Patent Publication Number: US-7712230-B2

Title: Footwear upper with flexible collar assembly

Description:
This is a division of prior U.S. application Ser. No. 10/961,898, filed Oct. 8, 2004 (now U.S. Pat. No. 7,293,372). 
    
    
     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. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a side view of an article of footwear incorporating the present invention; 
         FIG. 2  is a side view of an article of footwear incorporating the present invention flexed forward; 
         FIG. 3  is a side view of an article of footwear incorporating the present invention flexed rearward; 
         FIG. 4  is a top view of the article of footwear; 
         FIG. 5  is a sectional view along line V-V in  FIG. 4 ; 
         FIG. 6  is a sectional view similar to that along line V-V in  FIG. 4 , when the article of footwear is flexed forward; 
         FIG. 7  is a perspective view of an article of footwear incorporating the present invention. 
         FIG. 8  is a side view of an article of footwear incorporating a first alternative embodiment of the present invention. 
         FIG. 9  is a cross sectional view of the  FIG. 8  embodiment. 
         FIG. 10  is a side view of the article of footwear incorporating a second alternative embodiment of the present invention. 
         FIG. 11  is a cross sectional view of the  FIG. 10  embodiment. 
     
    
    
     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 in  FIG. 1 , and generally designated  10 . For purposes of this disclosure, an upper assembly  30  will 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 collar  12 , such as full-height boots and high-top athletic shoes. In the illustrated embodiment, the footwear upper assembly  30  generally includes the collar  12  flexibly joined only at its forward edge to a lower portion  20  of the upper  30  creating a flexible region of material  22  so that the collar  12  may flex forward and rearward in relation to the lower portion  20  of the upper  30 . In this embodiment, the upper  30  further includes a neck portion  14  that extends upwardly from the remainder of the lower portion  20  and wraps around an Achilles region. The illustrated upper also includes a gusset  16  joined between the neck  14  and the collar  12 . 
     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 boot  10 , shown in  FIGS. 1-7 , generally includes the upper assembly  30  and a sole assembly  26 . The upper assembly  30  is manufactured from conventional materials, for example, leather, fabric or other sufficiently durable and flexible material. The style of the upper assembly  30  and the manner of securing it to the sole assembly  26  will vary depending on the design of the footwear. The upper assembly  30  may 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 boot  10  may include essentially any type of sole assembly  26 . For example, the sole assembly  26  may includes a conventional cement, welt, direct attach, Opanka, stroble or other sole construction. Accordingly, the sole assembly  26  will not be described in detail herein. 
     In the illustrated embodiment, the upper assembly  30  includes the collar  12  and the lower portion  20 . The lower portion  20  generally includes one or more sections of material that are configured to define a space adapted to receive the wearer&#39;s foot. The lower portion  20  of the illustrated embodiment extends from the toe region through the heel regions and defines an ankle opening. In this way, the lower portion  20  forms an essentially closed space for the wearer&#39;s foot. The lower portion  20  is not necessarily closed, however, and may include open regions for ventilation or other purposes. The boot  10  of the illustrated embodiment includes a relatively conventional lacing system for selectively securing the boot  10  on the wearer&#39;s foot. As shown, the lower portion  20  of this embodiment includes a plurality of conventional lacing loops or eyelets that permit the lower portion  20  to be selectively snuggly secured over the wearer&#39;s foot. The boot  10  may alternatively include other closure systems, such as snaps, buckles, Velcro® fasteners or other lacing systems. The collar  12  generally includes one or more sections of material configured to wrap around the wearer&#39;s leg roughly at or above the ankle region. The collar  12  includes a forward edge that is joined to the lower portion  20  creating the flexible region of material  22  so that the collar  12  may flex forward and rearward in relation to the lower portion  20 . In one embodiment, the collar  12  is joined by stitching to the lower portion  20 ; however, the collar  12  may also be a continuous extension of the lower portion  20 . Furthermore, the collar  12  may be an extension from a lacing system that attaches to the lower portion  20 , or attach to the lower portion by another conventional manner. The collar  12  of the illustrated embodiment supports a plurality of lacing loops that permit the collar to be selectively drawn snuggly around the wearer&#39;s leg. As with the other portions of the upper  30 , the collar  12  may by padded and include other conventional lining materials as desired. 
     In the illustrated embodiment, the upper  30  further includes a neck  14  portion that extends upwardly from the remainder of the lower portion  20  wrapping around the ankle and/or Achilles region. The precise height of the neck  14  may vary from application to application. In fact, the neck  14  may be eliminated in some applications. The neck  14  generally 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 neck  14  is a separate component that is secured to the lower portion  20  by stitching. Although the neck  14  of the illustrated embodiment is stitched to the lower portion  20 , it may equally be a continuous extension of the lower portion  20  or joined to the lower portion  20  by another conventional manner. In the embodiment shown in the figures, the collar  12  surrounds at least the upper portion of the neck  14  forming an overlapping telescopic region  28 . In this embodiment, the flexible region of material  22  allows the collar  12  to flex forward or rearward in relation to the neck  14  causes the collar  12  to move over the neck  14  in a sliding telescopic manner. 
     The upper assembly  30  of the illustrated embodiment further includes a gusset  16  connected to the neck  14  and collar  12 . As noted above, the collar  12  is flexibly movable in the forward/rearward direction between a rearward position, a central (unflexed) position and a forward position. In one specific embodiment, the gusset  16  is a flexible material having one edge connected to the top  15  of the neck  14  and another edge connected to the bottom  13  of the collar  12 . The gusset  16  includes sufficient slack to permit the collar  12  to flex freely forwardly and rearwardly through the desired range of motion. The size of the gusset  16  may be selected to provide a limit on the amount of forward and rearward movement of the collar  12 . For example, the collar may include only one inch of slack to limit forward and rearward movement of the collar  12  to only one inch. In the illustrated embodiment, the gusset  16  is hidden behind the collar  12  providing the aesthetic appearance of a conventional looking boot. The collar  12 , neck  14  and gusset  16  may be configured so that the gusset  16  is hidden only in one or more of these collar positions or so that the gusset  16  is exposed regardless of the position of the collar  12 . For example, the collar  16  may be extended beyond the overlapping region  28  down over the ankle region. The gusset  16  may 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 collar  12  flexes 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 gusset  16 , as the collar  12  flexes forward about the flexible region of material  22 , the rearward part of the collar  12  slides upwardly over the neck  14  decreasing the extent of the overlapping region  28 . Simultaneously, the gusset  16  is pulled upwardly with the collar  12 . As the collar  12  flexes rearward about the flexible region of material  22 , the rearward part of the collar  12  slides downwardly over the neck  14 , which increases the extent of the overlapping region  28  and pulls the gusset  16  downward. As the collar  12  moves forwardly and rearwardly, the gusset  16  keeps debris from entering the boot through the space between collar  12  and the neck  14 . As shown, the gusset  16  is hidden underneath the collar  12  when the collar  12  is in a central (unflexed) position. As the collar  12  moves, it slides along the neck  14  and does not directly ride along the upper heel or Achilles region of the wearer&#39;s foot. Accordingly, the neck  14  protects the wearer from discomfort. 
     Alternative Embodiments 
     A first alternative embodiment is shown in  FIGS. 8 and 9 . In this embodiment, the article of footwear  100  includes an upper assembly  130  including a collar  112  and a lower portion  120  of the upper  130 . Similar to the previous embodiment, a forward edge of the collar  112  may be flexibly joined to the lower portion  120 , creating a flexible region of material  122 . As shown in  FIG. 8 , the flexible region  122  may be wider than that shown in the previous embodiment, such that it includes the lacing trim of the boot  100  as well as additional material for joining the collar  112  and lower portion  120 . The width of this flexible region  122  may be altered to a variety of sizes, depending on the desired amount of flexibility in the flexible region  122 . Like the previous embodiment, the collar  112  may be joined to the lower portion  120  by sewing the collar  112  to the lower portion, or the collar  112  may be an extension of the lower portion  120 . As shown in  FIG. 9 , the upper assembly  130  further includes a gusset  116  and a liner material  131  extending behind the gusset  116 . The gusset  116  may be a flexible material with one edge that extends from a bottom edge  113  of the collar  112 . A lower edge of the gusset  116  may attach to the lower portion  120 , for instance, by stitching the lower edge between an outer layer  127  and an inner layer  129  of the lower portion  120 . The liner  131  is manufactured from a stretchable material, such as Lycra, and may be attached between the collar  112  and the lower portion  120 , such as by stitching an upper portion of the liner  131  to the collar  112  and a lower portion of the liner between the inner  129  and outer  127  layers of the lower portion  120 . As shown, the gusset  116  includes a region of slack that is provided with a fold  117  by stitching an intermediate portion of the gusset  116  to the liner  131 . The gusset  116  may be attached to the liner  131  so that the fold  117  is hidden behind the collar  112 . The liner  131  may be positioned on the inside of the boot  100  to prevent gusset  116  from rubbing against the Achilles region of the wearer of the boot. 
     A second alternative embodiment is shown in  FIGS. 10 and 11 . This embodiment is similar to the first alternative embodiment, wherein the upper assembly  230  includes a collar  212  and a lower portion  220 . The collar  212  includes a forward edge that is flexibly joined to the lower portion  220  by a flexible region of material  222  similar to the joining of the collar  112  and lower portion  120  of the first alternative embodiment. In this embodiment, the lower portion  220  includes a heel support  250  and an ankle support  260 . The ankle support  260  extends upwardly from the heel support  250  in the ankle and/or Achilles region. The ankle support  260  may be stitched to the heel support  250 , and as shown may be comprised of a material similar to the collar  212  material. Alternatively, the ankle support  260  may be a continuous extension of the heel support  250 . The gusset  216  extends between the bottom edge  213  of the collar  212  and the top edge  215  of the ankle support  260 . The gusset  216  may be a flexible extension of the collar  212  and ankle support  260 , or it may be a separate material that is stitched to the collar  212  or ankle support  260 . As in the first alternative embodiment, a stretchable liner  231  may be attached between the collar  212  and the lower portion  220 , such as between the collar  212  and the ankle support  260 . As shown in  FIG. 11 , the gusset  216  may be provided with a first fold  217  extending behind the collar  212  by stitching a portion  251  of the gusset  216  to the liner  231  behind the collar  212 , and a second fold  219  extending behind the ankle support  260  by stitching another portion  252  to the liner  231  behind the ankle support  260 . 
     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 collar  112  flexes forward about the flexible region of material  122  the rearward part of the collar  112  moves upwardly, pulling the gusset  116  upwardly with the collar  112  and unfolding the fold  117 . As the collar  112  moves forwardly and rearwardly, the gusset  116  keeps debris from entering the boot through the space between collar  112  and the lower portion  120 . In the second alternative embodiment, as the collar  212  flexes forward, about the flexible region of material  222  the rearward part of the collar  212  moves upwardly, pulling the gusset  216  upwardly and unfolding the fold  217 . The lower portion  120  may further move downwardly to pull and gusset  216  down and unfold the fold  219 . The gusset  216  prevents debris from entering the boot  200 . As shown, the folds  117 ,  217 ,  219  of the gusset  116 ,  216  are hidden underneath the collar  112 ,  212  and the ankle support  260  when the collar  112 ,  212  is in a central (unflexed) position. The liner  131 ,  231  may be provided in each embodiment so that as the collar  112 ,  212  moves it does not directly ride along the upper heel or Achilles region of the wearer&#39;s foot. As the ankle flexes forward or rearward and the gusset  216  is pulled upward, the liner  231  stretches behind the gusset  216  to accommodate for the movement of the collar  212  and gusset  216 . 
     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.