ARTICLE OF FOOTWEAR

Description

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Application No. 63/728,049, filed on Dec. 4, 2024, and entitled “ARTICLE OF FOOTWEAR,” which is incorporated by reference herein in its entirety.

REFERENCE REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not applicable

SEQUENCE LISTING

Not applicable

BACKGROUND

1. Field of the Disclosure

The present disclosure relates generally to an article of footwear including an upper.

2. Description of the Background

Many conventional shoes or other articles of footwear generally comprise an upper and a sole attached to a lower end of the upper. The upper in combination with the sole can create an internal space, i.e., a void or cavity, that receives and secures a foot of a user to the article of footwear. When securing the foot of the user within the article of footwear, the upper influences a user's experience and perceived comfort of the shoe. As such, in many cases, articles of footwear having uppers with increased flexibility, cushioning, and comfort are desired.

SUMMARY

In some embodiments, an article of footwear may include an upper that comprises a base layer that includes a first layer and a second layer. The second layer may be a series of cushioning elements that extend outward from the first layer and a top layer that is partially connected to a perimeter of the base layer such that a void is disposed between the base layer and the top layer. Further, at least one of the cushioning elements of the series of cushioning elements may be located within the void defined between the base layer and the top layer. In some embodiments, at least one of the cushioning elements of the series of cushioning elements has a rectangular cross section. In some embodiments, at least one of the cushioning elements of the series of cushioning elements may have an ellipse-shaped cross section. In some embodiments, at least one of the cushioning elements of the series of cushioning elements may define a depth that is between about 1.5 millimeters and about 2.5 millimeters. Further, the depth of at least one of the cushioning elements may be measured from a centrally located inner point of the cushioning element and a centrally located outer point of the cushioning element. In some embodiments, at least one cushioning element of the series of cushioning elements may define a depth that is between about 1.8 millimeters and about 2.2 millimeters. In some embodiments, at least one cushioning element of the series of cushioning elements may define a major axis and a minor axis that is shorter than the major axis. The major axis may extend in a medial-lateral direction from a medial side to a lateral side of the article of footwear, and the minor axis may extend in a heel-toe direction from a heel end to a toe end of the article of footwear.

In some embodiments, an article of footwear may include an upper that comprises a base layer that includes a first layer and a second layer. The second layer may be a series of cushioning elements that extend from the first layer and a top layer that is partially connected to a perimeter of the base layer such that a void is defined between the base layer and the top layer within which the series of cushioning elements is disposed. In some embodiments, the first layer of the base layer may include a first section that is made of an elastane or spandex material and a second section that is made of a knitted material. In some embodiments, the first section may be located in a forefoot region of the article of footwear and the second section may be located in a midfoot region of the article of footwear. In some embodiments, only a portion of the series of cushioning elements is disposed within the void. In some embodiments, at least one of the cushioning elements of the series of cushioning elements is located on an internal side of the first layer of the base layer. In some embodiments, the series of cushioning elements is arranged in a cushioning element pattern that includes a series of rows that extend from a medial side of the article of footwear to a lateral side of the article of footwear. In some embodiments, the cushioning element pattern includes between 20 and 40 rows. In some embodiments, the cushioning element pattern includes more rows on the lateral side of the article of footwear than on the medial side of the article of footwear. In some embodiments, the article of footwear is configured to be a cleat and includes a plurality of cleats that extend from a sole structure.

In some embodiments, an article of footwear includes a sole structure and an upper that is attached to the sole structure and comprises a base layer that includes a first layer and a second layer. The second layer comprises a series of cushioning elements arranged in a cushioning element pattern and a top layer that may be partially connected to a perimeter of the base layer such that a void is defined between the base layer and the top layer that the series of cushioning elements may be located within. In some embodiments, at least one cushioning element of the series of cushioning elements comprises cushioning element subsections that include two straight sides that connect two curved sides such that the cushioning element subsections have an oval shape. In some embodiments, the cushioning element pattern includes a first group of cushioning elements arranged in a series of curved columns that extend from a toe end of the article of footwear to a lateral side of a midfoot region of the article of footwear, and the cushioning element pattern includes a second group of cushioning elements arranged in a second series of curved columns that extend from the toe end of the article of footwear to a medial side of the article of footwear. In some embodiments, the first layer of the base layer defines an internal side and an external side, and at least one of the cushioning elements of the series of cushioning elements is located on the internal side of the first layer of the base layer and at least one of the cushioning elements of the series of cushioning elements is located on the external side of the first layer of the base layer. In some embodiments, at least one of the cushioning elements of the series of cushioning elements located on the internal side of the first layer overlaps with at least one of the cushioning elements of the series of cushioning elements located on the external side of the first layer of the base layer.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a lateral side view of an article of footwear configured as a right shoe that includes an upper and a sole structure, according to an embodiment of the disclosure;

FIG. 2A is a bottom view of the article of footwear of FIG. 1;

FIG. 2B is a top view of an article of footwear shown as a left shoe that includes an upper and a sole structure, according to an embodiment of the disclosure;

FIG. 3 is rear, top, and medial side perspective view of the article of footwear of FIG. 1;

FIG. 4 is a top view of the upper of FIG. 1 shown removed from the article of footwear and in a first configuration that only includes a first layer of a base layer;

FIG. 5 is a top view of the upper of FIG. 4 shown in a second configuration that only includes the first layer and a second layer of the base layer;

FIG. 6 is a perspective view of a first section of the upper of FIG. 5;

FIG. 7 is an enlarged view of a portion of the upper of FIG. 5;

FIG. 8 is an enlarged cross-sectional schematic view taken along plane 8-8 of FIG. 7;

FIG. 9 is a top view of the upper of FIG. 4 shown in a third configuration that includes the first and second layers of the base layer and a first layer of a top layer;

FIG. 10 is a top view of the upper of FIG. 4 shown in a fourth configuration that includes the first and second layers of the base layer and a first layer and a second layer of the top layer;

FIG. 11 is a top view of the upper of FIG. 4 shown in a fifth configuration that includes the first and second layers of the base layer and a first layer, a second layer, and a third layer of the top layer;

FIG. 12 is a top view of the upper of FIG. 4 shown in a sixth configuration that includes the first and second layers of the base layer and a first layer, a second layer, a third layer, and a fourth layer of the top layer;

FIG. 13 is a cross-sectional schematic taken along plane 13-13 of FIG. 12;

FIG. 14 is a top view of a base layer of an upper shown separated from an article of footwear;

FIG. 15 is an enlarged view of a portion of the base layer of FIG. 14;

FIG. 16 is a top view of a base layer of an upper shown separated from an article of footwear;

FIG. 17 is a top view of a base layer of an upper shown separated from an article of footwear;

FIG. 18 is a top view of a base layer of an upper shown separated from an article of footwear;

FIG. 19 is a bottom view of the base layer of FIG. 18;

FIG. 20 is a top view of the base layer of FIG. 18 with the first layer being shown transparent;

FIG. 21 is a cross-sectional schematic of the base layer taken along plane 21-21 of FIG. 18;

FIG. 22 is a top view of a base layer of an upper shown separated from an article of footwear;

FIG. 23 is a bottom view of the base layer of FIG. 22;

FIG. 24 is a top view of the base layer of FIG. 22 with the first layer being shown transparent;

FIG. 25 is a top view of a third layer of a top layer of an upper shown separated from an article of footwear;

FIG. 26 is a top view of a fourth layer of a top layer of an upper shown separated from an article of footwear; and

FIG. 27 is a fourth layer of a top layer of an upper shown separated from an article of footwear.

DETAILED DESCRIPTION OF THE DRAWINGS

The following discussion and accompanying figures disclose various embodiments or configurations of a shoe and a shoe upper. Although embodiments of a shoe or shoe upper are disclosed with reference to a cleat, such as a soccer cleat or a football cleat, concepts associated with embodiments of the shoe or the shoe upper may be applied to a wide range of footwear and footwear styles, including cross-training shoes, golf shoes, hiking shoes, hiking boots, ski and snowboard boots, walking shoes, track spikes, and track cleats, for example. Concepts of the shoe or the shoe upper may also be applied to articles of footwear that are considered non-athletic, including dress shoes, sandals, loafers, slippers, and heels. In addition to footwear, particular concepts described herein may also be applied and incorporated in other types of apparel or other athletic equipment, including helmets, padding or protective pads, shin guards, socks, and gloves. Even further, particular concepts described herein may be incorporated in cushions, backpack straps, golf clubs, golf bags, or other consumer or industrial products. Accordingly, concepts described herein may be utilized in a variety of products.

The term “about,” as used herein, refers to variation in the numerical quantity that may occur, for example, through typical measuring and manufacturing procedures used for articles of footwear or other articles of manufacture that may include embodiments of the disclosure herein; through inadvertent error in these procedures; through differences in the manufacture, source, or purity of the ingredients used to make the compositions or mixtures or carry out the methods; and the like. Throughout the disclosure, the terms “about” and “approximately” refer to a range of values ±5% of the numeric value that the term precedes.

As used herein in the context of geometric descriptions, unless otherwise limited or defined, “substantially” indicates correspondence to a particular shape or dimension within conventional manufacturing tolerances for components of a similar type or that are formed using similar processes. In this regard, for example, “substantially round” can indicate a profile that deviates from a circle to within acceptable manufacturing tolerances. Further, as used herein, unless otherwise defined or limited, directional terms are used for convenience of reference for discussion of particular figures or examples. For example, references to “downward,” or other directions, or “lower” or other positions, may be used to discuss aspects of a particular example or figure, but do not necessarily require similar orientation or geometry in all installations or configurations.

The present disclosure is directed to an article of footwear and/or specific components of the article of footwear, such as an upper. Referring to FIGS. 1, 2A, and 3-13, embodiments of an article of footwear 100 are shown that include an upper 104 extending from a sole structure 108. The upper 104 is attached to the sole structure 108 and together define an interior cavity 112 into which a foot may be inserted. In some embodiments, the sole structure 108 includes cleats 116 such that the article of footwear 100 is configured for use as, e.g., a soccer cleat or a football cleat. However, as discussed above, the concepts associated with embodiments of the article of footwear 100 as a whole and the upper 104 in isolation may be applied to a wide range of footwear and footwear styles that are not limited to cleats.

For reference, an exemplary embodiment of the article of footwear 100B is shown in FIG. 2B. It is appreciated that all noted elements shown within the article of footwear 100B are also present within the article of footwear 100, and all other embodiments as discussed herein. The article of footwear 100B includes a forefoot region 120, a midfoot region 124, and a heel region 128. Additionally, the article of footwear 100B defines a toe end 132, a heel end 136, a lateral side 140, and a medial side 144. The forefoot region 120 is located on the toe end 132 of the article of footwear 100 and generally corresponds with portions of the article of footwear 100B that encase portions of a user's foot that includes the toes, the ball of the foot, and joints connecting the metatarsals with the toes or phalanges. The midfoot region 124 is proximate and adjoining the forefoot region 120, and generally corresponds with portions of the article of footwear 100B that encase the arch of the foot, along with the bridge of the foot. The heel region 128 is located on the heel end 136 and is proximate and adjoining the midfoot region 124 and generally corresponds with portions of the article of footwear 100B that encase rear portions of the foot, including the heel or calcaneus bone, the ankle, and/or the Achilles tendon. The lateral side 140 corresponds to an outside portion of the article of footwear 100B and the medial side 144 corresponds to an inside portion of the article of footwear 100B. As such, left and right articles of footwear have opposing lateral and medial sides 140, 144 such that the medial sides 144 are closest to one another when a user is wearing the articles of footwear 100B, while the lateral sides 140 are defined as the sides that are farthest from one another while being worn. The medial side 144 and the lateral side 140 adjoin one another at opposing, distal ends of the article of footwear 100B.

Unless otherwise specified, the forefoot region 120, the midfoot region 124, the heel region 128, the toe end 132, the heel end 136, the lateral side 140, and the medial side 144 are intended to define boundaries or areas of the article of footwear 100B. To that end, the forefoot region 120, the midfoot region 124, the heel region 128, the toe end 132, the heel end 136, the lateral side 140, and the medial side 144 generally characterize sections and sides of the article of footwear 100B.

Further, the upper 104 and the sole structure 108 may be characterized as having portions within the forefoot region 120, the midfoot region 124, the heel region 128, and on the toe end 132, the heel end 136, the lateral side 140, and the medial side 144. Therefore, the upper 104 and the sole structure 108, and/or individual portions of the upper 104 and the sole structure 108, may include portions thereof that are disposed within the forefoot region 120, the midfoot region 124, the heel region 128, and/or on the toe end 132, the heel end 136, the lateral side 140, and/or the medial side 144.

Referring now to FIGS. 1, 2A, and 3, the sole structure 108 is connected or secured to the upper 104 and extends between the foot of a user and the ground when the article of footwear 100 is worn by the user. The sole structure 108 may be rigid and formed from one or more materials to impart durability, wear-resistance, abrasion resistance, or traction to the sole structure 108. The sole structure 108 may comprise a PU plastic, such as a TPU material, for example. Other thermoplastic elastomers consisting of block copolymers are also possible. In some embodiments, the sole structure 108 can include carbon fiber or high-density wood, for example. The sole structure 108 can also include any combination or pattern of cleats 116 or of other ground engaging members (e.g., spikes, teeth, and barbs) extending from the sole structure 108 to aid in traction.

In some embodiments, the sole structure may include one or more cushioning members (not shown) that may be made of an EVA-Solid-Sponge (“ESS”) material, an EVA foam (e.g., PUMA® ProFoam Lite™, IGNITE Foam), polyurethane, polyether, an olefin block copolymer, a thermoplastic material (e.g., a thermoplastic polyurethane, a thermoplastic elastomer, a thermoplastic polyolefin, etc.), or a supercritical foam. Further, the one or more cushioning members may be of a single polymeric material or may be of a blend of materials, such as an EVA copolymer, a thermoplastic polyurethane, a polyether block amide (PEBA) copolymer, and/or an olefin block copolymer. One example of a PEBA material is PEBAX®. Additionally, the sole structure 108 may include a separate outsole. For example, in some embodiments, a sole structure used in a generic athletic shoe may include an outsole for traction for a user. The upper 104 is connected to an upper portion of the sole structure 108. As best shown in FIG. 3, the upper 104 includes a base layer 148 and a top layer 152 that are partially connected such that a void 156 is formed between the base layer 148 and the top layer 152.

Referring to FIGS. 4-12, the upper 104 is shown separated from the article of footwear 100. In FIGS. 4-12 the upper 104 is configured to be in a planar position with the toe end 132 being located on the bottom of each respective figure, the lateral side 140 being at the left side of each respective figure, and the medial side 144 being at the right side of each respective figure. FIG. 4 shows the upper 104 in a first configuration 160, which includes only a first layer 164 of the base layer 148. The first layer 164 is configured to be positioned such that a bottom side of the first layer 164 directly faces the interior cavity 112 of the article of footwear 100. The first layer 164 comprises a first section 168 that is positioned generally in the forefoot region 120 and a second section 172 that is positioned generally in the midfoot region 124 and heel region 128. The first section 168 has a “U” like shape and the second section 172 has a “V” like shape. The heel end 136 of the first section 168 is shaped to receive the toe end 132 of the second section 172.

The first section 168 and the second section 172 can be coupled together by sewing, gluing, heat pressing, or any other manufacturing practice known in the art. The first section 168 located in the forefoot region 120 comprises an elastane material or any other spandex-like fabric (e.g., Lycra®). In some embodiments, the use of an elastane material can provide a user with a sock-like fit and secure the foot within the article of footwear 100. The second section 172 located in the midfoot region 124 and heel region 128 comprises a knitted material. A knitted material is a knit or a knitted textile, which includes textiles formed by way of warp knitting, weft knitting, flat knitting, circular knitting, and/or other suitable knitting operations. Further, a knitted material or textile may have a plain knit structure, a mesh knit structure, and/or a rib knit structure, for example.

In some embodiments, the first section 168 and the second section 172 are both made of an elastane material and may be formed as a unitary component. In some embodiments, both the first and second sections 168, 172 are made out of a knitted material and may be formed as a unitary component. In some embodiments, one or both of the first and second sections 168, 172 may be made out of a woven textile and/or a non-woven textile. Woven textiles include, but are not limited to, textiles formed by way of any of the numerous weave forms, such as plain weave, twill weave, satin weave, dobbin weave, jacquard weave, double weaves, and/or double cloth weaves, for example. Non-woven textiles include textiles made by air-laid and/or spun-laid methods, for example. Textiles may comprise a variety of materials, such as a first yarn, a second yarn, and/or a third yarn, which may have varying properties or varying visual characteristics. In some embodiments, the first and second sections 168, 172 may be made from a combination of multiple elements (e.g., textiles, polymer foam, polymer sheets, leather, and synthetic leather) that are joined through bonding or stitching at a seam.

Referring to FIG. 5, the upper 104 is shown in a second configuration 176 that includes the first layer 164 and a second layer 180 of the base layer 148. The second layer 180 is provided on the top of the first layer 164 such that the second layer 180 extends away from the interior cavity 112 of the article of footwear 100. The second layer 180 includes a series of cushioning elements 184. The cushioning elements 184 are arranged in a cushioning element pattern 188 that is located entirely along the first section 168 of the first layer 164. As further discussed below, the cushioning elements 184 may be arranged in a cushioning element pattern 188 that is located on both the first and second sections 168, 172 of the base layer 148. Further, a cushioning element pattern may include cushioning elements 184 located on both sides of the base layer 148 such that some of the cushioning elements 184 extend inwardly, toward the interior cavity 112, and some of the cushioning elements 184 extend outwardly, away from the interior cavity 112.

As best shown in FIG. 7, which illustrates an enlarged view of a portion 190 shown in FIG. 5, each of the individual cushioning elements 184 defines a major axis 192, a minor axis 196, and a depth 200 (see FIG. 8). Here, the major axis 192, i.e., the axis defined along the longer of the two sides of each respective cushioning element 184, is the width of each respective cushioning element 184. Further, the minor axis 196, i.e., the axis defined along the shorter of the two sides of each respective cushioning element 184, is the height of each respective cushioning element 184. As discussed below, a major axis 192 may correspond with a height of a cushioning element 184 and a minor axis 196 may correspond with a width of a cushioning element 184.

For the cushioning elements 184 in FIGS. 1-13, the major axis 192 is measured from a point on the lateral side 140 of the cushioning element 184 to a point on the medial side 144 of the cushioning element 184. Further, the minor axis 196, which is consistent with the height, is measured from the toe end 132 to the heel end 136 through a midpoint 202 of the major axis 192, which is a point about halfway between the lateral side 140 of the cushioning element 184 and the medial side 144 of the cushioning element 184. The major axis 192 is measured orthogonally with respect to the minor axis 196. As best shown in FIG. 8, the depth 200 is shown via an enlarged cross-sectional schematic taken along plane 8-8 of FIG. 7, and is measured from a centrally located inner point of the cushioning element 184 to a centrally located outer point of the cushioning element 184. An average depth is taken as an average of the depths measured along the entire width, i.e., along the entire length of the major axis 192, of the cushioning element 184.

Referring to FIGS. 5-7, the cushioning elements 184 can define a variety of shapes, sizes, and orientations. The cushioning elements 184 can include a range of major axis 192 lengths that can range between about 0.1 centimeter and about 30 centimeters, or between about 1 centimeter and about 3 centimeters, or between about 2 centimeters and about 4 centimeters, or between about 3 centimeters and about 5 centimeters, or between about 4 centimeters and about 6 centimeters, or between about 6 centimeters and about 10 centimeters, or between about 10 centimeters and about 20 centimeters, or between about 15 centimeters and about 25 centimeters, or between about 20 centimeters and about 30 centimeters.

The cushioning elements 184 can also include a range of minor axis 196 lengths that can range between about 0.1 centimeter and about 30 centimeters, or between about 1 centimeter and about 3 centimeters, or between about 2 centimeters and about 4 centimeters, or between about 3 centimeters and about 5 centimeters, or between about 4 centimeters and about 6 centimeters, or between about 6 centimeters and about 10 centimeters, or between about 10 centimeters and about 20 centimeters, or between about 15 centimeters and about 25 centimeters.

Further, the cushioning elements 184 can also include a range of depths 200 that can be between about 0.2 millimeters and about 4 millimeters, or between about 0.4 millimeters and about 3 millimeters, or between about 0.6 millimeters and about 2 millimeters, or between about 0.8 millimeters and about 1 millimeter. In some embodiments, the depth 200 of the cushioning elements 184 can be between about 1.5 millimeters and about 2.5 millimeters, or between about 1.8 millimeters and about 2.2 millimeters, or about 2 millimeters. In some embodiments, the depth 200 of the cushioning element 184 may be variable across the cushioning element 184. In some embodiments, the depth 200 may be the same across the cushioning element 184.

As best shown in FIG. 7, the cushioning elements 184 can be provided as ellipse-like shapes that include a rounded lateral side 204 and a rounded medial side 208. Connecting the rounded lateral and medial sides 204, 208 are a curved heal side 210 and a curved toe side 212. The curved heel side 210 and the curved toe side 212 each curve in a similar manner such that a consistent height, i.e., minor axis length, is provided as the cushioning elements 184 extend between the rounded lateral side 204 and the rounded medial side 208 of each respective cushioning element 184. The cushioning elements 184 can have a variety of orientations. For example, the cushioning elements 184 on the left side of plane 8-8 in FIG. 7 are shown to be oriented such that the curved heel side 210 and the curved toe side 212 curve downward to the toe end 132. The cushioning element 184, in this orientation, is further defined as having a concave shape toward the toe end 132 and a convex shape toward the heel end 136.

On the right side of the plane 8-8, the curved heel side 210 and the curved toe side 212 curve upward to the heel end 136. Accordingly, in this orientation, the cushioning element 184 has a convex shape toward the toe end 132 and a concave shape toward the heel end 136. In certain instances, all of the cushioning elements 184 of the second layer 180 may resemble the same convex shape or concave shape in the same respective direction as one another. A level of curvature, (e.g., degree of radii of the curved heel side 210 and curved toe side 212), for each cushioning element 184 can further define the general shape of the cushioning element 184. Particularly, the second layer 180 may include cushioning elements 184 that have dissimilar radii of curvature. For example, the cushioning elements 184 near the toe end 132 or within the toe region 120 (see FIG. 5) may generally have a larger radius of curvature on the curved heel and toe sides 210, 212 than the cushioning elements 184 positioned near a heel end 136 or within a midfoot and heel region 124, 128 (see FIG. 5). Additionally, the cushioning elements 184 on the lateral side 140 may generally have a larger radius of curvature on the curved heel and toe sides 210, 212 than the cushioning elements 184 on the medial side, or vice versa. Alternatively, all of the cushioning elements 184 may generally have the same radius of curvature on the respective curved heel and toe sides 210, 212.

In some embodiments, the curved heel and toe sides 210, 212 may be straight or curve outward from one another such that the cushioning element 184 has an ellipse-like shape. In some embodiments, the cushioning element 184 may be rectangular and not include a radius of curvature on any of the heel side 210, the toe side 212, the rounded lateral side 204, and the rounded medial side 208. In some embodiments, the cushioning element 184 may include heel and toe sides 210, 212 that include undulations as the heel and toe sides 210, 212 extend from the rounded lateral side 204 to the rounded medial side 208.

Referring back to FIG. 5, the cushioning element pattern 188 extends across the forefoot region 120 and the midfoot region 124 of the upper 104. The cushioning element pattern 188 includes a plurality of rows 224 that extend from the lateral side 140 to the medial side 144. Each row 224 can include between one and about ten individual cushioning elements 184 that are separated by a space 228. In some embodiments, each row 224 can include more than ten cushioning elements 184 that are separated by spaces 228. In some embodiments, the row 224 may only include one cushioning element 184.

As shown in FIG. 7, the spaces 228 are measured along an axis 232 that extends between the lateral side 140 of a first cushioning element 184 and the medial side 144 of a second cushioning element 184 that is directly adjacent to the first cushioning element 184 and in the same row 224 (see FIG. 5) as the first cushioning element 184. The spaces 228 can be of similar lengths as the major and minor axes 192, 196. Referring again to the cushion element pattern 188 as a whole, the pattern 188 may include at least thirty rows 224. In some embodiments the pattern 188 may include fewer than 30 rows 224 or more than 30 rows 224. In some embodiments, the cushioning element pattern 188 may include between 25 and 35 rows 224. In some embodiments, the cushioning element pattern 188 may have between 20 and 30 rows 224, or the cushioning element pattern 188 may have between about 15 and 25 rows 224, or the cushioning element pattern 188 may have between five and 15 rows 224, or the cushioning element pattern 188 may have between one and 10 rows 224. In some embodiments, the cushioning element pattern 188 may have more rows 224 on the lateral side 140 than the medial side 144. In some embodiments, the cushioning element pattern 188 may have more rows 224 on the medial side 144 than on the lateral side 140. In some embodiments, the cushioning element pattern 188 may have the same number of rows on the lateral side 140 as the cushioning element pattern 188 has on the medial side 144.

The rows 224 of cushioning elements 184 that extend from the lateral side 140 to the medial side 144 of the upper 104 are separated by gaps 236 that extend from the toe end 132 to the heel end 136. The gaps 236 are measured between a first cushioning element 184 located in a first row 224 and a second cushioning element 184 located in a second row 224 that is directly adjacent to the first row 224. The gaps are also measured along an axis 240 that extends between the toe end 132 of the first cushioning element 184 and the heel end 136 of the second cushioning element 184. The cushioning element pattern 188 includes rows 224 of cushioning elements 184 and gaps 236 that are arranged to allow the forefoot and midfoot regions 120, 124 (see FIG. 5) of the base layer 148 and the upper 104 to flex in strategic locations. The gaps 236 between respective rows 224 of cushioning elements 184 create flex zones, i.e., portions of the upper 104 that are more flexible than the portions of the upper 104 that have the second layer 180 since the added layer of the cushioning element 184 reduces the amount of flexibility for the respective portion of the upper 104. The gaps 236 are located strategically throughout the base layer 148 along areas that have been identified as zones where the upper 104 is likely to bend during normal use of the article of footwear 100.

Now referring to FIG. 9, the upper 104 is shown in a third configuration 244 that includes the first and second layers 164, 180 of the base layer 148, and a first layer 248 of the top layer 152 that is partially connected to the base layer 148. In the present embodiment, the first layer 248 of the top layer 152 is made of synthetic suede. In some embodiments, the first layer 248 of the top layer 152 may be made of any sport-like material or any other fabric-like material. The first layer 248 of the top layer 152 extends around the forefoot and midfoot regions 120, 124 of the upper 104 and includes a large aperture 252 in the forefoot and midfoot regions 120, 124 of the first layer 248 such that some of the cushion elements 184 and the base layer 148 are exposed. The first layer 248 of the top layer 152 and the base layer 148 are attached to one another in the forefoot region 120 and the first layer 248 of the top layer 152 is not attached to the base layer 148 in the midfoot region 124 such that the base layer 148 and the top layer 152 are partially connected to create the void 156 (see FIG. 3) between the two layers 148, 152. In some embodiments, the base layer 148 and the top layer 152 are fully connected such that there is no void 156 formed between the base and top layer 148, 152.

Now referring to FIG. 10, the upper 104 is shown in a fourth configuration 256 that includes the base layer 148, and the first layer 248 and a second layer 260 of the top layer 152. The second layer 260 of the top layer 152 is an inner skin that extends across the forefoot and midfoot regions 120, 124 and includes a plurality of triangular apertures 264. The triangular apertures 264 are provided on the inner skin 260 to reduce the amount of material impeding the upper 104 from flexing during the use of the article of footwear 100 by a user. The triangle shape of the triangular apertures 264 provides a reduction in “clicking” noises in comparison to linear apertures along the zones of the upper 104 that bend during normal use of the article of footwear 100. However, in some embodiments, the apertures 264 provided on the inner skin 260 may be a variety of shapes and orientations such as linear apertures, square apertures, rectangular apertures, and/or a combination thereof. Further, in some embodiments, the inner skin 260 may not include any apertures 264. In some embodiments, the upper 104 may not include the second layer 260 of the top layer 152.

Referring now to FIG. 11, the upper 104 is shown in a fifth configuration 266 that includes the base layer 148 and the first layer 248, the second layer 260, and a third layer 268 of the top layer 152. The third layer 268 is provided as a single mesh layer with polyester and monoyarns. The third layer 268 includes transparent rows 272 and opaque rows 276. In some embodiments, the third layer 268 may be completely opaque or completely transparent. In some embodiments, the third layer 268 may be translucent. In some embodiments, the third layer 268 may be made of a combination of open and closed mesh. In some embodiments, the upper 104 may not include the third layer 268.

Referring now to FIG. 12, the upper 104 is shown in a sixth configuration 280 that includes the base layer 148 and the first layer 248, the second layer 260, the third layer 268, and a fourth layer 284 of the top layer 152. The fourth layer 284 of the top layer 152 is an outer skin and configured to be the outermost layer of the upper 104 such that it is configured to directly face the environment surrounding the article of footwear 100. The fourth layer 284 is shown to be opaque, but in some embodiments the fourth layer 284 may be transparent, translucent, or a combination thereof. The fourth layer 284, i.e., the outer skin, is made of polyurethane and may include ridges (not shown) that are provided to aid a user in controlling a soccer ball when a user kicks the soccer ball. In some embodiments, the fourth layer 284 may not include ridges.

FIG. 13 shows an illustrative schematic cross-sectional view taken along plane 13-13 of FIG. 12 after the base layer 148 and the top layer 152 are attached to one another. In some embodiments, the respective layers 164, 180, 248, 260, 268, 284 are heat pressed together. In some embodiments, adhesive or sewing is used to attach the various layers together. In some embodiments, a combination of methods are used to attach each respective layer. As shown in FIG. 13, the void 156 is provided between portions of the first and second layers 164, 180 of the base layer 148 and the second layer 260 of the top layer 152. Further, although the base layer 148 is shown to have two layers and the top layer 152 is shown to have four layers, the upper 104 in some embodiments may have one or more than two layers for the base layer 148 and fewer than four or more than four layers for the top layer 152.

FIG. 14 shows another embodiment of a base layer 348 of an upper 304 for an article of footwear (not shown). In many aspects, the base layer 348 is similar to the base layer 148 described above and similar numbering in the series is used for the base layer 348. Additionally, the base layer 348 could be used in combination with the top layer 152 of the upper 104 as part of the article of footwear 100. Further, the base layer 348 includes a forefoot region 320, a midfoot region 324, a heel region 328, a toe end 332, a heel end 336, a lateral side 340, and a medial side 344. Still further, the base layer 348 includes a first layer 364 that includes a first section 368 made of an elastane material and a second section 372 made of a knitted material. Additionally, the base layer 348 includes a second layer 380 that includes cushioning elements 384 that may be made of the same material and include the same dimension ranges as the cushioning elements 184 of the base layer 148 of upper 104.

In some aspects, however, the base layers 148, 348 differ from one another. For example, the first section 368 of the base layer 348 extends into the midfoot region 324 on the lateral side 340, but does not significantly extend (or extend at all) into the midfoot region 324 on the medial side 344. Further, the second section 372 of the first layer 364 extends into the forefoot region 320 halfway between the lateral and medial sides 340, 344. Additionally, as shown in FIG. 14, the cushioning elements 384 provided as the second layer 380 of the base layer 348 are arranged in a cushioning element pattern 388 that differs from the pattern 188. The cushioning element pattern 388 includes a first group of cushioning elements 392, a second group of cushioning elements 396, and a third group of cushioning elements 400. The first group of cushioning elements 392 is located within the forefoot and midfoot regions 320, 324 on the lateral side 340 and includes cushioning elements 384 that are arranged in a first series of curved columns 404 that extend from the toe end 332 of the forefoot region 320 to the lateral side 340 of the midfoot region 324. The second group of cushioning elements 396 is located within the forefoot region 320 on the medial side 344 and includes a second series of curved columns 408 that extend from the toe end 332 of the forefoot region 320 to the medial side 344 of the forefoot region 320. The third group of cushioning elements 400 includes a series of rows 412 that extend across the forefoot and midfoot regions 320, 324. The rows 412 create a V-like pattern as each row 412 extends from the lateral side 340 to the medial side 344. On the far medial side 344, the rows 412 curve back toward the toe end 332.

As best shown in FIG. 15, which shows an enlarged view of a portion 414 of FIG. 14, the cushioning elements 384 that are included in the cushioning element pattern 388 include a series of cushioning element subsections 416 that allow the cushioning element 384 to more easily flex when compared with a cushioning element 384 without a series of cushioning element subsections 416. As shown, the cushioning element subsections 416 can be interconnected subsections 418 that are configured to be connected to one or more interconnected subsections 418 to form a cushioning element 384. Additionally, the cushioning element subsections 416 can be located in close proximity to one or more cushioning element subsections 416 to form a cushioning element 384. As best shown with the cushioning element subsections 416 that are not interconnected, the cushioning element subsections 416 are oval shaped since the cushioning element subsections 416 include two rounded sides located on opposing sides that are connected with two straight sides.

FIG. 16 shows another embodiment of a base layer 548 of an upper 504 for an article of footwear (not shown). In many aspects, the base layer 548 is similar to the base layers 148 and 348 described above and similar numbering in the series is used for the base layer 548. Additionally, the base layer 548 could be used in combination with the top layer 152 of the upper 104 as part of the article of footwear 100. Further, the base layer 548 includes a forefoot region 520, a midfoot region 524, a heel region 528, a toe end 532, a heel end 536, a lateral side 540, and a medial side 544. Still further, the base layer 548 includes a first layer 564 that includes a first section 568 made of an elastane material and a second section 572 made of a knitted material. Additionally, the base layer 548 includes a second layer 580 that includes cushioning elements 584 that may be made of the same material and include the same dimension ranges as the cushioning elements 184, 384 of the base layers 148, 348.

In some aspects, however, the base layers 148, 348, 548 differ from one another. For example, the cushioning elements 584 provided as the second layer 580 of the base layer 548 are arranged in a cushioning element pattern 588 that differs from the patterns 188, 388. In a similar fashion as the cushioning element pattern 388, the cushioning element pattern 588 includes a first group of cushioning elements 592, a second group of cushioning elements 596, and a third group of cushioning elements 600. The first group of cushioning elements 592 is located within the forefoot and midfoot regions 520, 524 on the lateral side 540 and includes cushioning elements 584 that are arranged in a first series of curved columns 604 that extend from the toe end 532 of the forefoot region 520 to the lateral side 540 of the midfoot region 524, which is similar to the cushioning element pattern 388.

The second group of cushioning elements 596 of the cushioning elements 584 is located within the forefoot region 520 on the medial side 544 and includes a second series of curved columns 608 that extend from the toe end 532 of the forefoot region 520 to the medial side 544 of the forefoot region 520. The third group of cushioning elements 600 of the cushioning element pattern 588 includes a series of rows 612 that extend across the forefoot and midfoot regions 320, 324. The rows 612 create a “V” like pattern as each row 612 extends from the lateral side 540 to the medial side 544. On the far medial side 544, the rows 612 curve back toward the toe end 532. However, in the cushioning element pattern 588, there are fewer rows 612 provided in the third group of cushioning elements 600 when compared to the third group of cushioning elements 400 of the cushioning pattern 388.

FIG. 17 shows another embodiment of a base layer 748 of an upper 704 for an article of footwear (not shown). In many aspects, the base layer 748 is similar to the base layers 148, 348, and 548 described above and similar numbering in the series is used for the base layer 748. Additionally, the base layer 748 could be used in combination with the top layer 152 of the upper 104 as part of the article of footwear 100. Further, the base layer 748 includes a forefoot region 720, a midfoot region 724, a heel region 728, a toe end 732, a heel end 736, a lateral side 740, and a medial side 744. Still further, the base layer 748 includes a first layer 764 that includes a first section 768 made of an elastane material and a second section 772 made of a knitted material. Additionally, the base layer 748 includes a second layer 780 that includes cushioning elements 784 that may be made of the same material and include the same dimension ranges as the cushioning elements 184, 384, 584 of the base layers 148, 348, 548.

In some aspects, however, the base layers 148, 348, 548, and 748 differ from one another. For example, the base layer 748 includes ribbed knitting 792 in the second section 772 of the first layer 764. The ribbed knitting 792 extends across the midfoot region 724 in a plurality of rows that have undulations that form a wave like pattern. The ribbed knitting 792 is provided as a tubelike structure that protrudes from the knitted material of the second section 772. The ribbed knitting 792 is provided to add additional cushioning to a user's foot when the article of footwear (not shown) is used to contact a ball.

FIGS. 18-21 show another embodiment of a base layer 848 of an upper 804 of an article of footwear (not shown). In many aspects, the base layer 848 is similar to the base layers 148, 348, 548, and 748 described above and similar numbering in the series is used for the base layer 848. Additionally, the base layer 848 could be used in combination with the top layer 152 of the upper 104 as part of the article of footwear 100. Further, the base layer 848 includes a forefoot region 820, a midfoot region 824, a toe end 832, a heel end 836, a lateral side 840, and a medial side 844. Still further, the base layer 848 includes a first layer 864 that includes a first section 868 made of an elastane material and a second section (not shown) made of a knitted material. Additionally, the base layer 848 includes a second layer 880 that includes cushioning elements 884 that may be made of the same material and include the same dimension ranges as the cushioning elements 184, 384, 584, 784 of the base layers 148, 348, 548, 748.

In some aspects, however, the base layers 148, 348, 548, 748, and 848 differ from one another since the second layer 880 of the base layer 848 is provided as a series of cushioning elements 884 with at least one cushioning element 884 located on an internal side of the first layer 864 and at least one cushioning element 884 located on an external side of the first layer 864. FIG. 18 shows a top view of the base layer 848 such that the cushioning elements 884 that are located on the external facing side of the base layer 848 are visible. FIG. 19 shows a rear view of the base layer 848 such that the cushioning elements 884 that are located on the internal facing side of the base layer 848 are visible. FIG. 20 shows the base layer 848 in a configuration where the first layer 864 is transparent such that the cushioning elements 884 located on the internal and external sides of the base layer 848 can be seen together.

As shown in FIG. 20, the cushioning elements 884 provided on the internal and external sides of the first layer 864 are located such that the cushioning elements 884 form a cushioning elements pattern 888 where most of the internal and external cushioning elements 884 do not overlap one another. In some embodiments, most of the internal and external cushioning elements 884 may overlap one another. FIG. 21 shows a schematic cross-sectional view of the base layer 848. In this embodiment, the cushioning elements 884 are provided with an ellipse-shaped cross section. However, some embodiments with cushioning elements 884 may include a rectangular, square, circular, or another geometric shape. Further, the first layer 864 is shown to include an optional first sublayer 892 and a second sublayer 896 that are both made of an elastane material. The optional first sublayer 892 is provided to form a barrier between the internal facing cushioning elements 884 and a user's foot. The second sublayer 896 is provided to serve the same role as the first layers 164, 364, 564, and 764, which are discussed above.

FIGS. 22-24 show another embodiment of a base layer 948 of an upper 904 of an article of footwear (not shown). In many aspects, the base layer 948 is similar to the base layer 148, 348, 548, 748, and 848 described above and similar numbering in the series is used for the base layer 948. Additionally, the base layer 948 could be used in combination with the top layer 152 of the upper 104 as part of the article of footwear 100. Further, the base layer 948 includes a forefoot region 920, a midfoot region 924, a heel region 928, a toe end 932, a heel end 936, a lateral side 940, and a medial side 944. Still further, the base layer 948 includes a first layer 964 that includes a first section 968 made of an elastane material and a second section 972 made of a knitted material. Additionally, the base layer 948 includes a second layer 980 that includes cushioning elements 984 that may be made of the same material and include the same dimension ranges as the cushioning elements 184, 384, 584, 784, 884 of the base layers 148, 348, 548, 748, 848.

In some aspects, however, the base layers 148, 348, 548, 748, 848, and 948 differ from one another. For example, as best shown in FIG. 23, the base layer 948 includes cushioning elements 984 that are located on an internal side of the first layer 964. The cushioning elements 984 located on the internal side of the first layer 964 define a series of cushioning element columns 992. Each of the columns of the series of cushioning element columns 992 comprises a single cushioning element 984, which is possible due to the large size of each respective cushioning element 984. Each of the cushioning elements 984 are separated by a gap 996. FIG. 24 shows the base layer 948 in a configuration where the first layer 964 is transparent such that the cushioning elements 984 located on the internal and external sides of the base layer 948 can be seen together.

FIG. 25 shows another embodiment of a third layer 1168 of a top layer 1052 of an upper 1004 for an article of footwear (not shown). In many aspects the third layer 1168 is similar to the third layer 268 of the top layer 152 of the upper 104 that is for the article of footwear 100 described above and similar numbering in the series is used for the third layer 1168. Additionally, the third layer 1168 could be used in combination with any of the base layers 148, 348, 548, 748, 848, and 948 described above. Further, the third layer 1168 includes a forefoot region 1020, a midfoot region 1024, a toe end 1032, a heel end 1036, a lateral side 1040, and a medial side 1044.

In some aspects, however, the third layers 268, 1168 differ from one another. For example, the third layer 1168 is made of open mesh and extends across the entire forefoot region 1020 and midfoot region 1024 of the third layer 1168. The third layer 1168 includes a series of open mesh sections 1092 provided as rows that extend across the forefoot region 1020 and midfoot region 1024. In some embodiments, the open mesh sections 1092 may not be included in the third layer 1168 such that the sections 1092 are provided as apertures. In some embodiments, different types of open mesh made be provided in each respective section 1092.

FIG. 26 shows another embodiment of a third layer 1368 of a top layer 1252 of an upper 1204 for an article of footwear (not shown). In many aspects the third layer 1368 is similar to the third layer 268 of the top layer 152 of the upper 104 that is for the article of footwear 100 described. Additionally, the third layer 1368 is similar to the third layer 1168 described above. Similar numbering in the series is used for the third layer 1368 as was used for the third layers 268 and 1168. The third layer 1368 could be used in combination with any of the base layers 148, 348, 548, 748, 848, and 948 described above. Further, the third layer 1368 includes a forefoot region 1220, a midfoot region 1224, a heel region 1228, a toe end 1232, a heel end 1236, a lateral side 1240, and a medial side 1244.

In some aspects, however, the third layers 268, 1168, 1368 differ from one another. For example, the third layer 1368 includes a series of printed ridges 1292 that extend across the forefoot and midfoot regions 1220, 1224. The ridges 1292 each define a depth that is measured from a centrally located internal point to a centrally located external point. The ridges 1292 can include variable depths such that some of the ridges 1292 may have a depth of about 0.4 millimeters and some of the ridges 1292 may have a depth of about 0.8 millimeters. In some embodiments, each of the ridges 1292 may all have the same depths. In some of the embodiments, the ridges 1292 may have a depth between about 0.1 millimeters and 1.5 millimeters, or between about 0.3 millimeters and about 1.2 millimeters, or between about 0.5 millimeters and about 0.8 millimeters. In some embodiments, the ridges may have a depth of about 0.4 millimeters, about 0.6 millimeters, or about 0.8 millimeters. In some embodiments, the ridges 1292 may be screen printed or 3D printed onto the third layer 1368, which may be constructed from open and/or closed mesh. In some embodiments, the ridges 1292 may be printed on a clear skin (not shown) and then vacuumed on the mesh of the third layer 1368.

FIG. 27 shows another embodiment of a fourth layer 1584, i.e., an outer skin, of a top layer 1452 of an upper 1404 for an article of footwear (not shown). In many aspects, the fourth layer 1584 is similar to the fourth layer 284, of the top layer 152 of the upper 104 that is for the article of footwear 100 described above and similar numbering in the series is used for the fourth layer 1584. Additionally, the fourth layer 1584 could be used in combination with any of the base layers 148, 348, 548, 748, 848, and 948 described above. The fourth layer 1584 can be used with any of the third layers 268, 1168, 1368 described above. Further, the fourth layer 1584 includes a forefoot region 1420, a midfoot region 1424, a heel region 1428, a toe end 1432, a heel end 1436, a lateral side 1440, and a medial side 1444.

In some aspects, however, the fourth layers 284, 1584 differ from one another. For example, the fourth layer 1584 includes a series of printed ridges 1492 that extend across the forefoot and midfoot regions 1420, 1424 in a wave like pattern.

In other embodiments, other configurations are possible. For example, certain features and combinations of features that are presented with respect to particular embodiments in the discussion above can be utilized in other embodiments and in other combinations, as appropriate. Further, any of the embodiments described herein may be modified to include any of the structures or methodologies disclosed in connection with other embodiments. Additionally, the present disclosure is not limited to articles of footwear of the type specifically shown. Still further, aspects of the articles of footwear of any of the embodiments disclosed herein may be modified to work with any type of footwear, apparel, or other athletic equipment.

As noted previously, it will be appreciated by those skilled in the art that while the invention has been described above in connection with particular embodiments and examples, the invention is not necessarily so limited, and that numerous other embodiments, examples, uses, modifications and departures from the embodiments, examples and uses are intended to be encompassed by the claims attached hereto. The entire disclosure of each patent and publication cited herein is incorporated by reference, as if each such patent or publication were individually incorporated by reference herein. Various features and advantages of the invention are set forth in the following claims.

INDUSTRIAL APPLICABILITY

Numerous modifications to the present invention will be apparent to those skilled in the art in view of the foregoing description. Accordingly, this description is to be construed as illustrative only and is presented for the purpose of enabling those skilled in the art to make and use the invention. The exclusive rights to all modifications which come within the scope of the appended claims are reserved.