Article of footwear having a comfortable and protective toe cap

Abstract

An article of footwear includes an upper having a toe box and a forefoot portion adjacent the toe box. The forefoot portion has a first region having a first stiffness. The article of footwear also includes a transition region including an elastomeric transition layer disposed on and partially covering the first region. The transition region has a second stiffness that is greater than the first stiffness. The article of footwear further includes a toe cap disposed on and partially covering the elastomeric transition layer at the toe box.

What is claimed is: 
     
         1 . An article of footwear comprising:
 an upper having a toe box and a forefoot portion adjacent the toe box;   wherein the forefoot portion has a first region having a first stiffness;   a transition region including an elastomeric transition layer disposed on and partially covering the first region;   wherein the transition region has a second stiffness that is greater than the first stiffness; and   a toe cap disposed on and partially covering the elastomeric transition layer at the toe box.   
     
     
         2 . The article of footwear of  claim 1 , wherein the toe cap has a third stiffness that is greater than the second stiffness. 
     
     
         3 . The article of footwear of  claim 1 , wherein the elastomeric transition layer partially overlays the first region and partially underlays the toe cap. 
     
     
         4 . The article of footwear of  claim 1 , wherein the upper has a heel portion spaced apart from the toe box such that the forefoot portion is disposed between the heel portion and the toe box, and further wherein the toe cap has an arcuate edge facing the heel portion that does not contact the first region. 
     
     
         5 . The article of footwear of  claim 1 , wherein the elastomeric transition layer has a first thickness and the toe cap has a second thickness that is greater than the first thickness. 
     
     
         6 . The article of footwear of  claim 1 , wherein the upper has a medial side, a lateral side opposite the medial side, and a second region abutting the first region and disposed along at least one of the medial side and the lateral side, and further wherein the second region has a fourth stiffness that is less than the first stiffness. 
     
     
         7 . The article of footwear of  claim 6 , wherein the second region has a stiffening pattern that includes a plurality of stiffened portions and a non-stiffened portion disposed between adjacent ones of the plurality of stiffened portions. 
     
     
         8 . The article of footwear of  claim 7 , wherein the forefoot portion is formed from a fusible yarn having a variable stiffness, and the first region and the plurality of stiffened portions include a fused thermoplastic. 
     
     
         9 . The article of footwear of  claim 1 , wherein the upper has an exterior, and further including:
 an ankle collar defining a foot-receiving cavity that is spaced apart from the exterior;   a sole structure attached to the upper at a bite line disposed along the exterior; and   a tape adhered to the sole structure and the upper and covering the bite line.   
     
     
         10 . The article of footwear of  claim 9 , wherein the tape is adhered to an entirety of the bite line such that the tape encircles the sole structure at the bite line and covers a portion of the toe cap. 
     
     
         11 . The article of footwear of  claim 9 , wherein the tape is formed from at least one of a light-reflective material and a waterproof material configured to inhibit fluid transmission through the bite line to the foot-receiving cavity. 
     
     
         12 . An article of footwear comprising:
 an upper having a medial side, a lateral side opposite the medial side, a toe box, a heel portion spaced apart from the toe box, and a forefoot portion disposed between the toe box and the heel portion;   wherein the forefoot portion has a first region having a first stiffness;   a transition region including an elastomeric transition layer disposed on and partially covering the first region;   wherein the transition region has a second stiffness that is greater than the first stiffness;   a toe cap disposed on and partially covering the elastomeric transition layer at the toe box; and   an ankle collar defining a foot-receiving cavity;   wherein the ankle collar and the heel portion define a seam channel therebetween such that:
 an entirety of the ankle collar is spaced apart from the heel portion by the seam channel on the lateral side; 
 a first portion of the ankle collar is spaced apart from the heel portion by the seam channel on the medial side; and 
 a second portion of the ankle collar is connected to the heel portion on the medial side. 
   
     
     
         13 . The article of footwear of  claim 12 , wherein the ankle collar is spaced apart from the forefoot portion by the seam channel on the lateral side and the medial side. 
     
     
         14 . The article of footwear of  claim 13 , wherein the heel portion is spaced apart from the forefoot portion by the seam channel on the lateral side and the medial side. 
     
     
         15 . The article of footwear of  claim 14 , wherein the seam channel does not completely encircle the ankle collar. 
     
     
         16 . The article of footwear of  claim 12 , wherein the ankle collar is a unitary structure attached to the forefoot portion at the seam channel such that the article of footwear does not include a tongue connected to the forefoot portion. 
     
     
         17 . The article of footwear of  claim 12 , wherein the heel portion includes a padded heel cup having a contour, disposed within the foot-receiving cavity, and extending from the medial side to the lateral side. 
     
     
         18 . The article of footwear of  claim 17 , wherein the seam channel abuts the contour on the lateral side such that the seam channel completely divides the ankle collar from the heel portion on the lateral side, and further wherein the seam channel abuts the contour on the medial side such that the ankle collar is partially attached to the heel portion on the medial side. 
     
     
         19 . The article of footwear of  claim 12 , wherein the upper has an exterior spaced apart from the foot-receiving cavity, and further wherein the toe cap is formed from a non-metal and disposed on the exterior at the toe box. 
     
     
         20 . The article of footwear of  claim 19 , further including:
 a sole structure attached to the upper at a bite line; and   a tape adhered to the sole structure and the upper on the exterior and covering an entirety of the bite line such that the tape encircles the sole structure.