Footwear upper with flexible collar assembly

A footwear upper having a collar assembly that is joined at its forward edge to the lower portion of the upper by a flexible region of material so that the collar may flex forward and rearward in relation to the lower portion of the upper. In one aspect of the invention, the upper includes a neck portion that is telescopically overlapped by the collar. In another aspect, the upper includes a gusset that extends between the lower portion and the collar, with at least a portion of the gusset being substantially hidden from view.

BACKGROUND OF THE INVENTION

The present invention relates to footwear, and more particularly to a flexible collar assembly for an article of footwear.

A wide variety of articles of footwear include a collar assembly that functions to provide support to the ankle region. The function of support is generally accomplished by providing a rigid or relatively stiff material in the collar region that presents resistance to movement of the upper in the ankle region. The collar helps to reduce the risk of supranation, pronation, and hyperextension. However, conventional collars suffer in that they limit the range of motion of the ankle and otherwise lead to discomfort in that area.

Many conventional upper constructions are formed from a continuous piece of material that wraps around the ankle region. This typical construction provides support to the ankle region, but compromises the range of motion of the footwear in both the forward/rearward and medial/lateral directions. When the ankle flexes forward or rearward during walking, the collar assembly impedes the natural motion of the ankle and therefore may result in discomfort. Furthermore, the relatively inflexible collar assembly may cause unnecessary rubbing in the Achilles region which may lead to discomfort or soft tissue injuries in that region.

Some efforts toward a more flexible footwear upper have been made in the area of ski boots and skate boots. Due to the nature of these activities, and the extra support they require, ski and skate boots are typically comprised primarily of very rigid materials, such as injection molded plastic. In an effort to provide some flexibility in a forward/rearward direction, some of these ski and skate boots include cutouts in the rigid material in the front and/or rear of the ankle region. The cutouts provide flexion only in the forward/rearward direction so the boot is essentially rigid in the medial/lateral direction. The cutouts may be closed with a flexible insert attached to the exterior of the upper that allows the cutout to open and close with the flexion of the ankle. These inserts protect the ankle in the areas of the cutouts, but they are often bulky and unsightly.

The above noted efforts provide at least some degree of flexibility in the forward/rearward direction, however, they are tailored for use with the rigid materials of ski and skate boots and do not provide sufficient flexibility for many other applications. Furthermore, the components used to provide flexibility to the collar are exposed and visible, and therefore affect the overall aesthetics of the footwear.

SUMMARY OF THE INVENTION

The aforementioned problems are overcome by the present invention wherein an article of footwear includes a footwear upper having a lower portion and a collar assembly joined directly to the lower portion. The collar may be a separate component that is attached to the lower portion or it may be a continuous extension of the lower portion. In one aspect of the invention, the upper also includes a gusset joining the collar to the lower portion along the edge portions not directly joined to the lower portion. At least a portion of the gusset is hidden from view by the collar or the lower portion.

In another aspect, the upper further includes a neck portion that extends upwardly from the remainder of the lower portion and wraps around the Achilles region. The collar is telescopically fitted over the neck creating an overlapping region so that the collar slides over the neck during flexion of the footwear. The neck may be a flexible material, such as padded fabric, that is secured to a lower portion or may be a continuous extension of the lower portion. In one embodiment, a gusset extends between and interconnects the neck and the collar.

The present invention provides a relatively high degree of support in the lateral/medial direction while at the same time providing a range of relatively free movement in the forward/rearward direction. The present invention allows movement of the collar in relation to the lower portion, resulting in improved range of motion and decreased forces exerted on the lower leg during flexion of the upper forward or rearward. In those embodiments that include a neck, the neck lays against the Achilles region of the wearers foot protecting it from rubbing that might otherwise be caused by movement of the collar. The neck also provides comfort and support to the ankle region. Further, in those embodiments that include a gusset, the gusset prevents foreign material from entering the boot and may be hidden within the collar providing the aesthetic appearance of conventional looking footwear.

These and other objects, advantages, and features of the invention will be more readily understood and appreciated by reference to the detailed description of the current embodiments and the drawings.

DETAILED DESCRIPTION OF THE CURRENT EMBODIMENTS

An article of footwear having a footwear upper with a collar assembly according to a preferred embodiment of the present invention is illustrated inFIG. 1, and generally designated10. For purposes of this disclosure, an upper assembly30will be described in connection with a conventional mid-height boot; however, the invention is equally well-suited for use in other types of footwear that may incorporate a collar12, such as full-height boots and high-top athletic shoes. In the illustrated embodiment, the footwear upper assembly30generally includes the collar12flexibly joined only at its forward edge to a lower portion20of the upper30creating a flexible region of material22so that the collar12may flex forward and rearward in relation to the lower portion20of the upper30. In this embodiment, the upper30further includes a neck portion14that extends upwardly from the remainder of the lower portion20and wraps around an Achilles region. The illustrated upper also includes a gusset16joined between the neck14and the collar12.

The components of the assembly may be constructed from one continuous piece of material or joined by other conventional ways such as stitching, adhering, stapling, or cementing. Furthermore, as used herein, terms such as “forward,” “rearward,” “top,” and “bottom” will be used with respect to the direction viewed by a user wearing the footwear. Such terms are used merely for convenience of reference, and not intended to be taken as limiting in any regard.

The boot10, shown inFIGS. 1-7, generally includes the upper assembly30and a sole assembly26. The upper assembly30is manufactured from conventional materials, for example, leather, fabric or other sufficiently durable and flexible material. The style of the upper assembly30and the manner of securing it to the sole assembly26will vary depending on the design of the footwear. The upper assembly30may include multiple layers. For example, the upper may include a conventional lining material, padding layer, an insulating layers, a waterproof layer or other conventional materials. The boot10may include essentially any type of sole assembly26. For example, the sole assembly26may includes a conventional cement, welt, direct attach, Opanka, stroble or other sole construction. Accordingly, the sole assembly26will not be described in detail herein.

In the illustrated embodiment, the upper assembly30includes the collar12and the lower portion20. The lower portion20generally includes one or more sections of material that are configured to define a space adapted to receive the wearer's foot. The lower portion20of the illustrated embodiment extends from the toe region through the heel regions and defines an ankle opening. In this way, the lower portion20forms an essentially closed space for the wearer's foot. The lower portion20is not necessarily closed, however, and may include open regions for ventilation or other purposes. The boot10of the illustrated embodiment includes a relatively conventional lacing system for selectively securing the boot10on the wearer's foot. As shown, the lower portion20of this embodiment includes a plurality of conventional lacing loops or eyelets that permit the lower portion20to be selectively snuggly secured over the wearer's foot. The boot10may alternatively include other closure systems, such as snaps, buckles, Velcro® fasteners or other lacing systems. The collar12generally includes one or more sections of material configured to wrap around the wearer's leg roughly at or above the ankle region. The collar12includes a forward edge that is joined to the lower portion20creating the flexible region of material22so that the collar12may flex forward and rearward in relation to the lower portion20. In one embodiment, the collar12is joined by stitching to the lower portion20; however, the collar12may also be a continuous extension of the lower portion20. Furthermore, the collar12may be an extension from a lacing system that attaches to the lower portion20, or attach to the lower portion by another conventional manner. The collar12of the illustrated embodiment supports a plurality of lacing loops that permit the collar to be selectively drawn snuggly around the wearer's leg. As with the other portions of the upper30, the collar12may by padded and include other conventional lining materials as desired.

In the illustrated embodiment, the upper30further includes a neck14portion that extends upwardly from the remainder of the lower portion20wrapping around the ankle and/or Achilles region. The precise height of the neck14may vary from application to application. In fact, the neck14may be eliminated in some applications. The neck14generally includes a flexible padded material that provides cushion and support to the ankle area, but may be any of a variety of other conventional materials. In the illustrated embodiment, the neck14is a separate component that is secured to the lower portion20by stitching. Although the neck14of the illustrated embodiment is stitched to the lower portion20, it may equally be a continuous extension of the lower portion20or joined to the lower portion20by another conventional manner. In the embodiment shown in the figures, the collar12surrounds at least the upper portion of the neck14forming an overlapping telescopic region28. In this embodiment, the flexible region of material22allows the collar12to flex forward or rearward in relation to the neck14causes the collar12to move over the neck14in a sliding telescopic manner.

The upper assembly30of the illustrated embodiment further includes a gusset16connected to the neck14and collar12. As noted above, the collar12is flexibly movable in the forward/rearward direction between a rearward position, a central (unflexed) position and a forward position. In one specific embodiment, the gusset16is a flexible material having one edge connected to the top15of the neck14and another edge connected to the bottom13of the collar12. The gusset16includes sufficient slack to permit the collar12to flex freely forwardly and rearwardly through the desired range of motion. The size of the gusset16may be selected to provide a limit on the amount of forward and rearward movement of the collar12. For example, the collar may include only one inch of slack to limit forward and rearward movement of the collar12to only one inch. In the illustrated embodiment, the gusset16is hidden behind the collar12providing the aesthetic appearance of a conventional looking boot. The collar12, neck14and gusset16may be configured so that the gusset16is hidden only in one or more of these collar positions or so that the gusset16is exposed regardless of the position of the collar12. For example, the collar16may be extended beyond the overlapping region28down over the ankle region. The gusset16may have a variety of folds, such as a single fold or several folds in an accordion fashion. As an alternative to providing the gusset with slack, the gusset may be manufactured from an elastic material that stretches when the collar12flexes in the forward/rearward direction. In this alternative embodiment, the size, shape and elasticity of the gusset may be selected to provide limits on the forward/rearward range of motion of the collar.

The operation of the invention provides a range of relatively free forward and rearward flexibility about the ankle region, while still providing substantial ankle support. In an embodiment that includes the gusset16, as the collar12flexes forward about the flexible region of material22, the rearward part of the collar12slides upwardly over the neck14decreasing the extent of the overlapping region28. Simultaneously, the gusset16is pulled upwardly with the collar12. As the collar12flexes rearward about the flexible region of material22, the rearward part of the collar12slides downwardly over the neck14, which increases the extent of the overlapping region28and pulls the gusset16downward. As the collar12moves forwardly and rearwardly, the gusset16keeps debris from entering the boot through the space between collar12and the neck14. As shown, the gusset16is hidden underneath the collar12when the collar12is in a central (unflexed) position. As the collar12moves, it slides along the neck14and does not directly ride along the upper heel or Achilles region of the wearer's foot. Accordingly, the neck14protects the wearer from discomfort.

ALTERNATIVE EMBODIMENTS

A first alternative embodiment is shown inFIGS. 8 and 9. In this embodiment, the article of footwear100includes an upper assembly130including a collar112and a lower portion120of the upper130. Similar to the previous embodiment, a forward edge of the collar112may be flexibly joined to the lower portion120, creating a flexible region of material122. As shown inFIG. 8, the flexible region122may be wider than that shown in the previous embodiment, such that it includes the lacing trim of the boot100as well as additional material for joining the collar112and lower portion120. The width of this flexible region122may be altered to a variety of sizes, depending on the desired amount of flexibility in the flexible region122. Like the previous embodiment, the collar112may be joined to the lower portion120by sewing the collar112to the lower portion, or the collar112may be an extension of the lower portion120. As shown inFIG. 9, the upper assembly130further includes a gusset116and a liner material131extending behind the gusset116. The gusset116may be a flexible material with one edge that extends from a bottom edge113of the collar112. A lower edge of the gusset116may attach to the lower portion120, for instance, by stitching the lower edge between an outer layer127and an inner layer129of the lower portion120. The liner131is manufactured from a stretchable material, such as Lycra, and may be attached between the collar112and the lower portion120, such as by stitching an upper portion of the liner131to the collar112and a lower portion of the liner between the inner129and outer127layers of the lower portion120. As shown, the gusset116includes a region of slack that is provided with a fold117by stitching an intermediate portion of the gusset116to the liner131. The gusset116may be attached to the liner131so that the fold117is hidden behind the collar112. The liner131may be positioned on the inside of the boot100to prevent gusset116from rubbing against the Achilles region of the wearer of the boot.

A second alternative embodiment is shown inFIGS. 10 and 11. This embodiment is similar to the first alternative embodiment, wherein the upper assembly230includes a collar212and a lower portion220. The collar212includes a forward edge that is flexibly joined to the lower portion220by a flexible region of material222similar to the joining of the collar112and lower portion120of the first alternative embodiment. In this embodiment, the lower portion220includes a heel support250and an ankle support260. The ankle support260extends upwardly from the heel support250in the ankle and/or Achilles region. The ankle support260may be stitched to the heel support250, and as shown may be comprised of a material similar to the collar212material. Alternatively, the ankle support260may be a continuous extension of the heel support250. The gusset216extends between the bottom edge213of the collar212and the top edge215of the ankle support260. The gusset216may be a flexible extension of the collar212and ankle support260, or it may be a separate material that is stitched to the collar212or ankle support260. As in the first alternative embodiment, a stretchable liner231may be attached between the collar212and the lower portion220, such as between the collar212and the ankle support260. As shown inFIG. 11, the gusset216may be provided with a first fold217extending behind the collar212by stitching a portion251of the gusset216to the liner231behind the collar212, and a second fold219extending behind the ankle support260by stitching another portion252to the liner231behind the ankle support260.

Both of the alternative embodiments operate similar to the first disclosed embodiment, in that they provide a range of relatively free forward and rearward flexibility about the ankle region, while still providing substantial ankle support. In the first alternative embodiment, as the collar112flexes forward about the flexible region of material122the rearward part of the collar112moves upwardly, pulling the gusset116upwardly with the collar112and unfolding the fold117. As the collar112moves forwardly and rearwardly, the gusset116keeps debris from entering the boot through the space between collar112and the lower portion120. In the second alternative embodiment, as the collar212flexes forward, about the flexible region of material222the rearward part of the collar212moves upwardly, pulling the gusset216upwardly and unfolding the fold217. The lower portion120may further move downwardly to pull and gusset216down and unfold the fold219. The gusset216prevents debris from entering the boot200. As shown, the folds117,217,219of the gusset116,216are hidden underneath the collar112,212and the ankle support260when the collar112,212is in a central (unflexed) position. The liner131,231may be provided in each embodiment so that as the collar112,212moves it does not directly ride along the upper heel or Achilles region of the wearer's foot. As the ankle flexes forward or rearward and the gusset216is pulled upward, the liner231stretches behind the gusset216to accommodate for the movement of the collar212and gusset216.

The above descriptions are those of current embodiments of the invention. Various alterations and changes can be made without departing from the spirit and broader aspects of the invention as defined in the claims, which are to be interpreted in accordance with the principles of patent law, including the doctrine of equivalents. Any reference to an item in the disclosure or to an element in the claim in the singular using the articles “a,” “an,” “the,” or “said” is not to be construed as limiting the item or element to the singular unless expressly so stated.