# US 8,464,440 B2 · Article of footwear including a composite upper > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 8,464,440 B2 - Document ID: US8464440B2 - Status: Granted - Kind: B2 - Application number: 13/018,596 - Filed: 2011-02-01 - Published: 2011-05-26 - Granted: 2013-06-18 - Earliest claimed: 2007-09-13 - Assignees: NIKE, Inc. - Applicants: Paul Hooper; Peter A. Hudson; Fabio Marniga - Inventors: Paul Hooper; Peter A. Hudson; Fabio Marniga - Web page: https://patentgrep.com/patent/US8464440B2 ## CPC - A43B 23/0225: {Composite materials, e.g. material with a matrix} - A43B 1/14: made of plastics (A43B1/028 takes precedence) - A43B 23/0235: {Different layers of different material} - A43D 111/00: Shoe machines with conveyors for jacked shoes {or for shoes or shoe parts} - A43B: CHARACTERISTIC FEATURES OF FOOTWEAR; PARTS OF FOOTWEAR - A43D: MACHINES, TOOLS, EQUIPMENT OR METHODS FOR MANUFACTURING OR REPAIRING FOOTWEAR ## Abstract An upper made of a composite material is disclosed. The composite material comprises a layer of carbon fiber material and a flexible substrate. The composite material also includes a thin outer coating of TPU. The upper is generally flexible and lightweight. ## Claims ### Claim 1 An article of footwear, comprising: an upper comprising a flexible composite material; the flexible composite material including a layer of carbon fiber material, a flexible substrate, and a coating layer; wherein the layer of carbon fiber material is attached to the flexible substrate; wherein the coating layer is applied to an exposed side of the layer of carbon fiber material; wherein the flexible composite material is configured to bend simultaneously in opposite directions at two adjacent and contiguous regions; wherein the layer of carbon fiber material is a flexible carbon fiber weave including a plurality of exposed ends associated with the exposed side; and wherein the coating layer covers at least a portion of the plurality of exposed ends. ### Claim 2 (depends on 1) The article of footwear according to claim 1, wherein the flexible composite material corresponds to an S-like shape when bent simultaneously in opposite directions at the two adjacent and contiguous regions. ### Claim 3 (depends on 1) The article of footwear according to claim 1, wherein the layer of carbon fiber material is attached to the flexible substrate using a hot melt adhesive. ### Claim 4 (depends on 1) The article of footwear according to claim 1, wherein the upper is formed from at least a toe portion, a heel portion, and a middle portion; wherein the toe portion, the heel portion, and the middle portion are joined together to form the upper; and wherein the toe portion, the heel portion and the middle portion each include a portion of the flexible composite material. ### Claim 5 (depends on 4) The article of footwear according to claim 4, wherein the toe portion, the heel portion, and the middle portion are joined by stitching. ### Claim 6 (depends on 1) The article of footwear according to claim 1, wherein the upper is associated with an outsole, the outsole including a composite plate. ### Claim 7 An article of footwear, comprising: an upper including a flexible composite material; the flexible composite material further comprising: a first layer including a flexible substrate; a second layer including a woven carbon fiber material; and a third layer including a coating material applied onto an outer portion of the woven carbon fiber material; wherein the second layer is disposed between the first layer and the third layer; wherein the flexible composite material is configured to simultaneously bend in a first direction at a first region and in a second direction at a second region, the second direction being opposite the first direction; and wherein the flexible composite material includes an inflection point located between the first region and the second region, the inflection point being associated with the transition between bending in the first direction and bending in the second direction; wherein a thickness associated with the first layer is substantially equal to a thickness associated with the second layer, and wherein a thickness associated with the third layer is substantially smaller than the thickness associated with the first layer and the second layer; wherein the woven carbon fiber material further includes a plurality of exposed ends; and wherein the thickness associated with the third layer is configured such that the coating material substantially covers the plurality of exposed ends. ### Claim 8 (depends on 7) The article of footwear according to claim 7, wherein the upper is associated with an outsole, the outsole including a composite plate. ### Claim 9 (depends on 7) The article of footwear according to claim 7, wherein the first region and the second region are adjacent and contiguous. ### Claim 10 (depends on 9) The article of footwear according to claim 9, wherein the flexible composite material corresponds to an S-like shape when bent simultaneously in the first direction at the first region and in the second direction at the second region. ### Claim 11 (depends on 7) The article of footwear according to claim 7, wherein the upper is formed from at least a toe portion, a heel portion, and a middle portion; wherein the toe portion, the heel portion, and the middle portion are joined together to form the upper; and wherein the toe portion, the heel portion and the middle portion each include a portion of the flexible composite material. ### Claim 12 (depends on 11) The article of footwear according to claim 11, wherein the toe portion, the heel portion, and the middle portion are joined by stitching. ### Claim 13 (depends on 11) The article of footwear according to claim 11, wherein the toe portion, the heel portion, and the middle portion are joined by adhesive. ### Claim 14 An article of footwear, comprising: an upper made of a composite material, the composite material consisting essentially of including a layer of carbon fiber material made of a flexible fiber weave, a flexible substrate comprising one of nylon or canvas, and a thin outer coating layer associated with an outer portion of the carbon fiber material; the upper comprising a toe portion, a heel portion, and a middle portion; wherein the toe portion, the heel portion, and the middle portion each include a portion of the layer of carbon fiber material; wherein the toe portion, the heel portion, and the middle portion are joined together to form the upper; and wherein the composite material allows for increased flexibility in the upper. ### Claim 15 (depends on 14) The article of footwear according to claim 14, wherein the upper has a weight of 190 grams or less for a men's size 9 article of footwear. ### Claim 16 (depends on 15) The article of footwear according to claim 15, wherein the weight of the upper is proportional for other sizes of articles of footwear. ### Claim 17 (depends on 14) The article of footwear according to claim 14, wherein the upper further includes a tongue portion that includes a portion of the layer of carbon fiber material. ### Claim 18 (depends on 14) The article of footwear according to claim 14, wherein the toe portion, the heel portion, and the middle portion are joined by stitching. ### Claim 19 (depends on 14) The article of footwear according to claim 14, wherein the layer of carbon fiber material comprises the woven carbon fiber material including a plurality of exposed ends; and wherein the coating layer includes at least a portion of the plurality of exposed ends.