Patent Publication Number: US-10327498-B2

Title: Method of making knit footwear having an integral footbed

Description:
BACKGROUND OF THE INVENTION 
     The present invention relates to a method of manufacturing footwear, and more particularly to a method of making an article of footwear incorporating a knit upper that includes an integral footbed. 
     Most footwear include an upper and a sole secured to a lower surface of the upper. The upper provides a void that receives a wearer&#39;s foot and positions the foot with regard to the sole. The sole may provide traction or cushion for the foot under a variety of conditions, e.g., walking, running and/or standing. Uppers typically are formed from conventional materials, such as injection molded polymers, fabric manufactured from spooled yarn or thread, and leather or leather-like materials that are fit and assembled on a last to form a 3D shape for a foot. The upper may include more than one layer of materials to define an exterior layer, an intermediate layer, and an interior layer. 
     In many cases, the upper may be formed of multiple sections that are joined together to form the completed upper. These sections may be obtained by cutting the material from a larger sheet of material (e.g., a sheet of textile), injection molding techniques, and knitting or weaving a finished textile section. Synthetic or natural materials may be used in creating these sections, which are often joined and formed about a last to produce the upper. In this way, the sections are mechanically manipulated into conforming to the 3D contour of the last. 
     Footwear manufacturing techniques have evolved through time, however, most are still impaired by associated labor costs and overhead. For example, most conventional footwear are constructed from a variety of components that are precisely fit and overlapped relative to one another, then stitched together by a worker to form the upper of the footwear. The stitching process is very labor intensive and time-consuming. While many footwear manufacturers have outsourced their manufacturing process to countries having significant labor forces, the minimum wage and social tax in those countries has greatly increased the cost of labor in recent years. In turn, this has increased the cost to manufacture footwear. 
     Accordingly, there remains room for improvement in the area of footwear manufacturing to reduce labor costs and material costs. 
     SUMMARY OF THE INVENTION 
     A method is provided for making a footwear upper, as well as a related footwear upper. 
     In one embodiment, a method of making a footwear upper assembly includes: (a) knitting a tube from a plurality of strands of material so that the tube forms a first sock portion and a second sock portion joined with one another at an intermediate ankle portion, (b) defining in the first sock portion a first sock void configured to receive a human foot and a first opening adjacent a first toe portion of the first sock portion, (c) defining in the second sock portion a second sock void configured to receive a human foot and a second opening adjacent a second toe portion of the second sock portion, (d) turning the second sock portion inside out so that it acquires an inside out configuration, (e) folding the second sock portion relative to the intermediate ankle portion, (f) moving the second sock portion, in the inside out configuration, into the first sock void, (g) forming a footbed void between a first lower panel of the first sock portion and a second lower panel of the second sock portion, (h) inserting a footbed through the first opening into the footbed void, between the first lower panel and the second lower panel, and (i) closing the first opening so that the footbed is trapped between the first lower panel and the second lower panel. 
     In another embodiment, an upper construction for footwear includes first and second sock portions, a footbed void, and a footbed. The first sock portion includes a first toe portion, a first lower panel, and a first opening adjacent the first toe portion. The first sock portion defines a first sock void. The second sock portion includes a second lower panel and the second sock portion is disposed within the first sock void. The first and second sock portions can be formed by knitting a tube and can be joined together at an intermediate ankle portion or some other portion along the upper, optionally at the respective toe or forefoot sections of the construction. The footbed void is defined between the first and second lower panels, and the footbed is disposed in the footbed void. The footbed is inserted through the first opening of the first sock portion into the footbed void, after which the first opening is closed so that the footbed is trapped between the first lower panel and the second lower panel. 
     In yet another embodiment, the textile upper can be made using a plurality of strands of material that include at least one fusible monofilament strand knit throughout at least a portion of the upper. A perimeter of the footbed void is heated to fuse the fusible monofilament strands of the first lower panel and the second lower panel such that the perimeter of the footbed void is fused and the footbed is entrapped within the footbed void. 
     In still another embodiment, a method of making a footwear upper assembly includes: (a) knitting a tube from a plurality of strands of material so that the tube forms a first sock portion and a second sock portion joined with one another at an intermediate portion, the sock portions are knit in an inside-out configuration, (b) defining in the first sock portion a first sock void, (c) defining in the second sock portion a second sock void and a second opening adjacent a second toe portion of the second sock portion, (d) placing the knit tube on a last, optionally so that a first lower portion of the first sock portion is adjacent a portion of the last corresponding to a foot bottom, (e) placing a footbed and/or footbed material adjacent the first lower panel of the first sock portion, and optionally adjacent a portion of the last corresponding to a foot bottom, with the first lower panel between the last and the footbed, (f) optionally closing the first opening of the first sock portion, (g) turning the second sock portion right-side out so that it acquires an aesthetic or right-side out configuration, (h) folding the second sock portion relative to the intermediate portion, (i) moving the second sock portion in the aesthetic or right-side out configuration over and/or around an exterior surface of the first sock portion that faces away from the last, (j) entrapping the footbed between the first lower panel of the first sock portion and a second lower panel of the second sock portion, and (k) closing the second opening of the second sock portion, with the footbed secured between the first lower panel and the second lower panel, within the footbed void between those panels. 
     In yet another embodiment, the method can include placing a portion of the textile upper into a mold cavity. For example, when the first sock portion is on the last, the last can be placed adjacent a mold cavity with the lower panel adjacent and/or partially in the mold cavity. A plastic, foam material, or other cushioning material, such as ethylene-vinyl acetate (EVA) or polyurethane, can be injected into the mold cavity to injection mold a footbed directly onto the first lower panel of the first sock portion. 
     These and other objects, advantages, and features of the invention will be more fully understood and appreciated by reference to the description of the current embodiment and the drawings. 
     Before the embodiments of the invention are explained in detail, it is to be understood that the invention is not limited to the details of operation or to the details of construction and the arrangement of the components set forth in the following description or illustrated in the drawings. The invention may be implemented in various other embodiments and of being practiced or being carried out in alternative ways not expressly disclosed herein. Also, it is to be understood that the phraseology and terminology used herein are for the purpose of description and should not be regarded as limiting. The use of “including” and “comprising” and variations thereof is meant to encompass the items listed thereafter and equivalents thereof as well as additional items and equivalents thereof. Further, enumeration may be used in the description of various embodiments. Unless otherwise expressly stated, the use of enumeration should not be construed as limiting the invention to any specific order or number of components. Nor should the use of enumeration be construed as excluding from the scope of the invention any additional steps or components that might be combined with or into the enumerated steps or components. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is perspective view of a completed footwear upper assembly, according to a current embodiment; 
         FIG. 2  is a perspective cutaway view of the completed footwear upper assembly, including a cut-away portion of the footwear upper assembly; 
         FIG. 3  is a perspective view of a textile upper of the footwear upper assembly, illustrating the textile upper before a turning inside-out step; 
         FIG. 4  is a cross sectional view of the textile upper taken along line  4 - 4  of  FIG. 3 ; 
         FIG. 5  is a cross sectional view of the textile upper and a footbed, before the footbed is inserted into a footbed void; 
         FIG. 6  is a cross sectional view of the completed footwear upper assembly of  FIG. 1 ; 
         FIG. 7  is a flowchart for a method of making the footwear upper assembly of  FIG. 1 ; 
         FIG. 8  is a cross-sectional view of a completed footwear upper assembly, according to a first alternate embodiment; and 
         FIG. 9  is a flowchart for a method of making the footwear upper assembly of  FIG. 8 . 
     
    
    
     DESCRIPTION OF THE CURRENT EMBODIMENTS 
     A footwear upper assembly, and a method of manufacturing the footwear upper assembly, in accordance with a current embodiment is shown in  FIGS. 1-6  and generally designated  10 . The completed footwear upper assembly  10  includes a textile upper  12  and an entrapped footbed  14 . Although not shown, the footwear upper assembly  10  may be joined with a sole assembly, typically having a midsole and outsole. Further, the footwear can include other conventional upper components disposed in the interior and/or exterior of the upper. 
     Although the current embodiments are illustrated without the remaining portions of footwear, the footwear upper assembly may be incorporated into any type or style of footwear, including performance shoes, hiking shoes, trail shoes and boots, hiking boots, all-terrain shoes, barefoot running shoes, sneakers, conventional tennis shoes, walking shoes, multisport footwear, casual shoes, dress shoes or any other type of footwear or footwear components. It also should be noted that directional terms, such as “vertical,” “horizontal,” “top,” “bottom,” “upper,” “lower,” “inner,” “inwardly,” “outer” and “outwardly,” are used to assist in describing the invention based on the orientation of the embodiments shown in the illustrations. Further, the terms “medial,” “lateral” and “longitudinal” are used in the manner commonly used in connection with footwear. For example, when used in referring to a side of the shoe, the term “medial” refers to the inward side (that is, the side facing the other shoe) and “lateral” refers to the outward side. When used in referring to a direction, the term “longitudinal direction” refers to a direction generally extending along the length of the shoe between toe and heel, and the term “lateral direction” refers to a direction generally extending across the width of the shoe between the medial and lateral sides of the shoe. The use of directional terms should not be interpreted to limit the invention to any specific orientation. 
     Further, as used herein, the term “arch region” (or arch or midfoot) refers generally to the portion of the footwear corresponding to the arch or midfoot of the wearer&#39;s foot; the term “forefoot region” (or forefoot) refers generally to the portion of the footwear forward of the arch region corresponding to the forefoot (for example, including the ball and the toes) of a wearer&#39;s foot; and the term “heel region” (or heel) refers generally to that portion of the footwear rearward of the arch region corresponding to the heel of the wearer&#39;s foot. The forefoot  80 , arch or midfoot  82 , and heel  84  regions are generally identified in  FIG. 1 , however, it is to be understood that delineation of these regions may vary depending upon the configuration of the footwear upper assembly and footwear. 
     With reference to  FIGS. 1-4 , the textile upper  12  is formed by knitting, for example circular knitting, a tube from a plurality of strands of material so that the tube forms a first sock portion  20  and a second sock portion  30  joined together at an intermediate ankle portion  40 . Of course, other types of knitting can be used to produce the tube, with secondary operations if needed. The tube, as shown in  FIGS. 3 and 4 , can be two foot-shaped knit members joined together in mirror image relationship. The tube can be nearly fully closed, with the exception of an opening in one, or optionally both, forefoot portions  80  of the tube, as described in greater detail below. Of course, the openings can be placed elsewhere along the tube, in regions corresponding to the toes, phalanges, arch, heel, and/or ankle of a wearer relative to the finished upper. 
     The first sock portion  20  includes a first toe portion  22 , a first lower panel  24 , and a first opening  26  adjacent the first toe portion  22 . The first sock portion  20  defines a first sock void  28  configured to receive a human foot and the second sock portion  30 . Similarly, the second sock portion  30  includes a second toe portion  32 , a second lower panel  34 , and a second opening  36  adjacent the second toe portion  32 . Further, the second sock portion  30  defines a second sock void  38  configured to receive a human foot. The first and second lower panels  24  and  34  can correspond to the lower surface of the textile upper  12 , which is underfoot when worn. Optionally, the second opening  36  in the second sock portion  30  may be eliminated. 
     In the unfinished state, illustrated in  FIGS. 3-5 , the first and second sock portions  20  and  30  can be knitted as an integral textile upper in substantially mirror image arrangement, including identical components, and integrally joined together at the intermediate ankle portion  40 . The textile upper  12  defines an aesthetic show surface  12   a  and a non-show surface  12   b ; more specifically, the first and second sock portions  20  and  30  each define a show surface  20   a ,  30   a  and a non-show surface  20   b ,  30   b . As with knit textiles, one side is the knit side, which is typically the intended show surface, and the other side is the purl side, which is the non-show surface that is generally not visible when worn. Accordingly, the textile upper  12  can be knit with the show surfaces  20   a ,  30   a  on an exterior of the knit tube; the non-show surfaces  20   b ,  30   b  can be on the on the interior of the knit tube. The second sock portion  30 , with the show surface  30   a  of the second sock portion  30  on the exterior of the textile upper  12 , can be turned inside out so that it is in an inside out configuration, meaning the non-show surface  30   b  of the second sock portion  30  is then on the exterior of the textile upper  12 . To accomplish this, the second toe portion  32  of the second sock portion  30  is effectively pushed into the second sock void  38 . The inside-out second sock portion  30 , led by the second toe portion  32 , is then inserted into the first sock void  28 . In this configuration, the textile upper  12  is substantially made of two layers: a right-side out first sock portion  20  with the show surface  20   a  defining the exterior of the textile upper  12 , and an inside-out second sock portion  30  substantially lining the first sock portion  20 , with the non-show surface  30   b  defining the interior of the textile upper  12 . Accordingly, the non-show surface  20   b  of the first sock portion  20  and the show-surface  30   a  of the second sock portion  30  engage and/or contact one another and are “inside” the surfaces of the upper assembly  10 . 
     The intermediate ankle portion  40  includes a first collar portion  42  and a second collar portion  44 . When the second sock portion  30  is inserted into the first sock void  28  of the first sock portion  20 , the first and second collar portions  42  and  44  are effectively folded-over and in juxtaposition. The first and second collar portions  42  and  44  can also be knitted in substantially mirror image arrangement and can be integrally joined for form the intermediate ankle portion  40 . Further, the first and second collar portions  42  and  44  can be substantially equidistant from respective first and second lower panels  24  and  34 . The intermediate ankle portion  40  can be configured to engage an ankle of wearer, and may be knit with a yarn that includes elastic properties to hold the intermediate ankle portion  40  tight against the wearer&#39;s ankle so as to keep the completed footwear upper assembly  10  in place on the wearer&#39;s foot. Optionally, the intermediate ankle portion  40  can include certain elastic strands inlaid into surrounding knitted loops to provide elasticity to the ankle portion. The intermediate portion, in general, can be considered to be any portion of the tube between the ends/perimeter of the tube. 
     With the second sock portion  30  inserted into the first sock portion  20 , a footbed void  50  is defined between the first and second sock portions  20  and  30 ; more specifically, the footbed void  50  is the 3D space bounded by the first and second lower panels  24  and  34  of the first and second sock portions  20  and  30  and extending the length and width of the first and second lower panels  24  and  34 . 
     Referring to  FIG. 5 , the footbed  14  is positioned within the footbed void  50  and is sandwiched between the first and second lower panels  24  and  34  of the first and second sock portions  20  and  30 . More particularly, the footbed  14  defines an upper surface  14   a  and a lower surface  14   b . The upper surface  14   a  is adjacent the second lower panel  34 , and the lower surface  14   b  is adjacent the first lower panel  24 . The first and second openings  26  and  36  in respective first and second lower panels  24  and  34  may be closed at respective first and second seams  52  and  54 , or by any other suitable joining means. The first and second openings  26  and  36  each define a forward edge  26   a ,  36   a  and a rearward edge  26   b ,  36   b . The forward edge  26   a ,  36   a  delineates the edge nearest the first and second toe portions  22  and  32 ; the rearward edge  26   b ,  36   b  delineates the edge nearest the midfoot region  82 . The seams  52 ,  54  can be formed by sewing a strand between opposing edges  26   a  and  26   b  and  36   a  and  36   b , respectively. Further, the seams  52 ,  54  can be disposed in the forefoot region  80 , for example, under a wearer&#39;s toes. Alternatively, the seams  52 ,  54  can be disposed substantially under the ball of a wearer&#39;s foot, near the transition between the forefoot region  80  and the midfoot region  82 , or within the midfoot region  82 . The seams  52 ,  54  can be aligned above/below one another, or may be staggered in the fore-aft direction, depending on the application. 
     The footbed  14  is secured within the footbed void  50  so that the footbed  14  cannot be removed without destroying at least one of the first sock portion  20  and the second sock portion  30 . The footbed  14  provides underfoot padding which is concealed within footwear upper assembly  10  and is generally formed of a cushioning foam material, such as ethylene-vinyl acetate (EVA), polyurethane, thermoplastic polyurethane, phylon, or other suitable foams. Accordingly, the footbed  14  can attenuate ground reaction forces and can absorb energy associated with running, walking, or other activities. Although referred to as a footbed, it should be noted that the footbed  14  can be in the form of a conventional footbed, a cushion element, an insole, a midsole or some other sole component. Indeed, reference to a footbed herein can refer to any of the foregoing or other cushioning or support components. 
     The textile upper  12  is knit from a plurality of strands including at least one fusible monofilament strand knit throughout at least a portion of the textile upper  12 . The textile upper  12  is formed by a knitting process, such as circular knitting, flat knitting, raschel knitting or any other knitting processes and the fusible monofilament strand can extend throughout the entire textile upper  12 . Although seams  52 ,  54  may be used to close the first and second openings  26  and  36 , a majority of the textile upper  12  can include a substantially seamless configuration. Moreover, the textile upper  12  may be formed of unitary knit construction. As utilized herein, the textile upper  12  is defined as being formed of “unitary knit construction” when formed as a one-piece element through a knitting process. That is, the knitting process substantially forms the various shapes and structures of the textile upper  12  without the need for significant additional manufacturing steps or processes. Although portions and edges of the textile upper  12  may be joined to each other (e.g., seams  52  and  54  closing the first and second openings  26  and  36 ) following the knitting process, the textile upper  12  remains formed of unitary knit construction because it is formed as a one-piece knit element. 
     The textile upper  12  optionally forms substantially all of the footwear upper  12 ; however, a variety of additional elements may be incorporated into the footwear upper assembly  10 . For example, the textile upper  12  may also include one or more of: (a) a lace that assists with tightening the upper around the foot, (b) a heel counter in the heel region  84  for enhancing stability, (c) a toe guard in forefoot region  80  that is formed of a wear-resistant material, and (d) logos, trademarks, and placards with care instructions and material information. Optionally, eyelets may be knitted or die cut into the textile upper  12  so that a shoe lace can be threaded therethrough and utilized to tighten the upper around the wearer&#39;s foot. Further optionally, a separate component including eyelets can be affixed to the textile upper  12  to receive the laces. The heel counter and/or toe guard can be added as exterior layers formed of leather, synthetic leather, or a rubber material to impart a relatively high degree of wear-resistance and added stability. Optionally, the textile upper  12  can be knitted with two or more different knit patterns. Certain knit patterns can be disposed in certain regions to impart various physical attributes, such as breathability, rigidity, support, elasticity, and/or to mimic a heel counter, toe guard, or other component. Accordingly, the textile upper  12  may incorporate a variety of other features and elements, in addition to the features and elements discussed herein and shown in the figures. 
     The textile upper  12  can be formed as a knit element produced via a mechanical knitting process performed on an automated knitting machine. Optionally, the knitting machine can be a circular knitting machine, such as a sock or tube knitting machine. Alternatively, the knitting machine can be a flat knitting machine or a jacquard raschel knitting machine. The knitting process can produce the knitted tube, and can incorporate a variety of different knit patterns in the knitted tube and/or the textile upper  12  in general. With regard to knit patterns, the strands forming the textile upper  12  may have one type of knit pattern in one area and another type of knit pattern in another area. Depending upon the types and combinations of knit patterns utilized, areas of the textile upper  12  can have a plain knit structure, a mesh knit structure, a rib knit structure, and various combinations thereof, for example. Different types of knit patterns can be incorporated into specific locations of the textile upper  12  to modify the physical properties or aesthetics of the textile upper  12 , such as elasticity, air permeability, stiffness and abrasion-resistance. 
     Optionally, the textile upper  12  can have one type of yarn formed from multiple strands, optionally twisted together, in one area and another type of yarn in another area. The textile upper  12  also can incorporate yarns with different deniers, materials (e.g., cotton, elastane, polyester, rayon, wool, nylon and mixtures thereof), and degrees of twist. The different types of yarns can affect the physical properties of the textile upper  12 , including aesthetics, stretch, thickness, air permeability and abrasion-resistance. By varying and/or combining various types and combinations of knit patterns and yarns, each area of the textile upper  12  may have specific properties that enhance the comfort, durability, and performance of the footwear. 
     Further optionally, the yarn can include one or more fusible strands knit throughout all or a portion of the textile upper  12 . Fusible strands may be heated to fuse to other strands, whether fusible or non-fusible, in selected areas of the textile upper  12  to increase stretch-resistance, stability, support, abrasion-resistance, durability, and/or stiffness, optionally in preselected areas of the footwear. Fusible strands optionally can be in the form of a monofilament strand constructed from a thermoplastic polymer material, such as polyurethane, nylon, polyester and polyolefin. Of course, other types of fusible strands can be used depending on the application. The fusible or thermoplastic polymer material softens or melts when heated and returns to a solid state when cooled to bond adjacent strands of yarn together. Further, the yarn can include varying types and proportions of fusible strands and neutral strands, that is, strands that do not melt. 
     The textile upper  12  can include fused and unfused areas. The textile upper  12  can be formed to include yarns with fusible strands that are knit throughout substantially the entire textile upper  12 . When the yarns with fusible strands are included throughout the textile upper  12  and all areas of the textile upper  12  are heated, the entire upper  12  becomes generally fused. However, where only select areas of the textile upper  12  are heated this can form selected fused areas. Alternatively, the textile upper  12  can be knit to include yarns with fusible strands only through select areas of the textile upper  12 . When yarn with fusible strands are located only in select areas of the textile upper  12 , the entire textile upper  12  may be heated to form the selected fused areas, the unfused areas remaining. Generally, the first and second sock portions  20  and  30  can be knit with fusible strands, portions can be in contact with one another. Thus, the first and second sock portions  20  and  30  can be optionally fused to one another, forming a base layer and a top layer being fused to one another as a multilayer laminated knitted upper. 
     Further, a greater proportion of fusible strands may be included in the yarn in select areas of the upper, thereby increasing the durability and stiffness to the selected fused areas. Optionally, the greater the proportion of fusible strands included in the yarn, upon the application of heat or pressure, the greater the degree of durability and stiffness can be imparted to the fused area. For example, the yarn knitted in the first and second lower panels  24  and  34  may incorporate three fusible strands twisted with other non-fusible strands to form a yarn, and the instep region may incorporate one fusible strand twisted other non-fusible strands to form a yarn. Upon heating, the melted or fused area in the lower panels  24  and  34  can provide more strength and shape (precisely mimicking a wearer&#39;s foot), while the instep region can be more supple and stretchable so the wearer can don the upper/footwear easily, and so the textile upper  12  feels soft over the wearer&#39;s instep. 
     In one example, a perimeter  54  of the footbed void  50  is heated to fuse fusible strands of the first lower panel  24  and/or the second lower panel  34  such that the perimeter  54  is fused and the footbed  14  is entrapped within the footbed void  50 . The fusible strands in the first lower panel  24  can fuse to the fusible and non-fusible strands in the second lower panel  34 , and vice versa, to close the footbed void  50 . Optionally, sidewalls adjacent the lower panels  24 ,  34  of the first and second sock portions  20  and  30  and adjacent the footbed  14  contact one another and fuse together when heated. As with the lower panels  24 ,  34  fusing, fusible strands in the sidewall of the first sock portion  20  can fuse to the fusible and/or non-fusible strands in the sidewall of the second sock portion  30 , and vice versa, to close the footbed void  50 . In this manner, the footbed  14  is secured in the footbed void  50  so that the footbed  14  cannot be removed without destroying at least the first sock portion  20 , the second sock portion  30 , and/or the footbed  14  itself. 
     In another example, the fusible strands of the first lower panel  24  and the second lower panel  34  are heated to fuse the upper and lower surfaces of the footbed  14  to the respective first and second lower panels  24  and  34 , thus sealing the footbed  14  within the footbed void  50 . Again, the footbed  14  is secured in the footbed void  50  so that the footbed  14  cannot be removed without destroying at least the first sock portion  20  and/or the second sock portion  30 . 
     In yet another example, the first sock portion  20  can include a greater proportion of fusible strands in the yarn, and when fused provides a generally more rigid exterior of the footwear upper assembly  10 . In contrast, the second sock portion  30  can include a lesser proportion of fusible strands in the yarn, and when fused provides a generally softer interior of the footwear upper assembly  10  for contact with the wearer&#39;s foot. 
     Manufacture of the footwear upper assembly of the current embodiment is presented in the flow chart of  FIG. 7 . A method  100  of making a footwear upper assembly  10  can include: (a) knitting a tube from a plurality of strands of material so that the tube forms a first sock portion and a second sock portion joined with one another at an intermediate ankle portion, (b) defining in the first sock portion a first sock void configured to receive a human foot and a first opening adjacent a first toe portion of the first sock portion, (c) defining in the second sock portion a second sock void and a second opening adjacent a second toe portion of the second sock portion, (d) turning the second sock portion inside out so that it acquires an inside out configuration, optionally closing the second opening before doing so, (e) folding the second sock portion relative to the intermediate ankle portion, (f) moving the second sock portion in the inside out configuration into the first sock void, optionally so the second sock portion defines a third sock void configured to receive a human foot disposed within the first sock void configured to receive a human foot, (g) forming a footbed void between a first lower panel of the first sock portion and a second lower panel of the second sock portion, (h) providing in the footbed void, between the first lower panel and the second lower panel, optionally inserting the footbed through the first opening, and (i) closing the first opening so that the footbed is trapped between the first lower panel and the second lower panel. 
     The knitting, depicted as step  102  in  FIG. 7 , can be any type of conventional knitting, but optionally is performed via a circular knitting process that provides a knitted tube from strands of material so that the tube forms a first sock portion  20  and a second sock portion  30  joined with one another at an intermediate ankle portion  40 . As shown in  FIG. 3 , the first and second sock portions  20  and  30  are knitted in substantially mirror image arrangement. Further, the step of knitting  102  may include knitting fusible strands throughout substantially the entire tube, or optionally only parts of the tube and/or upper, for example, the second sock portion  30  only, and/or select areas of the first and second sock portions  20  and  30 . The yarn used for knitting can include at least one fusible monofilament strand with the yarn knit throughout at least a portion of the textile upper  12 , and specifically through at least the first and second lower panels  24  and  34 . 
     Defining the first sock void  28  and the first opening  26  adjacent the first toe portion  22  in the first sock portion  20  is depicted as step  104  in  FIG. 7 . Defining the second sock void  38  configured to receive a human foot and the second opening  36  adjacent the second toe portion  32  in the second sock portion  30  is depicted as step  106 . Optionally, the second opening  36  may be eliminated. 
     Turning the second sock portion  30  inside out so that it acquires an inside out configuration by moving the second toe portion  32  into the second sock void  38  is depicted as step  108 . In effect, the show surface  30   a  of the second sock portion becomes the non-show surface  30   b , and vice versa. Folding the second sock portion  30  relative to the intermediate ankle portion  40  is depicted as step  110 . The second collar portion  44  is folded down, inside and adjacent the first collar portion  42  of the first sock portion  20 . Moving the second sock portion  30 , still in the inside out configuration, into the first sock void  28  is depicted as step  112 . After steps  108 - 112 , the inside-out second sock portion  30  is disposed within the first sock void  28 , effectively forming two layers of textile upper  12 . The show surface  20   a  of the first sock portion  20  defines the exterior surface of the upper assembly  10 , and the non-show surface  30   b  of the second sock portion  30  defines the interior surface of the upper assembly  10 . As such, the non-show surface  20   b  of the first sock portion  20  and the show-surface  30   a  of the second sock portion  30  engage and/or contact one another and are “inside” the surfaces of the upper assembly  10 . Accordingly, mirror image portions of the first and second sock portions  20  and  30  are generally aligned. 
     Forming a footbed void  50  between the first lower panel  24  of the first sock portion  20  and the second lower panel  34  of the second sock portion  30  is depicted as step  114 . Inserting the footbed  14  through the first opening  26  into the footbed void  50  is depicted as step  116 . The footbed  14  is therefore positioned between the first lower panel  24  and the second lower panel  24  of the first and second sock portions  20  and  30 . 
     Closing the first opening  26  so that the footbed  14  is trapped between the first lower panel  24  and the second lower panel  34  is depicted as step  118 . The first opening  26  of the first sock portion  20  may be closed with a seam  52 . Additionally, the second opening  36  of the second sock portion  30  may be also closed with a seam  54 . Closing the second opening  36  may occur sequentially with closing the first opening  26 , or may be performed before the step  110  of turning the second sock portion  30  inside out. 
     Optionally, the method  100  may include heating the entire textile upper  12 , a portion of the textile upper  12 , and/or the perimeter  54  (see  FIG. 2 ) of the footbed void  50  to fuse the fusible strands of the first lower panel  24  and the second lower panel  34 , depicted as step  120 . In this manner, the lower surface of the textile upper  12  and/or the perimeter  54  of the footbed void  50  is fused and the footbed  14  is therefore entrapped within the footbed void  50 . Alternatively, the method  100  may include heating the fusible strands of the first lower panel  24  and the second lower panel  34  such that they are fused to the upper and lower surfaces of the footbed  14 . Thus, sealing the footbed  14  within the footbed void  50 . 
     Further optionally, the textile upper  12  can include fused and unfused areas, as described above. If yarns with fusible strands are included throughout the textile upper  12 , only select areas of the upper may be heated, forming the selected fused area. If the yarns with fusible strands are included only in select areas of the textile upper  12 , the entire textile upper  12  may be heated, forming the selected fused areas and leaving unfused areas. Accordingly, the step  120  of heating may include heating the entire upper or only select areas, as described above. When a greater proportion of fusible strands are included in the yarn in select areas, the select areas undergo more fusing and melting, and the durability and stiffness in the selected areas increases. Optionally, all areas of the textile upper  12  can fuse, but some areas can fuse more than others, producing different effects on stiffness, softness, etc. in different areas. 
     A first alternate embodiment of a footwear upper assembly  210  is similar to the first embodiment. Therefore, like parts will be identified with like numerals increased by 200, with it being understood that the description of the like parts of the first embodiment applies to the first alternate embodiment, unless otherwise noted. 
     Referring to  FIG. 8 , the first alternate footwear upper assembly  210  includes a textile upper  212  further optionally formed by knitting a tube from strands so that the tube forms a first sock portion  220  and a second sock portion  230  joined together at an intermediate ankle portion  240 . In the unfinished state, the textile upper  212  is knit in an inside-out configuration. That is, the textile upper  212  defines a show surface  212   a  and a non-show surface  212   b . As with knit textiles, one side is the knit side, which is typically the intended show surface, and the other side is the purl side, which is the non-show surface that is not visible. Accordingly, the textile upper  212  is knit with the surfaces turned inside-out; the non-show surface  212   b  is on the exterior, and the show surface  212   a  is on the interior. 
     The second sock portion  230  is turned right-side out so that it is in a right-side out configuration, and is then pulled, through a second opening  236  adjacent a second toe portion  232 , over the first sock portion  220 . In this state, the second sock portion  230  is right-side out, and the first sock portion  220  remains inside-out. In the completed state, the exterior of the finished textile upper  212  is defined by the show surface  212   a  of the second sock portion  230 , and the interior of the finished textile upper  212  is defined by the show surface  212   a  of the first sock portion  220 . 
     Similar to the first embodiment, the footbed  214  can positioned within the footbed void  250  and is sandwiched between the first and second lower panels  224  and  234  of the first and second sock portions  220  and  230 . The footbed  214  may be tacked, glued, or use any other suitable mechanical means of temporarily or minimally attaching the footbed  214  to the first lower panel  224  to hold it in place before the second sock portion  230  is turned right-side out. 
     Additionally, the first and second openings  226  and  236  in respective first and second lower panels  224  and  234  may be closed with sewn seams  252  and  254 , or by any other suitable joining means. These seams optionally can be sewn closed with a strand, for example a natural yarn. The first and second openings  226  and  236  each define a forward edge  226   a ,  236   a  and a rearward edge  226   b ,  236   b . The forward edge  226   a ,  236   a  delineates the edge nearest the first and second toe portions  222  and  232 ; the rearward edge  226   b ,  236   b  delineates the edge nearest the midfoot region  282 . The forward edge  226   a ,  236   a  and rearward edge  226   b ,  236   b  are sewn together to close respective first and second openings  226  and  236 . 
     Manufacture of the first alternative embodiment of the footwear upper assembly  210  is presented in the flow chart of  FIG. 9 . A method  300  of making the footwear upper assembly  210  can include: (a) knitting a tube from a plurality of strands of material so that the tube forms a first sock portion and a second sock portion joined with one another at an intermediate portion, the sock portions are knit in an inside-out configuration, (b) defining in the first sock portion a first sock void, (c) defining in the second sock portion a second sock void and a second opening adjacent a second toe portion of the second sock portion, (d) placing the knit tube on a last, (e) placing a footbed and/or footbed material adjacent a first lower panel of the first sock portion, (f) turning the second sock portion right-side out so that it acquires an aesthetic or right-side out configuration, (g) folding the second sock portion relative to the intermediate portion, (h) moving the second sock portion in the aesthetic or right-side out configuration around an exterior of the first sock portion, (i) entrapping the footbed in a footbed void formed between the first lower panel of the first sock portion and a second lower panel of the second sock portion, and (j) closing the second opening, with the footbed secured between the first lower panel and the second lower panel. 
     Knitting a tube from a plurality of strands of material so that the tube forms a first sock portion  220  and a second sock portion  230  joined with one another at an intermediate ankle portion  240  is depicted as step  302  in  FIG. 9 . The first and second sock portions  220  and  230  can be circle knitted in tube form and optionally can be in a substantially mirror image arrangement and knit in an inside-out configuration. 
     Placing the knit tube, or textile upper  212 , on a last (not shown) is depicted as step  308 , and placing the upper surface  214   a  of the footbed  214  adjacent a first lower panel  224  of the first sock portion  220  is depicted as step  310 . The footbed  214  may be tacked, glued, or use any other suitable mechanical means of temporarily and optionally minimally attaching the footbed  214  to the first lower panel  224  to temporarily hold it in place. 
     Turning the second sock portion  230  right-side out so that it acquires a right-side out configuration is depicted as step  312 . Folding the second sock portion  230  relative to the intermediate ankle portion  240  is depicted as step  314 , and moving the second sock portion  230 , still in the right-side out configuration, over an exterior of the first sock portion  220  is depicted as step  316 . After steps  312 - 316 , the right-side out second sock portion  230  is disposed exterior to the first sock portion  220 , effectively forming two layers of textile upper  212 . In this configuration, the second sock portion  230  is right-side out, and the first sock portion  220  remains inside-out. Accordingly, the exterior of the finished textile upper  212  is the show surface  230   a  of the second sock portion  230 , and the interior of the finished textile upper  212  is the show surface  220   a  of the first sock portion  220 . 
     Entrapping the footbed in a footbed void  250  formed between the first lower panel  224  of the first sock portion  220  and a second lower panel  234  of the second sock portion  230 , is depicted as step  318 . Closing the second opening  236  so that the footbed  214  is enclosed within the footbed void  250  is depicted as step  320 . The second opening  236  of the second sock portion  230  may be closed with a seam  254  so that the footbed  214  is enclosed within the footbed void  250 , forming a completed footwear upper assembly  210 . The completed footwear upper assembly  210  may then be removed from the last. 
     Optionally, the tube can be knit with or without a first opening  226  in the first sock portion  226 . If the tube includes the first opening  226 , the method  300  can include closing the first opening  226 , depicted as step  322 . Closing the first opening  226  can be performed at substantially any point in the method  300 , and optionally before step  308  of placing the tube on the last. 
     Further optionally, prior to the step of turning the second sock portion  230  right-side out, a portion of the textile upper  212  may be placed into a mold cavity. For example, the last upon which the first sock portion  220  is disposed can be placed adjacent and above a portion of a mold cavity. The lower panel  224  of the first sock portion  220  likewise can be placed adjacent and/or partially in the mold cavity. A plastic or foam material, such as ethylene-vinyl acetate (EVA) or polyurethane, can be injected into the mold cavity to injection mold a footbed  214  onto the first lower panel  224  of the first sock portion  220 . Optionally, injection molding the footbed  214  can replace step  310 . 
     Further optionally, the method  300  may include heating the entire textile upper  212 , a portion of the textile upper  212 , and/or the perimeter  254  of the footbed void  250  to fuse the fusible strands of the first lower panel  224  and the second lower panel  234 , depicted as step  324 . In this manner, the lower surface of the textile upper  212  and/or the perimeter  254  of the footbed void  250  is fused and the footbed  214  is therefore entrapped within the footbed void  250 . In addition, this heating can fuse the fusible strands so that the lower panels acquire a heat set, three-dimensional, self-supporting shapes. Likewise, the remainder of the upper also can be molded and set in a three-dimensional, self-supporting shape that mimics a foot of a wearer. The fusible strands can at least partially melt and bind to adjacent strands. When cured, the strands can hold and set the respective sock portions in a three dimensional form, optionally in the shape of a foot. Alternatively, the method  300  may include heating the fusible strands of the first lower panel  224  and the second lower panel  234  such that they are fused to the upper and lower surfaces of the footbed  214 . Thus, sealing the footbed  214  within the footbed void  250 . 
     Utilizing the described methods  100  and  300 , a footwear upper assembly can be manufactured with only a few steps and a small number of components. In turn, this can reduce assembly and/or construction time for the footwear, and in particular, the upper, which can lead to significant savings in labor and overall cost of the footwear. 
     Directional terms, such as “vertical,” “horizontal,” “top,” “bottom,” “upper,” “lower,” “inner,” “inwardly,” “outer” and “outwardly,” are used to assist in describing the invention based on the orientation of the embodiments shown in the illustrations. The use of directional terms should not be interpreted to limit the invention to any specific orientation(s). 
     The above description is that of current embodiments of the invention. Various alterations and changes can be made without departing from broader aspects of the invention as defined in the appended claims, which are to be interpreted in accordance with the principles of patent law including the doctrine of equivalents. This disclosure is presented for illustrative purposes and should not be interpreted as an exhaustive description of all embodiments of the invention or to limit the scope of the claims to the specific elements illustrated or described in connection with these embodiments. For example, and without limitation, any individual element(s) of the described invention may be replaced by alternative elements that provide substantially similar functionality or otherwise provide adequate operation. This includes, for example, presently known alternative elements, such as those that might be currently known to one skilled in the art, and alternative elements that may be developed in the future, such as those that one skilled in the art might, upon development, recognize as an alternative. Further, the disclosed embodiments include a plurality of features that are described in concert and that might cooperatively provide a collection of benefits. The present invention is not limited to only those embodiments that include all of these features or that provide all of the stated benefits, except to the extent otherwise expressly set forth in the issued claims. Any reference to claim elements in the singular, for example, using the articles “a,” “an,” “the” or “said,” is not to be construed as limiting the element to the singular. Any reference to claim elements as “at least one of X, Y and Z” is meant to include any one of X, Y or Z individually, and any combination of X, Y and Z, for example, X, Y, Z; X, Y; X, Z; and Y, Z, in any number of units within those combinations.