Publication Number Publication Date
WO2011056853A2 true WO2011056853A2 (en) 2011-05-12
WO2011056853A3 WO2011056853A3 (en) 2011-09-29

Family

ID=43743453

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/US2010/055277 WO2011056853A2 (en) 2009-11-09 2010-11-03 Article of footwear with integral upper and sole

Country Status (4)

Country Link
US (5) US8434245B2 (en)
EP (2) EP2498640B1 (en)
CN (5) CN105249619B (en)
WO (1) WO2011056853A2 (en)

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US9038287B2 (en) 2009-11-09 2015-05-26 Nike, Inc. Article of footwear with integral upper and sole

Families Citing this family (44)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US8453354B2 (en) 2009-10-01 2013-06-04 Nike, Inc. Rigid cantilevered stud
US8321984B2 (en) * 2009-10-21 2012-12-04 Nike, Inc. Composite shoe upper and method of making same
US8572866B2 (en) 2009-10-21 2013-11-05 Nike, Inc. Shoe with composite upper and foam element and method of making same
US8429835B2 (en) * 2009-10-21 2013-04-30 Nike, Inc. Composite shoe upper and method of making same
US10716357B2 (en) * 2010-01-04 2020-07-21 Applied Ft Composite Solutions Inc. Unibody construction footwear and method for making the same
US9609915B2 (en) 2013-02-04 2017-04-04 Nike, Inc. Outsole of a footwear article, having fin traction elements
US9848672B2 (en) * 2013-03-04 2017-12-26 Nike, Inc. Article of footwear incorporating a knitted component with integrally knit contoured portion
US9936757B2 (en) * 2013-03-04 2018-04-10 Nike, Inc. Article of footwear incorporating a knitted component with integrally knit contoured portion
JP5931800B2 (en) * 2013-05-31 2016-06-08 真▲線▼情寰榮有限公司 Clothing shoe body and manufacturing method thereof
US20140352174A1 (en) * 2013-06-04 2014-12-04 Christine Benkovic Method and apparatus for one-piece footwear
US9713362B2 (en) * 2013-09-12 2017-07-25 Nike, Inc. Article of footwear with upper having member with support arm
CN104757741A (en) * 2014-01-07 2015-07-08 维珍妮国际(集团)有限公司 Improvement on manufacture of shoes
US10463106B2 (en) 2014-02-13 2019-11-05 Nike, Inc. Sole assembly with textile shell and method of manufacturing same
TWI678169B (en) * 2015-01-28 2019-12-01 巨大機械工業股份有限公司 Sports shoes for rotary stepping exercise
TWI613978B (en) 2015-05-29 2018-02-11 耐克創新有限合夥公司 Article of footwear flat pattern and method of manufacturing article of footwear
TWI637702B (en) * 2015-05-29 2018-10-11 耐克創新有限合夥公司 Footwear manufacturing with an origin
TWI698195B (en) 2015-05-29 2020-07-11 荷蘭商耐克創新有限合夥公司 Article of footwear flat pattern upper having an upper portion and a footbed portion
TWI719293B (en) * 2015-05-29 2021-02-21 荷蘭商耐克創新有限合夥公司 Method of manufacturing an article of footwear and collection of materials
TW201701789A (en) * 2015-06-15 2017-01-16 島精機製作所股份有限公司 Shoe upper and method for knitting shoe upper
WO2017029957A1 (en) * 2015-08-19 2017-02-23 株式会社島精機製作所 Footwear
TWM520827U (en) * 2015-12-22 2016-05-01 Long John Tsung Right Ind Co Ltd Vamp with embossment
CN105533927A (en) * 2016-01-18 2016-05-04 福建狮牌商贸有限公司 Shoe upper forming method
CN108697190B (en) 2016-01-19 2021-12-24 耐克创新有限合伙公司 Footwear with embroidered transition between materials
EP3405059B1 (en) 2016-01-19 2020-10-28 NIKE Innovate C.V. Footwear with felting transition between materials
US10321738B2 (en) 2016-01-19 2019-06-18 Nike, Inc. Footwear with embroidery transition between materials
KR101852422B1 (en) * 2016-04-06 2018-04-30 최광수 Infant shoe and a method of manufacturing
CN105795599A (en) * 2016-05-13 2016-07-27 信泰(福建)科技有限公司 Embroidered instep process and instep applying same
CN105815876A (en) * 2016-05-20 2016-08-03 温州市瓯海康尼斯鞋业有限公司 Shoe middle part, shoe workpiece, shoe and manufacturing method of shoe
US10368614B2 (en) * 2016-06-01 2019-08-06 Nike, Inc. Footwear manufacturing with a nested flat pattern upper
CN105962542A (en) * 2016-06-28 2016-09-28 特步(中国)有限公司 One-piece vamp and making method thereof
CN105962546B (en) * 2016-06-30 2021-10-26 际华三五一三实业有限公司 Seamless butt joint process for shoemaking and integrated shoe enclosure thereof
US10448706B2 (en) 2016-10-18 2019-10-22 Nike, Inc. Systems and methods for manufacturing footwear with felting
CN108606409B (en) * 2017-01-10 2020-04-14 信泰(福建)科技有限公司 Improved shutter type stereo stripe vamp
TWI632265B (en) * 2017-03-10 2018-08-11 薩摩亞商紘織國際有限公司 Method for integrally weaving an extended shoe with a flat knitting machine
TWI712372B (en) 2017-05-31 2020-12-11 荷蘭商耐克創新有限合夥公司 Article of footwear with side seam manufactured from flat pattern and method of manufacturing the same
US11059249B2 (en) 2017-06-19 2021-07-13 Under Armour, Inc. Footwear and method of formation
US11452338B2 (en) 2017-12-13 2022-09-27 Nike, Inc. Article of footwear
US10716362B2 (en) * 2018-07-03 2020-07-21 Under Armour, Inc. Article with ribbon structure having nodes and links
US10617170B1 (en) * 2019-06-14 2020-04-14 Stephen Arnold Sandal or slip-on footwear with improved optional-use heel strap and related methods
WO2021016189A1 (en) * 2019-07-25 2021-01-28 Nike Innovate C.V. Article of footwear
US11452340B2 (en) * 2019-08-30 2022-09-27 Under Armour, Inc. Braided article with reinforced stitch
US10918163B1 (en) 2020-04-25 2021-02-16 Daniel R. Blondeau One piece footwear
USD950897S1 (en) 2020-04-25 2022-05-10 Daniel R. Blondeau Footwear
DE102022001531A1 (en) 2022-05-02 2023-11-02 Adidas Ag Shoe with a combination of a lightweight upper construction

Family Cites Families (89)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US336913A (en) * 1886-03-02 graff
US983576A (en) * 1909-12-17 1911-02-07 George H Smith Shoe-upper.
US1104357A (en) * 1913-10-30 1914-07-21 Nels H Hassel Foldable slipper.
US1359377A (en) * 1919-03-29 1920-11-16 Michael J Hollenbeck One-piece slipper
US1888862A (en) * 1929-08-20 1932-11-22 Dun Deer Sandals Inc Shoe
GB395274A (en) * 1933-01-23 1933-07-13 Karl Grosz Improvements in the connection of uppers to soles in the manufacture of footwear
US2119233A (en) * 1936-10-07 1938-05-31 Glenn D Judkins Slipper
US2220534A (en) * 1938-10-19 1940-11-05 Frank W Mclean Footwear
US2200080A (en) * 1938-11-16 1940-05-07 Fein Jacob Shoe
US2340578A (en) * 1941-08-15 1944-02-01 Us Rubber Co Shoe
US2384927A (en) * 1942-11-24 1945-09-18 Charles A Julianelli Shoe construction
US2438711A (en) * 1945-03-02 1948-03-30 Raymond A Leach Shoe with detachable upper
US2444822A (en) * 1946-05-02 1948-07-06 Emma E Griffin Bootee
US2552943A (en) * 1948-03-04 1951-05-15 Jones & Malyon Ltd Shoe having a detachable upper
US2548961A (en) * 1948-06-29 1951-04-17 Wilbur A Foster Edge binding and counter construction for moccasins
US2513005A (en) * 1948-10-20 1950-06-27 Crawford Company Sandal with overlapping side and end panels
US2551723A (en) * 1949-01-04 1951-05-08 Cesar G G Camero Sandal with vamp piece spaced above sole
US2494617A (en) * 1949-06-27 1950-01-17 Hogan Rose One-piece foot covering
US2682713A (en) * 1952-05-29 1954-07-06 Eiger Ida One-piece shoe construction
US2748501A (en) * 1953-12-18 1956-06-05 Kidlets Inc Child's bootie construction
US2974427A (en) * 1958-08-01 1961-03-14 William C Wolff Shoe construction comprising an integral upper and insole
US3002297A (en) * 1960-02-19 1961-10-03 Mary D Neilson Footwear
FR1311055A (en) * 1962-01-19 1962-11-30 Improved manufacturing process for sandals and resulting products
US3050876A (en) * 1962-04-20 1962-08-28 Penobscot Shoe Company Easily lasted moccasin construction
US3378940A (en) * 1964-06-22 1968-04-23 R J Potvin Shoe Company Inc Moccasin shoe and blank therefor
US3538628A (en) * 1968-09-23 1970-11-10 Lord Geller Federico & Partner Footwear
US3603006A (en) * 1970-07-10 1971-09-07 Gen Tire & Rubber Co Footwear article
US3762075A (en) * 1972-07-27 1973-10-02 D Munschy Disposable shoe
US3775873A (en) * 1973-01-26 1973-12-04 D Small Disposable plastic slipper
BE807747R (en) * 1973-11-23 1974-03-15 Vanderlinden Pierre ANALOGUE MULE OR SLIPPER
US3845576A (en) * 1974-01-17 1974-11-05 Safety Inc Protective device for safety shoes
US4107857A (en) * 1977-04-11 1978-08-22 Devlin Gerard P Athletic shoe construction
US4150498A (en) * 1977-11-28 1979-04-24 Peds Products, Inc. Foot cover and blank therefor
US4300294A (en) * 1979-10-09 1981-11-17 Riecken George C Article of footwear
DE3043266A1 (en) * 1980-11-15 1982-06-03 Georg 7272 Altensteig Spreng SPORTSHOE
US4592152A (en) * 1985-05-20 1986-06-03 Brown Group, Inc. Unlasted shoe
US4713895A (en) * 1986-07-08 1987-12-22 Francois Vallieres Sports shoe cover
US4976050A (en) * 1987-04-06 1990-12-11 Barbara Houghteling Baby bootie
AU1939088A (en) 1987-06-04 1989-01-04 Benito Mignani One-piece slipper and method of making the same
US4751784A (en) * 1987-07-10 1988-06-21 Al Petker Disposable slipper and method for forming same
US4896439A (en) * 1987-08-24 1990-01-30 Morgan Clyde S Sound proof cover for soles of sportsmen's shoes and method for use
FR2634630B1 (en) 1988-07-29 1991-01-18 Proteor Sa PROTECTIVE COVER FOR ORTHOPEDIC SHOES
US4972609A (en) * 1989-11-30 1990-11-27 Pioneer Interstate, Inc. Protective shoe apparatus
DE9010863U1 (en) * 1990-07-21 1990-10-04 Kuehnreich, Heinz-Peter, 5210 Troisdorf, De
AU1977192A (en) * 1991-06-17 1993-01-12 Puma Aktiengesellschaft Rudolf Dassler Sport Method of producing a shaped shoe part from a strip of fabric, and a shaped shoe part produced by this method
CN1039987C (en) * 1992-09-04 1998-09-30 于在平 Production process for nutritious photosynthetic liquid fertilizer
FR2695808A1 (en) * 1992-09-18 1994-03-25 Ets Delage Alain Upper and inner sole for slipper - is cut out in one piece, with upper sole joined to upper
US5317822A (en) * 1992-10-19 1994-06-07 Johnson Joshua F Athletic shoe with interchangeable wear sole
FR2744342A1 (en) 1996-02-02 1997-08-08 Bouchemel Marie Louise Moccasin manufacture
US5727334A (en) * 1996-05-10 1998-03-17 Cougar; Daniel Duane Safety shoe with high-traction replaceable sole
US5946737A (en) * 1996-05-20 1999-09-07 Fleege; Robert Combined elbow and foot protector
CN1072920C (en) * 1997-01-03 2001-10-17 展昌塑胶股份有限公司 Simple structure of assembled slipper and sandals, and method for making same
US5992058A (en) * 1998-04-02 1999-11-30 Jneid; Hudson Detachable shoe strap system
US6299962B1 (en) * 1998-12-22 2001-10-09 Reebok International Ltd. Article of footwear
US6185845B1 (en) * 1999-01-22 2001-02-13 Arcticshield, Inc. Thermal foot cover
US7237345B2 (en) * 1999-08-05 2007-07-03 Thomas Jeff C C Disposable and non-disposable foot cap
US20060179549A1 (en) * 2000-04-20 2006-08-17 Dance Paws Llc Adjustable formfitting protective footwear
US7179414B2 (en) * 2001-03-12 2007-02-20 E.S. Originals, Inc. Shoe manufacturing method
ATE401014T1 (en) * 2000-08-25 2008-08-15 Jon C Larson NON-SLIP OVERSHOE AND PIN MOUNTING
CA2319956A1 (en) * 2000-09-18 2002-03-18 John Mccrindle Temporary use bowling shoe
AR030082A1 (en) * 2001-07-31 2003-08-13 Eduardo Jorge Bianchi COUPLING DEVICE IN FOOTWEAR WITH BUTTON MECHANISM TO JOIN AN INTERACTING SOIL INTERCHANGEABLE COATINGS
US6792697B2 (en) * 2002-07-01 2004-09-21 Medical Device Group, Inc. Foot protection kit and method of making same
CN2588818Y (en) * 2002-12-03 2003-12-03 侯鹰 Air blowing collapsible rain boot
US6874253B2 (en) * 2003-03-24 2005-04-05 Katrina Hollis-Lorent Footwear for feet beautification
US7272897B2 (en) * 2003-03-28 2007-09-25 Zu Sheng Yu Sandal having a variety of lacing styles
US20040216329A1 (en) * 2003-05-02 2004-11-04 Joyce Evans One piece sandal
US7210251B1 (en) * 2003-05-03 2007-05-01 Rolle Gwendolyn M W Shoe with interchangeable covers
US7080466B2 (en) * 2003-07-22 2006-07-25 Fischbein Amy J Article of footwear
CN2631261Y (en) * 2003-08-14 2004-08-11 吴金林 Ventilating waterproof shoes or boots
US6931766B2 (en) * 2003-11-12 2005-08-23 Nike, Inc. Footwear with a separable foot-receiving portion and sole structure
US7082703B2 (en) * 2004-01-30 2006-08-01 Nike, Inc. Article of footwear for sand sports
US7168189B2 (en) * 2004-09-22 2007-01-30 Phelan Ann C Interchangeable footwear system
US7219443B2 (en) * 2004-12-07 2007-05-22 Eric Czaplewski Protective booties and leggings
US7549238B2 (en) * 2005-12-21 2009-06-23 Patakos Nikolaos D Reversible hygiene shoe
US7849609B2 (en) * 2006-03-31 2010-12-14 Nike, Inc. Interior and upper members for articles of footwear and other foot-receiving devices
US7832117B2 (en) * 2006-07-17 2010-11-16 Nike, Inc. Article of footwear including full length composite plate
US7464491B2 (en) * 2006-09-21 2008-12-16 Yoko Nakayama Packaged shoes
US7945343B2 (en) 2006-12-18 2011-05-17 Nike, Inc. Method of making an article of footwear
GB0701697D0 (en) * 2007-01-30 2007-03-07 Thoraval Michael C Ballet pointe shoes
US7797857B2 (en) * 2007-02-22 2010-09-21 Alyssa Marie Mattia Transformational shoes
US8307570B2 (en) * 2007-03-16 2012-11-13 Urshuz Inc. Attachment system for shoe uppers
US7669352B2 (en) * 2007-03-30 2010-03-02 Jerry Stefani Interchangeable component shoe system
US8544191B2 (en) * 2007-04-10 2013-10-01 Reebok International Limited Smooth shoe uppers and methods for producing them
WO2008130839A1 (en) * 2007-04-18 2008-10-30 Nike, Inc. Article of footwear construction with binding portions
US8266826B2 (en) * 2007-10-09 2012-09-18 Nike, Inc. Article of footwear with sole structure
US7941943B2 (en) * 2007-10-22 2011-05-17 Nike, Inc. Ball control insert
US7987617B2 (en) * 2007-11-13 2011-08-02 Nike, Inc. Self assembled article of footwear with customized designs
US20090193684A1 (en) * 2008-02-06 2009-08-06 Laurence Diamond Convertible shoe
US8434245B2 (en) 2009-11-09 2013-05-07 Nike, Inc. Article of footwear with integral upper and sole

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US9038287B2 (en) 2009-11-09 2015-05-26 Nike, Inc. Article of footwear with integral upper and sole
US9044058B2 (en) 2009-11-09 2015-06-02 Nike, Inc. Article of footwear with integral upper and sole
US9554618B2 (en) 2009-11-09 2017-01-31 Nike, Inc. Article of footwear with integral upper and sole
US9554619B2 (en) 2009-11-09 2017-01-31 Nike, Inc. Article of footwear with integral upper and sole

Also Published As

Publication number Publication date
CN105342062A (en) 2016-02-24
CN102711541A (en) 2012-10-03
US9044058B2 (en) 2015-06-02
CN105361354B (en) 2018-11-13
WO2011056853A3 (en) 2011-09-29
EP2498640A2 (en) 2012-09-19
US8434245B2 (en) 2013-05-07
CN105342061B (en) 2018-03-20
CN105249619B (en) 2018-12-14
EP2498640B1 (en) 2016-12-21
CN102711541B (en) 2015-11-25
EP3158887B1 (en) 2018-09-26
US9038287B2 (en) 2015-05-26
US20110107620A1 (en) 2011-05-12
CN105342061A (en) 2016-02-24
EP3158887A2 (en) 2017-04-26
US9554618B2 (en) 2017-01-31
US20150223559A1 (en) 2015-08-13
US20130291402A1 (en) 2013-11-07
US20150157084A1 (en) 2015-06-11
EP3158887A3 (en) 2017-07-12
CN105249619A (en) 2016-01-20
US9554619B2 (en) 2017-01-31
CN105361354A (en) 2016-03-02
US20130291403A1 (en) 2013-11-07

Similar Documents

Publication Publication Date Title
US9554619B2 (en) Article of footwear with integral upper and sole
US7987617B2 (en) Self assembled article of footwear with customized designs
US8151491B2 (en) Reversible article of footwear
US6442874B1 (en) Athletic shoe with an adjustable sizing system
US7159341B2 (en) Closure system
CN103402384A (en) Thermoplastic polyuerethane infused mesh
JP7245240B2 (en) footwear assembly
CN102697241A (en) Footwear
JP5242630B2 (en) Shoe making kit
US20220312896A1 (en) Article of footwear with pivoting tongue and anchoring strap
JP4230444B2 (en) Shoes and manufacturing method thereof

Legal Events

Date Code Title Description
WWE Wipo information: entry into national phase

Ref document number: 201080060970.0

Country of ref document: CN

121 Ep: the epo has been informed by wipo that ep was designated in this application

Ref document number: 10800793

Country of ref document: EP

Kind code of ref document: A1

NENP Non-entry into the national phase

Ref country code: DE

REEP Request for entry into the european phase

Ref document number: 2010800793

Country of ref document: EP

WWE Wipo information: entry into national phase

Ref document number: 2010800793

Country of ref document: EP