US20130081307A1

US20130081307A1 - Footwear having a woven portion

Info

Publication number: US20130081307A1
Application number: US13/631,375
Authority: US
Inventors: Stefano Del Biondi; Dale Bathum
Original assignee: Crocs Inc
Current assignee: Crocs Inc
Priority date: 2011-09-30
Filing date: 2012-09-28
Publication date: 2013-04-04
Also published as: CN103027440A

Abstract

An article of footwear is constructed from moldable foam and includes a sole portion and an upper. The upper includes a woven portion that is constructed by interweaving a number of vertical bands with a number of horizontal bands. The vertical bands can have beveled edges to reduce a bulging effect resulting from the interwoven bands.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application No. 61/541,851, filed on Sep. 30, 2011, the entirety of which is incorporated herein by reference.

BACKGROUND

Traditional textile and leather footwear products have included woven components. Molded articles, for example foam injection molded and/or articles made from ethylene vinyl acetate (EVA) foam, often do not include woven components, because the appearance of woven components can often be molded directly into a one-piece non-woven component. However, such faux woven patterns often do not have the same appearance or performance as footwear products that feature components that are actually woven together.

SUMMARY

This summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used, in isolation, as an aid in determining the scope of the claimed subject matter. At a high level, embodiments of the invention relate to a molded-foam footwear product having a partially-woven construction.
While multiple embodiments are disclosed, still other embodiments of the present invention will become apparent to those skilled in the art from the following detailed description, which shows and describes illustrative embodiments of the invention. Accordingly, the drawings and detailed description are to be regarded as illustrative in nature and not restrictive.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention is described in detail below with reference to the attached drawing figures, wherein:

FIG. 1 is a side view of a boot in accordance with embodiments of the invention;

FIG. 2A depicts a cross-sectional view of a vertical band in accordance with embodiments of the invention;

FIG. 2B depicts a cross-sectional view of a vertical band interwoven with a horizontal band in accordance with embodiments of the invention;

FIG. 3A is a perspective view of part of the outside of a woven portion of the boot of FIG. 1 in accordance with embodiments of the invention;

FIG. 3B is a perspective view of part of the inside of a woven portion of the boot of FIG. 1 in accordance with embodiments of the invention;

FIG. 4 is a side view of a flat in accordance with embodiments of the invention;

FIG. 5A is a first side view of a boot shell in accordance with embodiments of the invention;

FIG. 5B is a second side view of the boot shell of FIG. 5A in accordance with embodiments of the invention;

FIG. 5C is a rear perspective view of the boot shell of FIG. 5A in accordance with embodiments of the invention;

FIG. 5D is a side perspective view of a part of the boot shell of FIG. 5A in accordance with embodiments of the invention;

FIG. 5E is a bottom perspective view of the boot shell of FIG. 5A in accordance with embodiments of the invention;

FIG. 6A is a side view of a set of horizontal-band portions in accordance with embodiments of the invention;

FIG. 6B is a top perspective view of the set of horizontal-band portions of FIG. 6A in accordance with embodiments of the invention;

FIG. 6C is a side view of the set of horizontal-band portions of FIG. 6A, showing the set of horizontal-band portions disposed over a shaft portion of the boot shell of FIG. 5A in accordance with embodiments of the invention;

FIG. 7A is a top perspective view of a part of a boot in accordance with embodiments of the invention;

FIG. 7B is a bottom perspective view of a part of the boot of FIG. 7A in accordance with embodiments of the invention;

FIG. 7C is a bottom view of the boot of FIG. 7A in accordance with embodiments of the invention;

FIG. 7D is a side view of the boot of FIG. 7A and a perspective view of an liner in accordance with embodiments of the invention;

FIG. 8 is a flowchart depicting a method of constructing a boot in accordance with embodiments of the invention; and

FIG. 9 is a flowchart depicting a method of constructing a flat in accordance with embodiments of the invention.

DETAILED DESCRIPTION

The subject matter of embodiments of the invention is described with specificity to meet statutory requirements. However, the description itself is not intended to limit the scope of this patent. Rather, the inventors have contemplated that the claimed subject matter might also be embodied in other ways, to include different steps or features or combinations of steps or features similar to the ones described in this document, in conjunction with other technologies. Moreover, although aspects of methods of constructing products according to embodiments of the invention are described with reference to “blocks,” the term “block” should not be interpreted as implying any particular order among or between various aspects unless the order of individual aspects is explicitly described.
Additionally, the terms “vertical” and “horizontal,” as the terms are used herein, refer to a general orientation and are not meant to specifically refer to a perfectly vertical and horizontal orientation, respectively. Rather, the terms “vertical” and “horizontal,” as used herein, are used to convey a relative orientation with respect to what is commonly understood to be the bottom (e.g., the portion nearest the ground when the article is being worn by a wearer that is standing) and top (e.g., the portion farthest from the ground when the article is being worn by a wearer that is standing) of an article of footwear, as well as with respect to each other.
Embodiments of the invention include a molded-foam footwear product having a partially-woven construction. The footwear product can be a shoe, a boot, a sandal, or any other type of footwear product having at least one woven portion. Embodiments of the invention can include different combinations of the features and components described herein, additional features or components that are not described herein, and components made from different materials or combinations of materials than those described herein. All such implementations are considered to be within the ambit of the invention.
FIG. 1 depicts a boot 1 having a partially-woven construction in accordance with embodiments of the invention. As illustrated in FIG. 1, the boot 1 includes a sole assembly 10 and an upper 12 disposed on top of the sole assembly 10. The sole assembly 10 includes a sole body 14 defined by an outsole 16, a sole periphery 18 that extends generally upwardly along the periphery of the outsole 16, and an insole (not illustrated in FIG. 1 for the purposes of clarity and brevity of description). In embodiments, the outsole 16 includes a sole base 20 having a number of recesses 26 and 28 configured to receive a corresponding number of outsole inserts 30 and 32. In some embodiments, the outsole 16 can be a single, solid piece. According to embodiments, a shank 34 is disposed between the recesses 26 and 28 and provides support to the wearer's arch.
The upper 12 includes a vamp 40 disposed on top of the sole assembly 10 and configured to cover a wearer's foot. In embodiments, the vamp 40 has a generally solid construction, thereby providing a continuous surface 42 enclosing the wearer's foot. In other embodiments, the vamp 40 can include any number of openings that can, for example, provide ventilation to the inside of the boot 1. As is illustrated in FIG. 1, the vamp 40 includes an upper opening 46.
A shaft 50 extends generally upwardly from the upper opening 46 of the vamp 40. The shaft 50 includes a woven portion 52 disposed between a lower opening 54 and an upper opening 58, which is defined by an upper edge 60. According to embodiments, the woven portion 52 extends the entire distance between the lower opening 54 and the upper opening 58. In other embodiments, the shaft 50 includes one or more non-woven portions (not illustrated) disposed at any position of the shaft 50. In embodiments, the vamp 40 and the shaft 50 are coupled by way of a continuous construction, as is described in more detail below.
The woven portion 52 of the shaft 50 includes a number of horizontal bands 70 that are interwoven with a number of vertical bands 72. According to various embodiments of the invention, the woven portion 52 can include any number of horizontal bands 70 and vertical bands 72. Additionally, the horizontal bands 70 and vertical bands 72 can be constructed of any desired width. In some embodiments, for example, the horizontal bands 70 have approximately the same width as the vertical bands 72, while in other embodiments, the horizontal bands 70 have a different width than the vertical bands 72. Additionally, as shown in FIG. 1, the configuration of the weave of the horizontal bands 70 and vertical bands 72 is such that gaps 71 are formed in the woven portion 52 of the shaft 50. According to embodiments, the horizontal 70 bands and/or the vertical bands 72 can be sized such that the size of the gaps 71 is increased or decreased. For instance, larger gaps 71 in the woven portion 52 can be utilized to facilitate ventilation of the boot 1.
In some embodiments, the woven portion 52 of the shaft 50 can be constructed according to a diagonal configuration. For example, in an embodiment, a first set of bands is oriented in a first diagonal direction with respect to the horizontal (assuming that the outsole 16 is resting on a horizontal surface), while a second set of bands is oriented in a second diagonal direction with respect to the horizontal. In some embodiments, additional sets of bands can be interwoven with the first two sets of bands, as well.
According to various embodiments, the weave of the bands can have any number of different configurations. For example, in FIG. 1, the weave of the bands can be referred to as an “over one-under one” type of weave. That is, each horizontal band 70 passes over a vertical band 72, then under the next vertical band 72, then over the next vertical band 72, and so on. In another embodiment, the weave is an “over one-under two” type of weave, in which each horizontal band 70 passes over a vertical band 72, then under the next two vertical bands 72, then over the next one vertical band 72, and so on. Any other configuration of weave is also considered to be within the ambit of the invention.
It should be recognized by individuals having skill in the relevant arts that interweaving the horizontal bands 70 with the vertical bands 72 can cause a bulging effect at each location where one type of band crosses the other. To minimize this bulging effect, in embodiments of the invention, each vertical band includes a beveled edge 73 along each side. According to embodiments of the invention, the horizontal bands 70, rather than the vertical bands 72 include beveled edges to achieve the desired effect. In further embodiments, both sets of bands 70 and 72 include beveled edges. However, for the purposes of clarity and brevity of description, only vertical bands 72 with beveled edges 73 are illustrated herein.
FIGS. 2A, 2B, 3A and 3B illustrate the beveled edges 73. FIG. 2A depicts a cross-sectional view of a vertical band 72 for the purpose of illustrating an exemplary beveled edge 73, in accordance with embodiments of the invention. As shown in FIG. 2A, the vertical band 72 includes an outside surface 74 (e.g., a surface that faces toward the outside of the shaft 50) and an opposed (and, at least approximately, parallel) inside surface 76 (e.g., a surface that faces toward the inside of the shaft 50). The vertical band 72 includes a beveled edge 73 on each side that is defined by an angled surface 78 extending from an edge of the outside surface 74 to a corresponding edge of the inside surface 76. As FIG. 2A depicts, the overall cross section of the vertical band 72 approximately defines a trapezoid, where the beveled edges 73 taper inward such that the outside surface 74 is wider than the inside surface 76. In other embodiments, the angled surface 78 can be curved such that the beveled edge 73 is concave.
FIG. 2B depicts the cross-section of the vertical band 72 in an assembled position—that is, the vertical band 72 is depicted as being disposed above to a horizontal band 70. As illustrated in FIG. 2B, the horizontal band 70 also includes an outside surface 80 (e.g., a surface that faces toward the outside of the shaft 50) and an opposed (and, at least approximately, parallel) inside surface 82 (e.g., a surface that faces toward the inside of the shaft 50). As shown, the beveled edge 73 allows the vertical band 72 to lay relatively flat against the horizontal band 70 by partially accommodating the curved portion 84 of the outside surface 80 of the horizontal band 70, which is curved due to the interaction between the horizontal band 70 and an adjacent vertical band (not shown).
FIG. 3A shows a perspective view of the outside of the woven portion 52 of the shaft 50 of a boot 1, illustrating the “anti-bulging” effect facilitated by the beveled edges 73 of the vertical bands 72, as described above. Similarly, FIG. 3B is a perspective view of the inside of the woven 52 portion of the shaft 50, which more clearly shows the angled surface 78 extending from the outside surface 74 to the inside surface 76 of a vertical band 72, thereby defining the beveled edge 73, which accommodates the curved portion 84 of the horizontal band 70.
FIG. 4 shows a flat 100 in accordance with embodiments of the invention. As shown, the flat 100 includes a sole assembly 110 and an upper 112 disposed on top of the sole assembly 110. As shown in FIG. 4, the upper 112 includes a first portion 114 and a second portion 116. A woven portion 118 is disposed between the first portion 114 and the second portion 116. In embodiments, the first portion 114 and the second portion 116 have a smooth, continuous surface, although, according to some embodiments, the continuous surfaces of the first portion 114 and the second portion 116 are textured, as desired. The woven portion 118 includes a number of vertical bands 120 that are interwoven with a number of horizontal bands 122. In embodiments, each horizontal band 122 is secured to itself, or to a vertical band 120 or another part of the flat 100. In an embodiment, for example, the horizontal bands 122 are secured in a hidden region 123 in the heel area of the flat 100. As with the boot 1, described above, the woven portion 118 of the flat 100 can include a diagonal weave and can be constructed from any number of sets of bands and according to any number of different weave configurations. According to various embodiments, each vertical band 120 includes a beveled edge 125 similar to the beveled edge 73 described above with reference to FIGS. 2A, 2B, 3A, and 3B.
FIG. 4, the flat 100 further includes a trim portion 130 that is secured along a top edge (not shown) of the second portion 116 of the upper 112. In embodiments, the trim portion 130 is secured using a series of stitches 131, although any other suitable method of securing the trim portion 130 to the second portion 116 of the upper 112 can be used. As shown, the trim portion 130 forms a perimeter around the top of the upper 112, defining an opening 132, into which a wearer (not shown) can place the wearer's foot (not shown). As is further illustrated in FIG. 4, the flat 100 includes an insert 134. According to various embodiments, the insert 134 can be constructed from any suitable type of fabric or other material and can provide added comfort to the wearer. In embodiments, the insert 134 is an insole that covers only the inside surface of the sole assembly 110, while in other embodiments, the insert 134 covers the entire inside surface of the flat 100, or any portion thereof.
As shown in FIG. 4, the sole assembly 110 includes a sole body 140 that is secured, at its upper edge 142, to the first portion 114 of the upper 112. An outsole 144 is disposed along the bottom of the sole body 140. The sole body 140 can be constructed according to any desired shape. For example, as shown in FIG. 4, the illustrated sole body 140 includes a heel portion 146 and a forefoot portion 148, with a shank 150 disposed between them. According to various embodiments of the invention, tread features 152 are included on one or more portions of the outsole 144. For instance, in an embodiment, the outsole 144 includes recesses (not shown), such as those described above with respect to the boot 1, that are configured to receive tread inserts (not shown). In other embodiments, tread features 152 are integrated into the construction of the outsole 144.
FIGS. 5A-5E, 6A-6C, and 7A-7D show a process for constructing a boot 201 (shown, fully constructed, in FIG. 7D) in accordance with embodiments of the invention. With particular reference to FIGS. 5A and 5B, the boot is constructed by first creating a boot shell 200. According to various embodiments of the invention, the boot shell 200 is a single, continuous piece, molded from a material such as ethylene vinyl acetate (EVA) foam, polyurethane foam, or a combination of materials. For instance, in embodiments, to form the boot shell 200, liquid EVA is injected into a clamshell-type mold, which are brought together with a third mold piece inserted between them to create a cavity 205 in the boot shell, shown in FIG. 5C. An example of such a molding process is described in U.S. Pat. No. 6,439,536 to Piccolo, which is incorporated herein by reference.
As shown in FIGS. 5A and 5B, the boot shell 200 includes a sole portion 210 and an upper portion 212. The upper portion 212 includes a vamp 214 and a shaft portion 216. As is further illustrated, the shaft portion 216 is molded with a number of vertical grooves 218 disposed therein. The vertical grooves 218 define a number of adjacent vertical-band portions 220 that can be separated from one another to create vertical bands 201B. In other embodiments, the boot shell 200 is molded such that the shaft portion 216 includes a number of (already separated) vertical bands 201B. In embodiments, a hole 221 is disposed at the lower end 222 of each vertical groove 218, as shown in FIG. 5D. As is further shown in FIGS. 5A and 5B, the boot shell 200 further includes a transverse groove 223 that indicates the location of the top of the woven portion 201A of the fully-constructed article 201. FIG. 5E shows the sole portion 210 of the boot shell 200, which includes a sole body 210A, which is defined by an outsole 210B and a sole periphery 210C. As illustrated, in embodiments, the outsole 201B includes recesses 210D disposed in a heel portion 211A and a forefoot portion 211B. A shank 210E is disposed between the recesses 210D. According to embodiments, any number of different portions of the sole portion 210 of the boot shell 200 can be constructed to be thicker than other portions of the boot shell 200, thereby providing additional support and comfort for the wearer.
According to various embodiments of the invention, the vertical grooves 218 serve as guides for cutting the shaft portion 216 to separate the vertical-band portions 220 from one another, thereby forming vertical bands 201B such as, for example, the vertical bands 201B depicted in FIG. 7D. According to embodiments, the hole 221 indicates the location of the beginning of the cut and can facilitate the cutting process by allowing a cutting tool (not shown) to be inserted therein and moved upwardly along the vertical groove 218, thereby avoiding fraying or splitting the shaft portion 216, which may result from forcing a cutting tool into the vertical groove 218.
Moreover, in embodiments, the design of the vertical grooves 218 can facilitate the creation of beveled edges 201C such as those described above with reference to FIGS. 2A, 2B, 3A, and 3B. FIGS. 5C and 5D show a perspective view of the boot shell 200 in accordance with embodiments of the invention and more clearly shows the design of the vertical grooves 218. As shown, a vertical groove 218 includes a thin webbing 230 extending between an edge 232 of a first vertical-band portion 234 and an edge 233 of a second, adjacent, vertical-band portion 236. The thin webbing 230 runs from the corresponding hole 221 to the top of the shaft portion 216 of the boot shell 200.
In this manner, the edges 232 and 233 of the adjacent vertical- band portions 234 and 236 are spaced apart, thereby allowing for insertion of a cutting tool (not shown) at an angle. Inserting the cutting tool at an angle facilitates cutting (along the vertical groove 218) the adjacent vertical- band portions 234 and 236 apart such that an angled edge surface is created, as described above with reference to FIGS. 2A, 2B, 3A and 3B, to form the beveled edge 201C. For instance, in some embodiments, a cutting tool having two opposed, angled cutting surfaces is used to cut along the two edges 232 and 233 of the adjacent vertical- band portions 234 and 236, thereby simultaneously forming a beveled edge 201C along both edges 232 and 233. In other embodiments, the edges 232 and 233 are molded to include the bevel, in which case the adjacent vertical- band portions 234 and 236 are spaced apart by cutting the thin webbing 230 (e.g., an angled cutting surface is not necessary).
In addition to forming the boot shell 200, methods of constructing the boot 201 according to embodiments of the invention include forming a number of horizontal bands 201D. In embodiments, as described above, the horizontal bands 201D are formed as continuous, molded bands, using a foam material such as, for example, EVA. In some embodiments, the horizontal bands 201D are formed individually, while, in other embodiments, the horizontal bands 201D are formed as a set of horizontal-band portions that can be separated from one another to create horizontal bands 201D. FIGS. 6A-6C depict the latter scenario, in which a set 300 of horizontal-band portions 310 has been formed using a single molding process. As with the formation of the boot shell 200 described above, in an embodiment, the set 300 of horizontal-band portions 310 is formed by injecting liquid EVA into a clamshell-type mold and bringing the two sides of the mold together, with a mold insert disposed between them to provide a cavity 312, shown in FIG. 6B, in the set 300.
As shown in FIGS. 6A and 6C, according to various embodiments, the shape of the set 300 of horizontal-band portions 310 is configured to correspond to the shape of the shaft portion 216 of the boot shell 200. In this manner, when the horizontal bands 201D are interwoven with the vertical bands 201B, the weave meshes well and provides the desired shape of the resulting boot 201. For instance, as shown in FIGS. 6A and 6C, the overall shape of the set 300 of horizontal-band portions 310 is constructed such that a top section 314 of the set 300 is wider than a lower section 316. Additionally, as shown, a lower-most horizontal-band portion 317 is configured to taper outwardly from top to bottom to accommodate the shape of the boot shell 200 where the vamp 214 meets the shaft portion 216.
As illustrated in FIGS. 6A-6C, the set 300 of horizontal-band portions 310 includes a horizontal groove 320 between each pair of adjacent horizontal-band portions 310. To construct the boot, the horizontal-band portions 310 are separated from one another by cutting along each horizontal groove 320 using a cutting tool, thereby forming horizontal bands 201D. Then, each horizontal band 201D can be slid, from the top of the boot shell 200, downward, interweaving the horizontal band 201D with the vertical bands 201B. According to embodiments, the top edge of the upper-most horizontal band 201D is aligned with the transverse groove 223 defined in the boot shell 200. As shown in FIG. 7A, a trim portion 330 is secured to the top of the shaft portion 216. In embodiments, the trim portion 330 can be any suitable material such as, for example, EVA, leather, or other material and can be attached using any number of attaching devices such as, for example, a series of stitches 332.
According to various embodiments, as illustrated in FIGS. 7B and 7C, the sole assembly 350 of the boot is completed by disposing tread inserts 352 within the recesses 210D defined in the outsole 210B. The tread inserts 352 can be attached using any number of different attachment mechanisms such as glue, stitches, or the like. Additionally, a fabric insert 355, shown in FIG. 5D, is disposed within the constructed boot 201 to add comfort for the wearer. Other embodiments do not include a fabric insert. Any number of additional features or combinations of features can be included in the constructed boot 201, as well, without departing from the scope of the invention.
FIG. 8 is a flowchart depicting a method 800 of constructing a boot in accordance with embodiments of the invention. For example, the method 800 can be used to construct the boot 1 shown in FIG. 1. A boot shell having a sole portion and an upper is molded (block 810). The upper includes a vamp and a shaft portion. In embodiments, the shaft portion of the boot shell (e.g., the boot shell 200 shown in FIGS. 5A and 5B) includes a number of vertical grooves that define adjacent vertical-band portions, which can be separated from one another to create vertical bands. In embodiments, the boot shell is molded as a single continuous piece. In some embodiments, the boot shell is molded such that a hole is provided at the lower end of each vertical groove. In other embodiments, the boot shell is molded such that the shaft portion includes a number of separated vertical bands. Additionally, in some embodiments, the vertical grooves include a webbing extending between adjacent vertical-band portions to facilitate beveling of the edges of the resulting vertical bands.
A set of continuous horizontal-band portions is molded (block 812). In some embodiments, the horizontal bands are molded individually. In other embodiments, the set of horizontal-band portions is molded as a single, continuous piece (e.g., the set 300 of horizontal-band portions 310 shown in FIGS. 6A-6C) having horizontal grooves disposed between adjacent horizontal-band portions such that cutting along the horizontal grooves separates the horizontal-band portions from one another, thereby creating horizontal bands. According to various embodiments, the set of horizontal-band portions is configured to correspond to the shape of the shaft portion of the boot shell.
As indicated in FIG. 8, the vertical grooves of the boot shell are separated to create vertical bands (block 814). According to various embodiments, the vertical grooves are cut such that the edges of each resulting vertical band are beveled. In other embodiments, the beveled edges are formed during the molding of the boot shell. The horizontal-band portions are separated from each other to form horizontal bands (provided that the set of horizontal bands was formed as a single piece with horizontal grooves) (block 816). It will be readily appreciated that, in embodiments in which the horizontal bands are formed individually, the step of separating the horizontal bands from one another should be unnecessary.
A first, lower-most, horizontal band is interwoven with the vertical bands (block 818). According to embodiments, the interweaving is performed by sliding the first horizontal band downwardly, from the top of the boot shell, in an interwoven fashion with respect to the vertical bands. Similarly, as indicated at block 820, the additional horizontal bands are interwoven with the vertical bands. In the method 800, a trim portion is attached to the top of the shaft of the boot (block 822). According to various embodiments, the constructed boot is augmented with tread features, lining inserts, and the like.
FIG. 9 is a flowchart depicting a method 900 of constructing a flat shoe in accordance with embodiments of the invention. For example, the method 900 can be used to create the flat 100 shown in FIG. 4. A flat shell with vertical grooves is molded (block 910). In embodiments, the flat shell is molded as a single continuous piece. In some embodiments, the flat shell is molded such that a hole is provided at the lower end of each vertical groove. In other embodiments, the flat shell is molded to include separated vertical bands. Additionally, in embodiments, the vertical grooves include a thin webbing extending between adjacent vertical-band portions to facilitate beveling of the edges of the vertical-band portions. In some embodiments, the edges of the vertical-band portions are molded to include the beveled edges. According to embodiments, the flat shell includes a sole portion, while, in other embodiments, a sole portion is constructed separately.
As indicated at block 912, a set of horizontal bands is molded. In some embodiments, the set of horizontal bands is molded as a single piece, while, in other embodiments, each horizontal band is molded individually. The vertical grooves are cut to create vertical bands (block 914) and, as shown at block 916, a first horizontal band is interwoven with the vertical bands. The first horizontal band is secured (block 918). Similarly, as indicated at block 920, each additional horizontal band is interwoven with the vertical bands and, each of the additional horizontal bands is secured (block 922). According to embodiments, each horizontal band can be secured by attaching it to itself, to a vertical band, or to another part of the shoe. In some embodiments, for example, the horizontal bands are secured at a hidden position in the heel-area of the flat such as the hidden position 123 shown in FIG. 4. As shown in FIG. 9, a trim portion is attached (block 924) and the sole assembly (if constructed independently from the flat shell) is attached (block 926). According to various embodiments, the constructed flat can be augmented with tread features, lining inserts, and the like.
The present invention has been described in relation to particular embodiments, which are intended in all respects to be illustrative rather than restrictive. Alternative embodiments will become apparent to those of ordinary skill in the art to which the present invention pertains without departing from its scope. It will be understood that certain features and subcombinations are of utility and may be employed without reference to other features and subcombinations. This is contemplated by and is within the scope of the claims.

Claims

What is claimed is:

1. A footwear product, comprising:

a sole portion; and

an upper having a woven portion, the woven portion comprising:

(1) a first set of bands, wherein the first set of bands is formed as part of a shell molded from a foam material; and

(2) a second set of bands, formed from the foam material, that is interwoven with the first set of bands.

2. The footwear product of claim 1, wherein the woven portion extends at least partially between a lower opening defined in the upper and an upper opening defined in the upper.

3. The footwear product of claim 1, wherein each of the first set of bands has a width that is approximately the same as a width of each of the second set of bands.

4. The footwear product of claim 1, wherein each of the first set of bands has a width that is different than a width of each of the second set of bands.

5. The footwear product of claim 1, the woven portion further comprising a plurality of gaps.

6. The footwear product of claim 1, wherein the first set of bands is oriented in a first diagonal direction and the second set of bands is oriented in a second diagonal direction.

7. The footwear product of claim 1, wherein the first set of bands is oriented in a vertical direction and the second set of bands is oriented in a horizontal direction.

8. The footwear product of claim 1, wherein the woven portion comprises an over one-under one type of weave.

9. The footwear product of claim 1, wherein the woven portion comprises an over one-under two type of weave.

10. The footwear product of claim 1, wherein each of first set of bands includes a beveled edge.

11. The footwear product of claim 1, wherein the footwear product comprises at least one of a shoe, a boot, and a sandal.

12. A method of creating a footwear product, the method comprising:

molding a shell having a sole portion and an upper, wherein the upper includes a plurality of vertical bands;

molding a plurality of horizontal bands; and

interweaving the plurality of vertical bands with the plurality of horizontal bands.

13. The method of claim 12, wherein the upper includes a plurality of vertical grooves defining a plurality of vertical-band portions, the method comprising separating the plurality of vertical-band portions to create the plurality of vertical bands.

14. The method of claim 13, wherein each of the plurality of vertical grooves comprises a webbing extending between adjacent vertical-band portions to facilitate beveling of edges of each of the plurality of vertical bands.

15. The method of claim 12, wherein molding the plurality of horizontal bands comprises molding a single, continuous piece having horizontal grooves disposed between adjacent horizontal-band portions, the method further comprising separating the plurality of horizontal-band portions to create the plurality of horizontal bands.

16. The method of claim 12, wherein molding the plurality of horizontal bands comprises molding a plurality of individual horizontal bands.

17. The method of claim 12, further comprising attaching a trim portion to a top edge of the upper.

18. A footwear product comprising:

a sole portion; and

an upper having a woven portion, the woven portion comprising:

(1) a plurality of vertical bands, wherein the plurality of vertical bands are formed by separating a plurality of vertical-band portions from one another, wherein the plurality of vertical-band portions are formed as part of a shell molded from a foam material; and

(2) a plurality of horizontal bands, formed from the foam material, that are interwoven with the plurality of vertical bands.

19. The footwear product of claim 18, wherein each of plurality of vertical bands includes a beveled edge.

20. The footwear product of claim 18, wherein the woven portion comprises at least one of an over one-under one type of weave and an over one-under two type of weave.