SPORTS SHOE AND METHOD FOR THE MANUFACTURE THEREOF
20220256967 · 2022-08-18
Inventors
- Angus Wardlaw (Herzogenaurach, DE)
- Zachary Clinton Coonrod (Herzogenaurach, DE)
- James Tarrier (Herzogenaurach, DE)
- Heiko Schlarb (Herzogenaurach, DE)
- Paul Leonard Michael Smith (Herzogenaurach, DE)
- Warren Freeman (Herzogenaurach, DE)
Cpc classification
A43B9/00
HUMAN NECESSITIES
A43B13/141
HUMAN NECESSITIES
A43B13/181
HUMAN NECESSITIES
A43B13/186
HUMAN NECESSITIES
International classification
A43B7/28
HUMAN NECESSITIES
A43B9/00
HUMAN NECESSITIES
Abstract
A shoe, in particular a running shoe, may include an upper and a sole unit. The upper is attached to the sole unit such that in a midfoot region there is a gap between a lower side of the upper and a top side of the sole unit. The gap may extend from a lateral side of the shoe to a medial side of the shoe.
Claims
1-22. (canceled)
23. A shoe comprising: a. an upper, and b. a sole unit, c. wherein the upper is attached to the sole unit in a midfoot region, d. wherein there is a gap between a lower side of the upper and a top side of the sole unit, e. wherein the upper comprises a knitted material, and f. wherein the sole unit comprises particles of expanded material.
24. The shoe according to claim 23, wherein the gap extends from a lateral side of the shoe to a medial side of the shoe.
25. The shoe according to claim 23, wherein the upper is attached to the sole unit in a heel region and a forefoot region and wherein the heel region is a minimum of 15% of the longitudinal shoe length from the rear of the shoe and the forefoot region is a minimum of 20% of the longitudinal shoe length from the front of the shoe.
26. The shoe according to claim 23, wherein the gap has a longitudinal extension up to 20 cm.
27. The shoe according to claim 23, wherein the gap extends essentially over the length of the arch of a foot of a user.
28. The shoe according to claim 27, wherein in the midfoot region the lower side of the upper has a shape configured to adapt to a lower side of the arch of the foot of the user.
29. The shoe according to claim 23, wherein in the midfoot region where the gap is located the upper is configured to allow a minimum strain of 5% in both the medial-lateral direction and the forefoot-to-rearfoot direction and/or wherein in the midfoot region where the gap is located the upper is configured to allow a maximum strain of 150% in both the medial-lateral direction and the forefoot-to-rearfoot direction.
30. The shoe according to claim 23, wherein a material of the upper comprises an elastic content.
31. The shoe according to claim 30, wherein a material of the upper comprises at least one of: a natural material, a synthetic material, synthetic fibers, synthetic leather, thermoplastic polyurethane, leather, cotton, elastane fibers, and combinations thereof.
32. The shoe according to claim 23, wherein a material of the upper comprises Shoe according to any one of the preceding examples, wherein the upper comprises a knitted material, in particular at least one of: a circular knitted material, a flat knit material, a warp knit material, and/or wherein the upper comprises an engineered mesh.
33. The shoe according to claim 23, wherein in the midfoot region, the lower side of the upper is seamless.
34. The shoe according to claim 23, wherein the upper encompasses the arch of a foot of a user.
35. The shoe according to claim 23, wherein the upper comprises at least one reinforcing element extending from a medial side of the instep around the lower side of the upper to a lateral side of the instep.
36. The shoe according to claim 23, wherein the reinforcing element connects to or is integrated with a lacing system of the shoe on the medial and the lateral side of the instep.
37. The shoe according to claim 35, wherein the reinforcing element comprises a flexible and tear resistant material including at least one of the following: a textile material, a synthetic material, a synthetic hybrid material, polyurethane, thermoplastic polyurethane, polyamide, polyethylene, polypropylene, and combinations thereof.
38. The shoe according to claim 35, wherein the reinforcing element comprises at least one of: a webbing, a stretchable webbing, a non-stretch webbing, a mesh, and combinations thereof.
39. The shoe according to claim 35, wherein the reinforcing element is printed or welded or stitched to a fabric of the upper.
40. The shoe according to claim 23, wherein the upper further comprises a lacing element extending from a heel region to a lateral and/or a medial side of the instep and connecting to a lacing system of the shoe.
41. The shoe according to claim 23, wherein the lacing element is integrally provided as one piece and extends from the medial side of the instep around the heel to the lateral side of the instep.
42. The shoe according to claim 23, wherein the sole unit comprises particles of an expanded material, in particular particles of at least one of: expanded thermoplastic polyurethane, expanded polyetherblockamide, expanded polyamide.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0030] In the following detailed description, embodiments of the invention are described referring to the following figures:
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BRIEF DESCRIPTION
[0052] The present invention seeks to provide an improved shoe, in particular and improved sports shoe, for example, a running shoe.
[0053] The problem outlined above is at least partially solved by a shoe, according to claim 1. In embodiments, the shoe comprises an upper and a sole unit, wherein the upper is attached to the sole unit such that in a midfoot region there is a gap between a lower side of the upper and a top side of the sole unit. This region is also termed the “adaptive region”.
[0054]
[0055] As a result of the gap between the lower side of the upper and the top side of the sole unit in the midfoot region, in certain embodiments, the upper moves, essentially independently, of the sole unit in the midfoot region. Consequently, the upper may better adapt to the individual characteristics of the musculoskeletal system of the user and/or to the movements and forces the musculoskeletal system is subject to during movement of the user, for example, during a gait cycle. The independent movement of the upper may allow the upper to remain in close proximity to the foot of the user whilst the user is moving. This close proximity of the upper to the foot of the user may support or stimulate the musculoskeletal system so that the system is better equipped to handle the forces acting, for example, through stimulating the arch of the foot to engage the onward postural chain to avoid possible negative effects, for example, arch collapse, thus, increasing the stability of the foot and musculoskeletal system of the user. Furthermore, the gap may prevent or limit rubbing and chafing of the foot. The gap may also increase ventilation to the sole of the foot, consequently enabling a more comfortable environment for the foot of the user.
[0056] There may be a connection between the upper and the sole unit in the adaptive region, namely in the region of the gap, the connection being provided in such a manner that the independence of movement of the shoe upper in the adaptive region is not significantly impeded. For example, the adaptive region may be covered on the sides of the shoe by a shoe panel, for example, comprised of mesh or foil. This may help to prevent the ingress of foreign matter, for example, stones or dirt into the gap. The ingress of foreign matter may be undesirable for a number of reasons, for example, a stone could protrude into the lower surface of the upper and press into the plantar region of the foot causing discomfort to the user. Alternatively the ingress of matter may ruin the visual appearance of the shoe in this region.
[0057] The gap in the adaptive region may extend from a lateral side of the shoe to a medial side of the shoe.
[0058] This may help to decouple the movements of the upper over the entire width of the shoe.
[0059] The medial-lateral direction is shown in
[0060] The adaptive region consists of a region approximately over the midfoot of the user. As already mentioned, the upper may be attached to the sole unit in the heel region and the forefoot region. The heel region may be a minimum of 15% of the longitudinal shoe length from the rear of the shoe. The heel region may also be a minimum of 25% of the longitudinal shoe length from the rear of the shoe. The forefoot region may be a minimum of 20% of the longitudinal shoe length from the front of the shoe. The forefoot region may also be a minimum of 40% of the longitudinal shoe length from the front of the shoe.
[0061] The gap may have a longitudinal extension of at least 2 cm, at least 5 cm, at least 10 cm, at least 15 cm, at least 20 cm of a UK size 8.5 sample size shoe. For a UK size 8.5 sample size shoe, the gap may be in the range of 2 cm to 10 cm.
[0062] It will be apparent to the skilled person that the desired gap extension will vary dependent upon the shoe size chosen for the user, for example, a UK size 12 is approximately 32 cm in total length whereas a UK size 6 is approximately 23 cm in length. Clearly the skilled person will realise that the desired gap extension chosen will need to be scaled up or down dependent upon the size of the shoe.
[0063] A gap with such a longitudinal extension provides a good compromise between independence of the movement of the upper on the one hand, and ensuring sufficient stability of the shoe upper on the sole unit on the other hand.
[0064] The gap may extend essentially over the length of the arch of a foot of a user.
[0065] The plantar region of the foot, and in particular the arch of a foot, is subject to significant movement and forces during user movement, for example, during a gait cycle. A gap extending essentially along the length of the user's arch may promote stability of the musculoskeletal system and/or enhance the ability of the musculoskeletal system to react to the forces incurred. The arch of a foot is also a sensitive part of the foot, thus, the upper to extend essentially over the length of the arch of the foot is desirable for the comfort of the shoe for the user.
[0066] In certain embodiments, in the midfoot region the lower side of the upper has a shape configured to adapt to a lower side of the arch of the foot of the user.
[0067] As a result, the fit of the upper may be improved, thus, further increasing the aforementioned stabilization and engagement effect. Through three-dimensionally pre-shaping the upper such that the shape of the upper is configured to adapt to the lower side of the arch of the foot, the arch may be particularly well ventilated, thus enhancing the comfort of the user in this region of the foot.
[0068] In the midfoot region where the gap is located, i.e. in the adaptive region, the upper may be configured to allow a minimum strain of 5% in both the medial-lateral direction and the forefoot-to-rearfoot direction (longitudinally along the shoe). As already stated above, the medial-lateral direction is illustrated in
[0069] The material of the upper may comprise an elastic content. The material of the upper may comprise or be comprised of any material that may perform the stated performance criteria, examples of such materials are: any knitted material, a natural material, a synthetic material, synthetic fibres, synthetic leather, thermoplastic polyurethane (TPU), leather, cotton. Further, the material of the upper may comprise elastane fibres, for example, Lycra which is manufactured under trademark by Invista under license from Koch, formerly part of DuPont.
[0070] By using elastane fibres, and in some embodiments Lycra fibres, the upper provided may be flexible but also tear-resistant.
[0071] The upper may comprise a different material in the midfoot region than in the heel region and/or in the forefoot region, wherein the different material may be restricted to the lower side of the upper above the gap.
[0072] As a result, the material in the midfoot region may be specifically manufactured to provide certain stretch and/or support characteristics for the adaptive region. Using a different material may also allow for tailoring of the remaining regions of the upper to other desired characteristics of these regions.
[0073] The upper may be a knitted upper. The knitted upper may be a circular knitted upper. The knitted upper may be a flat knit upper. The knitted upper may be a warp knit. The upper may be an engineered mesh. The upper may also be only partially comprised of at least one of these kinds of materials.
[0074] The lower side of the upper, in particular, in the midfoot region, may be seamless.
[0075] This may facilitate comfort for the user of the shoe since the region of the arch of the foot is free from areas that may promote rubbing, chafing or pressure points in these sensitive regions of the foot. Furthermore, the lack of any seam in these regions may increase the stability, tear-resistance and fit of the upper.
[0076] In certain embodiments, the entire upper may be seamless. The seamless upper may, for example, be provided by circular knitting.
[0077] A circular knit upper may allow a three-dimensionally preshaped upper to be provided without an upper blank having to be sewn up at a designated place(s). Thus, unwanted seams in the upper may be avoided and the three-dimensionally preshaped upper may have a particularly good fit and the additional aforementioned benefits of a seamless midfoot region.
[0078] The upper may encompass and/or conform to the arch of the foot of the user. Furthermore, particularly in the region of the gap, the upper may abut the foot of the user on all sides of the foot. This may be achieved by using a lacing system.
[0079] A lacing system may be used to tie in or secure the foot of a user within the shoe upper. The lacing system can, for example, comprise a shoe lace, or it may comprise a shoe lace and a cord lock, or it may comprise a hook and loop fastener or any other appropriate system for securing the foot of a user.
[0080] As a result of the arch of the foot being encompassed by the upper, the beneficial effects indicated above may be further improved. In particular, a particularly comfortable feel and good stabilization and engagement of the foot and onward musculoskeletal system may be achieved.
[0081] The upper may have at least one reinforcing element extending from a medial side of the instep around the lower side of the upper to the lateral side of the foot. The reinforcing element can, for example, be arranged on the outside of the upper, or on the inside of the upper, or be integrated within the upper.
[0082] The reinforcing element may serve the purpose of increasing the stabilisation and engagement of the foot in the upper, assisting in stabilising the musculoskeletal system of the user. The reinforcing element may be additional to the stability and reinforcement of the upper in the adaptive region. The reinforcing element may be used in conjunction with the upper to provide the desired performance in the adaptive region.
[0083] The reinforcing element may connect to or be integrated with a lacing system of the shoe on the medial and the lateral side of the instep. The reinforcing element may also be separate from the lacing system.
[0084] The reinforcing element may comprise a flexible yet highly tear resistant material. The material may be a textile material. The material may be a synthetic material. The material may be a synthetic hybrid material. Examples of potential materials are: polyurethane (PU), thermoplastic polyurethane (TPU), compact materials for example, polyamide (PA), polyethylene (PE), polypropylene (PP). The reinforcing element may comprise a webbing. The reinforcing element may comprise a stretchable webbing. The reinforcing element may comprise a non-stretch webbing. The reinforcing element may comprise a mesh. It will be apparent to the skilled person that other similar materials may be used that may perform the basic functionality described herein. The reinforcing element may entirely or only partially be comprised of at least one of these kinds of materials.
[0085] A flexible and tear resistant material is particularly suitable for such a reinforcing element, as it will enable a balance between free movement of the upper to allow the aforementioned benefits but also control the stretchability and upper movement which may allow improvements in the aforementioned comfort and stability benefits and/or a tailoring of the resultant properties of the adaptive region for different designs/uses of a shoe incorporating it.
[0086] The reinforcing element may be attached to the fabric of the upper, for example, by printing, welding or sewing.
[0087] By attaching the reinforcing element to the outer side of the fabric, seams or other unwanted connecting regions that could rub on the foot of the user and thus make the shoe less comfortable to wear may be avoided. Also, a potential tearing of the reinforcing element and the upper in such connecting regions under high load may be avoided. Attaching the reinforcing element to the upper also enables manufacturing processes to be more efficient. For example, in certain embodiments, a process may be streamlined to use the same uppers but apply different reinforcing materials to create shoes with varying degrees of reinforcement.
[0088] The reinforcing element may be incorporated into the material of the upper in the midfoot region by increasing the strength and density of the upper material in this region. The reinforcing element may have greater reinforcing properties on the medial side compared with the lateral side.
[0089] The benefits of incorporating the reinforcing element are as those stated earlier and additionally that the process of manufacture is simplified, thus, reducing complexity and cost.
[0090] In certain embodiments, the upper includes a lacing element extending from a heel region to the lateral side and/or medial side of the instep and connecting to the lacing system of the shoe. The lacing element may not be connected to the sole unit in the midfoot region.
[0091] With such a lacing element, the heel region of a foot of a user may be firmly secured to the upper and the strength and stability of the upper in the heel region may be increased, which may be desirable to prevent injuries caused by twisting one's ankle. The lacing element may be formed from a tear-resistant material, for example leather, and it may cooperate with the lacing system to allow for tight lacing of the upper. Not connecting the lacing element to the sole unit may be advantageous as there is no restricting connection between the upper and the sole in the region of the midfoot, thus, this will not interfere with the independent movement of the upper.
[0092] The lacing element may be integrally provided as one piece and extend from the medial side of the instep around the heel to the lateral side of the instep.
[0093] With a lacing element that is integrally provided as one piece, the overall stability of the upper may be further improved and it may also simplify the manufacture of the shoe since less individual parts need to be processed.
[0094] In certain embodiments, in the heel region, the upper is three-dimensionally shaped to abut the back of the user's foot in the region of the Achilles' tendon. In combination with the gap in the midfoot region, an upper provided in this manner may beneficially be used to better lock in the foot while still maintaining sufficient adaptivity of the upper. Also, the fit of the upper in the heel region may be generally improved. In particular rubbing of the upper at the Achilles' tendon may be prevented. Such rubbing may lead to extremely unpleasant irritations, particularly during dynamic movements such as occur when walking or running.
[0095] The shoe may comprise an insole, which is not connected to the upper in the midfoot region.
[0096] With such an insole, which is not connected to the upper in the midfoot region, the shoe may again be made more comfortable to wear. It may allow the insole to abut the bottom of the foot of a user during the entire gait cycle, thus providing for a consistently pleasant wearing sensation.
[0097] The insole may be connected to the upper in the heel region and the forefoot region of the shoe but free in the midfoot region of the shoe. The insole may comprise a “bone-like” shape akin to the surface impression a footprint leaves on the ground.
[0098] Such an insole may provide a design that is adjusted to the anatomy of the foot. Consequently, the stress on the foot may be reduced to prevent injuries and to facilitate endurance.
[0099] The sole unit may comprise particle(s) of expanded material, in particular, expanded thermoplastic polyurethane (eTPU), and/or expanded polyetherblockamide (ePEBA), and/or expanded polyamide (ePA). The particles may be randomly arranged. The particles may also be connected to each other, for example, at their surfaces. The particles may be connected to each other by providing heat energy provided by pressurized steam, for example, during steam chest molding, or electromagnetic radiation, or radio frequency radiation, or microwave radiation, or infrared radiation, or ultraviolet radiation, or electromagnetic induction. The particles may be connected to each other by providing heat energy provided by a combination of the methods of providing heat energy. The particles may be connected to each other by steam molding. The particles may be connected to each other by use of a binding agent. Alternatively or additionally, the particles may be connected to each other by using a combination of the aforementioned methods. It is to be understood that expanded particles are to be interpreted in the context of the field of particle foams, namely, that the particle has already been expanded or “foamed” prior to being placed within the mold. Therefore, the resulting particle foam component is comprised of a plurality of individual particle foam beads, each bead having already been foamed (to a level that establishes the properties of the foam) prior to be formed into the final component. For example, expanded TPU beads are placed in the mold and then a chemical reaction occurs to form the resulting particle foam components. It should be noted that there are a number of synonymous terms used within the art that describe the same concept, for example, “foamed bead(s)”, “foamed pellet(s)”, “particle foams” to name just some.
[0100] A sole unit comprising expanded particles, i.e. particle foam, may provide good cushioning properties over a wide temperature range. At the same time, sole units with such particles may return a large share of the energy exerted to deform the sole during impact back to the foot when the sole expands again later in the gait cycle. This may facilitate efficiency in walking or running and thus increase the endurance of the user. The particles may be randomly arranged which might facilitate ease of manufacture. Alternatively, a conventional ethylene-vinyl-acetate (EVA) or any other shoe sole could be used, and also sole units with combinations of particles from expanded materials and other materials, for example, EVA, eTPU, ePEBA and/or ePA are possible.
[0101] The sole unit may comprise a support element, in particular to enhance the ability to limit overpronation and/or underpronation. The support element may be arranged in the midfoot region.
[0102] With such an additional support element, the stress on the foot may be further relieved. This may further help in stabilising the foot and musculoskeletal system of the user and aid in preventing injuries or fatigue.
[0103] The support element may also serve to adjust the bending stiffness and/or torsional stiffness of the sole unit in the midfoot region. The support element can, for example, be embedded in the material of the sole unit.
[0104] A further aspect of the invention is given by a method for the manufacture of a shoe, in particular a sports shoe like a running shoe, comprising the following steps: Mounting an upper on a last and connecting the upper to a sole unit only in a forefoot region and a heel region, such that in a midfoot region there is a gap between a lower side of the upper and a top side of the sole unit.
[0105] In some embodiments of such an inventive method, it is possible to combine the optional design possibilities for an inventive shoe discussed above in various combinations and thus adjust the properties of the manufactured shoe to the respective requirements during manufacture.
[0106] The last may comprise a concave shape in the midfoot region, wherein, during the step of connecting, the upper abuts the last in the midfoot region. The concave shape may be in correspondence with the arch of a foot of a user.
[0107] As a result of the upper being mounted during the method on a last, whose shape may be in correspondence with the arch of the foot, undesired distortions or deformations of the upper may be prevented. The upper may be mounted on the last “under tension” so that it abuts the last in a form-fit manner.
[0108] The shape, dimensions and configuration of the concave region of the last may be adjusted to control and influence the degree of tension imparted to the resultant upper in the midfoot region.
[0109] The last may comprise a smaller cross-sectional area than the foot of a user with respect to a sectional plane arranged in the midfoot region where the gap is located and with the longitudinal direction of the shoe being approximately perpendicular to the sectional plane. The cross-sectional area of the last may for example be less than 80% of the corresponding cross-sectional area of the average foot (for example measured when the foot is inserted into the finished shoe), or less than 70% or less than 60%, or less than 50%.
[0110] In certain embodiments, the sole unit includes particles of an expanded material, in particular of expanded thermoplastic polyurethane (eTPU), and/or of expanded polyetherblockamide (ePEBA), and/or of expanded polyamide (ePA). The particles may be randomly arranged. The particles may also be connected to each other.
[0111] The beneficial properties of these materials for use in a sole unit have already been described above.
DETAILED DESCRIPTION
[0112] The subject matter of embodiments of the present invention is described here with specificity to meet statutory requirements, but this description is not necessarily intended to limit the scope of the claims. The claimed subject matter may be embodied in other ways, may include different elements or steps, and may be used in conjunction with other existing or future technologies. This description should not be interpreted as implying any particular order or arrangement among or between various steps or elements except when the order of individual steps or arrangement of elements is explicitly described.
[0113] Possible embodiments of the present invention are described in the following detailed description mainly in relation to running shoes. However, emphasis is placed on the fact that the present invention is not limited to these embodiments. Instead, it may also be applied to other types of shoes, such as sports shoes in general, leisure shoes, etc.
[0114] It is also to be noted that only individual embodiments of the invention are described in greater detail below. However, it is clear to the person skilled in the art that the design possibilities described in relation to these specific embodiments may also be further modified and combined in a different manner with one another within the scope of the present invention and that individual features may also be omitted where they appear to be unnecessary. In order to avoid repetition, reference is made to the explanations in the previous sections, which also remain applicable to the following detailed description.
[0115]
[0116] The shoe 100, which may be used as a running shoe, comprises an upper 110 and a sole unit 120. Here, the upper 110 is attached to the sole unit 120 such that in a midfoot region of the shoe 100 there is a gap 130 between a lower side 115 of the upper 110 and a top side 125 of the sole unit 120.
[0117] In the shoe 100, the gap 130 extends from a lateral side 102 of the shoe 100 to a medial side 105 of the shoe 100. This means that the gap 130 extends over the entire width of the shoe 100. This may be seen in
[0118] In the embodiments shown in
[0119] By way of example,
[0120]
[0121] Exemplary dimensions for three samples of an inventive shoe 10 of size UK 5.5 are listed in the table of
[0122] Clearly the skilled person will realise that the desired gap adaptive region 30 and therefore gap length will have to be scaled up or down for different size shoes, for example, scaled up for a UK size 16 and scaled down for a UK size 4. The minimum length of the forefoot region 20 is 15% of the overall length of the shoe 10. The minimum length of the heel region 40 is 20% of the overall length of the shoe 10. Depending on the size of the shoe 10, the gap may have a longitudinal extension of up to 20 cm, for example a longitudinal extension in the range from 2 cm-10 cm. The gap may for example extend essentially over the length of the arch of a foot of a user having the respective shoe size. The considerations put forth with regard to
[0123] Returning to the discussion of
[0124] In the midfoot region where the gap 130 is located, i.e. in the adaptive region, the upper 110 may be configured to allow a minimum strain of 5% in both the medial-lateral direction and forefoot-to-rearfoot direction (also called the anterior-to-posterior direction). The allowed minimum strain may also be 10% or 15% or 20% or 30% or 50%. In the midfoot region where the gap is located, i.e. in the adaptive region, the upper 110 may be configured to allow a maximum strain of 150% in both the medial-lateral direction and forefoot-to-rearfoot direction. The allowed maximum strain may also be 125% or 110% or 100% Or 80%. The medial-lateral direction is illustrated in
[0125] The strain may in part be comprised of a strain imparted to the upper 110 during manufacture of the upper 110. The strain may in part be imparted when the user inserts their foot into the upper 110. The strain may be imparted during use of the shoe 100 by the user. The strain may in part be imparted to the adaptive region by a combination of strain imparted in manufacture and during insertion of the foot of a user and during use.
[0126] To illustrate with an example, uppers comprising a material that may be stretched in all four directions (front or anterior, rear or posterior, medial, lateral) were tested and allowed a minimum strain of 60% under a load of 100 N/cm in a warp direction of the mesh, and a minimum strain of 130% in a weft direction of the mesh. The weft direction of the mesh is aligned to allow the stretch in the medial and lateral directions. The above mentioned load of 100 N/cm refers to laboratory test method for material testing where a strip of mesh approximately 2.54 cm wide is tested. The strain values stated above are based on an internal laboratory test method which is why the strain values are much higher than the values stated with regard to the upper, as the forces acting during running are lower than the recited test values in the laboratory.
[0127] An FEA (Finite Element Analysis) virtual simulation study was conducted that showed that the strain when the material is pulled over the last was on average 50%-60% in the adaptive region with a maximum of 92% at the midfoot seam. Once the last was removed from the upper some of this strain imparted by the last is removed whilst some is retained in the final shoe upper. The amount of strain retained will be dependent on the material used for the upper.
[0128] To evaluate the performance of the shoe during use, testing was performed using an Aramis system from GOM mbH. The system is a calibrated digital image correlation (DIC) device which allows for dynamic real time surface strain measurement. The results found that the materials selected for the upper strained 6-14% under the load of the bodyweight of the user. Further strain was seen when the user was running, an average material strain being 20% with a maximum strain of 48% in the medial midfoot region. It will be apparent to the skilled person that the values quoted are testing values for the specific examples. The values will change depending upon the type of movement being performed and also the individual user.
[0129] The material of the upper 110 may comprise an elastic content. The material may comprise or be comprised of any material that may perform the stated performance criteria, examples of such materials are: any knitted material, a natural material, a synthetic material, synthetic fibres, synthetic leather, thermoplastic polyurethane (TPU), leather, cotton. Further, the material of the upper 110 may comprise elastane fibres, for example, Lycra which is manufactured under trademark by DuPont.
[0130] The upper 110 may be a knitted upper. The knitted upper may be a circular knitted upper. The knitted upper may be a flat knit upper. The knitted upper may be a warp knit. The upper 110 may be an engineered mesh. The upper 110 may also be only partially comprised of at least one of these kinds of materials.
[0131] In some embodiments, a shoe 100, as shown in
[0132] In the embodiments shown in
[0133] However, in other embodiments, the lower side of the upper 110 may be without a seam in the midfoot region. As already mentioned, the upper 110 may for example be provided in the midfoot region by circular knitting- or even the entire upper 110 may be provided by circular knitting. Circular knitting may allow providing a three-dimensionally shaped textile component without a seam. Further alternatives to circular knitting could be: 3D formed uppers (e.g. 3D printed uppers), overinjected textiles, molded materials, injected materials or vacuum formed materials.
[0134] In the midfoot region, the upper 110 of the shoe 100 may comprise a reinforcing element 140. Any number (e.g. one, two, three, four, five, etc.) of reinforcing elements and/or reinforcing elements with different widths than shown here are also possible. The reinforcing element 140 extends from the medial side 105 of the instep around the lower side 115 of the upper 110 and beneath the arch of the foot to the lateral side 102 of the instep.
[0135] The reinforcing element 140 can, for example, comprise thermoplastic polyurethane, which may be welded to the fabric of the upper 110 on the outside of the upper 110 as shown in
[0136] The reinforcing element may also be arranged on the inside of the upper 110 or be integrated within the upper 110.
[0137] By way of example,
[0138] Moreover, the shoe 100 may also be without a reinforcing element.
[0139] The reinforcing element 140 may connect to or be integrated with a lacing system of the shoe 100 on the medial side 105 and the lateral side 102 of the instep. The reinforcing element 140 may also be separate from the lacing system. With the help of the lacing system, the foot of a user may be secured within the upper 110 of the shoe 100.
[0140] The reinforcing element 140 may comprise a flexible yet highly tear resistant material. The material may be a textile material. The material may be a synthetic material. The material may be a synthetic hybrid material. Examples of potential materials are: polyurethane (PU), thermoplastic polyurethane (TPU), compact materials for example, polyamide (PA), polyethylene (PE), polypropylene (PP). The reinforcing element 140 may comprise a webbing. The reinforcing element 140 may comprise a stretchable webbing. The reinforcing element 140 may comprise a non-stretch webbing. The reinforcing element 140 may comprise a mesh. It will be apparent to the skilled person that other similar materials may be used that may perform the basic functionality described herein. The reinforcing element 140 may entirely or only partially be comprised of at least one of these kinds of materials.
[0141] The reinforcing element 140 may be attached to the fabric of the upper 110, for example, by printing, welding or sewing, and on the inside of the upper 110 as well as on the outside.
[0142] In the case of the embodiments of the shoe 100 shown in
[0143] As can be seen in
[0144] An advantage of this approach is that the reinforcing element 240, which is not yet connected in the unconnected state of the blank 200, may be particularly well printed on, welded or otherwise applied to the blank 200. In the case of an already three-dimensionally preshaped blank, this could be more difficult or involve greater expense.
[0145] Returning to the discussion of the embodiments of a shoe 100 shown in
[0146] For the shoe 100, the lacing element 150 is integrally provided as one piece and extends from the medial side 105 of the instep around the heel to the lateral side 102 of the instep. In these regions, the lacing element 150 is sewn up to the reinforcing element 140 to increase the stability of the upper 110. However, it should be understood that other types of attachment for securing or attaching the lacing element 150 may be utilized.
[0147] A heel counter 155 for an improved securing of the heel in the upper 110 is also integrated into the lacing element 150. The heel counter may help in preventing the foot from sliding and blisters from forming. In the heel region, the upper 110 is also three-dimensionally shaped to abut the back of the user's foot in the region of the Achilles' tendon. To this end, the upper 110 comprises a heel groove 158 in this region, which abuts the back of the user's foot.
[0148] The shoe 100 further comprises an optional insole 160. The insole 160 is not connected to the upper 110 in the midfoot region. Instead, the insole 160 is connected to the upper 110 merely in the heel region and in a forefoot region of the foot. Consequently, the insole 160 may by and large move independently of the upper 110, such that the insole 160 may be in contact with the bottom side of the foot during much of a gait cycle and the shoe 100 is particularly comfortable to wear.
[0149] The sole unit 120 shown in
[0150] The support element 170 may also enhance the ability of the sole unit 120 to limit overpronation and/or underpronation, to support the arch of the foot or to otherwise compensate for malposition or disadvantageous characteristic motion patterns of a user.
[0151] The sole unit 120 of the shoe 100 comprises a midsole 122, which comprises particles of an expanded material. The particles may be randomly arranged and they may be connected to each other, for example at their surfaces. For the shoe 100, randomly arranged particles from expanded thermoplastic polyurethane (eTPU) were used, which were welded to each other by providing heat to their surfaces. The heat may, for example, be provided in the form of pressurized steam, for example, during steam chest molding, or electromagnetic radiation, or radio frequency radiation, or microwave radiation, or infrared radiation, or ultraviolet radiation, or electromagnetic induction. The particles may be connected to each other by providing heat energy provided by a combination of the methods of providing heat energy. The use of a binding agent is also possible. In addition, particles from expanded polyetherblockamide (ePEBA) and/or from expanded polyamide (ePA) may also be used.
[0152] The sole unit 120 also comprises an outsole 180. In the present case, the outsole 180 is provided in a net- or lattice-form to reduce the weight and still allow good traction of the shoe 100. In certain embodiments, the outsole 180 may include, for example, thermoplastic polyurethane and/or rubber.
[0153] In certain embodiments, the sole unit 120 need not necessarily comprise a support element. By way of example,
[0154]
[0155] The shoe 300 comprises an upper 310 and a sole unit 320, wherein the upper 310 is attached to the sole unit 320 such that in a midfoot region of the shoe 300 there is a gap 330 between a lower side of the upper 310 and a top side of the sole unit 320.
[0156] The shoe 300 comprises a reinforcing element 340 extending from a medial side of the instep around the lower side of the upper 310 and beneath the arch of the foot to a lateral side of the instep. The reinforcing element 340 connect to a lacing system of the shoe 300, here the shoe lace 390, on the medial and the lateral side of the instep. In the embodiments shown in
[0157] Unlike the reinforcing element 140, the reinforcing element 340 is, at least partially, not fixedly connected to the upper 310. Instead, the reinforcing element 340 may in parts move independently of the upper 310. In the embodiments show in
[0158] In the embodiments shown in
[0159]
[0160] The shoe 500 comprises an upper 510 and a sole unit 520. The upper 510 is attached to the sole unit 520 such that in a midfoot region of the shoe 500 there is a gap between a lower side of the upper 510 and a top side of the sole unit 520.
[0161] In the embodiments shown in
[0162] As shown in
[0163]
[0164] In the embodiments shown in
[0165] During the connecting, the upper 410 may abut the last 401 in the midfoot region. With a suitable design of the concave region 405 of the last 401, the desired degree of predetermined tension may be imparted to the upper 410 in the manufactured shoe in order to achieve the desired fit.
[0166] The amount of pre-tension imparted to the upper 410 in the manufacture of the shoe may also be adjusted and influenced by varying the ratio of the cross-sectional area of the last 401 in the region of the gap and the cross-sectional area of the foot of a user in the corresponding region. This concept is illustrated in
[0167] In some embodiments, the sole unit 420 may comprise particles of expanded thermoplastic polyurethane (eTPU), and/or of expanded polyetherblockamide (ePEBA), and/or of expanded polyamide (ePA). The particles may be connected to each other, for example at their surfaces, and they may be randomly arranged. The connection of particles may be achieved during the method 400, for example by adding a binding agent. Or the particles are welded to each other during the method 400 by providing heat energy to them, for example in the form of steam.
[0168]
[0169] The shoe 500 comprises an upper 110 and a sole unit 120, wherein the upper 110 is attached to the sole unit 120 such that in a midfoot region of the shoe 500 there is a gap 130 between a lower side 115 of the upper 110 and a top side of the sole unit 120. The sole unit 120 may have a midsole 122 and an outsole 180. In addition, shoe 500 may comprise a lacing element 150.
[0170] In the shoe 500, the material of the upper 110 may be different in the midfoot region compared to the heel region and/or the forefoot region of the upper, wherein the different material may be restricted to the lower side 115 of the upper above the gap 130. In some embodiments, the different material is located on the lower side 115 and a portion of one or more additional areas of the upper 110. One example of the different material may be seen in
[0171] Using different materials also allows for optimizing a part or all of the other regions of the upper 110 to other technical characteristics. For example, the midfoot region may be manufactured to be a piece providing a higher rigidity for an increased support of the arch of the user of the shoe. By contrast, the other regions of the upper in the forefoot and/or the heel region may for example be more flexible and elastic to improve the wearing comfort. Alternatively or additionally, such regions may have a higher tensile strength to provide increased support for lateral sports such as tennis or hockey with many lateral movements of the foot.
[0172] In the following, further examples are described to facilitate the understanding of the invention:
[0173] Example 1. Shoe, in particular a running shoe, comprising:
[0174] a. an upper; and
[0175] b. a sole unit, wherein
[0176] c. the upper is attached to the sole unit such that in a midfoot region there is a gap between a lower side of the upper and a top side of the sole unit.
[0177] Example 2. Shoe according to the preceding example, wherein the gap extends from a lateral side of the shoe to a medial side of the shoe.
[0178] Example 3. Shoe according to any one of the preceding examples, wherein the upper is attached to the sole unit in a heel region and a forefoot region and wherein the heel region is a minimum of 15% of the longitudinal shoe length from the rear of the shoe and the forefoot region is a minimum of 20% of the longitudinal shoe length from the front of the shoe.
[0179] Example 4. Shoe according to any one of the preceding examples, wherein the gap has a longitudinal extension up to 20 cm, in particular in the range of 2 cm-10 cm.
[0180] Example 5. Shoe according to any one of the preceding examples, wherein the gap extends essentially over the length of the arch of a foot of a user.
[0181] Example 6. Shoe according to the preceding example 5, wherein in the midfoot region the lower side of the upper has a shape configured to adapt to a lower side of the arch of the foot of the user.
[0182] Example 7. Shoe according to any one of the preceding examples, wherein in the midfoot region where the gap is located the upper is configured to allow a minimum strain of 5% in both the medial-lateral direction and the forefoot-to-rearfoot direction and/or wherein in the midfoot region where the gap is located the upper is configured to allow a maximum strain of 150% in both the medial-lateral direction and the forefoot-to-rearfoot direction.
[0183] Example 8. Shoe according to the preceding example 7, wherein the strain is in part comprised of a strain imparted to the upper during manufacture of the upper.
[0184] Example 9. Shoe according to any one of the preceding examples, wherein a material of the upper comprises an elastic content, in particular at least one of: a natural material, a synthetic material, synthetic fibres, synthetic leather, thermoplastic polyurethane, leather, cotton, elastane fibres.
[0185] Example 10. Shoe according to any one of the preceding examples, wherein the upper comprises a knitted material, in particular at least one of: a circular knitted material, a flat knit material, a warp knit material, and/or wherein the upper comprises an engineered mesh.
[0186] Example 11. Shoe according to any one of the preceding examples, wherein in the midfoot region the lower side of the upper is seamless.
[0187] Example 12. Shoe according to any one of the preceding examples, wherein the upper encompasses the arch of a foot of a user.
[0188] Example 13. Shoe according to any one of the preceding examples, wherein the upper comprises at least one reinforcing element extending from a medial side of the instep around the lower side of the upper to a lateral side of the instep.
[0189] Example 14. Shoe according to the preceding example 13, wherein the reinforcing element connects to or is integrated with a lacing system of the shoe on the medial and the lateral side of the instep.
[0190] Example 15. Shoe according to any one of the preceding examples 13 or 14, wherein the reinforcing element comprises a flexible and tear resistant material, in particular at least one of the following: a textile material, a synthetic material, a synthetic hybrid material, polyurethane, thermoplastic polyurethane, polyamide, polyethylene, polypropylene.
[0191] Example 16. Shoe according to any one of the preceding examples 13-15, wherein the reinforcing element comprises at least one of: a webbing, a stretchable webbing, a non-stretch webbing, a mesh.
[0192] Example 17. Shoe according to any one of the preceding examples 13-16, wherein the reinforcing element is printed or welded or stitched to a fabric of the upper.
[0193] Example 18. Shoe according to any one of the preceding examples 1-17, wherein the upper further comprises a lacing element extending from a heel region to a lateral and/or a medial side of the instep and connecting to a lacing system of the shoe.
[0194] Example 19. Shoe according to the preceding example 18, wherein the lacing element is integrally provided as one piece and extends from the medial side of the instep around the heel to the lateral side of the instep.
[0195] Example 20. Shoe according to any one of the preceding examples, wherein the shoe comprises an insole which is not connected to the upper in the midfoot region.
[0196] Example 21. Shoe according to the preceding example 20, wherein the insole is connected to the upper in a heel region and in a forefoot region.
[0197] Example 22. Shoe according to any one of the preceding examples, wherein the sole unit comprises particles of an expanded material, in particular particles of at least one of: expanded thermoplastic polyurethane, expanded polyetherblockamide, expanded polyamide.
[0198] Example 23. Shoe according to any one of the preceding examples, wherein the sole unit comprises a support element, in particular a support element to enhance the ability to limit overpronation and/or underpronation.
[0199] Example 24. Method for the manufacture of a shoe, in particular a running shoe, comprising the following steps:
[0200] a. mounting an upper on a last; and
[0201] b. connecting the upper to a sole unit only in a forefoot region and a heel region, such that in a midfoot region there is a gap between a lower side of the upper and a top side of the sole unit.
[0202] Example 25. Method according to the preceding example 24, wherein in the midfoot region the last comprises a concave shape and wherein during step b, the upper abuts the last in the midfoot region.
[0203] Example 26. Method according to any one of the preceding examples 24 or 25, wherein the last comprises a smaller cross-sectional area than the foot of a user with respect to a cross-sectional plane (A-A) arranged in the midfoot region where the gap is located and with the longitudinal direction of the shoe is approximately perpendicular to the sectional plane.
[0204] Example 27. Method according to one of the preceding examples 24-26, wherein the sole unit comprises particles of an expanded material, in particular particles of at least one of: expanded thermoplastic polyurethane, expanded polyetherblockamide, expanded polyamide.
Different arrangements of the components depicted in the drawings or described above, as well as components and steps not shown or described are possible. Similarly, some features and sub-combinations are useful and may be employed without reference to other features and sub-combinations. Embodiments of the invention have been described for illustrative and not restrictive purposes, and alternative embodiments will become apparent to readers of this patent. Accordingly, the present invention is not limited to the embodiments described above or depicted in the drawings, and various embodiments and modifications may be made without departing from the scope of the claims below.