TEXTILE FOOTWEAR ITEM AND METHOD OF MANUFACTURE

Abstract

A footwear item including a main textile element including a main textile bootie having a sole portion secured, at least partially, to at least one sole element, the main textile element also including one or more hot-melted textile portion(s). The sole portion includes a first through-opening, and the main textile element includes at least a first additional textile part of unitary textile construction with the main textile bootie and in connection with the first through-opening. The first additional textile part may project into or out of the foot-accommodating volume of the main bootie and potentially reinforce the attachment with the sole element.

Claims

1-23. (canceled)

24. A footwear comprising a main textile element comprising a main textile bootie having a sole portion attached, at least partially, to at least one sole element, the main textile element also comprises one or several hot melted textile portion(s), wherein the sole portion comprises a first through-opening, and wherein the main textile element comprises at least a first additional textile part, of unitary textile construction with the main textile bootie, and in connection with said first through-opening.

25. The footwear according to claim 24, wherein the main textile bootie comprises an external face, and wherein the first additional textile part partially wraps the external face of the main textile bootie.

26. The footwear according to claim 24, wherein the main textile bootie comprises an internal face, and wherein the first additional textile part partially wraps the internal face of the main textile bootie.

27. The footwear according to claim 24, wherein the first additional textile part at least partially wraps said sole element.

28. The footwear according to claim 27, wherein the first additional textile part comprises an intermediate textile portion disposed between the sole portion of the main textile bootie and said sole element.

29. The footwear according to claim 24, wherein said sole element comprises a peripheral edge, and wherein the first additional textile part at least partially covers said peripheral edge.

30. The footwear according to claim 24, wherein the first additional textile part comprises one or several hot melted textile portion(s) covering, at least partially, the sole element.

31. The footwear according to claim 24, wherein the first additional textile part comprises first and second textile layers and a receiving volume disposed between said first and second layers.

32. The footwear according to claim 24, wherein the main textile bootie comprises a first textile junction portion comprising one or several hot melted textile portion(s), superimposed, at least partly, with the first additional textile portion.

33. The footwear according to claim 32, wherein the first textile junction portion comprises one or several hot melted textile portion(s) which represents(s) at least 50% by mass of the total mass of the first textile junction portion.

34. The footwear according to claim 24, wherein the main textile element comprises a second additional textile part comprising one or several hot melted textile portion(s), and at least partially covers the internal face of the main textile bootie.

35. The footwear according to claim 34, wherein the second additional textile part forms an internal hard toe-puff.

36. The footwear according to claim 34, wherein the second additional textile part comprises first and second textile layers, and a receiving volume disposed between the first and second textile layers.

37. The footwear according to claim 34, wherein the second additional textile part is in connection, at least partly, with the edge of the first through-opening.

38. The footwear according to claim 24, wherein the main textile element comprises a third additional textile part comprising one or several hot melted textile portion(s), said third additional textile part is in connection, at least partly, with an area for introducing the foot into a foot-receiving volume of the main bootie.

39. The footwear according to claim 38, wherein the third additional textile part comprises first and second textile layers, and a receiving volume disposed between said first and second layers.

40. The footwear according to claim 38, wherein the main textile element comprises a second textile junction portion extending between the main bootie and the third additional textile part.

41. The footwear according to claim 24, wherein the main textile element comprises a fourth additional textile part comprising one or several hot melted portion(s), covering, at least partly, the internal face or the external face of a heel region of the main bootie.

42. The footwear according to claim 41, wherein the fourth additional textile part is in connection with the area for introducing the foot into a volume for receiving of the main bootie.

43. The footwear according to claim 41, wherein the fourth additional textile part comprises first and second textile layers, and a receiving volume disposed between said first and second layers.

44. The footwear according to claim 31, comprising a functional piece disposed in the receiving volume chosen among the volume(s) for receiving of the first additional textile part and second, third, and fourth additional textile parts.

45. The footwear according to claim 44, comprising a functional piece chosen among a foam, a film, a textile piece, a tag, or a combination thereof, disposed in one or several receiving volume(s) of the first additional textile parts.

46. The footwear according to claim 24, comprising an auxiliary textile bootie, comprising one or several hot melted textile portion(s), the auxiliary textile bootie being disposed on the main bootie and the sole element so as to cover, at least partly, the main textile bootie, the sole element and the junction between the main textile bootie and the sole element.

47. The footwear according to claim 46, wherein the auxiliary textile bootie covers, at least partly the portion of the first additional textile part at least partly covering the peripheral edge, and at least partly the external face of the sole element.

48. The footwear according to claim 24, wherein the edges of the first through-opening are not joined.

49. The footwear according to claim 46, wherein the auxiliary textile bootie comprises a through-opening whose edges are attached together.

50. A method for manufacturing a footwear, the method comprising the steps of: (i) providing a main textile element comprising a main textile bootie, having a sole portion and comprising one or several hot-meltable textile portion(s); (ii) subjecting said first main textile element to a temperature to obtain the melting of said hot-meltable portion(s); (iii) attaching, at least partially, at least one sole element, to the sole portion of the main textile bootie, step iii) taking place before, during or after step ii); wherein the sole portion comprises a first through-opening, and wherein the main textile element comprises a first additional textile part, of unitary textile construction with the main textile bootie, and in connection with said first through-opening.

Description

DESCRIPTION OF THE DRAWINGS

[0188] The disclosure will be better understood upon reading the following description of embodiments of the disclosure given by way of non-limiting examples, with reference to the appended drawings, in which:

[0189] FIG. 1 schematically illustrates a perspective and side view of a first example of main textile element according to the disclosure;

[0190] FIG. 2 schematically illustrates a bottom view of the main textile element represented in FIG. 1;

[0191] FIG. 3 schematically represents a bottom view of the main textile element represented in FIGS. 1 and 2, as well as a first additional textile part (A), and a second additional textile part (B);

[0192] FIG. 4 schematically represents a bottom view of the main textile element represented in FIGS. 1 and 2, as well as the first additional textile part (A) and the second additional textile part (B);

[0193] FIG. 5 schematically represents a side view of the main textile element of FIG. 1, disposed on a preform, including the first additional textile part (A) which engages with a sole element;

[0194] FIG. 6 schematically illustrates a side view of the main textile element of FIG. 1, disposed on a preform, including the first additional textile part (A) engaged with a sole element;

[0195] FIG. 7 schematically illustrates a side view of a first example of auxiliary textile bootie disposed on the main textile element represented in FIGS. 1 to 6;

[0196] FIG. 8 schematically illustrates a side view of the auxiliary textile bootie of FIG. 7 slightly folded to reveal the main textile bootie;

[0197] FIG. 9 schematically illustrates a side view of the assembly including the first example of the main textile element, the sole element and the auxiliary textile bootie of FIG. 7;

[0198] FIG. 10 schematically illustrates a bottom view of the assembly of FIG. 8;

[0199] FIG. 11 schematically illustrates the footwear obtained from the thermo-compressed assembly represented in FIGS. 7 to 10,

[0200] FIG. 12 schematically illustrates a side view of a second example of a main textile element further including third and fourth additional textile parts (C, D) according to the disclosure;

[0201] FIG. 13 schematically illustrates a side view of the main textile element of FIG. 12 including the third and fourth additional textile parts (C, D) deployed outside the foot-receiving volume of the main textile bootie;

[0202] FIG. 14 schematically illustrates a side view of the third and fourth additional textile portitions (C, D) of FIG. 13;

[0203] FIG. 15 schematically illustrates a bottom view of a third example of a main textile element according to the disclosure;

[0204] FIG. 16 schematically illustrates a side view of a fourth example of a main textile element according to the disclosure;

[0205] FIG. 17 schematically illustrates a side view of a fifth example of a main textile element.

DETAILED DESCRIPTION

[0206] FIG. 1 represents a first example of a main textile element 100 according to the disclosure disposed on a preform 10 and including a main textile bootie 200 and a first additional textile part (A) 300. The first additional textile part (A) includes an intermediate textile portion 320 and a wrapping textile portion 330. The main textile bootie 200 includes a sole portion 205, a medial portion 210, a lateral portion, a rear portion 215 and a front portion 220, and a through-opening 225 for the insertion of the foot into the interior volume of the main textile bootie 200 corresponding to the foot-receiving volume of the footwear 700. The main textile element 100 may include a temporary elastic textile piece 110 that allows maintaining the lateral and medial edges of the groove portion 218 of the main textile bootie 200 at a substantially constant distance, particularly during the thermo-forming step.

[0207] The main textile bootie 200 has a hollow elongated shape and includes a first through-opening 235 opening out into the interior volume of the main textile bootie 200 and disposed in the front part 206 of the sole portion 205, as well as a second through-opening corresponding to the opening 225 for introducing the foot.

[0208] The first additional textile part (A) 200 is in connection, in particular knitted connection, with the first through-opening 235, particularly with the edge of the opening 235, and projects outside the main textile bootie 200 from the edge of the first through-opening 235.

[0209] The main textile bootie 200 preferably includes a first textile junction portion 230, particularly including one or several at least partially hot-meltable yarn(s). The first textile junction portion 230 partially borders the periphery of the first through-opening 235. Preferably, the first junction portion 230 is disposed in the front part 206 of the sole portion 205, and includes at least partly hot-meltable yarns, particularly monofilament and monocomponent hot-meltable yarns.

[0210] The main textile bootie 200 also includes a partially annular textile region 240 disposed around the opening 225 for introducing the foot.

[0211] The main textile element 100 is in a knitted piece of unitary knitted construction. The annular region 240 is preferably in n*p rib stitches, for example in 1*1 rib, and optionally includes one or several elastic yarn(s).

[0212] Preferably, the first additional textile part (A) 300 is knitted, and is of unitary textile (knitted) construction with the main knitted textile element 100. The first part (A) 300 includes first and second textile layers 340, 350 substantially superimposed and including one or several at least partially hot-meltable yarn(s). The first textile layer 340 includes less than 50% by mass, in particular less than 20% by mass of at least partly hot-meltable yarn(s) relative to its total mass. The second textile layer 350 includes more than 80% by mass, in particular includes at least partially hot-meltable yarn(s) relative to its total mass.

[0213] The main textile element 100 includes a second additional textile part (B) 400 visible in FIGS. 3 and 4 in a deployed position out of the interior volume of the main textile bootie 200 through the first through-opening 235. This second additional textile part (B) 400 is preferably knitted, and is in knitted connection with the first opening 235 so that it is of unitary knitted construction with the main textile bootie 200.

[0214] In operation, this second additional textile part (B) 400 is folded into the interior volume of the main textile bootie 200, and disposed against the internal face of the main textile bootie 200, and partly covers the lateral 212 and medial 210 portions in the front part 206 of the main textile bootie 200, and partly the front portion 215 of the main textile bootie 200. The second additional textile part (B) 400 preferably includes first and second substantially superimposed textile layer(s) 410, 420, and including one or several at least partially hot-meltable yarn(s). Particularly, the first and second textile layers 410, 420 include single-component monofilament hot-meltable yarns. A receiving volume is arranged between the first and second layers 410, 420 and configured to receive a functional piece, such as a shock-absorbing or stiffening element. In this specific example, the receiving volume of the second additional part 20 (B) is empty. The two layers 410, 420 allow locally increasing the thickness of the second additional textile part (B) 400. The second additional textile part (B) 400 performs the hard toe-puff function once the at least partly melted hot-melt yarns thus form heat melted textile portions.

[0215] FIGS. 5 and 6 represent the main textile element 100 disposed on a rigid preform 10 (useful only for illustration purposes) and placed in connection with a sole element 500, in this specific example an outsole 510, in particular including multiple studs 520 projecting from the external face 515 of the outsole 510. The sole portion 205 of the main textile bootie 200 is disposed against the internal face 516 of the sole element 500, and the first additional textile part (A) 300 partially wraps the peripheral edge 517 of the sole element 500. The peripheral edge 517 extends between the internal face 516 and the external face 515 of the sole element 500, and is preferably substantially vertical. Particularly, the first additional textile part (A) 300 includes an intermediate textile portion 320 disposed between the sole portion 205 of the main textile bootie 200 and the internal face 516 of the sole element 500, and a wrapping portion 330, in the extension of the intermediate portion 320, and partially covering the peripheral edge 517 and partially the external face 515 of the sole element. The junction 20 between the main textile bootie 200 and the sole element 500 is thus locally reinforced, partially, in the front part 220 of the main textile bootie 200, and in this specific example partially in the lateral 212 and medial 210 parts. This junction 20 thus includes multiple textile thicknesses: the first and second textile layers 410, 420 of the second additional textile part (B) 400, the main textile bootie 200, and the first and second textile layers 340, 350 of the first additional textile part (A) 300. The junction 20 between the main textile bootie 200 and the sole element 500 is thus reinforced, in particular locally by the first additional textile part (A) 300. The resistance to abrasion and wear of the main textile bootie 200 and the resistance to delamination of the main textile bootie 200 of the sole element 500 will be improved when the at least partially hot-meltable yarns are melted.

[0216] It is also possible to cover the main textile element 100 and the sole element 500 with an auxiliary textile bootie 600 represented in particular in FIGS. 7 to 10. This auxiliary textile bootie 600 is preferably disposed around the main textile element 100 in connection with the sole element 500 as represented in FIG. 7. FIG. 8 represents the auxiliary textile bootie 600 slightly folded on itself to reveal the main textile element 100 disposed on the preform 10 and in connection with the sole element 500.

[0217] The auxiliary textile bootie 600 includes a rear portion 605, a medial portion 610, a lateral portion 615, a front portion 620 and a sole portion 625.

[0218] The auxiliary textile bootie 600 includes in its sole portion 625 receiving areas 626 represented in FIG. 10, particularly through-openings, receiving the studs 520 projecting from the external face of the sole element 500.

[0219] The auxiliary textile bootie 600 has a hollow elongated shape and includes first and second through-openings 630, 640. In this specific example, the second through-opening 640 is substantially superimposed with the second foot introducing through-opening 225 of the main textile bootie 200. The first through-opening 630 also opens out into the interior volume of the auxiliary textile bootie 600 but its lateral edges 632 and 634 are attached, for example by sewing. The first opening 630 of the auxiliary textile bootie 600 is therefore closed while the first opening 235 of the main textile bootie 200 remains open. The main 200 and auxiliary 600 booties are preferably knitted on a circular knitting loom of small diameter, hence their generally elongated and hollow shapes each including first and second through-openings. The second through-openings 225, 640 are substantially superimposed and correspond to the opening for introducing the foot into the footwear 700. The first through-opening 235 of the main textile bootie 200 remains open because the first additional textile part (A) projects therefrom. The rounded disposition of the second through-opening 235 kept open facilitates the partial wrapping of the substantially rounded peripheral edge 517 of the front part of the sole element 500.

[0220] The auxiliary textile bootie 600 includes an elastic annular region 650 bordering the second through-opening 640 for introducing the foot. Preferably, the elastic annular region 650 does not include hot-melt yarns.

[0221] The assembly including the main textile element 100 cooperating with the sole element 500, the auxiliary textile bootie 200, and optionally one or several reinforcing and/or stiffening and/or aesthetic element(s) is disposed in a mold in several parts, the preform 10 is replaced by an inflatable envelope housed in the foot-receiving volume of the main textile bootie 200. The parts of the mold are closed. The inflatable envelope is gradually inflated in order to press the textile parts of the assembly against the internal walls of the mold and against the inflatable envelope. The assembly is then heated to a temperature greater than or equal to the melting temperature(s) of the at least partially hot-meltable yarns in order to obtain the melting of the hot-meltable yarns and the formation of the hot melted textile portions. On leaving the thermo-compression step, the temporary elastic textile piece 110 is separated, in particular by cutting it, from the main textile bootie 200. The temperature conditions and the inflation pressure are determined by those skilled in the art depending on the nature of the implemented yarns, and possibly on the implemented functional piece(s).

[0222] The footwear 700 obtained is represented in FIG. 11 and includes an upper 710 including the textile element 100 and the thermo-compressed auxiliary textile bootie 200. The sole element 500 is disposed between the main textile bootie 200 and the auxiliary textile bootie 600. In this specific example, the sole element is a molded piece, for example in an abrasion-resistant elastomer. The first and second additional textile parts (A, B) 300, 400 respectively reinforce the junction 20 between the main textile bootie 200 and the sole element 500, as well as the front part 220 of the upper 710 by forming a hard toe-puff. The studs 520 project through the sole portion 625 of the auxiliary textile bootie 600 of the upper 710. The footwear 700 includes a longitudinal axis extending substantially between the back and the front of the article. The footwear 700 also includes a transverse axis, in particular substantially perpendicular, to the longitudinal axis.

[0223] In one embodiment, the sole portion 625 of the auxiliary textile bootie 600 includes hot melted textile, particularly transparent and/or opaque, portions making in particular the sole portion 205 of the visible main textile bootie 200. The hot melted portions are preferably arranged on the sole portion 625 facing the first through-opening 235 of the main textile bootie 200.

[0224] Advantageously, the footwear 700 has a weight on the order of 160 g.

[0225] The upper 710 of the footwear 700 could also not include an auxiliary textile bootie 600. The sole element 500 would therefore be almost completely visible. The first additional textile part (A) 300 then ensures alone resistance to the localized delamination.

[0226] FIG. 12 represents a second example of a main textile element 800 according to the disclosure disposed on a rigid preform 11 for representation purposes. This main textile element 800 is described below essentially according to its differences with the main textile element 300. The main textile element 800 includes a main textile bootie 860 including a sole portion 865, a rear portion 870, a front portion 875, a lateral portion 880 and a medial portion. This main textile element 800 also includes a temporary and therefore detachable textile piece 810, a first additional textile part (A) 850, a third additional textile part (C) 900 and a fourth additional textile part (D) 950, these third and fourth parts (C, D) 900, 950 being folded into the interior volume of the main textile bootie 860. The main textile bootie 860 includes a second through-opening 885 for introducing the foot into the interior volume of the main textile bootie 860. This second through-opening 885 is bordered partly by a region having a substantially C shape 890, particularly including n*p rib stitches, for example in 1*1 rib.

[0227] The main textile element 800 includes, in the extension of the region 890, a second textile junction portion 895, particularly including at least partially hot-meltable yarn(s). Preferably, the third additional textile part (C) 900 is in the extension of the second textile junction portion 895, and has a general C shape open towards the front part 875 of the main textile bootie 860. The third part (C) 900 includes first and second textile layers 862, 864 substantially superimposed as well as a receiving volume 863 disposed between the first and second layers 862 and 864. Preferably, the first textile layer 862 includes at least partially hot-meltable yarns representing at most 50%, in particular at most 20% by mass of the total mass of the first textile layer 862. Preferably, the second textile layer 864 includes at least partially hot-meltable yarns representing at least 80% by mass, in particular at least 95% by mass of the total mass of the second textile layer 864. Preferably, the second junction portion 895, the third part (C) 900 and the main textile bootie 860 are of unitary knitted construction. The main textile element 800 is therefore preferably a unitary knitted construction piece.

[0228] The second textile junction portion 895 extends from the edge of the second through-opening 885 of the main textile bootie 860. Particularly, the second textile junction portion 890 includes first and second substantially superimposed layers in connection with the first and second layers 862 and 864 of the third part (C) 900.

[0229] The main textile element 800 also includes a fourth additional textile part (D) 950 in connection with the second through-opening 885, in particular wholly or partly in a knitted connection with the edge of the second through-opening 885.

[0230] The fourth additional part (D) 950 includes first and second textile layers 952 and 954 delimiting therebetween a receiving volume 953. Preferably, the first and second textile layers 952, 954 each include one or several hot-meltable yarn(s) representing at least 80%, in particular at least 95%, by mass of the total mass of the fourth additional textile part (D) 950. Before the thermo-compression step, the third and fourth additional textile parts (C, D) 900, 950 as well as the second junction portion 895 are folded into the interior volume of the main textile bootie 860 as represented in FIG. 12. The fourth additional textile part (D) 950 is thus disposed, partly, between the third additional textile part (C) 900 and the internal face of the rear portion 870 of the main textile bootie 860. The second textile layer 864 of the third additional part (C) 900 thus comes against the first textile layer 952 of the fourth additional part (D) 950. The length of the fourth textile part (D) 950 is determined so as to preferably cover the entire height of the rear portion 870 and partly the lateral and medial portions.

[0231] Preferably, the receiving volume 863 of the third part (C) includes an elastic deformable piece, for example a foam, and the receiving volume of the fourth part (D) remains empty.

[0232] After the thermo-compression step, the third and fourth additional textile parts preferably form a rear stiffener. The second textile junction area 895, being essentially hot melted, absorbs any movements of the third and fourth textile parts 900 and 950 folded and superimposed during the thermo-compression.

[0233] Preferably, and generally in the present text, the first and/or second and/or third and/or fourth additional textile part(s) (A, B, C, D) is/are (each) in the form of a tube, in particular having one or two open end(s), in textile, in particular knitted, connection with all or part of the edge of a first or a second through-opening of the main textile bootie.

[0234] The auxiliary textile bootie could also include additional textile parts according to the present disclosure, in particular additional parts A, B, C or D depending on the functionalities sought.

[0235] The volume(s) for receiving the first and/or second and/or third and/or fourth additional textile part(s) may each include at least one functional piece, chosen in particular among a foam, a film, a textile piece, a tag, for example an RFID tag, or a combination thereof.

[0236] The footwear 700 described above may implement the arrangements described above at the level of the opening for introducing the foot 885 into the receiving volume of the main textile bootie, particularly a third additional textile part (C) and/or a fourth additional textile part (D).

[0237] FIG. 15 represents a third example of a main textile element 1000 including a main textile bootie 1100 including a sole portion 1110. The sole portion 1110 includes a front part 1120 and a rear part 1130. The sole portion 1110 includes a first through-opening 1140 opening out into the interior volume of the main textile bootie 1100 and which may be disposed in the front part 1120 or in the rear part 1130. The main textile bootie 1100 includes a first textile junction portion 1150 including one or several hot-melt yarn(s) bordering wholly or partly the edge of the first through-opening 1140. In FIG. 15, the first junction portion 1150 surrounds substantially all the first through-opening 1140. The main textile element 1000 includes a first additional textile part (A) not represented, and may include a second and/or third and/or fourth additional textile part(s) (B, C, D) according to the disclosure.

[0238] FIG. 16 represents a fourth example of a main textile element 1200 according to the disclosure including a main textile bootie 1210, a first additional textile part (A) 1220 and a second additional textile part (B) 1230 disposed in the interior volume of the main textile bootie 1210 and substantially superimposed.

[0239] FIG. 17 represents a fifth example of a main textile element 1300 including a main textile bootie 1310 according to the disclosure, a first additional textile part (A) 1320 and a second additional textile part (B) 1330. The first part (A) 1320 projects outside the main textile bootie 1310 and at least partially wraps the external face of the front part 1340 of the main textile bootie 1310. The second part (B) 1330 projects into the interior volume of the main textile bootie 1310 and at least partially covers the internal face of the front part 1340 of the main textile bootie. The first and second parts 1320, 1330 may be dimensioned so as to partially cover the medial and lateral parts of the main textile bootie 1310. The front part 1340 of the main textile bootie 1310 is thus sandwiched, at least partially, between the first part (A) 1320 and the second part (B) 1330.

[0240] It is thus possible to locally functionalize the external face and/or the internal face of the main textile bootie via one or several additional textile part(s) (A, B, C or D), which are advantageously of textile, in particular knitted, construction unitary with the main textile bootie so as to form a main textile element functionalized according to the use of the footwear, in particular according to a determined sport.

[0241] It is understood in the context of the present disclosure that the first additional textile part (A) may be the part B or C or D, and therefore include any one of the characteristics of the part B or C or D.

[0242] The main textile bootie 200 or 860 or 1100 or 1210 or 1310, and/or the auxiliary textile bootie 600 include(s) one or several wholly or partly hot-melt yarn(s) whose nature, mode of connection, stitch pattern for example, and quantity, vary according to the functions to be attributed to the upper of the footwear.