A shoe component, wherein the shoe component is formed by 3-dimensional weaving such that the shoe component has one or more woven layers, each having a warp direction and a fill direction, wherein the shoe component has one direction of stretch; a shoe containing at least one of the shoe components in an upper; and a shoe in which the entire upper, and optionally the midsole and/or outsole, are entirely formed by 3-dimensional weaving.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The present invention relates to a shoe component formed by 3-dimensional weaving, a shoe incorporating at least one 3-dimensionally woven shoe component, a shoe upper formed entirely from 3-dimensional weaving, a unitary structure comprising an upper and a midsole where the entire unitary structure is formed by 3-dimensional weaving, and a shoe comprising the unitary structure, as well as a shoe formed entirely by 3-dimensional weaving, including upper and entire sole.

Central to the present invention is the technique of 3-dimensional weaving. 3-dimensional weaving is a technique for creating a textile product by utilizing a three dimensional Cartesian coordinate system as the infrastructure for weaving simultaneous independent fabric layers in conjunction with weaving connectors between and among the layers. The 3-dimensional weaving technique is described in detail in U.S. Pat. Nos. 7,836,917 and 7,836,918, the entire contents of each of which are hereby incorporated by reference. This technique is used to form fabrics having a plurality of woven layers, into which can be directly woven various openings, pockets, and textures. The 3-dimensional weaving technique also provides a process for imparting a variety of properties to the resulting fabric, including different modulus, stretch and recovery characteristics.

The term “fiber” as used herein refers to a fundamental component used in the assembly of yarns and fabrics. Generally, a fiber is a component which has a length dimension which is much greater than its diameter or width. This term includes ribbon, strip, staple, and other forms of chopped, cut or discontinuous fiber and the like having a regular or irregular cross section. “Fiber” also includes a plurality of any one of the above or a combination of the above.

As used herein, the term “high tenacity fiber” means that class of synthetic or natural non-glass fibers having high values of tenacity greater than 10 g/denier, such that they lend themselves for applications where high abrasion resistance is important. Typically, high performance fibers have a very high degree of molecular orientation and crystallinity in the final fiber structure.

The term “filament” as used herein refers to a fiber of indefinite or extreme length such as found naturally in silk. This term also refers to manufactured fibers produced by, among other things, extrusion processes. Individual filaments making up a fiber may have any one of a variety of cross sections to include round, serrated or crenular, bean-shaped or others.

The term “yarn” as used herein refers to a continuous strand of textile fibers, filaments or material in a form suitable for weaving, or otherwise intertwining to form a textile fabric. Yarn can occur in a variety of forms to include a spun yarn containing staple fibers usually bound together by twist; a multi filament yarn containing many continuous filaments or strands; or a mono filament yarn which consists of a single strand.

The term “composite yarn” refers to a yarn prepared from two or more yarns (or “ends”), which can be the same or different. Composite yarn can occur in a variety of forms wherein the two or more ends are in differing orientations relative to one another, so long as the final composite yarn containing the two or more ends is stably assembled (i.e. will remain intact unless forcibly separated or disassembled). The two or more ends can, for example, be parallel, wrapped one around the other(s), twisted together, or combinations of any or all of these, as well as other orientations, depending on the properties of the composite yarn desired.

In using the 3-dimensional weaving technique in the present invention, the warp yarns can be any desired yarn having low levels of stretch, preferably less than 5% stretch, more preferably less than 3% stretch. The yarn can be a natural or synthetic yarn, and can be of any desired denier based upon the desired overall weight of the shoe component being made. Preferred deniers are from 10 to 400 denier, more preferably from 50 to 200 denier. The warp yarn can also be a composite yarn if desired, such as a core-sheath construction wherein a sheath yarn is wrapped around a core yarn. Again, the core and sheath of such constructions can be any natural or synthetic yarn, so long as the composite has the overall low levels of stretch desired.

The warp yarns are preferably a high tenacity fiber. Preferably the high tenacity fiber comprises a high molecular weight polyolefin, preferably high molecular weight polyethylene or high molecular weight polypropylene, an aramid, a high molecular weight polyvinyl alcohol, a high molecular weight polyacrylonitrile, liquid crystal polyesters or mixtures or copolymers thereof.

The fill yarns can likewise be made from any natural or synthetic yarns, and similarly have any desired denier based upon the desired overall weight of the shoe component being made. Such natural or synthetic fibers include, but are not limited to, cotton, wool, nylon, polyester, rayon, cellulose acetate, etc. The fill yarns preferably have deniers in the 10 to 400 denier range, more preferably from 50 to 200 denier. The fill yarn preferably has a higher level of stretch than the warp yarns, and more preferably is an elastomeric yarn having high stretch and recovery properties.

As the elastomeric yarn component, any elastomeric fiber may be used, as monofilament or multifilament yarn. Additionally, two or more elastomeric fibers can be combined in the core of a composite yarn, or used as a blend, twisted, in parallel, or air-tacked, etc. An elastomer is a natural or synthetic polymer that, at room temperature, can be stretched and expanded to typically twice its original length. After removal of the tensile load it will immediately return to its original length. Along with spandex, rubber and anidex (no longer produced in the United States) are considered elastomeric fibers. Spun from a block copolymer, spandex fibers exploit the high crystallinity and hardness of polyurethane segments, yet remain “rubbery” due to alternating segments of polyethylene glycol. Suitable elastomeric fibers include, but are not limited to, fibers made from copolymers having both rigid and flexible segments in the polymer chains, such as, for example, block copolymers of polyurethane and polyethylene glycol. Particularly suitable elastomeric fibers include, but are not limited to, Spandex, such as LYCRA (produced by United Yarn Products), ELASPAN (produced by Invista), DORLASTAN (produced by Bayer), CLEAR SPAN (produced by Radici) and LINEL (produced by Fillattice).

Elastomeric yarns typically have one or more of the following materials properties: can be stretched over 500% without breaking; able to be stretched repetitively and still recover original length; lightweight; abrasion resistant; poor strength, but stronger and more durable than rubber; soft, smooth, and supple; resistant to body oils, perspiration, lotions, and detergents; no static or pilling problem; very comfortable; and easily dyed.

The elastomeric yarn can be any desired denier, preferably from 10 to 400, more preferably from 15 to 350, most preferably from 50 to 200. The elastomeric yarn can be used alone or combined with one or more other yarns of any desired type, natural or synthetic, so long as the combination retains its elastomeric properties. If combined with one or more other yarns, the elastomeric yarn and other yarns are preferably blended, or the one or more other yarns are wrapped around the elastomeric yarn to provide an elastomeric core composite yarn, thus retaining the stretch property.

Elastomeric yarn containing composite yarns are further described in U.S. Pat. Nos. 5,568,657 and 5,442,815, the contents of which are incorporated herein by reference. Elastomeric yarn containing composite yarns having wicking properties are described in U.S. Provisional Application Ser. No. 61/020,790, filed Jan. 14, 2008, the contents of which are hereby incorporated by reference.

The present invention uses this 3-dimensional weaving process to generate shoe components, and in a preferred embodiment to generate an entire shoe upper/midsole unitary structure, which can be affixed to an outsole for providing a traction element or cushioning element, or can have a plurality of traction elements and/or cushioning elements affixed thereto on the exterior layer of the midsole portion. In a particularly preferred embodiment, the traction elements and/or cushioning elements are directly formed during the 3-dimensional weaving process by the use of yarns that provide traction properties to form at least a portion of the exterior layer of the midsole portion of the unitary structure. Such yarns for providing traction or cushioning properties include fuseable yarns, abrasion yarns, cushioning yarns, and high tenacity yarns.

In providing a cushioning effect to the lower midsole portion of the unitary structure of a preferred embodiment of the present invention, it is also preferred to weave in during the 3-dimensional weaving process various types of yarns and structures, such as pile yarns, air mesh constructions, hollow fibers, etc.

In the products of the present invention, the 3-dimensional weaving process is preferably performed using a rigid warp yarn with an elastomeric fill yarn. By using a plurality of successive fabric forming operations, resulting in incremental stretch capacity from each successive operation, the resulting multilayer 3-dimensionally woven fabric is provided with unidirectional stretch. The multilayer 3-dimensionally woven fabric exhibits high stretch/recovery properties in the fill direction (due to the elastomeric yarns used therein) and rigid or extremely low stretch properties in the warp direction.

This unidirectional stretch property can be used quite effectively in the construction of shoes. Various components of the shoe can be individually formed using the 3-dimensional weaving technique in order to provide varied levels and directions of stretch as needed. The unidirectional nature of the stretch in each component can provide a unique combination of stretch and rigidity that is highly beneficial in providing comfort and support in a shoe construction. The components of the shoe can be any portion of the shoe construction as desired, and are preferably selected from the group consisting of the tongue, quarters, vamp, heel seat, and toe box.

In a preferred embodiment of the present invention, a unitary structure in the general shape of a foot covering is formed by 3-dimensional weaving, such that the unitary structure contains a top portion that is a shoe upper, and a bottom portion corresponding to a shoe midsole (or even a full sole in some alternative embodiments). In the preparation of such a unitary structure, a flange can be preferably formed at the intersection of the upper and midsole portions. This flange is typically formed on an exterior surface of the unitary structure. The unitary structure can be turned inside-out to result in the flange being present on an interior surface if desired. Alternatively, the flange can be formed in such a manner as to externally protrude laterally and can be formed as a pair of flanges, one on each side of the unitary structure in a shape and size sufficient to externally wrap over the vamp portion of the shoe and connect one to another. In a preferred embodiment, the pair of flanges can be configured to have lacing holes and thus provide the capability to lace up the shoe on the foot, or can be configured to have another form of attachment, such as hook-and-loop (or “VELCRO”) type closures.

The unitary structure of a preferred embodiment of the present invention can be formed by weaving from top down or laterally. Additionally, in either top down or lateral weaving of the unitary structure, the warp direction can run in a heel to toe direction or in a medial-lateral direction. When the warp direction runs in a heel to toe direction, the resulting 3-dimensionally woven fabric has stretch in a medial-lateral direction. When the warp direction runs in a medial-lateral direction, the resulting 3-dimensionally woven fabric has stretch in a heel-to-toe direction.

The above noted cushioning elements can also be provided by insertion of a cushioning insert into a pocket formed in the midsole portion of the structure of the present invention. The pocket can have an opening to either the interior of the structure or to the exterior of the structure. In a further embodiment, this pocket can be used to house a support element which provides arch support for the wearer.

The shoe construction of the present can take on any typical shoe form, and is preferably a slip-on construction or lace-up construction. For a slip on construction, it is preferred to have at least a portion around the opening into which the wearer's foot enters the shoe to be made of the 3-dimensionally woven fabric in order to provide a more form fitting shoe. For the lace-up construction, the upper further preferably comprises a tongue portion. In the lace-up construction the tongue can be separately formed, or can be formed as a portion of the upper during the 3-dimensional weaving process.

One feature provided by the 3-dimensional weaving process is the ability to form pockets or compartments within and between the plurality of layers of the 3-dimensionally woven fabric. These pockets or compartments can be used as locations for inserts to provide various functions, such as antimicrobial inserts, charcoal or other odor reducing inserts, structural inserts, or as noted above support inserts.

In a particularly preferred embodiment of the present invention, the shoe of the present invention comprises an upper and midsole unitary structure formed by 3-dimensional weaving using yarns for both warp and fill of sufficiently low denier to provide a total shoe weight of from 5-10 ounces, most preferably from 6-8 ounces, including the weight of the lightweight outsole.

In a further preferred embodiment, the exterior layer of the midsole portion of the unitary structure of the present invention is formed from low melting (fuseable) yarns which permit the midsole portion to be affixed to the outsole upon application of sufficient heat to melt/fuse the low melting yarns, thus adhering the unitary structure to the outsole.

FIG. 1depicts a side view of an embodiment of the present invention. In the embodiment shown inFIG. 1, the warp direction of the weaving of footwear structure10is shown by lines12. In this regard, footwear structure10is formed with the warp yarns in the 3-dimensional weaving running in the medial-lateral direction. Footwear structure10includes upper20, midsole30, and outsole40. Upper20includes tongue28woven integrally with upper20. Upper20also includes apertures27for receiving shoelaces for securing the footwear structure to the foot of a person.

FIG. 2depicts a side view of another embodiment of the present invention. Footwear structure10ofFIG. 2includes the same components as footwear structure ofFIG. 1, however the warp direction12inFIG. 2is orthogonal to the warp direction12inFIG. 1. In particular, footwear structure10inFIG. 2is formed with the warp yarns in the 3-dimensional weaving running in the heel-to-toe direction.

FIG. 3shows a perspective view of footwear structure10. This footwear structure could have a warp direction as shown in either ofFIG. 1or2.FIG. 3also shows the flexibility of tongue28. As indicated by the arrow inFIG. 3, tongue28can be moved in a medial-lateral direction with respect to footwear structure10.

FIG. 4shows a cushioning or support insert50being inserted into footwear structure10. In addition,FIG. 4also shows outsole40being connected to midsole30of footwear structure10. In this embodiment, outsole40is separately formed from the integrally woven upper20and midsole30. The separately formed outsole40is then attached to midsole30.

FIG. 5shows an additional embodiment in which both midsole30and outsole40are separately formed from integrally woven upper20. Both midsole30and outsole40are then later attached to upper20.

FIG. 6illustrates a side view of one embodiment of a slip-on configuration shoe of the present invention. This embodiment is similar to that shown inFIG. 1, but does not include the apertures27and tongue28shown inFIG. 1. In a similar manner asFIG. 1, footwear structure10is formed with the warp yarns in the 3-dimensional weaving running in the medial-lateral direction.

FIG. 7illustrates a side view of one embodiment of a slip-on configuration shoe of the present invention. This embodiment is similar to that shown inFIG. 2, but does not include the apertures27and tongue28shown inFIG. 2. In a similar manner asFIG. 2, footwear structure10is formed with the warp yarns in the 3-dimensional weaving running in the heel-to-toe direction.

FIG. 8illustrates a side view of another embodiment of a slip-on configuration shoe of the present invention. This embodiment is similar to that shown inFIG. 1, but this footwear structure10is formed with the warp yarns in the 3-dimensional weaving running in a direction oblique to both the medial-lateral direction and the heel-to-toe direction. In this regard, the present invention includes footwear structures with the orientation of the upper in any possible angle relative to the warp.

FIG. 9shows a perspective view of a slip on footwear structure10. This footwear structure could have a warp direction as shown in either ofFIG. 6or7.

FIG. 10shows a cushioning or support insert50being inserted into the slip on footwear structure10. In addition,FIG. 9also shows outsole40being connected to midsole30of slip on footwear structure10. In this embodiment, outsole40is separately formed from the integrally woven upper20and midsole30. The separately formed outsole40is then attached to midsole30.

FIG. 11shows an additional embodiment in which both midsole30and outsole40are separately formed from integrally woven upper20. Both midsole30and outsole40are then later attached to upper20.

FIG. 12illustrates a top view of one embodiment of a slip-on footwear structure10formed with the warp yarns in the 3-dimensional weaving running in the medial-lateral direction.

FIG. 13illustrates a top view of one embodiment of a slip-on footwear structure10formed with the warp yarns in the 3-dimensional weaving running in the heel-to-toe direction.

FIG. 14illustrates an embodiment of a slip on footwear structure10which includes an opening32in midsole30. Opening32allows support insert50to be inserted inside of footwear structure10. Outsole40can then be attached to midsole30, which seals opening32.

FIG. 15is a top view of embodiment of a least a configuration of footwear structure10in which the warp yarns in the 3-dimensional weaving running in the medial-lateral direction. One example of such an embodiment is shown inFIG. 1.

FIG. 16is a top view of embodiment of a lace up configuration of footwear structure10in which the warp yarns in the 3-dimensional weaving running in the heel-to-toe direction. One example of such an embodiment is shown inFIG. 2.

FIG. 17illustrates an embodiment of a lace up configuration of footwear structure10which includes an opening32in midsole30. Opening32allows support insert50to be inserted inside of footwear structure10. Outsole40can then be attached to midsole30, which seals opening32.

FIG. 18shows various shoe components of the present invention formed by 3-dimensional weaving having the warp yarns running in direction12.

FIG. 19illustrates a top view of one embodiment of a slip-on configuration of footwear structure10formed with the warp yarns in the 3-dimensional weaving running in the medial-lateral direction and including a functional flange member22extending from one side.

FIG. 20illustrates a perspective view of a lace up configuration of footwear structure10including a functional flange member22extending from one side. Functional flange member22includes apertures27for receiving shoelaces.

FIG. 21depicts an embodiment of a lace-up configuration shoe of the present invention having a functional (or decorative) flange22that can be moved into place as indicated by the arrow. Functional flange22can then be affixed to either the upper20or to a second functional (or decorative) flange (not shown) on the other side of the shoe. As noted above, the flanges22of the present invention may be functional or decorative flanges. In particular, functional flanges may be part of the lacing system and/or may be used in securing the sole.

FIG. 22is an exploded view of a tongue-less lace-up shoe construction of footwear structure10showing the upper20, midsole30, and outsole40. The midsole30is a separate structure from the upper20, as is the outsole40. Midsole30and outsole40are affixed to upper20after integrally weaving upper20.

FIG. 23shows another view of a tongue-less lace-up shoe construction of the present invention.

FIG. 24shows a further embodiment of a slip-on shoe construction of the present invention.

FIG. 25is a cross-section view of footwear structure10having an upper portion20and a midsole portion30. Footwear structure10also includes a pair of functional flanges22on the sides which can be moved into place over the upper as indicated by the arrows.

FIG. 26shows the functional flanges22after they are rotated towards an upper portion of the shoe.

FIG. 27is a cross-section view of footwear structure10including functional flanges22rotated towards an upper portion of the shoe and additional flanges26located between functional flanges22and the midsole portion30. The present invention allows weaving of specific characteristics of the shoe (such as stretch, non-stretch, sweat-wicking, etc) where desired in a single unified upper. No (or very few) sewing or bonding processes are needed to create the upper. The programming of the type of weave, along with the choice of yarns, allows for simple changes to characteristics within the upper for different types of shoes, sizes and colors. Finally, there is no waste from cutting out dozens of materials, rather only the waste from cutting out the entire upper. Thus, the present invention provides both a process and performance enhancement.

The present invention also allows for a certain amount of shaping of the upper even before lasting, meaning the overall shape of a woven upper should be a 3-D shape rather than a flat one. This allows the upper to conform to the foot much better, and require less (perhaps none) forcing of 2-D materials around a 3-D last. This enhances the fit and performance of the end product, not only by shaping it in 3-D and minimizing layers, but also because the precision and consistency of the upper (with no human hands touching it as it goes down a stitching line) will be vastly improved.

Additional embodiments include weaving in the cushioning and traction elements that are currently cemented to the upper, thereby eliminating even more waste and processes.