Self assembled article of footwear with customized designs

A method of customizing an article of footwear that is configured for self assembly is disclosed. The method includes steps of applying customized designs to pre-cut portions, and packaging the pre-cut portions with a lace and a set of instructions into a kit of parts. The kit of parts can be taken home and assembled by the customer.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates generally to footwear and in particular to a method of customizing an article of footwear configured for self assembly.

2. Description of Related Art

Customization systems for some types of apparel have been previously proposed. Usually, designs may be applied to t-shirts. In some cases, apparel such as jeans may be modified and custom designed. Sometimes, the system through which the customer designs and orders the apparel may be the Internet. One example of such a system is disclosed in co-pending and commonly-owned U.S. application Ser. No. 11/612,320, filed on Dec. 18, 2006, and entitled “A Method of Making an Article of Footwear,” hereby referred to as “the customization case”, which is incorporated by reference herein in its entirety.

Sullivan (U.S. patent number 2005/0289018) discloses an online personal apparel design and sales technology with fulfillment techniques and processes. Sullivan teaches methods for customized and personalized design of apparel. The most common type of apparel taught by Sullivan includes various types of shirts and t-shirts. Generally, Sullivan teaches a system for customization, but does not disclose detailed processes by which the customized apparel is produced.

Costin (U.S. patent number 2005/0131571) teaches an Internet based technique for customization of apparel. Specifically, Costin teaches customization of denim apparel over the Internet. Costin uses a laser device that etches designs and patterns into denim apparel. Generally, techniques of applying intricate images and graphics involving multiple colors are not disclosed.

Allen et al. (U.S. patent number 2005/0071242) discloses a method and system for custom-manufacturing footwear. This system and method may allow a retailer to control the selection of choices given to the customer for custom-manufacturing the footwear. In the method of Allen, the designs of the article of footwear are pre-determined by the manufacturer, allowing the user the option of selecting between designs and in some cases, various colors for the designs. Generally, however, the method of Allen lacks provisions for allowing a full range of graphical designs and modifications to customize an article of footwear. There is no feature, for example, that allows a user to add a customized image of their choosing to an article of footwear.

Articles of footwear that may be designed by printing along a two-dimensional portion of an article of footwear have also been proposed. Davis et al. (U.S. Pat. No. 6,299,962) teaches an invention directed to an article of footwear and a method of making the same, where the article of footwear has a minimum number of upper pieces. In the method of Davis, the outer layer of the upper is molded using an embossing tool. Additionally, the outer layer may be decorated by screen printing, sublimation, large format in jet printing, cold and hot peel transfers, as well as other means. Generally, however, the method of Davis is limited to printing only a single portion of an upper.

While the related art teaches various methods for customizing apparel, there are many shortcomings. Generally, the automated methods used for producing customized apparel based on customized designs lack provisions for applying customized designs to objects with curved surfaces. Specifically, the methods used for producing customized t-shirts, which are themselves flat and two-dimensional, are not appropriate for articles of footwear that include many curved surfaces.

Additionally, the articles of footwear disclosed in the prior art lack customization and variability in the footwear portions that may be modified using a printer or other similar devices. There is therefore a need in the art for a customization system directed at articles of footwear including steps for customizing the article of footwear as well as steps for manufacturing the customized article of footwear.

Articles of footwear configured for self assembly have also been disclosed. Juveneton (French patent number 2,577,393) teaches a method for manufacturing a shoe from fabric in “ready-to-assemble” form for do it yourself construction. The shoe consists of fabric on which the pattern of the pair of shoes is traced. The patterns are then cut and the corresponding pieces are assembled by means of zigzag stitching.

Famolare (U.S. Pat. No. 3,742,625) is directed to an articulated clog. Famolare teaches an articulated clog construction which may be assembled by an unskilled person using only a simple tool, such as a hammer. The clog is comprised of three injection molded, hollow, rib reinforced plastic body elements. A one piece, contoured, flexible insole is attached by pins, rivets or nails to the body elements. Three sole elements are attached by pin-like projections to the body elements.

Although Juveneton and Famolare both teach articles of footwear that may be self assembled, they lack teachings of self customized portions. There is a need in the art for a system that solves this problem as well as the other problems of the prior art.

SUMMARY OF THE INVENTION

A method of customizing an article of footwear that is configured for self assembly is disclosed. In one aspect, the invention provides a method of customizing an article of footwear, comprising the steps of: providing a graphical interface system for designing a footwear representation; receiving a design including a footwear representation with a customized design; applying a customized design to a pre-cut portion according to the footwear representation; and providing a kit including the pre-cut portion, a lace, and a set of instructions for assembling the article of footwear.

In another aspect, the graphical interface system is provided on a computer at a retail store or kiosk.

In another aspect, the customized design is digitally printed to the pre-cut portion.

In another aspect, the customized design is stitched onto the pre-cut portion.

In another aspect, the invention provides a kit of parts, comprising: a first pre-cut portion and a second pre-cut portion, the first pre-cut portion including a customized design; a lace; a set of instructions; and wherein the first pre-cut portion and the second pre-cut portion may be attached using the lace to form an assembled article of footwear according to the set of instructions and where the lace may be used to adjustably fasten the assembled article of footwear.

In another aspect, the kit of parts includes four pre-cut portions.

In another aspect, the kit of parts includes a lateral side portion.

In another aspect, the kit of parts includes a medial side portion.

In another aspect, the kit of parts includes a bottom portion.

In another aspect, the kit of parts includes a tongue portion.

In another aspect, the lace includes a first end portion and a second end portion that are used to adjustably tighten the assembled article of footwear between an open position and a closed position.

In another aspect, the lace includes an intermediate portion that is disposed between the first end portion and the second end portion and where the intermediate portion is used to attach the first pre-cut portion to the second pre-cut portion.

In another aspect, the second pre-cut portion includes a customized design.

In another aspect, the invention provides an article of footwear, comprising: a first pre-cut portion and a second pre-cut portion; a lace including a first end portion, a second end portion and an intermediate portion that is disposed between the first end portion and the second end portion; the intermediate portion being used to attach the first pre-cut portion to the second pre-cut portion; and where the first end portion and the second end portion are used to adjustably tighten the article of footwear between an open position and a closed position.

In another aspect, the first end portion and the second end portion are associated with a set of lacing holes.

In another aspect, the lacing holes are disposed on a vamp portion of the article of footwear.

In another aspect, the peripheries of the first pre-cut portion and the second pre-cut portion include holes.

In another aspect, the intermediate portion is disposed through the holes.

In another aspect, the first pre-cut portion is stitched to the second pre-cut portion using the intermediate portion.

In another aspect, the invention provides an article of footwear, comprising: a pre-cut portion and a sole portion including at least one flap; a lace including a first end portion, a second end portion and an intermediate portion that is disposed between the first end portion and the second end portion; the intermediate portion being used to attach the pre-cut portion to sole portion; and where the lace is disposed through at least one hole in the at least one flap.

In another aspect, the sole portion includes a side flap.

In another aspect, the sole portion includes a front flap and a rear flap.

In another aspect, the lace is associated with a lace lock that is configured to prevent the first end portion from slipping through a lacing hole.

In another aspect, a liner is disposed over the sole portion.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

FIG. 1is a preferred embodiment of a process for making a self assembled article of footwear with customized designs. The term “self assembled”, as used throughout the remainder of this detailed description and in the claims, refers to any article of footwear that can be assembled by a customer, as opposed to a retailer or manufacturer. Additionally, the term “customized design” as used throughout this detailed description and in the claims refers to any design that is associated with an article of footwear by a customer.

During a first step102, a customer may design an article of footwear using a customization system of some kind. Provisions for customizing an article of footwear have been previously disclosed in the customization case. Once a customer has customized an article of footwear, the design may be printed to one or more pre-cut portions of the article of footwear, during a second step104.

Following this, during a third step106, the pre-cut portions of the article of footwear may be packaged together in a kit. The kit may also include a lace that is used to assemble the pre-cut portions. Additionally, the kit may include a set of instructions that provide directions for self assembly. Finally, during a fourth step108, the customer may receive the kit. At this point, the customer may assemble the pre-cut portions and the lace into an article of footwear using the set of instructions.

Referring toFIG. 2, the process of making articles of footwear that include customized designs for self assembly may be best understood by separating the steps associated with a customer and those associated with the retailer. In the current embodiment, customer200may access a graphical interface system to design an article of footwear during a first step202. In some embodiments, the graphical interface system may be a graphical editor of some kind. In a preferred embodiment, the graphical interface system may provide a set of tools that allow customer200to easily apply a customized design to an article of footwear. In some cases, customer200can access the graphical interface system by accessing a website on the Internet, as disclosed in the customization case. In other cases, customer200could travel to a retail store that includes a kiosk or computer configured to allow customers access to a graphical interface system of some kind.

Although the preferred embodiment includes the use of a graphical interface system, in other embodiments customer200could design portions of the article of footwear without the use of a graphical interface system. Instead, customer200may use a form to select pre-existing designs to be applied to one or more pre-selected portions of an article of footwear. Generally, during step202, customer200could use any provisions for associating customized designs with one or more portions of an article of footwear.

During a second step204, once customer200selects a finalized customized design for the article of footwear, the final article design may be submitted. In some embodiments, this could be accomplished by pressing a “submit” button associated with the graphical interface system. In other embodiments, customer200could mail in, or otherwise submit, a form to retailer201.

Preferably, once the final article design has been submitted, the design may be received by retailer201during a third step206. Generally, retailer201may be anyone configured to make and/or sell articles of footwear. In some cases, retailer201may be associated with a retail store. In other cases, retailer201may be associated with a kiosk in a mall. In still other cases, retailer201may be associated with one or more manufacturing locations. In such cases, customer200may not travel directly to retailer201, but instead may send the final article design to retailer201through the mail or Internet, and may receive articles of footwear from retailer201through the mail.

Once retailer201has received the final article design, retailer201may prepare a design layout for an article of footwear, during fourth step208. At this point, the customized design prepared by customer200may be associated with one or more portions of an article of footwear. In some embodiments, this step may be performed by a computer, as previously disclosed. In other embodiments, the layout may be manually prepared by a worker.

Preferably, during a fifth step210, the customized design may be applied to one or more pre-cut portions associated with the article of footwear. In the customization case, a single material was printed with a customized design and then individual portions were cut to form an assembled article of footwear. However, in the current embodiment, the portions associated with the article of footwear may be pre-cut prior to customization and printing. In other words, retailer201may have access to a set of pre-cut portions that have been manufactured at an earlier time.

Generally, any method for applying designs to various materials could be used. In some cases, the customized design may be printed to one or more portions of an article of footwear. In other cases, the customized design may be stitched, embroidered, laser etched, or otherwise applied to one or more portions of the article of footwear. In still other cases, the customized design could be applied using a combination of these various methods.

During a sixth step212, once the customized design has been applied to one or more pre-cut portions, retailer201may create a kit of parts that includes provisions for self assembling the article of footwear. In particular, the kit of parts may include the pre-cut portions, a lace and a set of instructions. The set of instructions preferably includes directions for assembling the article of footwear.

At this point, customer200may receive the kit during seventh step214. Then, customer200may take the kit home and open it up. During an eighth step216, customer200may read the instructions. Finally, during a ninth step218, customer200may assemble the article of footwear using the pre-cut portions and the lace supplied with the kit.

The following description discusses the details of the steps outlined and briefly described with reference toFIG. 2. In this preferred embodiment, customer200has access to a remote terminal or a computer located at a retail location. Using the remote terminal or computer, customer200may gain access to a website supplied by retailer201or a third party. In some embodiments, the website may include a graphical interface system, as discussed briefly in first step202.

Referring toFIG. 3, graphical interface system350preferably includes footwear representation352. The term “footwear representation”, refers to a three-dimensional embodiment of an article of footwear within a graphical interface system. Specifically, the term footwear representation preferably includes the structural design of the represented article of footwear. Additionally, the term footwear representation preferably includes any other design attributes including, but not limited to, patterns, shapes, designs, colors, images, and any other graphical features of the outer surface of the represented article of footwear.

In the current embodiment, footwear representation352is illustrated as a side portion of an article of footwear prior to assembly. As a user moves and/or rotates footwear representation352, various pre-assembly portions could be shown, including other side portions, bottom portions and tongue portions. However, in other embodiments, a footwear representation could be shown as an assembled article of footwear as well.

Generally, any type of footwear may be designed using the current method. In some embodiments, the method of customizing an article of footwear for self assembly may be applied to articles of footwear that do not require sophisticated attachment provisions, such as heavy duty adhesives or complicated stitching arrangements. In some cases, the current method may be used for customizing booties or other simple articles that can be easily self assembled. In a preferred embodiment, the current method may be used for customizing baby booties that are configured for self assembly.

It should be understood, however, that this method is not restricted to use with baby booties. In other embodiments, for example, additional provisions could be supplied for creating articles of footwear with increased structural support. For example, in other embodiments, the current method could include providing a rubber sole in a kit for self assembly, which may be used to create other types of footwear besides booties. Examples of other types of footwear that may be customized and configured for self assembly include but are not limited to, boots, basketball shoes, running shoes, dance shoes, as well as other kinds of footwear.

Additionally, throughout this specification, it should be understood that not only a single article of footwear, but a pair of footwear may be designed with a customization system. Any designs, tools, or other mechanisms applied to the design of one article of footwear may likewise be applied to a second, complementary, article of footwear. The term “complementary”, as used throughout this specification and in the claims, refers to the association of a left article of footwear with a right article of footwear and vice-versa. Also, it should be understood that each article of footwear of a pair may be designed independently. In other words, the complementary articles of footwear need not include identical designs.

In some embodiments, a graphical interface system may include provisions for modifying the view of a footwear representation. Generally, any of the provisions that have been previously disclosed in the customization case may be used in the current embodiment. In the current embodiment, graphical interface system350preferably includes directional tool354that may be used to move, rotate or otherwise modify the view of footwear representation352.

Additionally, a graphical interface system may include provisions for modifying a footwear representation. In some embodiments, graphical interface system350may include graphics tools configured to modify the design of footwear representation352. In a preferred embodiment, graphical interface system350may include tools similar to those found in many graphical editing programs, such as those that draw lines, add text, as well as other features.

Preferably, graphical interface system350may include toolbar360. Toolbar360is preferably a collection of various graphics tools. In some embodiments, toolbar360may include line tool362. Additionally, toolbar360may include text tool364. In some embodiments, toolbar360may also include shape tool366and magnification tool368. Generally, toolbar360may include many additional graphics tools. For illustrative purposes, only a few of the many possible graphics tools are shown here.

These tools may be used in any combination to create customized designs. It should be understood that the designs illustrated in this disclosure and in the customization case are only meant to be illustrative and in other embodiments any arrangement of lines, shapes or other types of graphics could be combined to create customized designs.

In some embodiments, graphical interface system350may include a set of pre-existing designs. For example, the pre-existing images may be associated with images or indicia suited for babies or toddlers and include, but are not limited to, images of teddy bears, flowers, rattles, hearts, as well as other images or indicia commonly associated with babies and toddlers. These pre-existing images may be loaded into memory associated with graphical interface system350and may be made available on a website or at a terminal in a kiosk, in some cases.

Referring toFIG. 4, graphical interface system350includes first image402within image palette404. In this embodiment, first image402is an image of a teddy bear. In other embodiments, first image402could be any type of image. In this case, first image copy410is applied to rear region406of footwear representation352. This may be accomplished by selecting first image402from image palette404. At this point, first image copy410may appear. Then, using directional tool354, first image copy410may be moved to rear region406. In other embodiments, first image402may be applied to any region or portion of footwear representation352using these same steps.

In other embodiments, a graphical interface system may include provisions for allowing a customer to import various designs or graphics from outside sources, as previously disclosed. In some embodiments, a customer may attach various media devices to a remote terminal or a computer in order to import various graphics or designs to the graphical interface system. In some cases, for example, a customer may upload pictures or photos from a digital camera or from another source. These customer imported images may generally be applied to a footwear representation in a manner similar to that described previously for first image402.

In another embodiment, shown inFIG. 5, one or more words could also be applied to footwear representation352, using text tool364. In this embodiment, first word570has been applied to side region572of footwear representation352. In this case, the word “Junior” is applied, however in other embodiments any words could be applied including the name of a baby or toddler as well as initials.

Once a customer has chosen a customized design, the finalized design may be submitted to the retailer. In some cases, the customized design can be submitted through the Internet. In other cases, the customized design can be submitted at a retail store using a form or through a remote terminal or computer at the retail store. In still other cases, the customized design may be mailed or faxed to the retailer for processing.

Referring toFIGS. 6-8, after receiving the customized design from the customer, a retailer may proceed to apply the customized design to one or more pre-cut portions associated with an article of footwear. In this embodiment, the retailer may receive pre-cut portions from a manufacturer prior to receiving a customized design. In other embodiments, the pre-cut portions could be cut from a sheet material at the retail location.

As previously mentioned, a customized design may be applied to one or more portions of an article of footwear using any known method for applying designs. In some embodiments, the customized design may be applied using a printer. In a preferred embodiment, the customized design could be digitally printed to one or more pre-cut portions.

FIG. 6is a preferred embodiment of a customized design being applied to a pre-cut portion. In this embodiment, first image402is applied to first pre-cut portion602using printer604. Generally, printer604may be any type of printer, including, but not limited to a dot matrix printer, an ink jet printer, a laser printer, as well as another kind of printer. In a preferred embodiment, printer604may be any digital printer. In this embodiment, first pre-cut portion602is a side pre-cut portion of an article of footwear. In other embodiments, first pre-cut portion602could be a tongue pre-cut portion, a bottom pre-cut portion, or any other type of pre-cut portion.

AlthoughFIG. 6only illustrates the printing of a single pre-cut portion, it should be understood that customized designs may also be applied to other pre-cut portions using printer604. In some embodiments, each pre-cut portion may be automatically or manually fed through printer604. In other embodiments, only pre-cut portions configured to receive customized designs may be fed through printer604. In other words, as some regions of an article of footwear may not include customized designs, the pre-cut portions associated with these regions may not be fed through a printer. In some embodiments, the pre-cut portions may be attached to cardstock or similar sheets of paper or paper-like material. In some embodiments, the pre-cut portions may be adhered to the cardstock, for example by using a removable adhesive. This configuration may permit the pre-cut portions to more easily be fed through printer604or other customization machine. After customization, the pre-cut portions may be peeled or otherwise removed from the cardstock for assembly.

In other embodiments, a customized design may be applied to one or more pre-cut portions by stitching. Referring toFIG. 7, first word570may be embroidered into first pre-cut portion702of an article of footwear using stitching machine704. In some cases, stitching machine704is a sewing machine. In other embodiments, stitching machine704is an embroidering machine. For purposes of illustration, a standard sewing machine is shown the current embodiment, however in a preferred embodiment stitching machine704may be an industrial sewing or embroidering machine.

AlthoughFIG. 7only illustrates the embroidering of a single pre-cut portion, it should be understood that customized designs may also be applied to other pre-cut portions using stitching machine704. In some embodiments, each pre-cut portion may be automatically or manually fed through stitching machine704. In other embodiments, only pre-cut portions configured to receive customized designs may be fed through stitching machine704. In other words, as some regions of an article of footwear may not include customized designs, the pre-cut portions associated with these regions may not be fed through stitching machine704.

FIGS. 6 and 7are only meant to illustrate possible methods of applying customized designs to pre-cut portions of an article of footwear. In other embodiments, customized designs could be applied to pre-cut portions using other methods. In some cases, the customized designs could be laser etched on the pre-cut portions. In other cases, the customized designs could be applied using other methods such as painting or stenciling.

In some cases, a customer may select the type of medium used for applying a customized design. For example, in some embodiments, a graphical interface system may include options for selecting ‘print’, ‘embroider’ or other methods of application. In other cases, the medium may be pre-selected by the retailer or manufacturer. In still other cases, some types of designs may be associated with specific types of mediums. For example, any designs created using the text tool could be embroidered onto the pre-cut portions, while any designs using a pre-designated image could be applied using a digital printer. Generally, any combination of application methods could be used to apply customized designs to one or more pre-cut portions.

In some embodiments, the pre-cut portions including portions with customized designs may be packaged into a kit of parts. In some cases, the kit of parts may also include additional provisions for assembly. In a preferred embodiment, the kit of parts may also include a lace that is used to attach the pre-cut portions together. Additionally, the kit of parts may also include a set of instructions for self assembly.

FIG. 8is a preferred embodiment of kit of parts800. In this embodiment, kit of parts800may include a plurality of pre-cut portions, including first pre-cut portion801, second pre-cut portion802, third pre-cut portion803and fourth pre-cut portion804. In a preferred embodiment, first pre-cut portion801is a lateral side portion of an article of footwear. Additionally, second pre-cut portion802is a medial side portion of an article of footwear. Also, third pre-cut portion803may be a bottom portion of an article of footwear. And finally, fourth pre-cut portion804may be a tongue portion of an article of footwear. Preferably, pre-cut portions801-804comprise all the portions of a single article of footwear.

Although four pre-cut portions are shown in the current embodiment, in other embodiments any number of pre-cut portions may be used. In other embodiments, the article of footwear may be associated with two or three pre-cut portions. In still other embodiments, the article of footwear may be associated with more than four pre-cut portions.

Generally, pre-cut portions may be made from any material. In some cases, the pre-cut portions could be made of natural leather. In other cases, the pre-cut portions could be made of synthetic leather. In still other embodiments, the pre-cut portions could be made of a fabric or textile of some kind, including both natural and synthetic materials. Additionally, in some cases, different pre-cut portions could be made of different materials. For example, a bottom pre-cut portion could be made of durable leather, while side pre-cut portions could be made of a lightweight fabric material.

Preferably, a kit of parts includes provisions for attaching one or more pre-cut portions to one another. Generally, the kit of parts may include any fastening mechanism to attach the pre-cut portions. Examples of fastening mechanisms include, but are not limited to, zippers, buttons, snaps, hook and loop fasteners as well as other types of fasteners. In a preferred embodiment, the kit of parts may include a lace that is used to stitch adjacent pre-cut portions together.

In the current embodiment, kit of parts800may include lace810. Preferably, lace810is a shoelace. The current embodiment includes only a single lace, however, in other embodiments, kit of parts800may comprise additional laces as well.

Preferably, pre-cut portions801-804include provisions for receiving lace810. In some embodiments, pre-cut portions801-804may include holes812. In a preferred embodiment, holes812may be disposed on peripheral portions814of pre-cut portions801-804. Using this arrangement, lace810may be used to stitch adjacent pre-cut portions to one another at peripheries814.

Kit of parts800may also include set of instructions830. In some embodiments, set of instructions830may include a list of directions for assembling an article of footwear from pre-cut portions801-804and lace810. In some cases, set of instructions830may include step by step directions. In other cases, set of instructions830may include diagrams as well.

Preferably, the components comprising kit of parts800may be gathered together for a customer. In some embodiments, the components comprising kit of parts800may be packaged together so a customer can carry kit of parts800home. In some cases, pre-cut portions801-804, lace810and set of instructions830may be packaged into box840. In other embodiments, the components comprising kit of parts800could be packaged in a retail bag. Using this arrangement, a customer may easily carry home kit of parts800or receive kit of parts800in the mail.

For illustrative purposes, only the components needed to assemble a single article of footwear are shown in the present embodiments. However, it should be understood that a second set of pre-cut portions as well as a second lace are preferably provided in a kit of parts to allow for the self assembly of a pair of footwear, rather than just a single article of footwear.

FIG. 9is a preferred embodiment of customer900assembling an article of footwear from pre-cut portions801-804and lace810. In this embodiment, customer900has removed pre-cut portions801-804, lace810and set of instructions830from box840. Using set of instructions830, customer900may assemble pre-cut portions801-804together using lace810.

In some cases, a customer who customizes and self assembles the articles of footwear such as a baby bootie may be an expecting mother, an expecting father or soon to be grandparents, as well as parents or grandparents of a young toddler. By customizing and assembling the articles of footwear, the customer gives something they made to the baby or toddler, which may increase the sentimental value of the articles of footwear and may give the customer a sense of accomplishment.

Referring toFIG. 10, pre-cut portions801-804may be stitched together using lace810. In some embodiments, lace810may be stitched through holes812of adjacent pre-cut portions in order to fasten adjacent pre-cut portions together. For example, in some cases, third pre-cut portion803may be fastened to first pre-cut portion801by stitching lace810between first set of holes1001and second set of holes1002. Likewise, third pre-cut portion803may be fastened to second pre-cut portion802by stitching lace810between third set of holes1003and fourth set of holes1004. This arrangement may stitch pre-cut portions801,802and803together along a bottom side of the article of footwear.

Additionally, second pre-cut portion802and first pre-cut portion801may be stitched together at a forward end1020by stitching lace810between fifth set of holes1005and sixth set of holes1006. Also, second pre-cut portion802and first pre-cut portion801may be fastened to third pre-cut portion803at a rearward end1022by stitching lace810between seventh set of holes1007and eleventh set of holes1113, as well as by stitching lace810between eighth set of holes1008and tenth set of holes1111. In some cases, a rear portion of third pre-cut portion803may be folded upwards and associated with pre-cut portions801and802prior to stitching. This arrangement generally forms a heel for the assembled article of footwear.

Finally, fourth pre-cut portion804may be fastened to pre-cut portions801and802at forward end1020by stitching lace810through fifth set of holes1005, sixth set of holes1006and ninth set of holes1009. Using this arrangement, fourth pre-cut portion804may be used as a tongue for the assembled article of footwear.

Preferably, lace810may be stitched through sets of holes1001-1009according to set of instructions830. Generally, any kind of stitching may be used to accomplish the attachment of pre-cut portions801-804to one another. In some cases, simple stitches can be used. In other cases, more complex stitches can be used. Examples of various stitches that may be used include, but are not limited to, backstitches, basting stitches, blind stitches, buttonhole stitches, chain stitches, cross-stitches, embroidery stitches, feather stitches, hemming stitches, lock stitches, padding stitches, running stitches, slip stitches, stretch stitches, top stitches, whip stitches, zigzag stitches as well as any other types of stitches.

In other embodiments, pre-cut portions801-804may not include pre-configured holes. Instead, pre-cut portions801-804may be stitched together using thinner laces that are configured to penetrate through pre-cut portions801-804. This alternative arrangement may allow for increased variety in stitching techniques, which may appeal to some customers.

In some embodiments, an article of footwear may include provisions for fastening an upper from an open position to a closed position around a foot. The term “open position” as used in this detailed description and throughout the claims, refers to a loosened position of an article of footwear in which a foot may be easily slipped into the article of footwear. The term “closed position”, as used throughout this detailed description and in the claims, refers to a tightened position of an article of footwear in which the article of footwear is tightly wrapped around the foot and cannot be generally removed.

In some cases, the article of footwear may include a lace of some kind for fastening the article. In this preferred embodiment, the lace used to attach one or more pre-cut portions together is also used to fasten the upper around a foot. In particular, the lace may include a first end portion, a second end portion and an intermediate portion. Preferably, the intermediate portion is disposed between the first end portion and the second end portion and is used to fasten one or more pre-cut portions together. Additionally, the end portions may be associated with a set of lacing holes and may be configured to adjustably fasten an upper of the article of footwear from an open position to a closed position.

FIG. 11is a preferred embodiment of article of footwear1100that has been assembled from pre-cut portions801-804, using lace810. In this embodiment, lace810preferably includes first end portion1102, second end portion1104and intermediate portion1106. Preferably, intermediate portion1106is disposed between first end portion1102and second end portion1104. In particular, intermediate portion1106may be inserted through multiple sets of holes and used to fasten the pre-cut portions together.

Referring toFIG. 12, first end portion1102and second end portion1104may be inserted through lacing holes1202. In this embodiment, lacing holes1202are associated with a top region1204of article of footwear1100. In some cases, top side1204may be a vamp portion. In other embodiments, lacing holes1202could be associated with other regions of article of footwear1100.

Using this arrangement, lace810may be used to tighten article of footwear1100from an open position to a closed position. In a preferred embodiment, this tightening may be accomplished by pulling end portions1102and1104through lacing holes1202, and in some cases, making a knot with end portions1102and1104.

In some embodiments, different portions of a lace may be made of different materials. In some cases, an intermediate portion may be made of a different material than one or more end portions. For example, the intermediate portion may be made of a durable plastic material for assembling the pre-cut portions. Likewise, the end portions may be made of a generally elastic material that provides increased tension at a fastening region of the article of footwear. In other embodiments, the different portions may be made of other materials. Materials that may be used include, but are not limited to, leather, cotton, textured polyester, spun polyester, nylon, polypropylene and plastic.

In some embodiments, an article of footwear may include provisions to prevent a lace from slipping through a set of lacing holes and interfering with the fastening of the pre-cut portions. In some cases, the lacing holes may include provisions to prevent the lace from slipping through the holes. In a preferred embodiment, the lace may include provisions so that it does not slip through the lacing holes after the article of footwear has been assembled.

FIG. 13illustrates a preferred embodiment of article of footwear1300with lace1310. Article of footwear1300may include all the various features discussed in the previous embodiments. In particular, article of footwear1300may be assembled from multiple pre-cut portions.

As discussed in the previous embodiments, a lace may include end portions and an intermediate portion. In this preferred embodiment, lace1310includes first end portion1302, second end portion1304and intermediate portion1380. Preferably, lacing holes1306are configured to receive first end portion1302and second end portion1304. Generally, first end portion1302and second end portion1304may be used to tighten article of footwear1300from an open position to a closed position. Additionally, intermediate portion1380may be associated with multiple sets of holes and may be used to assemble the pre-cut portions, as discussed in the previous embodiments.

After a customer assembles the pre-cut portions of article of footwear1300with intermediate portion1380of lace1310, the customer may deform first end portion1302of lace1310above first lacing hole1322. Additionally, the customer may deform second end portion1304above second lacing hole1324. Preferably, end portions1302and1304may be deformed to create crimped regions1350in lace1310.

Generally, a customer may deform end portions1302and1304using any known method to introduce crimped regions1350. In some cases, end portions1302and1304may be made of a material that is configured to substantially deform. In these cases, once a user bends end portions1302and1304to form crimped portions1350, portions1302and1304may remain substantially permanently deformed. Alternatively, a customer may first apply heat from a hair dryer or iron, for example, and then deform end portions1302and1304to create crimped regions1350. Preferably, end portions1302and1304are manufactured of a material with sufficient stiffness so that crimped regions1350remain deformed during the lifetime of article of footwear1300.

Using this configuration, crimped regions1350preferably block end portions1302and1304from slipping through lacing holes1322and1324, respectively. With crimped regions1350blocking lacing holes1322and1324, a customer may tighten or loosen article of footwear1300around a foot without interfering with the assembly of article of footwear1300. This may be particularly helpful when article of footwear1300is removed from a foot so that lace1310does not slip through lacing holes1322and1324and disrupt the assembly of the pre-cut portions.

In other embodiments, other provisions may be employed to block a lace from slipping through a set of lacing holes. In some cases, a kit of parts may include additional parts that may be configured to lock a lace so that it does not slide through a lacing hole. In a preferred embodiment, additional parts may be fitted around a lace so that it does not slide through a set of lacing holes.

FIG. 14is a preferred embodiment of article of footwear1400with lace locks1405snapped on lace1410. In this case, after a customer assembles article of footwear1400with lace1410, lace locks1405may be retrieved from a kit of parts and snapped on first end portion1402and second end portion1404of lace1410above first lacing hole1422and second lacing hole1424, respectively. Preferably, lace locks1405may be configured to remain fixed at a particular region on lace1410. This arrangement prevents lace1410from slipping through lacing holes1422and1424and allows the pre-cut portions of article of footwear1400to remain securely fastened.

In some embodiments, lace locks1405may be cylindrical in shape. In other embodiments, lace locks1405may be rectangular in shape. Generally, lace locks1405may be any shape and size that prevents lace locks1405from sliding through first lacing hole1422and second lacing hole1424. This arrangement preferably prevents end portions1402and1404from slipping through lacing holes1422and1424.

In these embodiments, provisions for securing first end portions and second end portions in place are adjacent to lacing holes at the bottom of a lacing region of an article of footwear. In other embodiments, however, provisions such as crimped regions or lace locks could be applied at other portions of a lace. Preferably, these provisions are applied near a boundary between an intermediate portion of a lace that is used to fasten pre-cut portions together and end portions of the lace that are used to tighten the article of footwear to a foot.

Although the preceding embodiments discuss a preferred embodiment of a self assembled baby bootie, it should be understood that in other embodiments, these same principle can be applied to make other types of footwear configured for self assembly. In particular, the provisions taught in this detailed description may be used to make articles of footwear that can be worn by both children and adults, as well as babies and toddlers. Often, children and adults require additional support at the bottom of an article of footwear. The following embodiments, illustrated inFIGS. 15-20, discuss additional provisions that may be used to increase support for a self assembled article of footwear. Using these additional provisions, a self assembled article of footwear can be configured to be worn by both children and adults.

An article of footwear may include provisions for supporting and providing comfort to a foot. In some embodiments, an article of footwear may include additional provisions to increase the structural support for a foot. Increased structural support may be useful for baby booties as well as other types of footwear, including boots, basketball shoes, running shoes, dance shoes, as well as other kinds of footwear. In some cases, a self assembled article of footwear may offer increased structural support to a foot by including a midsole.

FIGS. 15 and 16are schematic views of an article of footwear assembled from one or more pre-cut portions. Referring toFIGS. 15-16, article of footwear1500preferably includes midsole1505to provide additional support to a wearer. In a preferred embodiment, midsole1505may be included in a kit of parts associated with article of footwear1500. In other embodiments, midsole1505may be purchased separately from a kit of parts associated with article of footwear1500.

Midsole1505is preferably associated with bottom pre-cut portion1503. In particular, midsole1505may be disposed along a top side1513of bottom pre-cut portion1503. In a preferred embodiment, midsole1505may be disposed adjacent to the foot of a wearer, once midsole1505has been inserted into article of footwear1500.

Preferably, article of footwear1500includes provisions for securing midsole1505. In some embodiments, lateral pre-cut portion1501and medial pre-cut portion1502may include fastening strips1511to secure midsole1505within article of footwear1500. For ease of assembly, fastening strips1511may be attached to pre-cut portions1501and1502prior to sending the kit of parts to a customer. In some embodiments, fastening strips1511may be sewn on pre-cut portions1501and1502. In other embodiments, fastening strips1511may be attached with an adhesive to pre-cut portions1501and1502. Generally, fastening strips1511may be attached in any known manner.

Fastening strips1511may attach to midsole1505to secure midsole1505within article of footwear1500. Preferably, midsole1505includes first fastening region1506. Furthermore, fastening strips1511may include second fastening region1512. Generally, fastening regions1506and1512may include any type of fastening mechanism. Examples of fastening mechanisms include, but are not limited to, zippers, buttons, snaps, hook and loop fasteners as well as other types of fasteners. In this preferred embodiment, fastening regions1506and1512may be complementary sides of a hook and loop fastener, such as Velcro®. Using this arrangement, fastening strips1511may hold midsole1505in place with respect to bottom pre-cut portion1503.

In this embodiment, fastening strips1511include two strips to secure midsole1505. Similarly, midsole1505includes two corresponding fastening regions to attach to the two strips. In other embodiments, a different number of strips and/or fastening regions may be used. Furthermore, while this embodiment includes fastening strips1511secured to pre-cut portions1501and1502to secure midsole1505, in other embodiments midsole1505may be secured within article1500by other means. For example, fastening regions may be disposed on bottom pre-cut portion1503to attach to corresponding fastening regions on midsole1505. Generally, midsole1505may be secured within article of footwear1500in any known manner.

In the previous embodiments, an article of footwear included a bottom pre-cut portion made of an upper material, as previously discussed. In some embodiments, a self assembled article of footwear may be associated with a sole portion to provide increased support. The term “sole portion” as used throughout this detailed description and in the claims refers to a portion of an article of footwear that provides enhanced support for a foot. Generally, a sole portion may be made of a cushioning material that is configured for impact absorption. In some cases, a sole may include traction elements or cleats to provide increased traction with the ground.

Generally, a sole portion may be made of any material known in the art for making soles. In some embodiments, a sole portion may be made of polyurethane. In other embodiments, a sole portion may be made of thermoplastic or latex rubber. In still other embodiments, a sole portion may be made of ethyl vinyl acetate (EVA).

FIG. 17illustrates a preferred embodiment of sole portion1703. Preferably, sole portion1703is substantially thicker than other pre-cut portions that may be made of upper materials including leather and synthetic fibers. Furthermore, sole portion1703is generally configured to conform to the shape of a foot to provide additional structural support over a flat bottom pre-cut portion.

Preferably, a sole portion includes provisions for attaching to one or more pre-cut portions to form an assembled article of footwear. In some embodiments, sole portion1703may include side flaps1715. In some cases, side flaps1715may be configured to fasten adjacent pre-cut portions to sole portion1703. Furthermore, sole portion1703may include front flap1713and rear flap1714. Using this arrangement, flaps1713-1715may be used to fasten adjacent pre-cut portions together and to support a foot on top of sole portion1703.

In some embodiments, a sole portion may be associated with multiple pre-cut portions that may be assembled together using a lace. Generally, the assembled article of footwear may be configured to be worn by a baby, a child, or an adult. Each of the pre-cut portions may have any design. In some cases, the sole portion could include various designs, including different types of tread elements or cleats attached to an outsole of the sole portion.

Referring toFIG. 18, article of footwear1700may be associated with multiple pre-cut portions in addition to sole portion1703. In this embodiment, article of footwear1700includes first pre-cut portion1701and second pre-cut portion1702. In this case, pre-cut portions1701and1702may be side portions. Additionally, article of footwear1700may be associated with third pre-cut portion1704. In this case, third pre-cut portion1704may be a tongue portion.

In the current embodiment, article of footwear1700may be a shoe for a child. In some cases, article of footwear1700may preferably be an athletic shoe for a child. In this case, custom design1802has been applied to pre-cut portions1701and1702. Custom design1802may be applied using any of the provisions discussed in the previous embodiments for applying custom designs to one or more pre-cut portions. In other embodiments, other custom designs could also be applied to one or more pre-cut portions using a graphical interface system as discussed previously. Preferably, any type of custom design may be applied, and the types of designs that are applied are not limited to designs discussed in the previous embodiment of a baby bootie. Further examples of custom designs can be found in the customization case. With this arrangement, an article of footwear may be decorated for baby shoes, shoes for children, shoes for adults and other types of shoes.

In this current embodiment, portions1701-1704may assembled in a similar manner as discussed in the previous embodiment illustrated inFIG. 10. In some embodiments, lace1710may be stitched through holes1711of portions1701-1704to assemble article of footwear1700. The current embodiment discusses a preferred method of assembling portions1701-1704using lace1710, however, in other embodiment, different methods of assembling portions1701-1704with lace1710may be used as well. In this preferred embodiment, first pre-cut portion1701and second pre-cut portion1702may be fastened to sole portion1703by stitching lace1710through holes1711as mentioned in the discussion ofFIG. 10.

Preferably, a toe region may be formed from portions1701-1704. In some cases, first set of holes1720at forward end1725of first and second pre-cut portions1701and1702may be stitched to second set of holes1721of front flap1713. Also, third set of holes1722of front flap1713may be stitched to fourth set of holes1723of third pre-cut portion1704. This configuration preferably forms a toe region at forward end1725from portions1701-1704.

Preferably, a heel region may be formed from portions1701-1703. In some cases, first pre-cut portion1701and second pre-cut portion1702may include fifth set of holes1731at rearward end1735. Additionally, rear flap1714may include sixth set of holes1732. Fifth set of holes1731of pre-cut portions1701and1702may be stitched with lace1710to sixth set of holes1732of rear flap1714. Using this arrangement, a heel region may be formed at rearward end1735of article of footwear1700.

As discussed in the previous embodiments, a customer may stitch portions1701-1704together according to a set of instructions included in a kit of parts. Generally, any kind of stitching may be used to accomplish the attachment of portions1701-1704to one another. In other embodiments, portions1701-1704may not include pre-configured holes. Instead, pre-cut portions1701-1704may be stitched together using thinner laces that may penetrate portions1701-1704. This alternative embodiment may allow for increased variety in stitching techniques, which may appeal to some customers.

FIGS. 19 and 20are schematic views a preferred embodiment of an assembled article of footwear1900. In this embodiment, first pre-cut portion1901has been attached to sole portion1903using lace1910. In particular, lace1910is preferably stitched through side flaps1915of sole portion1903. Additionally, lace1910may be stitched through front flap1913and rear flap1914. In the current embodiment, flaps1913and1914are disposed on an interior side of article of footwear1900. However, in other embodiments, flaps1913and1914could be disposed on an outer side of article of footwear1900. By stitching lace1910through flaps1913-1915, sole portion1903may be securely fastened to other pre-cut portions.

In some embodiments, an article of footwear may include provisions to increase comfort for a foot and prevent chaffing or rubbing against an interior of the article. In some cases, a liner may be included in article of footwear1900. In the preferred embodiment illustrated inFIG. 20, liner1920is fitted over sole portion1903and partially covers first pre-cut portion1901and second pre-cut portion1902. For illustrative purposes, the thickness of liner1920is exaggerated in the current embodiment. In other embodiments, the thickness of liner1920may be less than the thickness of a pre-cut portion associated with article of footwear1900. With this arrangement, liner1920preferably covers the region where the bottom of a foot would fit in article of footwear1900. By providing a continuous smooth surface, liner1920may prevent potential rubbing on a bottom of a foot where portions1901-1903are stitched together.

In some embodiments, liner1920may be a disposable shoe liner. In other embodiments, liner1920may be a permanent but removable shoe liner. In this preferred embodiment, liner1920may be a permanent shoe liner constructed of a thermoplastic polymer. Generally, liner1920may be constructed of any suitable material.

Generally, the various components associated with an article of footwear and discussed in the previous embodiments may be included in a kit of parts or purchased separately. For example, a customer may choose additional components such as a liner or lace locks when the customer makes the initial purchase of a pair of articles of footwear from a retailer. In this case, the additional components selected may be included in a kit of parts for the assembly of a pair of articles of footwear. In other cases, a customer may choose to purchase additional components such as crimped laces or a midsole for a pair of self assembled articles of footwear at a later time after the initial purchase.

Accordingly, various embodiments of the present invention allow a customer to customize the design as well as choose a type of support for a pair of self assembled articles of footwear. A customer may add a liner or midsole or both to a sole portion to increase comfort and add more support. In addition, a self assembled article of footwear may include a sole portion to increase the traction for a wearer. Thus, the present invention provides a customized experience by allowing a customer to customize and design a self assembled article of footwear and choose associated components.