CN105050442A - Articles of footwear with welded uppers - Google Patents

Abstract

An article of footwear includes an upper (110) including a skin layer (185) that forms at least a portion of an exterior surface of the upper (110). The upper (110) also includes a reinforcing material (190) selectively located internally and adjacent to portions of the skin (185) to define a reinforced portion (195) of the skin and an unreinforced portion (200) of the skin. The reinforcing material (190) is selectively joined to the skin layer (185) by welding at a bonded region (205), the bonded region (205) having an outer exposed surface defining a portion of an exterior surface of the upper (110). Additionally, the skin layer (185) may have a first color and the outer exposed surface of the bonded region (205) may have a second color that is different from the first color.

Description

Articles of footwear with welded uppers

Cross References to Related Applications

This application is a Continuation-in-Part (CIP) of U.S. Patent Application Publication No. 2012/0297643 by Schaefer et al., published Nov. 29, 2012, which claims U.S. Provisional Patent Application No. 61/460,776, filed May 27, 2011 number priority. The entire disclosures of both applications are hereby incorporated by reference.

background

The present invention relates generally to material structures for articles of footwear, and more particularly to material structures for uppers of articles of footwear.

Conventional articles of athletic footwear include two primary elements: an upper and a sole structure. The upper provides a covering for the foot, comfortably receives the foot, and securely positions the foot relative to the sole structure. The sole structure is secured to the lower portion of the upper and is generally positioned between the foot and the ground. In addition to attenuating ground reaction forces (ie, providing cushioning) during walking, running, and other ambulatory activities, the sole structure can also, for example, affect foot motion (eg, by resisting pronation), impart stability, and provide traction. Accordingly, the upper and sole structure work together to provide a comfortable structure suitable for a wide range of athletic activities.

The upper is typically formed from a plurality of material elements that may be stitched or adhesively bonded together to define a void or cavity inside the footwear for comfortably and securely receiving the foot. More specifically, the upper forms a structure extending over the instep and toe areas of the foot along the lateral and medial sides of the foot and around the heel area of the foot. The upper may also incorporate a lacing system to open and close openings to cavities or chambers and to adjust the fit of the footwear within the upper. Additionally, the upper may include a tongue that extends beneath the lacing system to improve the adjustability and comfort of the footwear, and the upper may include a heel counter or other stabilizing structure.

The upper may also include devices for improved fit, comfort, and performance. Selection and placement of materials can be used to achieve certain desired characteristics. The design of many types of footwear is often driven by conflicting factors. As just one example, it is often desirable for an athletic shoe to have a construction that supports and protects the wearer's foot during a particular athletic endeavor. However, "breathability" is also a desirable quality in many types of athletic shoes. In particular, the air that flows between the interior and exterior of the shoe through the upper of the shoe can help alleviate the effects of heat and sweat that typically develop around the foot during physical activity. However, many materials that provide support and foot protection can block the flow of air and moisture through the upper. Conversely, many materials that aid in the flow of air and moisture provide little support or protection to the wearer's foot.

One solution is to make a shoe in which some parts are formed from a supportive/protective material and some parts are formed from a breathable material. However, this may increase the complexity and cost of the manufacturing process. Additionally, the use of material joining techniques such as stitching and adhesives may add weight to the footwear. Additionally, footwear design (including athletic footwear design) is also driven by aesthetics. The complex production processes developed to manufacture complex shoes can potentially limit the ability of the manufacturer to alter the design of the shoe to achieve different aesthetics.

overview

In one aspect, the present disclosure relates to an article of footwear having a sole structure fixedly attached to an upper configured to receive a foot of a wearer. The upper may include a skin forming at least a portion of an outer surface of the upper. The upper may also include reinforcement material selectively located on the interior and adjacent portions of the skin, thereby defining reinforced portions of the skin and unreinforced portions of the skin. The reinforcing material may be selectively joined to the skin by welding at a bonded region, the bonded region having an outer exposed surface defining a portion of the outer surface of the upper. Additionally, the skin layer can have a first color and the outer exposed surface of the bonded area can have a second color that is different from the first color.

In another aspect, the present disclosure relates to an article of footwear having a sole structure fixedly attached to an upper defining a cavity configured to receive a foot of a wearer. The upper may include a skin forming at least a portion of an outer surface of the upper, the skin being formed of a mesh material. In addition, the upper may include reinforcing material selectively located in the interior and adjacent to the skin, thereby defining a reinforced portion of the skin and an unreinforced portion of the skin. The unreinforced portion of the skin may provide direct ventilation through the mesh material of the skin to the interior cavity defined by the upper. Additionally, the reinforcing material may be selectively joined to the skin by welding at a bonded region, the bonded region having an outer exposed surface defining a portion of the outer surface of the upper. Furthermore, the skin layer may have a first color and the outer exposed surface of the bonded area may have a second color, the second color being different from the first color.

In another aspect, the present disclosure relates to an article of footwear having a sole structure fixedly attached to an upper configured to receive a foot of a wearer. The upper may include a skin forming at least a portion of an outer surface of the upper. The upper may also include reinforcement material selectively located on the interior and adjacent portions of the skin, thereby defining reinforced portions of the skin and unreinforced portions of the skin. The reinforcing material may be selectively joined together with the skin by welding at a bonded region, the bonded region having an outer exposed surface defining a portion of the outer surface of the upper. Additionally, the skin layer may have a first color and the reinforcing material may have a second color that is different from the first color. Also, the outer exposed surface of the bonding area may include a portion of the reinforcing material, thereby providing the outer exposed surface of the bonding area with substantially the same color as the reinforcing material.

In another aspect, the present disclosure is directed to a method of manufacturing an article of footwear that includes forming an upper configured to receive a foot of a wearer. The method may include selectively attaching the internal reinforcement material to the skin using welding. The method may also include arranging the skin to form at least a portion of the outer surface of the upper. The skin layer may have a first color and the reinforcing material may have a second color different from said first color. Welding the inner reinforcing material to the skin layer can form a bonded area, the bonded area has an outer exposed surface that defines a portion of the outer surface of the upper, the outer exposed surface of the bonded area includes a portion of the reinforcing material, thereby providing an externally exposed surface of the bonded area. The surface offers a different color than the top layer.

Brief description of the drawings

The invention can be better understood with reference to the following drawings and descriptions. The components in the figures are not necessarily to scale, emphasis instead being placed upon illustrating the principles of the invention. Furthermore, in the drawings, like reference numerals designate corresponding parts throughout the different views.

Figure 1 shows a perspective view of an embodiment of an article of footwear;

Figure 2 shows an exploded view of the article of footwear shown in Figure 1;

Figure 3 shows another perspective view of the article of footwear shown in Figure 1;

Figure 4 shows a rear perspective view and an interior view of the article of footwear shown in Figure 1;

Figure 5 shows an enlarged version of a portion of the view of the article of footwear shown in Figure 4;

Figure 6 shows a perspective view of an enlarged portion of the article of footwear and the upper of the article of footwear;

Figure 7 shows a cross-sectional view taken along line 4-4 of Figure 3;

8 shows an enlarged view of a portion of an upper of an article of footwear according to another embodiment;

9-11 illustrate an exemplary process for ultrasonically welding layers of an upper;

12 illustrates an exemplary tongue portion of an article of footwear;

Figure 13 shows a cross-sectional view of the tongue taken along line 13-13 of Figure 12; and

FIG. 14 shows a cross-sectional view of the tongue taken along line 14 - 14 of FIG. 12 .

detail

The following discussion and drawings disclose sole structures for articles of footwear. The footwear-related concepts disclosed herein may be applied to various athletic footwear types including, for example, running shoes, basketball shoes, soccer shoes, baseball shoes, football shoes, and golf shoes. Accordingly, the concepts disclosed herein are applicable to a variety of footwear types.

To aid and clarify the subsequent description of various embodiments, various terms are defined herein. Unless otherwise indicated, the following definitions apply throughout this specification, including the claims. For consistency and convenience, directional adjectives are used throughout this detailed description corresponding to the illustrated embodiments.

The term "longitudinal" as used throughout this detailed description and in the claims refers to a direction extending the length of the sole structure, ie, from the forefoot portion of the sole to the heel portion. The term "forward" is used to refer to the general direction in which the toes of the foot are pointing, and the term "rearward" is used to refer to the opposite direction, ie the direction in which the heel of the foot is facing.

The term "transverse direction" as used throughout this detailed description and in the claims refers to a side-to-side direction extending the width of the sole. In other words, the lateral direction may extend between a medial side of the article of footwear and a lateral side, where the lateral side of the article of footwear is the surface facing away from the other foot and the medial side is the surface facing the other foot.

The term "transverse axis" as used throughout this detailed description and in the claims means an axis oriented in a transverse direction.

As used throughout this detailed description and in the claims, the term "horizontal" means any direction substantially parallel to the ground, including longitudinal directions, transverse directions, and all directions in between. Likewise, the term "side" as used in this specification and claims refers to any portion of a component generally facing an outboard direction, a medial direction, a forward direction or a rearward direction, such as opposite an upward or downward direction.

The term "vertical" as used throughout this detailed description and in the claims refers to a direction generally perpendicular to the transverse and longitudinal directions. For example, where the sole is laid flat on a ground surface, the vertical direction may extend upwards from the ground surface. It will be understood that each of these directional adjectives may apply to various components of the sole. The term "upward" refers to a vertical direction of progress away from the ground, and the term "downward" refers to a vertical direction of progress towards the ground. Likewise, the terms "top", "upper" and other similar terms refer to that part of an object generally vertically farthest from the ground, while the terms "bottom", "lower" and other similar terms refer to the The part that is closest to the ground in a generally vertical direction.

The "interior" of a shoe refers to the space occupied by the wearer's foot when the shoe is put on. The "inside" of a panel or other shoe element refers to the face of the panel or element that is oriented toward (or will be toward) the interior of the shoe in the finished shoe. "Outside" of an element refers to the face of the element that is (or will be) oriented away from the interior of the shoe in the finished shoe. In some cases, the inner side of an element may have other elements between the inner side and the interior in the finished shoe. Similarly, the outer side of an element may have other elements between that outer side and the space outside of the finished shoe. Furthermore, the terms "inwardly" and "inwardly" shall refer to a direction toward the inside of the shoe, while the terms "outward" and "outwardly" shall refer to a direction toward the outside of the shoe.

For the purposes of this disclosure, when the above directional terms are used to refer to an article of footwear, it shall refer to the article of footwear when in an upright position with the sole facing the ground, that is, as the article of footwear is worn by the wearer. , which is positioned to stand on a generally horizontal surface.

Additionally, for the purposes of this disclosure, the term "fixedly attached" shall mean that two components are connected in such a way that the components cannot be easily separated (eg, without destroying one or both of the components). Exemplary forms of fixed attachment may include joining using permanent adhesives, rivets, stitches, nails, staples, welding or other thermal bonding or other joining techniques. Additionally, two components may be "fixedly attached" by virtue of being integrally formed, eg, in a molding process.

FIG. 1 depicts an embodiment of an article of footwear 100 . Footwear 100 may include sole structure 105 and upper 110 secured to sole structure 105 and configured to receive a foot. For reference purposes, footwear 100 may be divided into three general regions: forefoot region 115 , midfoot region 120 , and heel region 125 . Forefoot region 115 generally includes portions of footwear 100 that correspond to the toes and the joints connecting the metatarsals to the phalanges. Midfoot region 120 generally includes a portion of footwear 100 that corresponds to an arch area of the foot. Heel region 125 generally corresponds to the rear portion of the foot including the calcaneus. Regions 115 , 120 , and 125 are not intended to delineate precise regions of footwear 10 . Rather, regions 115, 120, and 125 are intended to represent generally relevant regions of footwear 100 to facilitate the following discussion. Because various features of footwear 100 extend beyond a region of footwear 100, the terms forefoot region 115, midfoot region 120, and heel region 125 apply not only to footwear 100, but also to various aspects of footwear 100. feature.

As shown in FIG. 1 , upper 110 may include one or more material elements (eg, mesh, textile, foam, leather, and synthetic leather) that may be joined to define an interior cavity configured to receive a foot. 130. Material elements may be selected and arranged to selectively impart properties such as light weight, durability, breathability, abrasion resistance, flexibility, and comfort. Upper 110 may define opening 135 configured to receive a wearer's foot into interior cavity 130 . Additionally, upper 110 may include laces 140 , which may be used to modify the dimensions of inner cavity 130 to secure the foot within inner cavity 130 and facilitate entry and removal of the foot from inner cavity 130 . Lace 140 may extend through lace receiving loop 145 in upper 110 . Lace receiving loop 145 may extend from reinforcement strap 150 proximate lace region 155 of upper 110 , which may be in instep region 157 of footwear 100 . As further shown in FIG. 1 , footwear 100 may also include tongue 800 .

In some embodiments, reinforcement strap 150 may include eyelets or holes configured to receive lace 40 . Additionally, upper 110 may alternatively implement any of a variety of other configurations, materials, or closure mechanisms. For example, optional closure mechanisms such as hook and loop fasteners (e.g., straps), buckles, clasps, straps, or any other means for securing the foot within the inner cavity 130 defined by the upper 110 .

Sole structure 105 may be fixedly attached to upper 110 (eg, using adhesives, stitching, welding, or other suitable techniques), and may have a configuration that extends between upper 110 and the ground. Sole structure 105 may include means for attenuating ground reaction forces (ie, cushioning and stabilizing the foot during vertical and horizontal loads). Additionally, sole structure 105 may be configured to provide traction, impart stability, and control or limit various foot motions, such as pronation, supination, or other motions.

The configuration of sole structure 105 may vary significantly depending on the type or types of ground on which sole structure 105 may be used. For example, the disclosed concepts may be applied to footwear configured for use on any of a variety of surfaces, including indoor or outdoor surfaces. The configuration of sole structure 105 may vary based on the nature and conditions of the surface on which footwear 100 is intended to be used. For example, sole structure 105 may vary depending on whether the surface is harder or softer. Additionally, sole structure 105 may be customized for use in wet or dry conditions.

In some embodiments, sole structure 105 may be configured for a particular specialized surface or condition. For example, in some embodiments, footwear 100 is shown in the drawings as a running shoe, and accordingly, sole structure 105 is shown configured to provide cushioning, stability, and traction on hard, slippery surfaces, such as pavement. friction. However, the proposed footwear upper construction can be adapted for any kind of footwear, such as basketball, soccer, rugby and other athletic activities. Accordingly, in some embodiments, sole structure 105 may be configured to provide traction and stability on a hard indoor surface (eg, hardwood), on a soft natural turf surface, or on a hard artificial turf surface. In some embodiments, sole structure 105 may be configured for use on a number of different surfaces.

In some embodiments, sole structure 105 may include a plurality of components that, individually or collectively, may provide footwear 100 with attributes such as support, stiffness, flexibility, stability, cushioning, comfort, reduced weight. or other attributes. In some embodiments, sole structure 105 may include an insole/sole (see FIG. 4 ), midsole 160, and ground-contacting sole member 165, which may have an exposed ground-contacting lower surface 170, as shown in FIG. shown in 1. However, in some cases, one or more of these components may be omitted.

An insole may be disposed within cavity 130 defined by upper 110 . The insole may extend through each of forefoot region 115 , midfoot region 120 , and heel region 125 of footwear 100 and between lateral side 175 and medial side 180 of footwear 100 . The insole may be formed from a deformable (eg, compressible) material, such as polyurethane foam or other polymer foam materials. Thus, the insole can provide cushioning by virtue of its compressibility and also conform to the foot to provide comfort, support and stability.

Midsole 160 may be fixedly attached to a lower region of upper 110 (eg, by stitching, adhesive bonding, thermal bonding (such as welding), or other techniques) or may be integrated with upper 110 . Midsole 160 may extend across each of forefoot region 115 , midfoot region 120 , and heel region 125 of footwear 100 and between lateral side 175 and medial side 180 of footwear 100 . In some embodiments, portions of midsole 160 may be exposed around the perimeter of footwear 100 , as shown in FIG. 1 . In other embodiments, midsole 160 may be completely covered by other elements, such as layers of material from upper 110 . Depending on the activity for which footwear 100 is intended, midsole 160 may be formed from any suitable material having the properties described above. In some embodiments, midsole 160 may comprise a foamed polymer material such as polyurethane (PU), ethylvinylacetate (EVA) or otherwise act as a foam when sole structure 105 contacts the ground during walking, running, or other athletic activities. Any other suitable material that attenuates ground reaction forces.

In some embodiments, at least a portion of an upper of an article of footwear may be formed by a skin layer. In some embodiments, internal reinforcement material may be welded to the skin in selected areas. The welded area may be provided with a different color variation than the exposed surface. Internal reinforcements provide support, protection and comfort in the appropriate areas based on the intended activity of the footwear. In addition, additional layers may cover the skin in one or more areas, such as the heel and toe areas, to provide additional durability. In some embodiments, these additional layers may also serve decorative purposes.

As used herein, the term "welding" (and its variations) is defined as a fastening technique between two components that involves softening or melting the material of at least one component such that the materials of the components, when cooled, bond to each other fixed. Similarly, the term "weld" or variations thereof is defined as a joint, connection, or structure that joins two elements by a process that involves softening or melting of material within at least one element such that the elements are Firm each other while cooling. In some embodiments, welding can involve the melting or softening of two parts so that the materials from each part mix with each other, that is, the material can diffuse through the boundary layer between the materials and become fixed when cooled together. In some embodiments, welding may involve melting or softening of the material in the first part such that the material extends or penetrates into the structure of the second part, such as into a crevice or chamber in the second part, or around the second part The filaments or fibers in one stretch or bond with filaments or fibers in a second part to hold the parts together as they cool. Thus, welding of two parts together may occur when material from one or both of the parts melts or softens. Accordingly, a weldable material such as a polymeric material may be provided in one or both of the components. Additionally, welding generally does not involve the use of stitching or adhesives, but involves directly bonding parts to each other with heat. In some cases, however, stitching or adhesives may be used to supplement welds or connections of components that are welded.

Various heating techniques can be used to weld components to each other. In some embodiments, suitable heating techniques may include conductive heating, radiative heating, high frequency heating, laser heating, or combinations of these techniques. In some embodiments, welding methods used to join portions of the upper may include high frequency welding methods, such as ultrasonic welding or radio frequency (RF) welding.

In embodiments where high frequency welding methods are used to form welds in the upper, the upper material may be any material suitable for such methods. For example, materials suitable for high frequency welding may include thermoplastic materials or natural materials coated with thermoplastic materials. Examples of materials suitable for high frequency welding methods include acrylic, nylon, polyester, polylactic acid, polyethylene, polypropylene, polyvinyl chloride (PVC), urethane, coated with one or more thermoplastic materials Natural fibers and combinations of these materials. In some embodiments, natural fibers such as cotton or wool may be coated with a thermoplastic material such as ethylene vinyl acetate or thermoplastic polyurethane.

The use of welding can provide several advantages over the use of adhesives or stitching. For example, the use of welding can produce lighter weight shoes due to the absence of seams and adhesives. By eliminating stitching and adhesives, the substances that would otherwise be imparted by the stitching and adhesives can be used for other structural elements that enhance performance attributes of the article of footwear, such as cushioning, durability, stability, and aesthetic properties. Another advantage is related to manufacturing efficiency and cost. The application of sutures and adhesives can be a relatively time-consuming process. By welding the parts, the manufacturing time can be shortened. Additionally, costs can be reduced by eliminating the expense of adhesive or suture materials. In addition, welding (ie, joining materials without using adhesives or stitching) can preserve the flexibility of the upper of the article of footwear because adhesives and stitching can increase the stiffness of the upper material. The flexibility of the upper allows the upper to conform to the wearer's foot, thereby providing an improved fit. The flexible upper may also provide improved comfort by conforming to the wearer's foot. In some embodiments, the skin can be a mesh skin. In parts of the upper, the mesh skin may remain unreinforced, allowing directional ventilation through the upper. That is, in the unreinforced portion, the skin may have an outwardly exposed outer surface and an inwardly exposed inner surface. Thus, in such embodiments, openings in the unreinforced skin mesh may allow ventilation through the upper. In addition to ventilation, the openings in the mesh skin can also provide other benefits, such as weight reduction, flexibility, and other advantages. In some embodiments, the upper may consist essentially of the skin in the unreinforced portion of the skin, and thus may not include any additional layers. In some areas, the grid may be provided in panels extending between the reinforcement panels, the grid and reinforcement panels being connected only at adjoining edges, eg with minimal overlap.

Upper 110 may include skin 185 that forms at least a portion of an exterior surface of upper 110 . Upper 110 may also include reinforcing material 190 that is selectively located inwardly and proximate portions of skin 185 , thereby defining reinforced portions 195 of skin 185 and unreinforced portions 200 of skin 185 . As shown in FIG. 1 , the reinforcement portion 195 may include a plurality of striped line portions. For example, enhancement portion 195 may include first enhancement portion 301 , second enhancement portion 302 , third enhancement portion 303 , fourth enhancement portion 304 , fifth enhancement portion 305 , sixth enhancement portion 306 , and seventh enhancement portion 307 . The arrangement of reinforced portion 195 and unreinforced portion 200 is discussed in more detail below.

In some embodiments, reinforcing material 190 may be selectively attached to skin 185 . For example, reinforcing material 190 may be selectively bonded to skin 185 at bonding region 205 by welding. As shown in FIG. 1 , bonding area 205 may have an outer exposed surface that defines a portion of the outer surface of upper 110 .

Reinforcement material 190 may provide advantages with regard to various properties such as strength, durability, support, stability, and other attributes. In some embodiments, reinforcement material 190 may be a material having a tensile strength or puncture strength that is substantially the same as or greater than skin layer 185 . Thus, in some embodiments, reinforcing material 190 may provide increased strength to upper 110 in selected areas. In some embodiments, reinforcement material 190 may be a material that has a greater wear resistance than skin layer 185 . In such embodiments, reinforcing material 190 may provide increased durability to upper 110 . In some embodiments, reinforcement material 190 may have the same or a lower elasticity than skin 185 . In such embodiments, reinforcing material 190 may provide additional support and stability to the wearer, for example by limiting the amount that skin 185 may stretch within reinforced portion 195 .

In some embodiments, portions of upper 110 may include one or more additional layers/components for reinforcement, support, padding, and stability. For example, in some embodiments, upper 110 may include one or more panels adhered to the exterior of or adjacent to skin 185 . Reinforcement strip 150 is one example of such additional layers/components. Additionally, as shown in FIG. 1 , upper 110 may include heel panel 210 . Additionally or alternatively, in some embodiments, upper 110 may include toe panel 215 . In some embodiments, additional panels of material such as heel panel 210 and toe panel 215 may be welded to skin 185 . Heel panel 210 and toe panel 215 may provide additional protection for the wearer's foot. Additionally, heel panel 210 and toe panel 215 may provide additional durability to upper 110 . Additionally, in some embodiments, heel panel 210 and toe panel 215 may provide additional stability to footwear 100 . Additionally, heel panel 210 and toe panel 215 may be configured to provide an aesthetic appearance.

In some embodiments, the grid surface layer may be a full-length layer. That is, skin 185 may extend throughout all or substantially all of upper 110 . In such embodiments, additional layers such as heel panel 210 and toe panel 215 may be adhered to the outer surface of skin layer 185 . In other embodiments, additional weight may be saved by using skin 185 only in areas of footwear 100 where skin 185 is exposed, such as between heel panel 210 and toe panel 215 .

In some embodiments, padding may be included in one or more portions of the upper to provide comfort and a snug fit against the contours of the foot. For example, in some embodiments, ankle region 220 of upper 110 proximate opening 135 may include compressible padding, such as foam padding, to provide cushioning and a snug fit against the wearer's ankle.

FIG. 2 is an exploded view of footwear 100 shown in FIG. 1 . FIG. 2 shows sole structure 105 and the various components that may make up an upper. For example, skin 185 is shown. The skin 185 is shown as a full length skin in FIG. 2 .

In some embodiments, as shown in FIG. 2 , heel panel 210 and toe panel 215 may be fixedly attached to the outer surface of skin 185 . This fixed attachment can be done by welding. However, it should be noted that, as discussed above, in some embodiments, skin layer 185 may be less than a full-length layer, and may instead extend between additional panel components such as heel panel 210 and toe panel 215 . In such an embodiment, heel panel 210 and toe panel 215 may overlap skin 185 only minimally, eg, bordering the edge of each panel at the perimeter. The shape and size of heel panel 210 and toe panel 215 may vary according to desired performance characteristics such as weight, foot protection, durability, aesthetic design, and other such characteristics. Additionally, the materials from which heel panel 210 and toe panel 215 may be formed may vary according to the same or similar desired performance characteristics.

Figure 2 shows the strip of reinforcing material 190 in a detached state. These bands may be placed against the inner surface of skin 185 . The placement of reinforcing materials in footwear 100 will be discussed in more detail below.

Additional panels may also be disposed around the throat opening of footwear 100 . For example, an inner liner panel 191 and a reinforced collar panel 192 may be disposed on the interior of the skin 185 . However, in some embodiments, enhanced collar panel 192 may be disposed on the exterior of skin 185 . FIG. 2 also shows a foam collar panel 193 that may be disposed between the inner lining panel 191 and the reinforced collar panel 192 . Foam collar panel 193 may be a compressible member that may conform to the contours of the foot near the ankle to improve fit and comfort. This compressible foam collar panel 193 may also provide ankle protection against impact and displacement of footwear 100 due to loads experienced during athletic activity.

As further illustrated in FIG. 2 , tongue 800 may include multiple components. For example, as shown in FIG. 2 , tongue 800 may include a grip portion 875 that may form an outer surface of an upper portion of tongue 800 . Grip portion 875 may provide a suitable area for gripping tongue 800 when footwear 100 is on the foot. Additionally, the grip portion 875 may provide a location for displaying indicia such as a logo or other graphic or text. Additionally, tongue 800 may include a skin 885 . Skin 885 may be formed of the same or similar material as skin 185, such as a mesh material. In some embodiments, skin layer 885 may form a substantial majority of the outer surface of tongue 800 . That is, the area of skin 885 not covered by grip portion 875 may form a substantial majority of the outer exposed surface of tongue 800 . As shown in FIG. 2 , skin 885 may extend the full length of tongue 800 , and thus, grip portion 875 may overlap skin 885 . However, in some embodiments, the skin 885 and the grip portion 875 may be joined at their peripheral edges, and thus may not overlap or may overlap minimally. This may save weight by reducing the amount of cover material used to form tongue 800 .

As shown in FIG. 2 , tongue 800 may also include a plurality of foam pads 880 and a lining 890 . Foam pad 880 may be disposed between skin 885 (or grip 875 ) and liner 890 . Foam sock 880 may be compressible, and thus, may provide comfort and an improved fit in the instep region of footwear 100 . Liner 890 may be formed from a material suitable for contacting the skin of a wearer's foot or a foot covered with a sock. Thus, liner 890 may be formed of a material that enables a sock-covered foot to slide in and out of footwear 100 with minimal effort. In addition, liner 890 may also have moisture-wicking properties to wick sweat from the wearer's foot.

The layers of tongue 800 may be joined using one or more joining techniques such as welding, stitching, thermal bonding, or other suitable construction methods. Additional details of the construction of tongue 800 are discussed below with respect to FIGS. 12-14.

In some embodiments, the skin may be exposed over a relatively large area of the upper. Accordingly, the reinforcing material and the bonded areas where the reinforcing material is bonded to the cover may serve to enhance the span of the cover between other footwear components. That is, a strip of reinforcing material may extend between footwear components. Similarly, a bonded region may include lines of bonded material extending between components of the article of footwear. For example, a strip of reinforcing material and a line of bonded areas may extend from a midsole of the article of footwear to a strip of reinforcement proximate a lace area of the article of footwear. This configuration can provide structural support in a generally vertical orientation. In some embodiments, however, the lines of the straps and bonded areas may be angled to strategically reinforce the upper in certain directions and orientations.

In some embodiments, first reinforcement portion 301 may extend from reinforcement strip 150 to sole structure 105 , for example to midsole 160 , as shown in FIG. 3 . As the first reinforcement portion 301 approaches the midsole 160, the first reinforcement portion 301 may extend not only in the vertical direction but also in the forward direction. The inclination of the first reinforcement portion 301 may provide structural support in the front-to-back direction. For example, first reinforced portion 301 may act in tension to resist forces that tend to translate upper 110 relative to sole structure 105 in a rearward direction. For example, such a force may be generated when an athlete accelerates in a forward direction. In addition, the first reinforcement portion 301 can also span between the reinforcement band 150 and the toe portion 215 , thereby providing further reinforcement to the upper 110 by connecting the skeleton structure of the upper 110 .

Second reinforcement portion 302 may also extend from reinforcement strip 150 to midsole 160 , as shown in FIG. 3 . Additionally, second reinforced portion 302 may extend in a generally vertical direction when viewed from the side of footwear 100 . Additionally, the second reinforced portion 302 may be connected to the reinforced band 150 proximate to the first reinforced portion 301 .

Third reinforcement portion 303 may extend from reinforcement strip 150 to midsole 160 , as shown in FIG. 3 . As the third reinforcement portion 303 approaches the midsole 160, the third reinforcement portion 303 may extend not only vertically but also in a rearward direction. The inclination of the second reinforcement portion 303 may provide structural support in the front-to-back direction. For example, third reinforced portion 303 may act in tension to resist forces that tend to translate upper 110 in a forward direction relative to sole structure 105 . For example, such forces may be generated when an athlete slows or stops his forward motion. Additionally, the third reinforcement portion 303 may be connected to the reinforcement band 150 proximate to the second reinforcement portion 302 .

Each of the first reinforcement portion 301 , the second reinforcement portion 302 and the third reinforcement portion 303 may be attached to the reinforcement band 150 adjacent to each other and provide supportive reinforcement in different directions (front, rear and vertical). This may aid in the stability of footwear 100 by maintaining the relative position of upper 110 with respect to sole structure 105 . In some embodiments, first reinforced portion 301 , second reinforced portion 302 , and third reinforced portion 303 may be in a forefoot portion of footwear 100 , for example, in an area corresponding to the first metatarsal head and the first metatarsophalangeal joint. Adjacent to each other are connected to the reinforcement bands 150 . This joint is the flexion point of the forefoot. Therefore, maintaining the positioning of upper 110 relative to sole structure 105 in this joint area is advantageous. This may promote the comfort, fit, and performance of footwear 100 .

First reinforced portion 301, second reinforced portion 302, and third reinforced portion 303 are strategically positioned on the lateral and medial sides of footwear 100 in the orientations discussed above to provide anteroposterior stability in the first metatarsophalangeal joint area, which may The first unreinforced region 311 in the forefoot region is made relatively wide across the unreinforced skin. This provides additional ventilation and reduces weight.

Fourth reinforced portion 304 and fifth reinforced portion 305 may extend from reinforcement strip 150 to midsole 160 , as shown in FIG. 3 . Additionally, the fifth reinforced portion 305 may be connected to the reinforcement band 150 proximate to the fourth reinforced portion 304 and may separate as the fourth and fifth reinforced portions 304 and 305 are proximate to the midsole 160 . Also, the sixth reinforcement portion 306 and the seventh reinforcement portion 307 may be arranged similarly to the fourth reinforcement portion 304 and the fifth reinforcement portion 305, ie, in an inverted "V" shape. This inverted "V" shape may provide structural support in a manner similar to the first reinforced portion 301, the second reinforced portion 302, and the third reinforced portion 303 discussed above.

It should also be noted that the arrangement of the upper ends of the reinforcing portions converging at different regions of the reinforcing strip 150 and diverging near the midsole 160 results in a structural connection between the reinforcing strip 150 and the diverging proximal midsole 160, although both parts have different lengths. That is, reinforcement strip 150 has a first length corresponding to a lace region, while midsole 160 has a second length that extends the full length of footwear 100 and is thus longer than the first length of reinforcement strip 150 .

In other embodiments, the reinforced portions of upper 110 may have other arrangements to provide strength, support, durability, and other performance characteristics. For example, in some embodiments, reinforcement portions may be arranged in an "X" configuration between various components of footwear 100 rather than an inverted "V" arrangement. Other arrangements are possible depending on where the enhancements are desired for performance benefit.

By strategically placing reinforced portions of upper 110, a relatively large portion of the surface area of upper 110 may be formed by an unreinforced skin. For example, in addition to the first non-reinforced part 311 , a second non-reinforced part 312 may also be disposed between the first reinforced part 301 and the second reinforced part 302 . In addition, a third non-reinforced portion 313 may be disposed between the second reinforced portion 302 and the third reinforced portion 303 . A fourth non-reinforced portion 314 may be disposed between the third reinforced portion 303 and the fourth reinforced portion 304 . Furthermore, a fifth non-reinforced portion 315 may be disposed between the fourth reinforced portion 304 and the fifth reinforced portion 305 . Also, a sixth non-reinforced portion 316 may be disposed between the fifth reinforced portion 305 and the sixth reinforced portion 306 . A seventh non-enhanced portion 317 may be disposed between the sixth enhanced portion 306 and the seventh enhanced portion 307 . And an eighth non-reinforced portion 318 may be disposed between the seventh reinforced portion 307 and the ankle region 220 .

Similar to second unenhanced section 312, third unenhanced section 313, fourth unenhanced section 314, fifth unenhanced section 315, sixth unenhanced section 316, seventh unenhanced section 317 and eighth unenhanced section 318 Additional unreinforced portions of the footwear 100 may be disposed on opposite sides. Thus, in some embodiments, the medial and lateral sides of upper 110 may be substantially mirror image images depending on the placement of reinforcement materials. In some embodiments, the common surface area of the unreinforced portions may form a substantial majority of the surface area of the exposed skin layers.

Furthermore, in some embodiments, the common surface area of the unreinforced portions may constitute a substantial majority of the surface area of upper 110 . By providing a relatively large portion of upper 110 as unreinforced, upper 110 may provide ventilation, flexibility, and reduced weight.

In some embodiments, welding may be used not only to join components but also to alter the appearance of those components by changing the surface color of the exterior portion of the footwear upper. For example, in some embodiments, the unreinforced skin layer can have a first color. As discussed in more detail below, the skin may be a mesh material, and thus, portions of the underlying reinforcement material may show through openings in the mesh skin. If the reinforcing material has a second color different from the first color of the skin, the appearance of the reinforced portion of the skin may have a third color that is a blend of the first color of the skin and the second color of the reinforcing material. In addition, the bonding area where the reinforcing material is bonded to the skin may have a fourth color. This fourth color may be substantially the same as the second color of the reinforcement material since the skin may become embedded in the reinforcement material during the welding process. In some embodiments, however, the bonding zone may have a color that is a blend of the first color of the skin and the second color of the reinforcing material. Additionally, other portions of the footwear may have a fifth color, which may be the same or different than the other components of the footwear. The difference in color can be used for aesthetic design purposes. Additionally, through color arrangements, color differences can be used to reveal different structural aspects of the footwear construction.

The unreinforced skin layer can have the first color. For example, as shown in FIG. 3, a first unenhanced portion 311, a second unenhanced portion 312, a third unenhanced portion 313, a fourth unenhanced portion 314, a fifth unenhanced portion 315, a sixth unenhanced portion 316 . The seventh unenhanced portion 317 and the eighth enhanced portion 318 may have a first color which is simply represented as a grid in FIG. 3 . Although not shown explicitly in FIG. 3 , the reinforcing material may have a second color. For purposes of discussion, FIG. 3 illustrates a configuration in which the second color of the reinforcing material is generally the same as the fifth color of other footwear components such as heel panel 210, toe panel 215, and reinforcement band 150, which Parts are shown in relatively dark stippling.

The appearance of the reinforced portion of the skin may have a third color blended from the first color of the skin and the second color of the reinforcing material. For example, as shown in FIG. 3, a first enhancement part 301, a second enhancement part 302, a third enhancement part 303, a fourth enhancement part 304, a fifth enhancement part 305, a sixth enhancement part 306 and a seventh enhancement part 307 may have a third color that is an intermediate color between the first color of the skin and the second color of the reinforcing material. Accordingly, the first enhanced portion 301, the second enhanced portion 302, the third enhanced portion 303, the fourth enhanced portion 304, the fifth enhanced portion 305, the sixth enhanced portion 306, and the seventh enhanced portion 307 use medium dark stippling. out.

Additionally, the bonding region 205 where the reinforcing material is bonded to the skin may have a fourth color. The fourth color may be substantially the same as the second color of the reinforcement material. Accordingly, the bonding region 205 is shown in FIG. 3 as having a relatively dark stippling. The outer exposed surface of the bonding area 205 may be given a fourth color different from the first color by welding a reinforcing material to the skin. It should be noted that in some embodiments, the additional layers/components discussed above, such as reinforcement strip 150 , heel panel 210 , and toe panel 215 , may be formed from the same or similar material as reinforcement material 190 . For example, these components could all be formed from relatively lightweight fabric. In some embodiments, the lines of bonded area 205 can be color matched to other footwear components to provide various decorative appearances. In some embodiments, one or more footwear components may have a different color than the reinforcement material and bonded area 205 to provide a different visual appearance.

The welding process may change the apparent color of the outer surface of upper 110 by relocating portions of reinforcement material to the outer surface of upper 110 . For example, the welding process may involve melting of the reinforcing material 190 such that the reinforcing material flows between the fibers of the skin 185 (eg, through openings in the skin mesh material) from the inside of the skin 185 to the outer exposed side of the skin 185 . Thus, the outer exposed surface of the bonding area 205 may include a portion of the reinforcing material, thereby providing the outer exposed surface of the bonding area 205 with substantially the same color as the reinforcing material. The mechanism by which the portion of reinforcement material is repositioned will be explained in more detail below.

Although the color of footwear 100 is shown in FIG. 3 in various shades of gray, it should be understood that components of footwear 100 may be of any suitable color. Furthermore, the difference in color between parts may be different shades of a given color, such as dark red and light red. In addition, the blending of colors can produce not only different shades of colors but also completely different colors. For example, in some embodiments, a yellow skin layer can be combined with a blue reinforcing material to form a reinforced portion or bonded area with a green appearance.

FIG. 4 shows a perspective view of access through opening 135 into cavity 130 within upper 110 of footwear 100 . FIG. 4 shows insole 225 and shows the strip of reinforcing material 190 extending upwardly from below insole 225 . As shown in FIG. 4 , portions of the skin layer 185 are exposed inwardly between the strips of reinforcement material 190 . Thus, these unreinforced portions of skin 185 are both externally and internally exposed. Thus, in some embodiments, while skin layer 185 may be a mesh material, unreinforced portions of skin layer 185 may provide direct ventilation through skin layer 185 to interior cavity 130 defined by upper 110 .

FIG. 5 is an enlarged view of a portion of FIG. 4 showing the interior surface of upper 110 . As shown in FIG. 5 , non-enhanced portions 196 (such as sixth unenhanced portion 316, seventh unenhanced portion 317, and eighth unenhanced portion 318) may be disposed on enhanced portion 190 (such as sixth enhanced portion 306 and between the seventh enhancement part 307). The reinforcing part may be welded to the skin, eg in the first bonding zone 321 , the second bonding zone 322 , the third bonding zone 323 and the fourth bonding zone 324 . It should be noted that the first bonding area 321 , the second bonding area 322 , the third bonding area 323 and the fourth bonding area 324 are shown in FIG. 5 as having the same color as the reinforcing material. Because FIG. 5 shows the inner side of upper 110 , the skin is not shown since it is not internally exposed near the bonding area. Thus, the bonded area may have the same color as the reinforcing material on the inner side of upper 110 .

It should also be noted that in some locations, two bonding regions can be connected to form more complex patterns. For example, as shown in FIG. 5 , second bond region 322 and third bond region 323 may converge to form an inverted "V" arrangement. This connection of bonded areas may provide a structural connection between the skeleton components of upper 110 . Additionally, in some embodiments, sixth reinforced portion 306 and seventh reinforced portion 307 may be formed from separate strips of reinforcing material. In such an embodiment, the bonding areas connecting the individual straps to the skin can provide a structural connection between the individual straps, thereby creating a truss-like structure.

6 and 7 illustrate the structure of the reinforced portion of upper 110 in more detail. The arrangement of skin 185 , reinforcement material 190 , and bonded areas 205 is shown in more detail in FIG. 6 , which shows an enlarged view of one of the striated regions of upper 110 created by reinforced portions 195 of skin 185 . As shown in FIG. 6, the skin layer 185 may be formed from a mesh material. As shown in the enlarged view portion of FIG. 6, the skin 185 may include a plurality of openings 230, which may provide weight reduction and ventilation. In unreinforced portion 200 , openings 230 may provide direct ventilation to the interior of footwear 100 . In certain embodiments, the mesh material can have more than 50% open area (eg, more than 50% of the surface area of the material includes open spaces through which air can freely flow from side to side).

In a substantial portion of reinforced portion 195 , reinforcing material 190 may be visible behind skin 185 through opening 230 . The reinforcement material 190 may remain adjacent to but free from the skin material 185 throughout a substantial portion of the reinforcement portion 195 . In selected portions of reinforced portion 195 , reinforcing material 190 may be applied to skin 185 to form bonded regions 205 . It should be noted that the unreinforced portion 200 of the skin 185 appears generally white, while the reinforced portion 195 appears generally gray due to the black reinforcement material 190 combined with the white mesh of the skin 185 . The bonded area 205 still appears darker because there are no white gridlines to interfere with the dark color of the reinforcement material 190 in the bonded area 205 .

It should be noted that in the figures the skin material is shown in a relatively simple grid representation. These grid representations are schematic only and are provided in this way for convenience and to avoid obscuring the drawing with too much detail. However, actual materials for surface grids, examples of which are provided below, may have relatively simple square or rectangular grid structures, similar to those shown in the figures. The orientation of the grid can vary. Additionally, in some embodiments, other more complex grid structures may be used for the surface grid material. Furthermore, the size of the grid openings can also vary. The construction of the surface mesh can be selected based on desired performance characteristics, including weight, strength, puncture resistance, ventilation and other properties.

In at least some embodiments, the mesh material of the skin 185 can be a single ply warp knit (or other type of woven material) with an open structure and can be made of nylon, polyester, nylon/polyester blends, recycled Polyethylene terephthalate (rePET) or other materials. However, the mesh material of skin 185 can be made of any desired material, with any desired mesh opening size. Reinforcement material 190 may be any suitable material, including fabrics, textiles, braids, knits, and other such materials. Reinforcing material 190 may be a material that is adhesively compatible with cover 185 and other materials of the shoe. In some embodiments, reinforcing material 190 may be a material that is adhesively compatible with skin 185 during welding. Suitable materials may include crystalline or semi-crystalline materials. In some embodiments, such materials may include thermoplastics. For example, suitable materials may include polyalkylenes such as polyethylene and polypropylene. Other materials may also be suitable for reinforcement, such as nylon, polyester, and other such materials. In some embodiments, reinforcement material 190 may be configured to melt under welding and thereby flow through openings 230 in the mesh of skin 185 , causing skin 185 to become embedded within reinforcement material 190 in the bonded region. In other embodiments, skin 185 and reinforcing material 190 may be configured to melt slightly and adhesively attach to each other (without skin 185 becoming embedded) during welding. In some embodiments, the reinforcing material may melt slightly so that the mesh of skin 185 becomes partially embedded in reinforcing material 190 during welding. In such embodiments, reinforcement material 190 and skin layer 185 may rely not only on a partially embedded structure but also on an adhesive bond created by partial melting of the reinforcement material. In order to achieve welding, the reinforcing material may have the same melting point as the skin layer or a lower melting point than the skin layer. This allows the reinforcing material to melt and flow through the openings in the mesh while the fibers of the mesh remain substantially intact.

As shown in FIG. 6 , bonding region 205 may span one or more openings 230 . Additionally, the amount of reinforcement portion 195 in which reinforcement material 190 is secured to skin 185 may vary. That is, the ratio of bonding region 205 to reinforcing portion 195 may vary from as low as 1:20 to as high as 19:20. In some exemplary embodiments, the straps on the medial and lateral sides of upper 110 may have a ratio of bonded area 205 to reinforced portion 195 of approximately 1:3. For example, as shown in FIG. 6 , the combined width of the lands 205 may be approximately one third of the total width of the reinforced portion 195 .

Because the skin 185 is directly bonded to the reinforcing material 190, the combined strength of the mesh skin 185 and the reinforcing material 190 can eliminate the need for another material on the lateral or medial surface of the upper 110 to provide tensile strength, puncture strength, durability. performance, stability, or other performance characteristics. This allows upper 110 to be lighter than may be used with various conventional shoe construction techniques.

Openings 230 in skin 185 allow air to flow through. This air flow helps cool and dry the foot of the wearer of footwear 100 . In some embodiments, skin layer 185 may be the only layer of upper 110 in certain portions of upper 110 . However, in other embodiments, additional reinforcing materials may be used. For example, reinforcing materials 190 may be selectively located in various portions of the outer layer 185, and additional internal reinforcing materials may provide more comfort and moisture management (eg, moisture away from the foot). This additional inner liner (not shown) may otherwise extend over the unreinforced portion of the other skin 185 . In some embodiments, this additional interior lining can be a relatively breathable material, and thus the ventilation benefits of the mesh skin 185 can be preserved.

FIG. 7 is a cross-sectional view of upper 110 taken at line 7 - 7 in FIG. 6 . As shown in FIG. 7 , the bond zone 205 may be created by embedding the mesh fibers of the skin 185 into the reinforcing material 190 at the time of welding. The fibers of skin 185 may be melted to a greater or lesser extent during the welding process. Thus, in some embodiments, the fibers of skin layer 185 may remain substantially intact when bonded region 205 is formed. In other embodiments, the fibers of the skin 185 may be substantially melted and mixed with the reinforcing material 190 . In some instances, it may be desirable for the fibers of the skin 185 to remain substantially intact in order to maintain the strength and durability of the skin 185 . In some embodiments, the fibers of skin 185 may be slightly deformed, as shown in FIG. 7 . This slight deformation, which may result from slight melting, may improve the bond between the fibers of skin 185 and reinforcement 190 while generally preserving the tensile strength of skin 185 as the fibers of skin 185 remain generally intact.

FIG. 7 also shows the deformation of the reinforcement material 190 in the bonding region 205 . This deformation may be created by heat and pressure applied by the welding process, which may compress reinforcement material 190 . Additionally, FIG. 7 also shows a reinforced portion 195 in which the reinforcing material 190 extends below the skin 185 and an unreinforced portion 200 in which the reinforcing material 190 does not extend.

Figure 8 provides a schematic illustration of an alternative configuration for the mesh material of the skin. For example, FIG. 8 shows a mesh skin 700 backed by reinforcement material 705 in reinforcement portion 730 . Reinforcement portion 730 extends to edge 710 of reinforcement material 705 . In addition, reinforcement material 705 is welded to skin 700 in first bond region 720 and second bond region 725 .

As shown in FIG. 8, the mesh of the surface layer 700 may have a hexagonal structure. This hexagonal structure can provide improved strength and inelasticity in multiple directions compared to square or rectangular grid structures. Grids with grids with other geometric structures can also be used. For example, the skin may be formed from a mesh material having a triangular or octagonal structure. Various shapes can be selected to provide desired performance properties such as directional strength and non-elasticity.

Although the mesh of the surface layer is shown as having a generally two-dimensional structure, in some embodiments, the mesh may have a three-dimensional structure. For example, in some embodiments, the skin may be comprised of a spacer grid or spacer fabric. Three-dimensional mesh structures can provide more complex and tailored performance properties, such as directional tensile strength and inelasticity, as well as puncture strength, abrasion resistance and ventilation.

Some embodiments may use one or more spacer mesh or spacer fabric materials, as described in U.S. Patent Application Publication No. 2013/0266773, Hazenberg et al., published October 10, 2013, and entitled "SpacerTextileMaterialsAndMethodsForManufacturingTheSpacerTextileMaterials," and in 2013 Discussed in US Patent Application Publication No. 2013/0263391 to Chao et al., published October 10 and entitled "Methods for Manufacturing Fluid-Filled Chambers Incorporating Spacer Textile Materials." The entire disclosures of these two patent applications are hereby incorporated by reference in their entirety. In some embodiments, a double needle bar Raschel weave or other three-dimensional weave may be used to form the mesh material of the skin. Exemplary three-dimensional weaves that may be used include two-needle bar Raschel knitting disclosed in "Three-Dimensionally Knit Spacer Fabrics: A Review of Production Techniques and Applications" by Bruer et al., Issue 4, Vol. 4, Summer 2005 , the entire disclosure of which is incorporated herein by reference.

In some embodiments, the bonded mesh composite panels of the upper may be created by assembling individual panels of material for the various layers into a flat configuration. The panels and other elements are assembled so as to have an arrangement in which the relative positions of the panels and elements correspond to the positions that those panels and elements will have in the finished shoe. After assembling the individual panels and other elements into a suitable arrangement and tacking the assembly at various locations, the assembly is subjected to a series of pressing operations to join the assembled elements. These operations result in a flat, one-piece unibody upper shell that can house many or all of the elements to be included in the finished upper. The edges of the monocoque upper shell may then be joined to create a three-dimensional upper body ready for further finishing and attachment to the midsole. Some embodiments may use one or more assembly procedures disclosed in U.S. Patent Application Publication No. 2012/0297643 to Shaffer et al., published November 29, 2012, and entitled "Shoe with Composite Upper and Method of Making the Same," the entire disclosure of which is incorporated by reference This article. Additionally, some embodiments may use U.S. Patent Application No. 13/029,502, filed Feb. 17, 2011 and entitled "Shoe with Composite Upper and Foam Element and Method of Making Same" by Dojan et al. (b) April 2011 U.S. Patent Application Publication No. 2011/0088285 to Dojan et al., filed April 21, and entitled "Composite Shoe Upper and Method of Making Same," and (c) U.S. Patent Application No. 2011/0088285 to Dojan et al., published April 21, 2011, and entitled "Composite Shoe Upper and Method of Making Same" One or more of the footwear assembly methods disclosed in Application Publication No. 2011/0088282. Each of these applications listed above is incorporated by reference in its entirety.

9-11 illustrate an exemplary ultrasonic welding process in more detail. As shown in FIG. 9 , skin 185 and reinforcement 190 (or other components of the upper) may be ultrasonically welded on anvil 235 . Anvil 235 may be a relatively rigid body upon which components may be ultrasonically welded. In some embodiments, anvil 235 can be a relatively flat surface, such as a table. In other embodiments, anvil 235 may be a shoe last upon which an article of footwear may be assembled. The schematic illustrations of FIGS. 9-11 are intended to cover the general use of anvils, and thus are not specific to any particular anvil configuration.

As further shown in FIG. 9 , an ultrasonic horn 240 may be provided to enable ultrasonic welding. As shown in FIG. 10 , ultrasonic horn 240 may compress skin 185 and reinforcement material 190 against anvil 235 . Additionally, ultrasonic horn 240 may vibrate at ultrasonic frequencies, as represented by vibration line 245 . This ultrasonic vibration may generate friction, which may generate heat that, together with the pressure of the sonotrode 240 against the anvil 235 , may at least partially melt a portion of the reinforcing material 190 . As a result of this melting, fibers of skin layer 185 may become embedded within reinforcement material 190 , effectively relocating portions of reinforcement material 190 to the outer surface of the upper, thereby forming bonded area 205 , as shown in FIG. 11 .

Using the techniques shown schematically in FIGS. 9-11, a method of manufacturing an article of footwear may be presented. Methods may include forming an upper configured to receive a foot of a wearer. Forming the upper may include selectively attaching inner reinforcement material 190 to skin 185 using ultrasonic welding. (In some embodiments, other welding techniques may be used.) The method may also include disposing skin 185 to form at least a portion of the outer surface of the upper. Ultrasonic welding of inner reinforcement material 190 to skin layer 185 may form bonded region 205 having an outer exposed surface defining a portion of the outer surface of the upper. In certain embodiments, skin layer 185 can have a first color, and reinforcement material 190 can have a second color that is different than the first color.

The outer exposed surface of the bonding area 205 may form part of the reinforcement material 190 , thereby providing the outer exposed surface of the bonding area 205 with a different color than the skin layer 185 . For example, ultrasonically welding inner reinforcing material 190 to skin 185 to form bonded area 205 may relocate portions of reinforcing material 190 to the outer surface of the upper at the outer exposed surface of bonded area 205, thereby providing the outer surface of bonded area 205. The exposed surface provides the same color as the reinforcement material 190 . In some embodiments, relocating portions of reinforcement material 190 to the outer surface of the upper may include pressing portions of reinforcement material 190 through openings into the mesh material of skin layer 185 . In addition, selectively attaching internal reinforcing material 190 to certain portions of skin 185 can form reinforced portions of skin 185, leaving unreinforced portions of skin 185 toward the interior cavity defined by the upper through the mesh material of skin 185. Provide direct ventilation.

Ultrasonic welding of inner reinforcement material 190 to skin layer 185 to form bonded region 205 may include forming lines of bonded material extending between components of the article of footwear. For example, forming the line of bonding material may include forming the line of bonding material extending from a sole structure of the article of footwear to a reinforcing band proximate an instep region of the article of footwear.

To form the bonding material line, a needle-like stylus-like ultrasonic horn 240 can be moved in a desired pattern. In other embodiments, the ultrasonic horn 240 may be an elongated structure formed in a desired pattern. Such a slender ultrasonic horn can simply squeeze material to be activated by welding and ultrasonic vibrations. Some embodiments may use Beye et al., U.S. Patent Application Publication No. ________ (now U.S. Patent Application No. 13/741,428, filed January 15, 2013 and entitled "Spacer Textile Material with Tensile Strand Having Multiple Entry and Exit Points" (Atty. One or more ultrasonic welding techniques for elongated horns discussed in Case No. 51-2687)), the entire disclosure of which is incorporated herein by reference.

In some embodiments, an exemplary article of footwear may include an additional layer of material positioned between a portion of the cover layer and a portion of the reinforcing material. For example, additional layers of material may include compressible foam, which may provide comfort, protection, and a snug fit. Such a layer of compressible foam may be provided, for example, in the tongue portion of the upper of an article of footwear. The line of bonded areas may enclose a pocket between the skin and reinforcement material, within which a layer of compressible foam may be disposed. In some embodiments, multiple compressible foam pads may be provided adjacent to each other. For example, multiple compressible foam pads may be separated by lines of bonding. Such an arrangement may create a quilted configuration that may provide comfort to the instep region of the footwear.

FIG. 12 shows a view of footwear 100 with tongue 800 generally exposed. As shown in FIG. 12, upper 110 may include tongue 800, which may be formed from multiple layers that may be joined using welding or stitching. For example, a plurality of bonding areas 805 may be provided in the form of lines for selectively attaching reinforcement material 190 to skin 885 . Additionally, stitching 840 may secure reinforcement material 190 to skin 885 in certain portions of tongue 800 , such as the peripheral edge, as shown in FIG. 12 .

As further shown in FIG. 12 , in some embodiments, footwear 100 may include an additional layer of material positioned between a portion of skin layer 885 and a portion of reinforcing material 190 . For example, the additional layer of material may comprise a compressible foam material. As shown in FIG. 12 , a first pocket 810 between the skin 885 and the reinforcing material 190 may contain a first foam pad 815 . The first pocket 810 may be surrounded by a plurality of land lines that define a polygonal pocket. For example, as shown in FIG. 12 , first bond zone line 820 , second bond zone line 825 , third bond zone line 830 , and fourth bond zone line 835 may surround first pocket 810 .

Additionally, at least one additional foam insert may be provided in tongue 800 . For example, a second foam insert 845 may be disposed within the second pocket 850 . The second pocket 850 may be surrounded by a fifth bond zone line 855 , a sixth bond zone line 860 , a seventh bond zone line 865 , and a fourth bond zone line 835 . The first foam pad 815 and the second foam pad 845 can be disposed generally proximate to each other, thereby forming a generally quilted configuration.

FIG. 13 shows a cross-sectional view taken along line 13 - 13 of FIG. 12 . As shown in FIG. 13 , a first foam liner 815 may be disposed within first pocket 810 between skin 885 and reinforcement material 190 . Likewise, a foam insert 845 may be disposed within the second pocket 850 . As shown in FIG. 12 , the second land line 825 and the third land line 830 bound the first pocket 810 . Likewise, the sixth bonded area line 860 and the seventh bonded area line 865 bound the second pocket 850 .

14 shows a cross-sectional view taken along line 14-14 of FIG. 12, which is generally perpendicular to line 13-13 along which the cross-section in FIG. 13 is taken. As shown in FIG. 14 , in addition to first foam pad 815 , tongue 800 may include third foam pad 846 and fourth foam pad 847 disposed between liner 890 and skin 885 . In some embodiments, liner 890 may be formed from reinforcement material 190 . Accordingly, liner 890 may provide structural support to tongue 800 .

As shown in FIG. 14, reinforcement material 190 may be attached to skin 885 to form a plurality of bonded regions. For example, reinforcement material 190 may be welded to skin layer 885 to form eighth land line 901 and ninth land line 902 . Eighth land line 901 and ninth land line 902 may separate third foam pad 846 from first foam pad 815 . In addition, the fourth land line 835 and the tenth land line 904 may separate the first foam pad 815 and the fourth foam pad 847 . Additionally, upper edge 905 may be formed using welding or other bonding processes. The upper edge 905 may form at least one side of the pocket within which the third foam pad 846 is disposed. Likewise, lower edge 906 may be formed using welding or other bonding processes. The lower edge 905 may form at least one side of the pocket within which the fourth foam pad 847 is disposed.

While various embodiments of the invention have been described, the specification is intended to be illustrative, not restrictive, and it will be apparent to those of ordinary skill in the art that many more embodiments are within the scope of the invention. and implementation schemes are possible. While many possible combinations of features are shown in the drawings and discussed in this detailed description, many other combinations of the disclosed features are possible. It is therefore to be understood that any of the features shown and/or discussed in this disclosure can be implemented together in any suitable combination. Accordingly, the invention is not to be restricted except in light of the appended claims and their equivalents. Furthermore, various modifications and changes may be made within the scope of the appended claims.

Claims (29)

1. an article of footwear, comprises footwear sole construction, and described footwear sole construction is fixedly attached to vamp, and described vamp is configured to the foot receiving wearer, and described vamp comprises:

Top layer, it forms the outer surface of described vamp at least partially; With

Reinforcing material, it is optionally positioned at inside and the part on contiguous described top layer, thus define the enhancing part on described top layer and described top layer do not strengthen part;

Wherein, described reinforcing material is linked together by welding and described superficial selective in land, and described land has outer exposed surface, and described outer exposed surface defines a part for the described outer surface of described vamp; And

Wherein, described top layer has the first color, and the described outer exposed surface of described land has the second color, and described second color is different from described first color.

2. article of footwear as claimed in claim 1, wherein, the described outer exposed surface of described land comprises the part of described reinforcing material, thus provides the color identical with described reinforcing material essence for the described outer exposed surface of described land.

3. article of footwear as claimed in claim 1, wherein, described top layer is formed by grid material.

4. article of footwear as claimed in claim 3, wherein, the described non-enhanced portion on described top layer is divided and is comprised outside exposed surface and inside exposed surface.

5. article of footwear as claimed in claim 3, wherein, the described part that do not strengthen on described top layer provides direct ventilation by the described grid material on described top layer to the inner chamber defined by described vamp.

6. article of footwear as claimed in claim 1, wherein, described land comprises bond material line, and described bond material line extends between the parts of described article of footwear.

7. article of footwear as claimed in claim 6, wherein, described bond material line extends to the reinforcing band of the instep region being close to described article of footwear from described footwear sole construction.

8. article of footwear as claimed in claim 1, wherein, described article of footwear comprises material additional panels, and described material additional panels is soldered to described top layer.

9. an article of footwear, comprises footwear sole construction, and described footwear sole construction is fixedly attached to vamp, and described vamp defines inner chamber, and described inner chamber is configured to the foot receiving wearer, and described vamp comprises:

Top layer, it forms the outer surface of described vamp at least partially, and described top layer is formed by grid material; With

Reinforcing material, it is optionally positioned at inside and contiguous described top layer, thus define the enhancing part on described top layer and described top layer do not strengthen part;

Wherein, the described part that do not strengthen on described top layer provides direct ventilation by the described grid material on described top layer to the described inner chamber defined by described vamp;

Wherein, described reinforcing material is linked together by welding and described superficial selective in land, and described land has outer exposed surface, and described outer exposed surface defines a part for the described outer surface of described vamp; And

Wherein, described top layer has the first color, and the described outer exposed surface of described land has the second color, and described second color is different from described first color.

10. article of footwear as claimed in claim 9, wherein, described land comprises bond material line, and described bond material line extends between the parts of described article of footwear.

11. article of footwear as claimed in claim 10, wherein, described bond material line extends to the reinforcing band of the instep region being close to described article of footwear from described footwear sole construction.

12. article of footwear as claimed in claim 9, wherein, described article of footwear comprises material extra play, between the part of described material extra play on described top layer and a part for described reinforcing material.

13. article of footwear as claimed in claim 12, wherein, described material extra play comprises compressible foam material.

14. article of footwear as claimed in claim 9, wherein, the described surface area not strengthening part on described top layer forms the essence major part of the surface area of the outer exposed surface on described top layer; And

Wherein, do not strengthen in part described in described top layer, described vamp is made up of described top layer in essence.

15. 1 kinds of article of footwear, comprise footwear sole construction, and described footwear sole construction is fixedly attached to vamp, and described vamp is configured to the foot receiving wearer, and described vamp comprises:

Top layer, it forms the outer surface of described vamp at least partially; With

Reinforcing material, it is optionally positioned at inside and the part on contiguous described top layer, thus define the enhancing part on described top layer and described top layer do not strengthen part;

Wherein, described reinforcing material is linked together by welding and described superficial selective in land, and described land has outer exposed surface, and described outer exposed surface defines a part for the described outer surface of described vamp;

Wherein, described top layer has the first color, and described reinforcing material has the second color, and described second color is different from described first color; And

Wherein, the described outer exposed surface of described land comprises the part of described reinforcing material, thus provides the color identical with described reinforcing material essence for the described outer exposed surface of described land.

16. article of footwear as claimed in claim 15, wherein, described land comprises bond material line, and described bond material line extends between the parts of described article of footwear.

17. article of footwear as claimed in claim 16, wherein, described bond material line extends to the reinforcing band of the instep region being close to described article of footwear from described footwear sole construction.

18. article of footwear as claimed in claim 15, wherein, described article of footwear comprises material extra play, between the part of described material extra play on described top layer and a part for described reinforcing material.

19. article of footwear as claimed in claim 18, wherein, described material extra play comprises compressible foam material.

20. article of footwear as claimed in claim 19, wherein, described material extra play is arranged in the flap part of described vamp.

21. article of footwear as claimed in claim 19, wherein, the extra play of compressible foam material to be arranged in the satchel between described top layer and described reinforcing material and to be surrounded by described land.

22. 1 kinds of methods manufacturing article of footwear, comprise the vamp being formed and be configured to the foot receiving wearer, described method comprises:

Utilize welding that inner reinforcing material is optionally attached to top layer; And

Arrange that described top layer is to form the outer surface of described vamp at least partially;

Wherein, described top layer has the first color, and described reinforcing material has the second color, and described second color is different from described first color; And

Wherein, described inner reinforcing material is welded to formation land, described top layer, described land has outer exposed surface, described outer exposed surface defines a part for the described outer surface of described vamp, the described outer exposed surface of described land comprises the part of described reinforcing material, thus provides the color being different from described top layer for the described outer exposed surface of described land.

23. methods as claimed in claim 22, wherein, described inner reinforcing material being welded to described top layer makes the part of described reinforcing material be repositioned onto the described outer surface of described vamp at the described outer exposed surface place of described land to form described land, thus provides the color identical with described reinforcing material essence for the described outer exposed surface of described land.

24. methods as claimed in claim 23, wherein, described top layer is formed by grid material.

25. methods as claimed in claim 24, wherein, the described outer surface part of described reinforcing material being repositioned onto described vamp comprises the described part of described reinforcing material pressed through the opening in described grid material.

26. methods as claimed in claim 24, wherein, what described inner reinforcing material is optionally attached to described top layer forms described top layer does not strengthen part, and the described part that do not strengthen provides direct ventilation by the described grid material on described top layer to the inner chamber defined by described vamp.

27. methods as claimed in claim 22, wherein, described inner reinforcing material is welded to described top layer and comprises formation bond material line to form described land, described bond material line extends between the parts of described article of footwear.

28. methods as claimed in claim 27, also comprise and footwear sole construction are fixedly attached to described vamp;

Wherein, form bond material line and comprise the bond material line forming the reinforcing band extending to the instep region being close to described article of footwear from the footwear sole construction of described article of footwear.

29. methods as claimed in claim 22, wherein, are welded to described top layer and comprise one in ultrasonic bonding and RF welding by described inner reinforcing material.