Mechanical lock sole structure for braided footwear

Patent metadata

Field	Value
Publication number	US-11547171-B2
Application number	US-202117172531-A
Country	US
Kind code	B2
Filing date	Feb 10, 2021
Priority date	May 30, 2017
Publication date	Jan 10, 2023
Grant date	Jan 10, 2023

Abstract

Present aspects are directed to an interlocking braided shoe and midsole system comprising a midsole insert having a plurality of protruding studs and a braided upper comprising a tubular containment structure. The tubular containment structure has a first zone comprising a first braid density and first braid configuration defining a plurality of apertures located on a top surface of the braided upper and a second zone having a second braid density and a second braid configuration defining a plurality of apertures located on the bottom surface of the braided upper. The plurality of apertures of the second braid configuration correspond to the plurality of protruding studs such that the plurality of protruding studs extend below an exterior surface of the braided upper through the plurality of apertures of the second braided configuration, coupling the bottom surface of the midsole insert with the braided upper.

First claim

The invention claimed is:

1. An interlocking braided shoe and midsole system comprising:
a midsole insert comprising a toe end opposite a heel end, a top planar surface opposite a bottom planar surface and a plurality of protruding studs extending below the bottom planar surface on at least a portion of the midsole insert, the midsole insert having a perimeter corresponding to a shoe bottom; and
a braided upper comprising a tubular containment structure having an ankle opening, a toe end, a heel end opposite the toe end, a top portion and a bottom surface, an internal cavity, an interior surface and an exterior surface, a first zone having a first braid density and a first braid configuration that defines a plurality of apertures located on the top portion of the braided upper and extending from the interior surface to the exterior surface, and a second zone having a second braid density and a second braid configuration that defines a plurality of apertures located on the bottom surface of the braided upper and extending from the interior surface to the exterior surface, wherein at least a portion of the tubular containment structure is braided to surround a perimeter of each of the plurality of apertures of the first braid configuration and the second braid configuration,
wherein the plurality of apertures of the second braid configuration corresponds to the plurality of protruding studs such that the plurality of protruding studs extend below the exterior surface of the braided upper through the plurality of apertures of the second braid configuration thereby coupling the bottom planar surface of the midsole insert with the braided upper to provide a 360-degree containment of each of the plurality of protruding studs, and further wherein each of the plurality of protruding studs comprises a ground-contacting outer sole that extends below the exterior surface of the braided upper.

2. The interlocking braided shoe and midsole system of claim 1 , wherein the plurality of protruding studs are located in one or more configurations within the perimeter of the midsole insert.

3. The interlocking braided shoe and midsole system of claim 1 , wherein the internal cavity encloses at least a portion of the midsole insert.

4. The interlocking braided shoe and midsole system of claim 3 , wherein the internal cavity comprises the plurality of apertures of the second braid configuration contacting at least a portion of the bottom planar surface of the midsole insert.

5. The interlocking braided shoe and midsole system of claim 1 , wherein each of the plurality of protruding studs extends below the bottom planar surface of the midsole insert a threshold distance.

6. The interlocking braided shoe and midsole system of claim 1 , wherein the first braid density and the second braid density comprise yarns of at least one or more materials.

7. The interlocking braided shoe and midsole system of claim 1 , wherein the at least a portion of the midsole insert is pre-molded with the plurality of protruding studs prior to being contained by the plurality of apertures of the first braid configuration and the second braid configuration of the braided upper.

8. The interlocking braided shoe and midsole system of claim 1 , wherein the plurality of protruding studs extending below the bottom planar surface are positioned on one or more of the toe end of the midsole insert, the heel end of the midsole insert, and across an entire bottom surface of the midsole insert.

9. The interlocking braided shoe and midsole system of claim 1 , wherein the plurality of protruding studs are keyed such that at least a portion of each of the plurality of protruding studs intersects the braided upper at a corresponding aperture of the second braid configuration proximate a horizontal plane of the braided upper, wherein each corresponding aperture encircles each intersecting, protruding stud.

10. The interlocking braided shoe and midsole system of claim 1 , further comprising a sprayed outsole, the sprayed outsole comprising a spray component applied to both the plurality of protruding studs extending below the bottom planar surface of the midsole insert and the exterior surface of the braided upper.

11. The interlocking braided shoe and midsole system of claim 10 , wherein the spray component comprises a polyurethane material.

12. The interlocking braided shoe and midsole system of claim 1 , wherein the midsole insert comprises one or more of a rubber material and an ethylene-vinyl acetate (EVA) material.

13. The interlocking braided shoe and midsole system of claim 1 , wherein the braided upper is formed from one or more of a nylon, carbon, polyurethane, polyester, cotton, aramid, polyethylene, and polypropylene yarns.

14. The interlocking braided shoe and midsole system of claim 1 , wherein the ground-contacting outer sole comprises a non-compressible material that maintains a first configuration upon ground contact.

15. The interlocking braided shoe and midsole system of claim 1 , wherein providing the 360-degree containment of each of the plurality of protruding studs comprises at least a portion of the tubular containment structure abutting a circumference of each of the plurality of protruding studs.

16. The interlocking braided shoe and midsole system of claim 1 , wherein the plurality of protruding studs comprises at least one of a uniform shape, a uniform height, and a uniform width.

17. The interlocking braided shoe and midsole system of claim 1 , wherein the midsole insert comprises a co-molded midsole.

18. The interlocking braided shoe and midsole system of claim 17 , wherein the co-molded midsole is flexibly joined with the braided upper during a three-dimensional assembly.

19. The interlocking braided shoe and midsole system of claim 1 , wherein the first braid density has different structural properties than the second braid density.

20. The interlocking braided shoe and midsole system of claim 1 , wherein the first braid density of the first zone is tighter and more dense than the second braid density of the second zone.

Assignees

• Nike Inc

Inventors

• Bruce Robert M
• Lee Eun Kyung

Classifications

• A43B9/00

  Footwear characterised by the assembling of the individual parts · CPC title

• A43B23/0245

  characterised by the constructive form · CPC title

• A43B3/244

  characterised by the attachment between upper and sole · CPC title

• A43B5/06

  Running shoes; Track shoes · CPC title

• A43B13/12

  Soles with several layers of different materials · CPC title