Footwear including woven upper

Abstract

A shoe component, wherein the shoe component is formed by 3-dimensional weaving such that the shoe component has one or more woven layers, each having a warp direction and a fill direction, wherein the shoe component has one direction of stretch; a shoe containing at least one of the shoe components in an upper; and a shoe in which the entire upper, and optionally the midsole and/or outsole, are entirely formed by 3-dimensional weaving.

1 . A shoe comprising:
 an upper; and   a sole,   wherein at least one portion of the upper is formed by 3-dimensional weaving, wherein said at least one portion has one or more woven layers, each having a warp direction and a fill direction, such that said at least one portion has one direction of stretch.   
     
     
         2 . The shoe of  claim 1 , wherein said at least one portion of the upper is at least one member selected from the group consisting of tongue, quarters, vamps, heel seat, and toe box. 
     
     
         3 . The shoe of  claim 1 , wherein the at least one portion of the upper formed by 3-dimensional weaving is the entire upper. 
     
     
         4 . The shoe of  claim 1 , wherein the sole comprises a midsole and an outsole, and the upper and the midsole form a unitary structure wherein the entire unitary structure is formed by 3-dimensional weaving. 
     
     
         5 . The shoe of any one of  claims 1 - 4 , wherein the one direction of stretch is in a heel-toe direction. 
     
     
         6 . The shoe of any one of  claims 1 - 4 , wherein the one direction of stretch is in a medial-lateral direction. 
     
     
         7 . The shoe of  claim 3 , wherein the upper comprises a lace closure. 
     
     
         8 . The shoe of  claim 7 , wherein the upper is woven from top down. 
     
     
         9 . The shoe of  claim 7 , wherein the upper is woven laterally. 
     
     
         10 . The shoe of  claim 3 , wherein the shoe is a slip-on construction. 
     
     
         11 . The shoe of  claim 10 , wherein the upper is woven from top down. 
     
     
         12 . The shoe of  claim 10 , wherein the upper is woven laterally. 
     
     
         13 . The shoe of  claim 4 , wherein the unitary structure comprises a lace closure. 
     
     
         14 . The shoe of  claim 13 , wherein the unitary structure is woven from top down. 
     
     
         15 . The shoe of  claim 13 , wherein the unitary structure is woven laterally. 
     
     
         16 . The shoe of  claim 4 , wherein the unitary structure is a slip-on construction. 
     
     
         17 . The shoe of  claim 16 , wherein the unitary structure is woven from top down. 
     
     
         18 . The shoe of  claim 16 , wherein the unitary structure is woven laterally. 
     
     
         19 . The shoe of  claim 4 , wherein the unitary structure comprises at least one 3-dimensionally woven flange externally projecting laterally from a vicinity of the midsole portion. 
     
     
         20 . The shoe of  claim 19 , wherein the at least one 3-dimensionally woven flange is a pair of 3-dimensionally woven flanges each externally projecting laterally from opposite sides of the midsole portion and having holes arranged therein such that the pair of flanges can be externally wrapped over a vamp portion and form lacing structures. 
     
     
         21 . The shoe of  claim 19 , wherein the at least one 3-dimensionally woven flange is a pair of 3-dimensionally woven flanges each externally projecting laterally from opposite sides of the midsole portion and wherein the pair of flanges contain a mechanism by which the flanges can be detachably connected to one another when externally wrapped over a vamp portion. 
     
     
         22 . The shoe of  claim 4 , wherein the outsole is a solid piece formed of a member selected form the group consisting of thermoplastic rubbers, natural and synthetic rubbers, crepe rubber, and composite materials; and is affixed to an underside of the midsole portion of the unitary structure. 
     
     
         23 . The shoe of  claim 4 , wherein the outsole comprises a plurality of woven portions on an underside of the midsole portion of the unitary structure, wherein the plurality of woven portions are formed from at least one member selected from the group consisting of fuseable yarns, abrasion resistant yarns, cushioning yarns, and high tenacity yarns. 
     
     
         24 . The shoe of  claim 23 , wherein the plurality of woven portions forming the outsole are woven into the underside of the midsole portion of the unitary structure during the 3-dimensional weaving process of forming the unitary structure. 
     
     
         25 . The shoe of  claim 4 , wherein the midsole portion of the unitary structure comprises a plurality of 3-dimensionally woven layers forming a pocket having an opening proximal to one end thereof, wherein said pocket runs substantially an entire length from toe to heel and substantially across an entire width of the midsole portion. 
     
     
         26 . The shoe of  claim 25 , wherein the opening for the pocket is in an external layer of the plurality of 3-dimensionally woven layers. 
     
     
         27 . The shoe of  claim 26 , further comprising a support member inserted in the pocket, such that a wearer of the shoe is provided with arch support. 
     
     
         28 . The shoe of  claim 27 , wherein the support member is formed so as to provide cushioning to a wearer's foot. 
     
     
         29 . The shoe of  claim 25 , wherein the opening for the pocket is in an internal layer of the plurality of 3-dimensionally woven layers. 
     
     
         30 . The shoe of  claim 29 , further comprising a support member inserted in the pocket, such that a wearer of the shoe is provided with arch support. 
     
     
         31 . The shoe of  claim 29 , further comprising an insert member inserted in the pocket, and providing odor and/or bacteria control to a wearer of the shoe. 
     
     
         32 . The shoe of  claim 4 , wherein the unitary structure comprises a plurality of 3-dimensionally woven layers, wherein an internal layer of the unitary structure comprises one or more yarns selected from the group consisting of cushioning yarns, antimicrobial yarns, and wicking yarns. 
     
     
         33 . In a conventional shoe construction formed of an upper portion and a sole portion, the improvement wherein the upper portion is a one piece upper formed by 3-dimensional weaving, wherein said one piece upper has one or more woven layers, each having a warp direction and a fill direction, such that said one piece upper has one direction of stretch. 
     
     
         34 . In the conventional shoe construction of  claim 33 , wherein the one direction of stretch is in a heel to toe direction. 
     
     
         35 . In the conventional shoe construction of  claim 33 , wherein the one direction of stretch is in a medial-lateral direction. 
     
     
         36 . A shoe component, wherein the shoe component is formed by 3-dimensional weaving such that the shoe component has one or more woven layers, each having a warp direction and a fill direction, wherein the shoe component has one direction of stretch. 
     
     
         37 . The shoe component of  claim 36 , wherein the shoe component is a member selected from the group consisting of tongue, quarters, vamps, heel seat, and toe box. 
     
     
         38 . The shoe component of  claim 36 , wherein the shoe component is a midsole component. 
     
     
         39 . The shoe component of  claim 38 , wherein the midsole component comprises a plurality of 3-dimensionally woven layers forming a pocket having an opening proximal to one end thereof, wherein said pocket runs substantially an entire length from toe to heel and substantially across an entire width of the midsole component.