Vacuum System for Article of Footwear or Apparel

This application claims priority under 35 U.S.C. § 119(e) to U.S. Provisional Application No. 63/572,408, filed on Apr. 1, 2024. The disclosure of this prior application is considered part of the disclosure of this application and is hereby incorporated by reference in its entirety.

The present disclosure relates generally to vacuum system and more particularly to a vacuum system for an article of footwear and/or apparel

This section provides background information related to the present disclosure and is not necessarily prior art.

Articles of footwear conventionally include an upper and a sole structure. The upper may be formed from any suitable material(s) to receive, secure, and support a foot on the sole structure. The upper may cooperate with laces, straps, or other fasteners to adjust the fit of the upper around the foot. A bottom portion of the upper, proximate to a bottom surface of the foot, attaches to the sole structure.

Articles of apparel such as garments and headwear and articles of footwear such as shoes and boots, typically include a receptacle for receiving a body part of a wearer. For example, an article of footwear may include an upper and a sole structure that cooperate to form a receptacle for receiving a foot of a wearer. Likewise, garments and headwear may include one or more pieces of material formed into a receptacle for receiving a torso or head of a wearer.

Articles of apparel or footwear are typically adjustable and/or are formed from a relatively flexible material to allow the article of apparel or footwear to accommodate various sizes of wearers, or to provide different fits on a single wearer. While conventional articles of apparel and articles of footwear are adjustable, such articles do not typically allow a wearer to conform the shape of the article to a body part of the wearer. For example, while clasps and elastic bands adequately secure an article of apparel to a wearer by contracting or constricting a portion of a garment around the wearer's upper body, they do not cause the garment to conform to the user's upper body. Accordingly, an optimum fit of the article of apparel around the upper body is difficult to achieve.

Corresponding reference numerals indicate corresponding parts throughout the drawings.

Example configurations will now be described more fully with reference to the accompanying drawings. Example configurations are provided so that this disclosure will be thorough, and will fully convey the scope of the disclosure to those of ordinary skill in the art. Specific details are set forth such as examples of specific components, devices, and methods, to provide a thorough understanding of configurations of the present disclosure. It will be apparent to those of ordinary skill in the art that specific details need not be employed, that example configurations may be embodied in many different forms, and that the specific details and the example configurations should not be construed to limit the scope of the disclosure.

The terminology used herein is for the purpose of describing particular exemplary configurations only and is not intended to be limiting. As used herein, the singular articles “a,” “an,” and “the” may be intended to include the plural forms as well, unless the context clearly indicates otherwise. The terms “comprises,” “comprising,” “including,” and “having,” are inclusive and therefore specify the presence of features, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, steps, operations, elements, components, and/or groups thereof. The method steps, processes, and operations described herein are not to be construed as necessarily requiring their performance in the particular order discussed or illustrated, unless specifically identified as an order of performance. Additional or alternative steps may be employed.

When an element or layer is referred to as being “on,” “engaged to,” “connected to,” “attached to,” or “coupled to” another element or layer, it may be directly on, engaged, connected, attached, or coupled to the other element or layer, or intervening elements or layers may be present. In contrast, when an element is referred to as being “directly on,” “directly engaged to,” “directly connected to,” “directly attached to,” or “directly coupled to” another element or layer, there may be no intervening elements or layers present. Other words used to describe the relationship between elements should be interpreted in a like fashion (e.g., “between” versus “directly between,” “adjacent” versus “directly adjacent,” etc.). As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items.

The terms first, second, third, etc. may be used herein to describe various elements, components, regions, layers and/or sections. These elements, components, regions, layers and/or sections should not be limited by these terms. These terms may be only used to distinguish one element, component, region, layer or section from another region, layer or section. Terms such as “first,” “second,” and other numerical terms do not imply a sequence or order unless clearly indicated by the context. Thus, a first element, component, region, layer or section discussed below could be termed a second element, component, region, layer or section without departing from the teachings of the example configurations.

In one configuration, an adjustment element for an article of footwear includes a bladder forming an interior void and a compressible component disposed within the interior void and including a first embedded structure tapering in a direction from a first end located at an outer perimeter edge of the compressible component to a second end, the compressible component movable from a first configuration having a first shape to a second configuration having a second shape in response to fluid being removed from the interior void.

The adjustment element may include one or more of the following optional features. For example, the first embedded structure may include a series of peaks and valleys. Peaks and valleys of the series of peaks and valleys may be positioned into individual V-shaped segments. The V-shaped segments may be aligned with one another along a central, longitudinal axis of the first embedded structure, the central, longitudinal axis of the first embedded structure extending through the first end of the first embedded structure and the second end of the first embedded structure. Additionally or alternatively, the V-shaped segments may be nested with one another.

In one configuration, the second end of the first embedded structure may be disposed at an interior location of the compressible component.

The compressible component may include a second embedded structure, the second embedded structure tapering in a direction from a third end located at an outer perimeter edge of the compressible component to a fourth end. In this configuration, the second end of the first embedded structure and the fourth end of the second embedded structure may be in contact with one another at a junction. Further, the first end of the first embedded structure and the third end of the second embedded structure may move toward one another when the compressible component is moved from the first configuration to the second configuration.

An article of footwear may incorporate the adjustment element.

In another configuration, an adjustment element for an article of footwear includes a bladder forming an interior void and a compressible component disposed within the interior void and including a first embedded structure having a series of peaks and valleys, the compressible component movable from a first configuration having a substantially planar profile to a second configuration having a curved profile in response to fluid being removed from the interior void.

The adjustment element may include one or more of the following optional features. For example, the compressible component may be formed from foam.

In one configuration, peaks and valleys of the series of peaks and valleys may be positioned into individual V-shaped segments. The V-shaped segments may be aligned with one another along a central, longitudinal axis of the first embedded structure, the central, longitudinal axis of the first embedded structure extending through a first end of the first embedded structure and a second end of the first embedded structure. Additionally or alternatively, the V-shaped segments may be nested with one another.

The first embedded structure may taper in a direction from a first end located at an outer perimeter edge of the compressible component to a second end. In this configuration, the compressible component may include a second embedded structure, the second embedded structure tapering in a direction from a third end located at an outer perimeter edge of the compressible component to a fourth end. Further, the second end of the first embedded structure and the fourth end of the second embedded structure may be in contact with one another at a junction. Additionally or alternatively, the first end of the first embedded structure and the third end of the second embedded structure may move toward one another when the compressible component is moved from the first configuration to the second configuration to form the curved profile.

An article of footwear may incorporate the adjustment element.

The details of one or more implementations of the disclosure are set forth in the accompanying drawings and the description below. Other aspects, features, and advantages will be apparent from the description, the drawings, and the claims.

Referring to, an article of footwearincludes an upperand a sole structure. The footwearis depicted as an enclosed athletic shoe, such as a tennis, basketball, and/or running shoe. However, it is also contemplated that the article of footwearmay include a sandal, such as a slide having a strap that extends across a foot of the wearer. The footwearmay further include an anterior endassociated with a forward-most point of the footwear, and a posterior endcorresponding to a rearward-most point of the footwear. A medial sideand a lateral siderespectively correspond with opposite sides of the footwearand extend from the anterior endto the posterior end. As used herein, a longitudinal direction refers to the direction extending from the anterior endto the posterior end, while a lateral direction refers to the direction transverse to the longitudinal direction and extending from the medial sideto the lateral side.

The article of footwearmay be divided into one or more regions. The regions may include a forefoot region, a mid-foot region, and a heel region. The forefoot regionis associated with phalanges and metatarsal bones of a foot. The mid-foot regionmay correspond with an arch area of the foot, and the heel regionmay correspond with rear portions of the foot, including a calcaneus bone.

The upperincludes interior surfaces that have an interior spaceand an ankle openingconfigured to receive and secure a foot for support on the sole structure. The upper, and components thereof, may be described as including various subcomponents or regions. For example, the upperincludes a toe capdisposed at the anterior endand extending over the toes from the medial sideto the lateral side. A pair of quarter panelsextend from the toe capin the mid-foot regionon opposite sides of the interior space. A throatextends across the top of the upperand includes an instep region extending between the quarter panelsfrom the toe capto the ankle opening. In the illustrated example, the throatis enclosed, whereby a material panel extends between the opposing quarter panelsin the instep region to cover the interior space. Here, the material panel covering the throatmay optionally be formed of a material having a higher modulus of elasticity than the material forming the quarter panels.

The upperof the article of footwearmay be further described as including heel side panelsextending through the heel regionalong the medial and lateral sides,of the ankle opening. A heel countermay be included and wraps around the posterior endof the footwearand connects the heel side panels. Uppermost edges of the throat, the heel side panels, and the heel countercooperate to form a collar, which includes the ankle openingof the interior space.

The uppermay include an inner bootiethat forms the interior space. The inner bootiemay be formed from one or more materials that are stitched or adhesively bonded together to form the interior space. Suitable materials of the uppermay include, but are not limited to, mesh textiles, foam, leather, and synthetic leather. The materials may be selected and located to impart properties of durability, air-permeability, wear-resistance, flexibility, and comfort. The example bootiemay be formed as an inner liner including a combination of one or more substantially inelastic or non-stretchable materials and/or one or more substantially elastic or stretchable materials disposed in different regions of the bootieto facilitate movement of the article of footwearbetween a tightened state and a loosened state. The one or more elastic materials may include any combination of one or more elastic fabrics such as, without limitation, spandex, elastane, rubber, or neoprene. The one or more inelastic materials may include any combination of one or more thermoplastic polyurethanes, nylon, leather, vinyl, or another material/fabric that does not impart properties of elasticity.

Referring to, an upper-torso article of apparelis illustrated and includes any garment configured to cover an upper-torso of a wearer. The illustrated upper-torso garmentincludes a bra, however the upper-torso article of apparelmay include other types of garments for a male or female, including a strapless bra, a camisole, a base-layer shirt, a singlet, swimwear, and/or other garments with built-in support.

The bramay include an anterior sideassociated with the front of the body of a wearer when the brais in use, and a posterior sideassociated with the back of the body of a wearer when the brais in use. The bramay further include an upper endassociated with the shoulders of the wearer, and a lower endassociated with the ribcage of a wearer. A longitudinal axis Aof the braextends along a height of the brafrom the upper endto the lower endperpendicular to a ground surface, and generally divides the brainto a right sideand a left side. Accordingly, the right sideand the left siderespectively correspond with opposite sides of the braand extend from the upper endto the lower end. As used herein, a longitudinal direction refers to the direction extending from the upper endto the lower end, a sagittal direction refers to the direction transverse to the longitudinal direction and extending from the anterior sideto the posterior side, and a frontal direction refers to the direction extending from the right sideto the left side.

The article of apparelmay be divided into one or more regions. The regions may include a shoulder region, a chest region, and a ribcage regionthat collectively form a body region of the article of apparel. The shoulder regionis associated with the clavicle and scapula bones of a shoulder. The chest regionmay correspond with the true ribs and breast tissue area of an upper-torso, and the ribcage regionmay correspond with the false and floating ribs of an upper-torso.

The brafurther includes an interior space, a neck-receiving opening, a torso-receiving opening, a right arm-receiving opening, and a left arm-receiving opening. As shown in, the neck-receiving openingis disposed on the upper endof the braand the torso-receiving openingis disposed on the lower endof the bra. The neck-receiving openingis further formed by a necklineextending along a perimeter of the neck-receiving opening. Similarly, the torso-receiving openingis further formed by a bandextending along a perimeter of the torso-receiving opening. While the bandis illustrated as being a continuous elastic band (), it may alternatively include two or more band segments connected by a clasp.

The bra, and components thereof, may further be described as including various subcomponents or regions. For example, the braincludes a front panelhaving a right paneldisposed at the anterior sideand extending from the chest regionto the ribcage regionand from the right sidetoward a center bridgedisposed between the right sideand the left side. The front panelfurther includes a left paneldisposed at the anterior sideand extending from the chest regionto the ribcage regionand from the left sidetoward the center bridge. The right paneland the left paneleach include a generally convex or cup shape to accommodate and provide support for the chest of the wearer while in-use.

The bramay further include a back paneland a pair of strapsextending between the anterior sideand the posterior sideof the bra. The back panelwraps across the posterior sidefrom the right sideto the left side, and includes a height that tapers in a direction from the a central region attached to the strapsto each of the respective right sideand left side. The strapsextend from the back paneland generally form a “T” or “Y” shape and, further, extend over the shoulders of the wearer and connect to the anterior sideof the bra.

Referring again to, the footwearand the bramay be collectively referred to herein as an article and/or the article and, unless otherwise specified, discussion regarding the article applies equally to both the footwearand the bra. The article includes an adjustment element. For example, the adjustment elementmay form a portion of the upperof the article of footwear. Alternatively, the adjustment elementmay form a portion of the straps, the center bridge, the band, and/or any one of the panels,,,of the bra. While described herein with respect to the article of footwearand article of apparel, it is generally contemplated that the adjustment elementmay be utilized with alternative articles including, but not limited to, sweatbands, knee braces, elbow braces, shoulder braces, headbands, and other articles that may be advantageously contoured or otherwise form- fitted to a wearer. The adjustment elementincludes a bladderforming an interior voidand having a compressible component or infilldisposed therein. The compressible componentmay include an infill structurethat may have a geometry that forms a plurality of recesses() and may be formed from a resilient material such as foam. For example, the infill structuremay have a wave configuration and/or an egg-crate configuration each forming the plurality of recesses. As described in more detail below, the infill structuremay include different geometrical configurations to impart different constriction profiles in different areas of the article.

For example,illustrates the compressible componentwith the infill structureconfigured with the wave configuration, such that the compressible componentis corrugated along a width Wof the compressible component. Stated differently, the infill structuremay be formed with the recessesinterspaced by ridges. The recessesmay expand and contract as the ridgesare manipulated during evacuation of the adjustment element, as described in more detail below.also illustrates the infill structureas having aperturesformed along a length L. The aperturesmay provide additional flexibility for the compressible component, such that the infill structure may have an increased degree of pliability during manipulation of the adjustment element.

In the illustrated examples of, the adjustment elementincludes an inner barrier layerand an outer barrier layerforming at least a portion of the article. Interior surfaces of the barrier layers,face each other and are joined to each other to form a chambersealed by a peripheral seamthat surrounds the interior voidof the bladder.

As used herein, the term “barrier layer” (e.g., barrier layers,) encompasses both monolayer and multilayer films. In some embodiments, one or both of barrier layers the,are each produced (e.g., thermoformed or blow molded) from a monolayer film (a single layer). In other embodiments, one or both of the barrier layers,are each produced (e.g., thermoformed or blow molded) from a multilayer film (multiple sublayers). In either aspect, each layer or sublayer can have a film thickness ranging from approximately 0.2 micrometers to approximately 1 millimeter. In further embodiments, the film thickness for each layer or sublayer can range from approximately 0.5 micrometers to approximately 500 micrometers. In yet further embodiments, the film thickness for each layer or sublayer can range from approximately 1 micrometer to approximately 100 micrometers.

One or both of the barrier layers,can independently be transparent, translucent, and/or opaque. As used herein, the term “transparent” for a barrier layer means that light passes through the barrier layer in substantially straight lines and a viewer can see through the barrier layer. In comparison, for an opaque barrier layer, light does not pass through the barrier layer and one cannot see clearly through the barrier layer at all. A translucent barrier layer falls between a transparent barrier layer and an opaque barrier layer, in that light passes through a translucent layer but some of the light is scattered so that a viewer cannot see clearly through the layer.

The barrier layers,can each be produced from an elastomeric material that includes one or more thermoplastic polymers and/or one or more cross-linkable polymers. In an aspect, the elastomeric material can include one or more thermoplastic elastomeric materials, such as one or more thermoplastic polyurethane (TPU) copolymers, one or more ethylene-vinyl alcohol (EVOH) copolymers, and the like.

As used herein, “polyurethane” refers to a copolymer (including oligomers) that contains a urethane group (—N(C—O)O—). These polyurethanes can contain additional groups such as ester, ether, urea, allophanate, biuret, carbodiimide, oxazolidinyl, isocynaurate, uretdione, carbonate, and the like, in addition to urethane groups. In an aspect, one or more of the polyurethanes can be produced by polymerizing one or more isocyanates with one or more polyols to produce copolymer chains having (—N(C═O)O—) linkages.

Examples of suitable isocyanates for producing the polyurethane copolymer chains include diisocyanates, such as aromatic diisocyanates, aliphatic diisocyanates, and combinations thereof. Examples of suitable aromatic diisocyanates include toluene diisocyanate (TDI), TDI adducts with trimethyloylpropane (TMP), methylene diphenyl diisocyanate (MDI), xylene diisocyanate (XDI), tetramethylxylylene diisocyanate (TMXDI), hydrogenated xylene diisocyanate (HXDI), naphthalene 1,5-diisocyanate (NDI), 1,5-tetrahydronaphthalene diisocyanate, para-phenylene diisocyanate (PPDI), 3,3′-dimethyldiphenyl-4, 4′-diisocyanate (DDDI), 4,4′-dibenzyl diisocyanate (DBDI), 4-chloro-1,3-phenylene diisocyanate, and combinations thereof. In some embodiments, the copolymer chains are substantially free of aromatic groups.

In particular aspects, the polyurethane polymer chains are produced from diisocynates including HMDI, TDI, MDI, Haliphatics, and combinations thereof. In an aspect, the thermoplastic TPU can include polyester-based TPU, polyether-based TPU, polycaprolactone-based TPU, polycarbonate-based TPU, polysiloxane-based TPU, or combinations thereof.

In another aspect, the polymeric layer can be formed of one or more of the following: EVOH copolymers, poly (vinyl chloride), polyvinylidene polymers and copolymers (e.g., polyvinylidene chloride), polyamides (e.g., amorphous polyamides), amide-based copolymers, acrylonitrile polymers (e.g., acrylonitrile-methyl acrylate copolymers), polyethylene terephthalate, polyether imides, polyacrylic imides, and other polymeric materials known to have relatively low gas transmission rates. Blends of these materials as well as with the TPU copolymers described herein and optionally including combinations of polyimides and crystalline polymers, are also suitable.

The barrier layers,may include two or more sublayers (multilayer film) such as shown in Mitchell et al., U.S. Pat. No. 5,713,141 and Mitchell et al., U.S. Pat. No. 5,952,065, the disclosures of which are incorporated by reference in their entirety. In embodiments where the barrier layers,include two or more sublayers, examples of suitable multilayer films include microlayer films, such as those disclosed in Bonk et al., U.S. Pat. No. 6,582,786, which is incorporated by reference in its entirety. In further embodiments, barrier layers,may each independently include alternating sublayers of one or more TPU copolymer materials and one or more EVOH copolymer materials, where the total number of sublayers in each of the barrier layers,includes at least four (4) sublayers, at least ten (10) sublayers, at least twenty (20) sublayers, at least forty (40) sublayers, and/or at least sixty (60) sublayers.

The chambercan be produced from the barrier layers,using any suitable technique, such as thermoforming (e.g. vacuum thermoforming), blow molding, extrusion, injection molding, vacuum molding, rotary molding, transfer molding, pressure forming, heat sealing, casting, low-pressure casting, spin casting, reaction injection molding, radio frequency (RF) welding, and the like. In an aspect, the barrier layers,can be produced by co-extrusion followed by vacuum thermoforming to produce the chamber.

The chamberdesirably has a low gas transmission rate. In some embodiments, the chamberhas a gas transmission rate for nitrogen gas that is at least approximately ten (10) times lower than a nitrogen gas transmission rate for a butyl rubber layer of substantially the same dimensions. In an aspect, chamberhas a nitrogen gas transmission rate of 15 cubic-centimeter/square-meter·atmosphere·day (cm/m·atm·day) or less for an average film thickness of 500 micrometers (based on thicknesses of the barrier layers,). In further aspects, the transmission rate is 10 cm/m·atm·day or less, 5 cm/m·atm·day or less, or 1 cm/m·atm·day or less.

In some implementations, the inner barrier layerand the outer barrier layercooperate to form a geometry (e.g., thicknesses, width, and lengths) of the chamber. The peripheral seammay extend around the chamberto seal the chamberand allow a vacuum (i.e., a negative pressure) to be applied to the chamber. Thus, the chamberis associated with an area of the bladderwhere interior surfaces of the inner and outer barrier layers,are not joined together and, thus, are separated from one another. The compressible componentis received within the chamberin areas where the barrier layers,are not joined together.

In some examples, the barrier layers,may include the same materials to provide the chamberwith a homogenous barrier construction, such that both sides of the adjustment elementwill contract and relax at the same rate when pressure within the chamberis adjusted. Alternatively, a first one of the barrier layers,may be at least partially constructed of a different barrier material and/or configuration than the other one of the barrier layers,to selectively impart a contour as the adjustment elementtransitions between the relaxed state and the contracted state. For example, one of the barrier layers,may be at least partially formed with a different modulus of elasticity and/or stiffness than the other barrier layer,, such that when the adjustment elementtransitions from the relaxed state to the constricted state, the first one of the barrier layers,contracts at a different rate than the other barrier layer,to cause the adjustment elementto curl.

The compressible componentis disposed within the interior voidof the adjustment elementand forms a transformable structure operable to transition the article between the relaxed state and the constricted state. A first surfaceof the compressible componentfaces the inner barrier layerand the second surfacefaces the outer barrier layer. In this example, the compressible componentincludes the infill structurehaving the plurality of recessesformed through the thickness T(i.e., direction from first surfaceto the second surface) of the compressible component. Generally, when a pressure within the chamberis reduced, the infill structureis configured to collapse within the chamberto transition the adjustment elementand the article from a relaxed or expanded state to a constricted state.

One or both surfaces,of the compressible componentmay be attached to the corresponding barrier layer,when the adjustment elementis assembled. In one configuration, one or both of the first surfaceand the second surfacemay be fully attached to the corresponding one of the barrier layers,. Thus, as the compressible componentmoves between the relaxed state and the contracted or constricted state, the surfaces,of the compressible componentdirectly pull the barrier layers,to transition the barrier layers,between the relaxed state and the constricted state.