Patent Description:
The present disclosure relates to footwear components made from lightweight textile structures that are selectively supported at various areas to provide desired local characteristics. The present disclosure relates to precursors to these components, to articles of footwear including one or more of these selectively supported components, to methods of making these footwear components, to articles of footwear containing these components, and/or to methods of making such articles of footwear. <CIT> discloses a shoe upper for a shoe, in particular a sports shoe, having a first portion and a second portion that are jointly manufactured as a knitted fabric, wherein only one of the first portion and the second portion the knitted fabric is reinforced by a coating of a polymer material applied to the shoe upper.

Conventional articles of athletic footwear include two primary elements, namely, an upper and a sole structure. The upper provides a covering for the foot that securely receives and positions the foot with respect to the sole structure. In addition, the upper may have a configuration that protects the foot and provides ventilation, thereby cooling the foot and removing perspiration. The sole structure is secured to a lower surface of the upper and generally is positioned between the foot and any contact surface. In addition to attenuating ground reaction forces and absorbing energy, the sole structure supports the foot and may provide traction and help control potentially harmful foot motion, such as over pronation. The general features and configurations of the upper and the sole structure are discussed in greater detail below.

The upper forms a void on the interior of the footwear for receiving the foot. The void has the general shape of the foot, and access to the void is provided at an ankle opening. Accordingly, the upper may extend over the instep and toe areas of the foot, along the medial and lateral sides of the foot, and around the heel area of the foot. A lacing system often is incorporated into the upper to allow selective changes to the size of the ankle opening and to permit the wearer to modify certain dimensions of the upper, particularly girth, to accommodate feet with varying proportions. In addition, the upper may include a tongue that extends under the lacing system to enhance the comfort of the footwear (e.g., to moderate pressure applied to the foot by the laces). The upper also may include a heel counter to limit or control movement of the heel.

The sole structure generally incorporates multiple layers that are conventionally referred to as an "insole," a "midsole," and an "outsole. " The insole (which also may constitute a sock liner) is a thin member located within the upper and adjacent the plantar (lower) surface of the foot to enhance footwear comfort, e.g., to wick away moisture and provide a soft, comfortable feel. The midsole, which is traditionally attached to the upper along the entire length of the upper, forms the middle layer of the sole structure and serves a variety of purposes that include controlling foot motions and attenuating impact forces. The outsole forms the ground-contacting element of footwear and is usually fashioned from a durable, wear-resistant material that includes texturing or other features to improve traction.

While numerous footwear models and characteristics are available on the market, additional lightweight, form-fitting, and stable, shape maintaining footwear components (e.g., uppers) and methods of making them would be welcome advances in the art.

SI-Unit: <NUM> inch = <NUM>.

The present invention is illustrated by way of example and not limited in the accompanying figures, in which like reference numerals indicate the same or similar elements throughout, and in which:.

The reader is advised that the various parts shown in these drawings are not necessarily drawn to scale.

The following description and the accompanying figures describe various example features of footwear components, precursors thereof, articles of footwear, and methods in accordance with aspects of the present invention. When the same reference number appears in more than one drawing, that reference number is used consistently in this specification and the drawings to refer to the same or similar parts or elements throughout.

As noted above, some aspects of this invention relate to footwear components made from lightweight textile structures that are selectively supported at various areas to provide desired local characteristics, as well as to methods of making such components, precursors to these components, and products and/or methods that utilize these precursors and components. The following paragraphs generally describe detailed features of these aspects of the invention followed by some specific examples of structures and methods according to this invention.

Some aspects of this disclosure relate to methods of forming selectively supported upper components for articles of footwear. Some examples of these methods may include one or more of: (a) engaging an upper base member with a jig such that the upper base member surrounds a first portion of the jig, wherein the first portion of the jig is substantially flat and thin, e.g., having a substantially planar first surface, a substantially planar second surface opposite the first surface, and a thickness of less than <NUM> inch between the first and second surfaces (and in some examples, a thickness of less than ½ inch or less than ¼ inch); (b) positioning a first support member adjacent a surface of the upper base member such that the upper base member is located between the first support member and the jig, wherein a surface of the first support member adjacent the surface of the upper base member includes a bonding or adhesive material (e.g., a hot melt layer); (c) applying a compressive force to the first and second surfaces of the jig through the upper base member and the first support member; and/or (d) heating the assembly (e.g., the jig, upper base member, and first support member under the compressive force) so as to engage the first support member to the upper base member via the bonding or adhesive material.

In these example methods, the upper base member may constitute a continuous structure that includes a first side located adjacent the first surface of the jig and a second side located adjacent the second surface of the jig. In some more specific examples, the upper base member may be a circular knitted structure, optionally having an open end (through which the jig is inserted) and a closed end defining an enclosed volume, such as a conventional sock or a sock-type garment structure. The closed end of the circular knitted structure may be closed off by a sewn seam (e.g., akin to a conventional sock construction).

The first support member may be a continuous structure that includes a first side positioned adjacent the first side of the upper base member and a second side positioned adjacent the second side of the upper base member (e.g., wrapping around a bottom and extending along opposite sides of the sock and the jig, e.g., akin to a taco shell). Two or more support members may wrap around the bottom of a single upper base member and jig in this same manner, if desired.

Alternatively, if desired, the first support member may be located on a single side of the upper base member and/or the jig. Optionally, if desired, a second, separate support member (or even more support members) may be provided, located at the same side or the opposite side of the jig and upper base member from the first support member. The second support member, when present, may mirror the structure of the first support member (e.g., to provide similar support on the opposite side of the upper base member) or it may be structured and/or oriented to provide different support characteristics from the first support member.

In some examples of this disclosure, the support member(s) may provide one or more of the following features: provide structural shape and/or support for at least some areas of the upper; provide impact force attenuation (e.g., include a midsole component); provide a ground contacting surface (e.g., include an outsole component); provide structures for engaging and/or supporting a shoe lace (e.g., one or more loops or eyelets; one or more inelastic bands, straps, or strands for supporting a lace and at least partially wrapping around the foot; etc.); provide wear and/or abrasion resistance or durability; provide water or moisture transmission resistance; provide adjustable and/or dynamic fit characteristics (e.g., one or more inelastic bands, straps, or strands at least partially wrapping around the foot to better fit the upper to the wearer's foot when the securing system is tightened); provide arch or plantar surface support; provide heel supports; provide desired colors and/or other aesthetics; etc. This support member may include one or more of a "skin" type material (e.g., made at least in part from a thermoplastic polyurethane); a textile material; a non-woven material; a suede or leather (natural or synthetic) material; an ethylvinylacetate ("EVA"), polyurethane, rubber, and/or other foam material; a spacer mesh material; etc. As some more specific examples, the support member may be of the types described in <CIT> (e.g., the "skin" and/or other material layers described in that patent).

In some examples of this disclosure, the heating step will include heating the jig, e.g., by inductive heating; using one or more resistor elements (such as flat resistors engaged with and/or recessed into the flat surface of the jig), which in turn will heat the bonding or adhesive material on the support member(s) through the upper base member (e.g., from the "inside" of the sock or sock-type structure); etc. Other heating methods also may be used, such as conductive or convective heating, ultrasonic heating, welding, hot press or hot die heating, laser heating, etc..

Some aspects of this disclosure relate to engaging footwear support components (e.g., of the types described above) with footwear upper base members (e.g., of the types described above) by transferring heat to the support component(s) through the material of the upper base member. Such methods may include one or more of: (a) positioning a support base in contact with a first surface of an upper base member (e.g., an interior surface of the upper base member); (b) positioning one or more support members adjacent a second surface of the upper base member (e.g., an exterior surface of the upper base member) such that the upper base member (optionally a single layer thereof) is located between the support member(s) and the support base, wherein at least a portion of a surface of the support member(s) adjacent the second surface of the upper base member includes a bonding or adhesive material (e.g., a hot melt adhesive material layer or coating); (c) applying a compressive force to hold at least a portion of the upper base member in place between the support member(s) and the support base; and/or (d) heating the support base so as to transfer heat from the support base to the support member(s) through the upper base member material and so as to engage the support member(s) to the upper base member via the bonding or adhesive material. For upper base members having a circular knitted, sock, and/or sock-type structure, this heating may take place from the "inside" of the upper base member (with the support member(s) including the bonding or adhesive material located at the outside of the upper base member and separated from the heat source by the material of the upper base member).

Heating through the material of the upper base member in this manner helps pull the bonding or adhesive material on the support member(s) into the structure of the upper base member (e.g., into the textile structure, such as into interstitial spaces between fibers of the textile and/or onto the fibers). This type of heat transfer may take place in pressing methods (e.g., flat press processing methods) described above or in other methods (e.g., processes using three dimension pressure, vacuum pressure, etc.). The heating may occur in any desired manner, such as by inductive heating, by activating heat elements, etc..

Some aspects of this disclosure relate to still other methods of forming components for articles of footwear including localized and selective support features. Such methods may include one or more of: (a) applying a reactive polymeric material (optionally as an aqueous solution) to one or more portions of an upper base member, wherein the reactive polymeric material exhibits thermoplastic properties as long as it is not exposed to curing conditions and thermosetting properties after it is exposed to curing conditions; and/or (b) exposing the reactive polymeric material on one or more portions of the upper base member to curing conditions (e.g., heating, optionally using heat and pressure to shape the upper base member) after the reactive polymeric material is applied to the upper base member so as to convert the reactive polymeric material at the selected portion(s) of the upper base member to a thermoset condition. If desired, the upper base member may include a textile component to which the reactive polymeric material is applied. In some more specific examples, the upper base member may be a circular knitted structure, optionally having an open end (through which a two or three dimensional support base may be inserted) and a closed end to thereby define an enclosed volume, such as a sock or a sock-type garment structure, and the reactive polymeric material may be applied at least to an outer or exterior surface of this upper base member. Alternatively or additionally, if desired, reactive polymeric material may be applied to an inner or interior surface of the upper base member and/or may be applied so as to soak into and/or through the material of the upper base member.

Some example methods according to this aspect of the disclosure will include methods of forming components for articles of footwear that include one or more of: (a) applying a first reactive polymeric material to a first portion of an upper base member (e.g., of the types described above), wherein the first reactive polymeric material exhibits thermoplastic properties as long as it is not exposed to curing conditions and thermosetting properties after it is exposed to curing conditions; (b) applying a second reactive polymeric material (which may be the same as or different from the first reactive polymeric material) to a second portion of the upper base member, wherein the second reactive polymeric material exhibits thermoplastic properties as long as it is not exposed to curing conditions and thermosetting properties after it is exposed to curing conditions; and (c) exposing the first and second reactive polymeric materials (simultaneously or separately) to curing conditions so as to convert the first and second reactive polymeric materials to thermoset conditions.

If desired, features of the first and second reactive polymeric materials and/or their application to the upper base member may be selected so as to provide different hardness and/or stiffness characteristics (or other characteristics) to the final footwear component product. In accordance with the disclosure, the first reactive polymeric material includes a first solution of a reactive polymer at a first concentration and the second reactive polymeric material includes a second solution of the reactive polymer at a second concentration that differs from the first concentration. Optionally further, in the steps of applying the first and second reactive polymeric materials, the first and second reactive polymeric materials may be applied to the upper base member at different application density levels (e.g., the first reactive polymeric material may be applied to at least some part of the first portion of the upper base member at an application density level greater than a first application density level and the second reactive polymeric material may be applied to at least some part of the second portion of the upper base member at an application density level lower than the first application density level). The term "application density level," as used herein, means an amount of reactive polymeric material (e.g., in grams) applied to a unit area (e.g., cm<NUM>) and/or to a unit volume (cm<NUM>) of an upper base member.

If desired, the final footwear component produced by these methods may have both cured and uncured reactive polymeric material(s) in or on it. In other words, a greater proportion of the upper base member surface or volume (including the entire upper base member surface or volume) may have reactive polymeric material initially applied to it than the proportion thereof having reactive polymeric material that is eventually cured. As a more specific example, the reactive polymeric material(s) may be applied to at least <NUM>% of a total surface area or total volume of the upper base member (e.g., by coating or spraying) and then only one or more selected portions of this surface area or volume (e.g., less than <NUM>% of the total surface area or volume) then will be exposed to the curing conditions. The "uncured" reactive polymeric material remaining may be cured in a later step, if desired. Methods according to some examples of this aspect of the disclosure may accomplish this "selective exposure" in various ways, such as: by applying an insulative "mask" over areas of the surface at which curing is not desired (so that insufficient heat transfers through the insulative mask to cure any reactive polymeric material(s) located behind the mask); by applying a heat conductive "mask" over areas of the surface at which curing is desired (so that sufficient heat quickly transfers through the heat conductive mask to the areas where curing of the reactive polymeric material(s) is desired); by selectively heating desired areas using laser radiation, a heat gun or other directable heat source, a heated die, etc.; by selectively activating an array of heat elements on a base member that supports the upper base member; by using a support base with heat elements or heat conductive material located only at certain desired areas for curing; etc..

Alternatively, if desired, the reactive polymeric material(s) may be applied selectively only to one or more portions of the upper base member where support (e.g., stiffening, hardening, etc.) is desired. In such methods, the reactive polymeric material(s) may be selectively applied by printing techniques (e.g., screen printing, jet printing, etc.); by masking techniques; by spraying techniques; by coating techniques; etc..

Any desired curable, reactive polymeric materials may be used without departing from this invention. In some more specific examples of this invention, reactive polymeric materials will be used that exhibit the following characteristics: the reactive polymeric material(s) will have thermoplastic properties below a certain temperature (e.g., it will become soft, pliable, and easily deformable when heated to a first temperature range), but after it is heated above a certain temperature (e.g., higher than the first temperature range) for a sufficient time period, it will "cure" and harden in an irreversible manner (e.g., thermoset by forming cross links, such as ester bond cross links). As some more specific examples, the reactive polymeric material(s) may include a water-based reactive polymer, and in some examples, the reactive polymeric material(s) may include an acrylic acid copolymer and a cross-linking agent. In some embodiments of this invention, the reactive polymeric material(s) will include a polymeric binder material free of formaldehyde, phenols, and isocyanates. As a specific example, reactive polymeric materials that may be used in at least some examples of this invention are available from BASF Corporation under the trademark ACRODUR®.

The reactive polymeric material will harden and/or stiffen the upper base member at the areas where effective thermoset curing takes place. Any desired area(s) of an upper base member may be treated and cured in this manner without departing from this invention. As some more specific examples, the reactive polymeric material may be applied and/or cured: over at least a portion of a bottom surface of the upper base member (e.g., to form a support plate for supporting all or some portion(s) of the plantar surface of a wearer's foot, such as an arch support or heel support); at an area around one or more sides and/or rear heel area of a wearer's foot (e.g., to provide a heel counter type structure); at an area along the sides or instep of a wearer's foot (e.g., to provide shape to the upper); at a toe area (e.g., to provide a more defined toe box); along the instep area to provide supports for a shoe lace (e.g., extending in a top-to-bottom direction of the upper base member at a medial or lateral side of the instep area located along the top instep sides (e.g., along a lace eyelet line), etc.); etc..

Additional features of this aspect of the disclosure may include engaging the upper base member (e.g., a circular knitted body, sock, or sock-type structure) with a support base (wherein at least a portion of the support base is located within an interior volume defined by the upper base member). In such methods, at least one reactive polymeric material may be applied to an exterior surface of the upper base member before and/or after the upper base member is engaged with the support base. The support base may be used to provide shape to the upper base member, while the reactive polymeric material retains shapeable, thermoplastic properties (e.g., upon adequate heating below its thermoset curing temperature and conditions). The exposing step(s) also may take place while the upper base member is engaged with the support base, if desired, although this is not a requirement.

Additional aspects of this disclosure relate to the upper base members and/or footwear components produced by the various methods described above, as well as to precursors to these components.

As more specific examples, components for articles of footwear (e.g., an upper) may include: (a) an upper base member including a textile material made from natural or synthetic fibers; and (b) a first cured, thermoset polymeric material coating individual fibers and/or provided in interstitial spaces between individual fibers of a first portion of the upper base member, wherein the first cured, thermoset polymeric material is formed at the first portion of the upper base member by curing a reactive polymeric material that coated individual fibers and/or was provided in interstitial spaces between individual fibers of the textile material at the first portion of the upper base member, and wherein the first portion of the upper base member has a greater hardness or stiffness as compared to a portion of the textile material that does not include the first cured, thermoset polymeric material. Cured, thermoset polymeric materials of this same type (having different concentrations, and optionally also the same or different compositions, and/or application density levels) may be provided at one or more other areas of the upper base member. When multiple areas of cured, thermoset polymeric materials are provided on a single upper base member, if desired, the different areas of the upper base member may have the same or different hardness or stiffness characteristics. Furthermore, if desired, the textile material of the upper base member may include one or more portions having uncured reactive polymeric material coating individual fibers and/or provided in interstitial spaces between individual fibers of the textile material, optionally wherein the "uncured" portion(s) of the upper base member has (have) thermoplastic properties. The reactive polymeric material(s) may be of the various types and/or have the various properties described above.

Additional potential features in accordance with some aspects of this disclosure include precursors to components for articles of footwear like those described above, wherein the precursors include: (a) an upper base member including a textile material made from natural or synthetic fibers; and (b) a first reactive polymeric material coating individual fibers and/or provided in interstitial spaces between individual fibers of a first portion of the upper base member, wherein the first reactive polymeric material exhibits thermoplastic properties as long as it is not exposed to thermoset curing conditions and is capable of becoming a first cured, thermoset polymeric material after it is exposed to thermoset curing conditions. Uncured reactive polymeric materials of this same type (having different concentrations, and optionally also the same or different compositions, and/or application density levels) may be provided at one or more other areas of the upper base member as well. The reactive polymeric material(s) may be of the various types and/or have the various properties described above. Such components including uncured reactive polymeric material(s) may be stored, optionally for an extended period of time (days, weeks, months, etc.), and then the reactive polymeric material may be cured in a desired manner (e.g., optionally selectively cured in a desired areas of portions of the upper base member so as to provide a desired final shape and/or pattern of hardened or stiffened areas). In this manner, a large bulk of "uncured" footwear components may be produced and stored, and these components can then be available for further production as desired or needed. A single "uncured" component may be produced and used for producing a wide variety of different finally "cured" component parts (e.g., depending on the upper properties desired, depending on user preferences, depending on commercial demand, etc.). Also, a single "uncured" component may be produced and used for producing different final sized footwear components.

Upper structures in accordance with still other examples of this disclosure may include:
(a) an upper base member having a seamless plantar support surface that extends continuously to form a support for at least a portion of a plantar surface of a wearer's foot (and optionally an entire plantar surface thereof) and continuously around a lateral, midfoot side edge and a medial, midfoot side edge of the upper base member; and (b) a first support member engaged with an exterior surface of the upper base member by a bonding or adhesive material, wherein the first support member extends continuously around the lateral, midfoot side edge of the upper base member, across the plantar support surface, and around the medial midfoot side edge of the upper base member. As another option or alternative, upper structures in accordance with other examples of this invention may include: (a) an upper base member having a seamless plantar support surface that extends continuously to form a support for at least a portion of a plantar surface of a wearer's foot (and optionally the entire plantar surface) and continuously around a lateral, midfoot side edge and a medial, midfoot side edge of the upper base member; (b) a first support member engaged with an exterior surface of the upper base member by a bonding or adhesive material, wherein the first support member extends continuously around the lateral, midfoot side edge of the upper base member and along a lateral, midfoot side portion of the plantar support surface; and (c) a second support member engaged with the exterior surface of the upper base member by a bonding or adhesive material, wherein the second support member extends continuously around the medial, midfoot side edge of the upper base member and along a medial, midfoot side portion of the plantar support surface, wherein the second support member is separate from the first support member. In such structures, the portion of the second support member (e.g., an edge or a portion of an edge thereof) may be separated from the portion of the first support member (e.g., an edge or a portion of an edge thereof) by a distance of less than <NUM> inch at a midfoot area of the plantar support surface of the upper base member, and in some examples, by a distance of less than ½ inch or even less than ¼ inch.

In such upper structures, the upper base member may have a circular knitted construction, such as a sock or sock-like structure as described above. The support member(s) may have any of the constructions described above and/or in more detail below, such as outsole components, ground engaging components, lace support components, shape providing components, etc..

Additional aspects of this disclosure relate to articles of footwear and methods of making articles of footwear that include the components (e.g., upper base members, uppers, etc.) as described above (and/or produced by the various methods described above). Such articles and methods may include, for example, a sole component engaged with the footwear components (e.g., upper base members) as described above. Such sole components may include one or more midsole components (e.g., foam midsole components, fluid-filled bladder midsole components, foam column type midsole components, mechanical force attenuating components, etc.), one or more outsole components (e.g., rubber, thermoplastic polyurethanes, etc.), one or more traction elements (e.g., cleats or spikes, bases for mounting cleats or spikes, etc.), etc. The sole component(s) may be engaged with the other footwear component(s) in conventional manners as are known or used in the art, such as by bonding (using adhesives or cements), by mechanical connectors, by sewing or stitching, etc..

In some examples of this aspect of this invention, the upper base member will include a single foot-insertion opening and an otherwise enclosed volume (e.g., a sock or sock-like structure, optionally one produced by a circular knitting process and having an open end and a closed end (e.g., closed by a sewn seam)). Additionally, these selectively supported footwear upper base members may be incorporated into overall footwear structures in relatively easy and simple manners. More specifically, in some examples of this invention, the footwear upper structures will be incorporated into a foot structure without the need for attachment of a strobel member at a bottom of the upper (e.g., to provide a seamless and/or continuous plantar support surface), without the need for forming a heel stitch or other stitching for the upper (e.g., because the upper may be formed as an enclosed volume with a single foot-insertion opening), etc. Thus, the upper base member may be a continuous structure that extends uninterrupted around a plantar support surface of the foot (e.g., without a seam or strobel member under the foot). Such advantageous features of some examples of this invention provide a comfortable foot support structure and can substantially reduce the time and/or labor involved in finally forming an upper and/or engaging an upper with a footwear sole structure.

As described above, some aspects of this disclosure relate to methods of forming upper components for articles of footwear using pressing processes, such as flat-pressing procedures. <FIG> illustrates an example "jig" or base support member <NUM> that may be used in pressing processes according to at least some examples of this disclosure. The jig <NUM> of this example includes a first major surface 102a and a second major surface 102b opposite the first major surface 102a. The first and second major surfaces 102a, 102b may be flat and parallel, and they may be separated by an overall jig thickness dimension of less than <NUM> inch, and in some examples, less than ½ inch or even less than ¼ inch.

<FIG> shows the jig <NUM> as being made as least in part (and optionally totally) as a metal component. Such structures can be particularly useful in heat transfer steps that may be used in some methods according to this disclosure, such as for inductive heating of the jig <NUM>. Also, <FIG> shows jig <NUM> as completely planar with two opposing, flat, parallel surfaces 102a, 102b. While this is a preferred arrangement in some embodiments of this disclosure, the surfaces 102a, 102b need not be perfectly flat and/or they need not be perfectly parallel. In other words, variations in the surface structures and/or surface orientations are possible without departing from this disclosure. As used in this specification, a base support surface will be considered "substantially flat:" (a) if at least <NUM>% of the surface changes in elevation by less than ¼ inch from a mean surface level (exclusive of any openings extending completely through the base support) and/or (b) if at least <NUM>% of the surface covered by an upper base member (described in more detail below) changes in elevation by less than ¼ inch from a mean surface level (exclusive of any openings extending through the base support. In other words, at least <NUM>% of one of the actual surfaces described above lies within ± ¼ inch of a central plane for the surface. Also, as used in this specification, base support surfaces will be considered "substantially parallel:" (a) if a direct thickness between the opposite surfaces varies by less than <NUM>% over at least <NUM>% of the overall surface area (exclusive of any openings extending completely through the base support) and/or (b) if a direct thickness between the opposite surfaces varies by less than <NUM>% over at least <NUM>% of the surface area covered by an upper base member (exclusive of any openings extending completely through the base support). The terms "substantially flat" and "substantially parallel" also encompass and include perfectly flat and perfectly parallel surfaces, respectively.

<FIG> further shows all (<NUM>%) of this example jig <NUM> has having flat and parallel surfaces. Other arrangements are possible without departing from this disclosure. For example, if desired, the portion of the jig <NUM> (if any) that will extend outside of an upper base member during production processes may include a ball, hole, slot, groove, ridge, or other structure, e.g., to enable the jig <NUM> to be grasped or handled more easily (e.g., by robotic arms or other machinery, by an operator, etc.).

<FIG> shows another example jig or base support structure <NUM>. In this example, heating elements or resistors <NUM> are provided on one or both surfaces 152a, 152b of the jig <NUM>. The heating elements or resistors <NUM> may be formed to have a flat structure and/or may be recessed into the surface(s) 152a, 152b such that the overall jig surface(s) 152a, 152b maintain substantially flat and/or substantially parallel characteristics as described above. If desired, a single heating element and/or single resistor <NUM> may be provided to simultaneously heat both sides or surfaces 152a, 152b of the jig <NUM> at a specific location. While the heating elements or resistors <NUM> may be powered in any desired manner, <FIG> illustrates conductor leads <NUM> for supplying power to the heating elements or resistors <NUM>. No specific circuit arrangement is required (or should be implied from the representative conductor leads <NUM> shown in <FIG>). As some more specific examples, flexible heating elements (such as heating elements in/on a silicone base or membrane) may be used in at least some examples of this invention. Flexible heating elements of suitable constructions are known and are commercially available.

<FIG> illustrates an upper base member <NUM> fit onto a substantially flat jig <NUM>, <NUM>, e.g., of the various types described above. In this illustrated example, the upper base member <NUM> constitutes a conventional ankle high sock structure, e.g., having a circular knit structure with one closed end 120a (optionally closed by a sewn seam) and one open end 120b, through which the jig <NUM>, <NUM> is inserted into the enclosed interior chamber defined by the sock. While other circular knit and/or sock-type structures may be provided as an upper base member <NUM>, in at least some examples of this disclosure, at least some of the upper base member <NUM> will constitute a textile component, e.g., formed from textile fibers, knitted, woven, and/or otherwise incorporated together. The jig <NUM>, <NUM> may be shaped so as to substantially fill the interior chamber defined by the upper base member <NUM>, but it may further include a portion <NUM> that extends out beyond the open end of the upper base member <NUM>. This extending portion <NUM> may be used, for example, for engaging the jig <NUM>, <NUM> with another component (e.g., manufacturing machinery) and/or for otherwise handling the jig <NUM>, <NUM>. Additionally or alternatively, the upper base member <NUM> may be specially shaped (different from a conventional sock, if desired) to better engage around and/or accommodate the jig <NUM>, <NUM>.

If desired, the upper base member <NUM> and/or the jig <NUM>, <NUM> may include markings, indentations, notches, and/or other components or indicia provided for alignment purposes (e.g., to assure that the upper base member <NUM> is properly oriented on the jig <NUM>, <NUM> for further processing). <FIG> and <FIG> illustrate jigs <NUM>, <NUM> as including one or more indicia <NUM> with which the top rim <NUM> of the upper base member <NUM> is to align when properly mounted on the jig <NUM> (see <FIG>). <FIG> further illustrates one or more notches or indentations <NUM> formed in the jig <NUM>, and the operator can engage the upper base member <NUM> with the jig <NUM>, <NUM> so that the notch(es) or indentation(s) <NUM> align with indicia <NUM> or other features provided on the upper base member <NUM> (e.g., by feeling the notch(es) or indentation(s) <NUM> through the fabric material of the upper base member <NUM>). While specific example top rim, rear heel, and top toe alignment aids are shown in <FIG>, any desired numbers, arrangements, and/or types of alignment aids can be used without departing from this disclosure. Also, if desired, at least some of the alignment aids and/or indicia may be removable from the upper base member <NUM> (e.g., washed off, etc.) so that they do not appear in the final upper construction. Additionally or alternatively, if desired, features of the alignment aids and/or indicia may be incorporated to blend into and/or form a portion of an overall aesthetic design of the upper component.

Some aspects of this invention relate to using a sock or other similar upper base member <NUM> as a base for forming a footwear upper component. In this manner, a footwear upper can be formed having a compliant, form fitting structure that can be incorporated into an article of footwear. The use of this type of sock or sock-like structure can also eliminate the need to use and engage upper components with a strobel member and/or the need to close off the heel area of the upper by stitching or sewing. The bottom, plantar support surfaces of such upper components may be continuous with the sides and seamless. Such upper base members <NUM> (formed as socks or sock-like structures) also are stretchable, form fitting, and comfortable to the wearer.

It would not always be desirable, however, to simply use a sock structure (or other similar, plain textile component) alone as an upper component because such textile components generally do not have the necessary construction to adequately perform some of the desired functions of a footwear upper. For example, some footwear uppers provide various support and/or containment functions, such as shape support, heel area support (e.g., heel counter type structures), lace or other securing system supports, motion control functions, foot positioning functions, etc. Additionally, some footwear uppers provide water-resistance, waterproofing features, stain resistance, dirt resistance, abrasion resistance, durability, and the like. Also, footwear uppers may help provide desired aesthetics (e.g., colors and color combinations) to the overall shoe construction. Conventional socks, by themselves, or even if engaged with a separate footwear sole structure, may not provide all the desired functions of a footwear upper.

Therefore, in accordance with at least some examples of this disclosure, a conventional sock or other upper base member <NUM> (e.g., a sock-like structure, a circular knitted component, etc.) may be engaged with one or more "support members. " <FIG> illustrate various example support members <NUM>, <NUM>, <NUM> of a "wrap around" type that are configured as contiguous (but optionally multi-part) structures that wrap around the bottom 120c of an upper base member <NUM> when mounted on a jig <NUM>, <NUM> and extend along an exterior surface 120d of the upper base member <NUM> along both sides of the jig <NUM>, <NUM>. One or more "wrap around" support members <NUM>, <NUM>, <NUM> of this type may be provided with a single upper base member <NUM> without departing from this disclosure. Various example features of these support members <NUM>, <NUM>, and <NUM> are described in more detail below.

Support member <NUM> (<FIG>) includes an exterior base component <NUM> to which additional support materials <NUM> are engaged on opposite sides of a central area <NUM> of the exterior base component <NUM>. In use, this example support member <NUM> will be oriented with respect to an upper base member (e.g., <NUM>) in a manner such that the support materials <NUM> will directly face and contact opposite sides of the exterior surface (e.g., 120d) of the upper base member <NUM> on jig <NUM>, <NUM>. Thus, an underside or interior of the support member <NUM> is illustrated in <FIG>. The support member <NUM> includes side heel support areas <NUM> (for both the lateral and medial sides of the upper), instep/midfoot support areas <NUM> (for both the lateral and medial sides), and forefoot side edge support areas <NUM> (for both the lateral and medial sides). In this illustrated example, the exterior base component <NUM> is a non-woven textile and the additional supports <NUM> include EVA foams. Other example exterior base components <NUM> include, but are not limited to: polyurethanes, TPUs, suedes, leathers (natural or synthetic), spacer meshes, other textiles, and the like. Other example support materials <NUM>, when present, include but are not limited to: polyurethanes or other foams, textiles, inelastic components, etc. Materials including the upper materials described in <CIT> may be used for base component <NUM> and/or additional support materials <NUM>. The additional support materials <NUM>, when present, may be engaged with the exterior base component <NUM> in any desired manner, such as by adhesives or cements, by stitching or sewing, etc..

The interior surface of the exterior base component <NUM> at these support areas <NUM>, <NUM>, and <NUM> in this example are predominantly covered by the additional support materials <NUM>, although a greater or lesser coverage by the additional support material(s) <NUM> may be used without departing from this disclosure (in fact, if desired, support material(s) <NUM> could be eliminated from this structure). The central area <NUM> of the exterior base component <NUM> supports the arch area of a wearer's foot, and in this example, remains uncovered by additional supports material <NUM>. While this illustrated central area <NUM> primarily supports the midfoot/arch area, support may be provided at the bottom heel, bottom forefoot, and/or any desired portion(s) or combination of portions of the plantar surface of the foot.

Any desired area, portion, or proportion of the base component <NUM> and/or the additional support material(s) <NUM> may include a bonding or adhesive agent (e.g., a layer) applied to it. As some more specific examples, if desired, at least some of the perimeter area of the base component <NUM> may include a bonding or adhesive material applied to it, such as a hot melt adhesive, a pressure sensitive adhesive, reactive polyurethane adhesives (PUR), etc. In some examples of this disclosure, the entire base component <NUM> and additional support material(s) <NUM>, if any, will not be covered with the bonding or adhesive materials so as to allow some relative movement or flexibility between layers of the overall upper structure. The bonding or adhesive agent may be applied to the base component <NUM> and/or additional support material(s) <NUM> in any desired manner, such as by coating, spraying, printing, etc..

The side instep/midfoot support areas <NUM> in this example structure <NUM> include elongated wire-like strands <NUM> of substantially inelastic material that extend along the sides and around the interior bottom central area <NUM> of the support member <NUM> at the midfoot area. These strands <NUM> help provide a close and adjustable fit around at wearer's foot (e.g., when a lace or other securing system is tightened). The term "substantially inelastic" as used herein in this context, means a material that does not increase in length more than <NUM>% in a direction of an applied tensile force, under forces typically used in tightening a shoe lace around a human foot.

A securing system for a footwear upper is provided as part of the support member <NUM> in this example construction. More specifically, the medial instep/midfoot support area <NUM> of this example structure includes a securing strap <NUM> at its free end. The free end of the securing strap <NUM> has one portion of a mechanical fastener <NUM> engaged with it (a portion of a hook-and-loop fastener, in this specific example, although a portion of a snap, buckle, or other securing component could be used). As will be described in more detail below, in use, this securing strap <NUM> portion will extend over the instep area of the upper at the midfoot to engage another portion of a mechanical fastener <NUM> provided on the exterior surface of the exterior base component <NUM> at the lateral instep/midfoot support area (another portion of a hook-and-loop fastener, not visible in the view of <FIG>, but see <FIG>). When the securing strap <NUM> is pulled tight around a wearer's foot to engage fastener portions <NUM>, <NUM> with one another, the strands <NUM> will at least partially wrap around the foot, holding and fitting the support member <NUM> to the wearer's foot.

<FIG> illustrates another example support member <NUM> that may be engaged with an upper base member, like member <NUM> shown in <FIG>. This example support member <NUM> is similar to that shown in <FIG> and includes an exterior base component <NUM> to which additional support materials <NUM> are engaged on opposite sides of a central area <NUM> of the exterior base component <NUM>. In use, this example support member <NUM> will be oriented with respect to an upper base member (e.g., <NUM>) in a manner such that the additional support materials <NUM> will directly face and contact opposite sides of the exterior surface (e.g., 120d) of the upper base member <NUM>. Thus, an underside or interior of the support member <NUM> is illustrated in <FIG>. A bonding or adhesive material, e.g., of the types described above, may be provided on some or all of the interior surface(s) of exterior base component <NUM> and/or additional support material(s) <NUM>.

Like the support member <NUM> of <FIG>, this example support member <NUM> includes side heel support areas <NUM> (for both the lateral and medial sides) and forefoot side edge support areas <NUM> (for both the lateral and medial sides). Rather than a single continuous additional support material <NUM> on each side of this support <NUM> (as shown in the example of <FIG>), in this illustrated example, each side of the interior of support member <NUM> includes two separate areas of additional support material <NUM> (e.g., made of EVA or other material as described above). More specifically, as shown in <FIG>, each side of support member <NUM> includes: (a) one additional support material area <NUM> covering a majority of the heel and midfoot/instep support areas <NUM> and (b) one additional support material area <NUM> at the front, forefoot support area <NUM> with a gap <NUM> of exposed base component <NUM> on each side of the support member <NUM> between these respective additional support areas <NUM>. More or fewer separate support areas <NUM> may be provided on each side of the support member <NUM>, if desired, without departing from this disclosure and the two sides may have different numbers of support areas <NUM>, if desired. Again, as in the embodiment of <FIG>, the central area <NUM> of the exterior base component <NUM> supports the arch area of a wearer's foot, and in this example, remains uncovered by additional support material <NUM>. More, less, and/or different areas of the plantar surface may be supported by the base component <NUM> and/or additional support component(s) <NUM>, if desired.

The instep/midfoot support areas <NUM> in this example structure <NUM> differ from those provided in the structure <NUM> of <FIG>. More specifically, in this example, the instep/midfoot support areas <NUM> include a plurality of elongated separated strips <NUM> that will extend along the medial and lateral sides of the footwear upper component in the final upper construction. While four strips <NUM> are shown on each side of support member <NUM> in this example, more or fewer support strips <NUM> may be provided (and a different number of support strips <NUM> may be provided on opposite sides) without departing from this disclosure. If desired, the free ends of these strips <NUM> may include holes, eyelets, loops, and/or other structures <NUM> for engaging a lace or other securing system for the final upper component. Some portion of these free ends may be free of bonding or adhesive material, e.g., so that the very free end(s) remains unattached to the upper base member <NUM> and freely available to engaged a lace.

While it is not a requirement, if desired, the exterior base component <NUM> of this support member <NUM> may be made of a material such that the strip(s) <NUM> provided along the instep/midfoot sides are substantially inelastic. Substantially inelastic strips <NUM> of this type (also called "bands" or "straps" herein) can provide at least some of the fit and securing functions of the substantially inelastic strands <NUM> described above in conjunction with <FIG>.

<FIG> illustrates another example support member <NUM>. This support member <NUM> is similar to those illustrated in <FIG> and <FIG>, and the same reference numbers are used to refer to the same or similar parts (and the detailed description thereof is omitted). In this illustrated example structure <NUM>, however, each individual strip <NUM> has one or more substantially inelastic strands <NUM> engaged with it. In this illustrated example, each strip <NUM> includes a single strand <NUM> engaged with it, and the strands <NUM> extend beyond the free end of each strip <NUM> to form an exposed loop <NUM>. The exposed loop <NUM> may be used to engage a shoe lace or other securing system for the upper. The opposite ends of the strands <NUM> extend down the strip <NUM> and toward the central area <NUM> and engage to at least one of and/or between the exterior base component <NUM> and/or the additional support material <NUM>.

<FIG> illustrate additional support materials <NUM> (e.g., EVA or other materials). These materials <NUM> may overlay other components or structures of supports <NUM>, <NUM>, <NUM>, including exterior support <NUM>, and these components <NUM>, <NUM>, etc. provide one or more desired characteristics to locations of the overall upper, such as shape support, stiffness, durability, abrasion resistance, water resistance, impact force attenuation, lace or engaging system support, etc. Again, any desired portion or proportion of support <NUM> (e.g., supports <NUM> and/or <NUM> (if any)) may have bonding or adhesive material applied to it, e.g., by coating, spraying, etc., so as to enable the support <NUM> to be engaged with an upper base member <NUM> as will be described in more detail below.

<FIG> illustrates an example of an upper base member <NUM> engaged with a jig <NUM>, <NUM> (e.g., as shown in <FIG>), with a support member (e.g., like support members <NUM>, <NUM>, or <NUM>) wrapped around and engaged with the exterior surface 120d of the upper base member <NUM>. The support member shown in <FIG> generally corresponds to the example support component <NUM> of <FIG> (and like references numbers are used in each figure to refer to the same or similar parts). If necessary or desired, a light adhesive, mechanical connectors, and/or other temporary securing means may be used to temporarily engage the support member <NUM> with the upper base member <NUM> to hold it in place until a desired time for further processing (as will be described in more detail below). The overall combination or assembly of the jig <NUM>, <NUM>, upper base member <NUM>, and support member <NUM> is represented in <FIG> by reference number <NUM>. Multiple support members may be provided on a single upper base member <NUM>, if desired, including separate support members on each side of jig/upper base member, if desired.

While the figures show support members <NUM>, <NUM>, <NUM> as relatively flat members, these members may have some non-flat shape/features without departing from this disclosure. For example, if desired, component <NUM> may be a molded structure (such as molded TPU) that does not have a completely flat shape. As an additional example, component <NUM> may have texturing or surface features. Additionally or alternatively, if desired, the additional support member(s) <NUM> (e.g., an EVA or polyurethane foam material) may have some significant thickness such that the overall combination of base support <NUM> and additional support(s) <NUM> have a varying thickness over the area of support <NUM>. Accordingly, it is not necessary that the support members <NUM>, <NUM>, and/or <NUM> be completely or substantially flat.

Also, in some examples of this disclosure, the upper base member <NUM> and/or the support member <NUM>, <NUM>, <NUM> may include markings, indentations, notches, and/or other components or indicia provided for alignment purposes (e.g., to assure that the support member <NUM>, <NUM>, <NUM> is properly oriented on the upper base member <NUM>). For example, <FIG> and <FIG> illustrate upper base member <NUM> as including one or more indicia <NUM> with which the front and rear of the central area <NUM> of the support member <NUM> may be aligned. Other types, numbers, positions, and/or arrangements of alignments aids may be provided without departing from this disclosure. If desired, at least some of the alignment aids and/or indicia may be removable (e.g., washed off, etc.) so that they do not appear in the final upper construction. Additionally or alternatively, if desired, features of the alignment aids and/or indicia may be incorporated to blend into and/or form a portion of an overall aesthetic design of the upper component.

<FIG> illustrates an example "assembly line" diagram that schematically illustrates some examples and features of methods according to this disclosure. "Station <NUM>" in this example is a loading station where an assembly <NUM> (e.g., including a jig <NUM>, <NUM>, an upper base member <NUM>, and a support member <NUM>) is mounted to a conveyance system that moves the assembly <NUM> through the process. While other arrangements are possible, in this illustrated example, the assembly <NUM> is mounted "upside down" so that the bottom <NUM> of the base support member <NUM> is located at a top of the mounted assembly <NUM> and maintained in contact with the upper base member <NUM> under the force of gravity (and optionally by some additional securing means). The connection of the assembly <NUM> to the conveyance system further may include electrical connections and/or hardware/connectors for other components necessary or desired for the production process (e.g., connections or hardware for heating elements <NUM>, for heating/coolant flow, for inductive heating, etc.).

In this illustrated example, the assembly <NUM> is substantially flat and thin. The mounted assembly <NUM> moves toward Station <NUM> along with two pressure plates <NUM>, one provided on each side of the assembly <NUM>. Optionally, the assembly <NUM> may be engaged with one or both pressure plates <NUM>. The pressure plates <NUM> may be connected to one another (e.g., by a hinge or other structure) or they may be separate from one another. The pressure plates <NUM> may support some or all of the electrical connections and/or hardware described above. Once all components are properly mounted and oriented with respect to one another, the pressure plates <NUM> close around at least a portion of the assembly <NUM>, as shown at Station <NUM> in <FIG> (e.g., so that pressure plate surfaces 402a contact the exterior of the assembly <NUM>). In at least some examples of this disclosure, the portion of the assembly <NUM> located between the pressure plates <NUM> when closed and under compressive force may be less than <NUM> inch thick, and in some examples, less than ¾ inch thick, less than ½ inch thick, or even less than ¼ inch thick.

At this point, the interior surface of support member <NUM> (with at least some portion of its interior surface provided with a bonding or adhesive component, such as a hot melt layer) may be pressed against the outside 120d of the upper base member <NUM> under some level of compressive force. From Station <NUM>, the assembly <NUM> between pressure plates <NUM> may be moved into and through a heat and/or compressive force application zone <NUM>, as shown in <FIG>. The zone <NUM> may include additional pressure applying devices (e.g., compressive rollers <NUM>), heating devices, cooling devices, and/or other hardware as necessary or desired to provide a desired level of heating and/or pressure to the assembly <NUM> located between the pressure plates <NUM>. If desired, the zone <NUM> may include programmable components to allow application of controlled and programmable heating, pressing, and/or cooling protocols to the assembly <NUM>. Also, if desired, the zone <NUM> may include coils and/or other appropriate components to induce inductive heating of jig <NUM>. The applied heat and/or pressure in zone <NUM>, optionally heating the hot melt material on support <NUM>/<NUM> from inside and through the material of the upper base member <NUM>, causes the hot melt material of the support member <NUM>, <NUM>, <NUM> to melt (and optionally draw into the structure of the upper base member <NUM> toward the heat source), which adheres the support member <NUM> to the upper base member <NUM>.

After the assembly <NUM> leaves the zone <NUM>, if necessary, it may move along the conveyance system to a removal location, shown as Station <NUM> in the example of <FIG>. The conveyance system may move the assembly through a cooling zone, if desired (e.g., if zone <NUM> does not itself include a cooling area and/or cooling protocol). Alternatively or additionally, the pressure plates <NUM> may remain clamped around the assembly <NUM> (and still applying a compressive force to the assembly <NUM>) for a sufficient time after they leave the zone <NUM> for cooling to occur and/or to assure an adequate bond has developed between the support member <NUM>, <NUM>, <NUM> and the upper base member <NUM>. Other processing may occur between zone <NUM> and Station <NUM>, if desired. At Station <NUM>, the pressure plates <NUM> can be opened (e.g., rotated open about hinge connection) and the assembly <NUM> can be removed from the pressure plates <NUM>.

In the example described above, the entire assembly <NUM> is attached to and removed from the pressure plates <NUM> and/or an area between pressure plates <NUM>. Other arrangements are possible without departing from the disclosure. For example, if desired, jigs <NUM>, <NUM> may remain engaged with (optionally removably engaged with) the pressure plate(s) <NUM>. In such a system, at Station <NUM> the upper base member <NUM> and support member(s) <NUM>, <NUM>, <NUM> may be engaged and properly positioned with respect to one another and with respect to the jig <NUM>, <NUM>, and at Station <NUM> the combined upper base member <NUM> and support member(s) <NUM>, <NUM>, <NUM> may be removed from its respective jig <NUM>, <NUM> as a combined, unitary, single component <NUM>. This combined, unitary, single component <NUM>, which may be comprised of a sock or sock-type component <NUM> having one or more support components <NUM>, <NUM>, <NUM> adhered to it by a bonding or adhesive material, then may be used for constructing an article of footwear as will be described in more detail below in conjunction with <FIG>.

Optionally, if desired, the combined, unitary, single footwear components <NUM> produced by the process described in conjunction with <FIG> may be stored until needed for further production. Their relatively flat production and structure at this time in the process makes storage and handling very space efficient. Also, because the overall components <NUM> may have some flexibility and stretchability (e.g., because of the sock-type construction of the upper base member <NUM>), a single sized upper component <NUM> (with a single sized support member <NUM>, <NUM>, <NUM> engaged with it) may be used for a range of final footwear sizes (e.g., for a range of <NUM>-<NUM> conventional shoe sizes in length and/or for a range of <NUM>-<NUM> conventional shoe sizes in width, and in some examples, for a range of <NUM>-<NUM> conventional shoe sizes in length and/or for a range of <NUM>-<NUM> conventional shoe sizes in width). This feature can save significant tooling and/or inventory costs (e.g., as compared to tooling/inventory costs associated with building molds and/or maintaining inventories for upper components at every specific size interval).

Also, while generally "flat pressing" processes are described with respect to <FIG>, if desired, the item pressed may have a three-dimensional structure. This may be accomplished in various ways. For example, if desired, the jig and pressure plates could be designed to have complementary shaped surfaces so as to allow pressure to be applied around the structure in various different directions. As another example, a three-dimensional jig and upper base member <NUM> (with one or more support members engaged therewith) could be mounted in a vacuum chamber in which an outer surface pulls inward under vacuum pressure to apply compressive force to the upper base member and jig surfaces inside the chamber.

<FIG> illustrates a support base <NUM> used in making footwear structures in accordance with at least some examples of this disclosure. At least some portion(s) of the exterior surface <NUM> of support base <NUM> of this example may be sized and shaped to produce a desired final shape of a footwear upper product, as will be described in more detail below. As some more specific examples, one or more of the side heel areas, the rear heel area, the instep side areas, the lace support areas, the plantar surface support areas (i.e., the bottom surface), and/or the toe box area of the support base <NUM> may be sized and shaped as desired for the final footwear product. The support base <NUM> may resemble a conventional footwear last.

Next, as shown in <FIG>, the upper component <NUM> (e.g., as produced in the processes described in conjunction with <FIG>) is applied over the exterior surface <NUM> of the support base <NUM>. <FIG> shows a bottom view of the combined upper component <NUM> mounted on the support base <NUM> (showing the outside of the plantar support surface <NUM> of the upper component <NUM>). When placed on the support base <NUM>, some or all of the support member <NUM>, <NUM>, <NUM> may be shaped and/or otherwise treated so as to be formed into and/or maintained in a desired shape (e.g., using thermoplastic or thermosetting properties, using shape memory materials, etc., the shape of at least some portion of the upper component <NUM> (e.g., support member <NUM>, <NUM>, <NUM>) may be modified). Additionally or alternatively, if desired, at least some portions of the support member <NUM>, <NUM>, <NUM> and/or the upper base member <NUM> may be maintained in the desired shape at this stage solely by the presence of the underlying support base <NUM>.

<FIG> and <FIG> illustrate an example footwear component <NUM> in which a support member <NUM> like that illustrated in <FIG> is engaged with the upper base member <NUM>. As shown in <FIG>, the upper base member <NUM> includes a securing flap <NUM> having a portion of a fastener system on its underside (<NUM>, see <FIG>) that engages a portion of the fastener system <NUM> included at the exterior surface of the support member <NUM>. The flap <NUM> extends over the wearer's instep area from one side of component <NUM> to the other and secures the upper to the wearer's foot in use.

Notably, as shown in <FIG>, because the upper base member <NUM> starts out as a circular knitted component, e.g., a sock or sock-like structure, the bottom plantar support surface (<FIG>) is a continuous structure such that no strobel element and/or bottom seam is needed to close off the foot-receiving chamber. Additionally, the rear heel area of this example upper base member <NUM> constitutes a continuous structure without the need for a rear heel seam and/or sewing step. These features provide a comfortable plantar support surface and/or eliminate significant manufacturing steps (thereby saving time, labor, and/or money) as compared to many conventional footwear structures and footwear production techniques.

Then, optionally while the support base <NUM> remains inside the upper component <NUM>, the upper component <NUM> may be engaged with at least a portion of a sole structure for an article of footwear. For example, as shown in <FIG>, the upper component <NUM> (including an upper base member <NUM> and one or more support members <NUM>, <NUM>, <NUM>) may be engaged with a midsole impact force attenuating component, such as one or more midsole foam elements <NUM> as shown in <FIG>. Any desired manner of connecting these components <NUM> and <NUM> may be used without departing from this disclosure, including manners conventionally known or used in the footwear art, such as one or more of: adhesive or cements (e.g., applied to portions of the exterior bottom and/or side surfaces of the upper component <NUM>, applied to the top surface of the midsole component <NUM>, etc.); mechanical connectors, such as hook-and-loop type fasteners (optionally releasable mechanical connectors); sewing or stitching; etc. Also, any desired type of midsole component construction may be applied to the upper component <NUM> without departing from this disclosure, including, for example, midsole components including one or more fluid-filled bladders, midsole components including one or more foam impact force absorbing columns, midsole components including mechanical impact force absorbing columns or elements, etc. If desired, the bottom surface of midsole component <NUM> may be structured to provide natural motion, traction, and/or durability and/or to otherwise engage a contact surface in use.

Additional sole components or structures may be applied to the midsole component <NUM> and/or the upper component <NUM> without departing from the disclosure, such as one or more outsole elements (e.g., rubber or TPU ground contacting pads), cleat base components, cleats (permanently or removably mounted), cup-sole components, etc. Also, any desired manner of connecting the outsole element(s) to the remainder of the structure may be used without departing from this disclosure, including manners conventionally known or used in the footwear art, such as one or more of: adhesive or cements, mechanical connectors, sewing or stitching, etc..

In contrast to the footwear securing system (strap <NUM> and hook-and-loop fastener <NUM>, <NUM>) shown in <FIG> and <FIG>, the footwear component <NUM> of <FIG> includes a different type of securing system. More specifically, the support member shown in <FIG> generally corresponds in structure to the support member <NUM> shown in <FIG>. As shown in <FIG>, this support member <NUM> includes substantially inelastic strands <NUM> along the instep side areas of the upper. Exposed portions of these strands <NUM> at the top instep area form loops <NUM> through which a conventional shoe lace <NUM> may be engaged (e.g., to lace up the upper in a generally conventional manner). When the lace <NUM> is tightened around a wearer's foot, the substantially inelastic strands <NUM> can be pulled to snugly engage the support member <NUM> and the overall component <NUM> around the sides of the wearer's foot.

Because of the sock type upper base member <NUM> in this example, a conventional tongue is not needed in this example article of footwear beneath the lace <NUM>, as shown in <FIG>. Rather the sock or sock-like structure of the upper base member <NUM> extends continuously over the instep area where a tongue would conventionally be provided (and may generally perform the functions of a conventional tongue). Additionally or alternatively, if desired, a conventional tongue member could be provided (e.g., sewn to upper base member <NUM>) and/or the upper base member <NUM> could be cut or slit (<NUM>) from the ankle opening downward, along the instep, and toward the toe area between the lace engaging loops <NUM> (e.g., if the upper base member <NUM> is not sufficiently stretchable to allow easy insertion and removal of a foot). A tongue member and/or instep slit <NUM> may be provided, if desired, before the upper <NUM> is engaged with sole component <NUM>.

<FIG> and <FIG> illustrate side and bottom views, respectively, of another example support member <NUM> engaged with an upper base component <NUM> (e.g., after an engaging process, like that described in conjunction with <FIG>) and applied over a support base (e.g., like that shown in <FIG>). While this example support member <NUM> includes a non-woven textile base structure, substantially inelastic strands <NUM>, and lace engaging loops <NUM> like those shown in <FIG> and <FIG>, the strands <NUM> in this example are more exposed along their lengths down the sides of the support member <NUM>. This support member <NUM> is more of a minimalist construction, e.g., with less support member <NUM> area, more and/or larger openings in the support member <NUM>, no additional support material <NUM>, etc. Also, separate strands <NUM> are provided on each side of the support member <NUM>, but as shown in <FIG>, in this example structure, the strands <NUM> from opposite sides of the support member <NUM> meet at the bottom <NUM> of the upper base member <NUM> and loop through one another (similar looped or intertwined strands <NUM> could be provided in the structure of <FIG>, if desired). This support member <NUM> and upper base component <NUM> combination may be engaged with a sole structure, e.g., in the manners described herein (including in the manner described above with respect to <FIG>). <FIG> and <FIG> further illustrate that the upper base component <NUM> may have an extended upper area <NUM> that extends up to or even beyond a wearer's ankle (and optionally beyond the top of support base <NUM>). If desired, this upper area <NUM> may be constructed and fit like a conventional sock (e.g., as a circular knitted construction). The example of <FIG> and <FIG> lacks the additional support materials <NUM> shown in some of the other example support members <NUM>, <NUM>, <NUM>.

The discussion above relates to footwear component structures and their formation (including one or more upper support members) for engagement with conventional sole structures in a conventional manner. Other options are possible. <FIG> illustrate an example construction in which a ground engaging sole structure is directly engaged with an upper base member <NUM> rather than to an upper base component that includes a support member <NUM>, <NUM>, <NUM>, e.g., as shown in the other figures. <FIG> shows an example sole component <NUM> formed as an integral web of generally triangular shaped pods <NUM> (e.g., in a tessellated configuration). Sole structures of this type also are described in <CIT>. This sole structure <NUM> may be made from a thermoplastic polyurethane, rubber, or other suitable material, optionally at least partially coated with a bonding or adhesive material (e.g., hot melt adhesive material) on one surface (which will contact the upper base member <NUM> in use). Because of the cutout material areas <NUM> between adjacent triangular pods <NUM>, this web of material can be made to have a very flexible overall construction (e.g., flexible or foldable in various different directions along aligned segments <NUM> of cutout material <NUM>), particularly if the pods <NUM> also are made from a flexible material. The web also can be cut into pieces to form any desired overall size and/or shape of web material. Webs and/or pods <NUM> of other shapes and constructions also may be used without departing from this invention.

<FIG> illustrate portions of this web sole structure <NUM> engaged with an upper base member <NUM>, e.g., by a substantially flat, hot-pressing process, optionally on a jig <NUM>, <NUM>, like the processes described above in conjunction with <FIG> and <FIG>. In this process, one of the aligned segments <NUM> of cutout material <NUM> was placed so as to align along the bottom edge <NUM> of the upper base member <NUM> and the jig <NUM>, <NUM> so that the sole structure <NUM> wrapped around the bottom edge <NUM> and laid substantially flat on the opposite sides of the upper base member <NUM>. The specific example of <FIG> and <FIG> further shows a substantially flat upper support member <NUM> engaged with the upper base member <NUM>, e.g., for providing shape or support for the sides of the final footwear component. If desired, the upper support member <NUM> and the sole structure <NUM> may overlap and/or may be applied to the upper base member <NUM> in a single flat pressing step. Substantially inelastic strands <NUM> also are provided, optionally with looped or closed free ends (<NUM>), for wrapping around the sides and/or bottom of the foot and/or supporting a lace or other type closure system.

The overall combination <NUM> shown in <FIG> (e.g., jig <NUM>, <NUM>, upper base member <NUM>, upper support(s) <NUM> (if any), and sole structure <NUM>) can be pressed together, e.g., in a process like those described in conjunction with <FIG> and <FIG>, to engage the upper support(s) <NUM> (if any) and/or sole structure <NUM> with an exterior surface of the upper base member <NUM>, e.g., using a hot melt adhesive. Then, if desired, as shown in <FIG> and <FIG>, the combined upper base member <NUM>, upper support(s) <NUM> (if any), and sole structure <NUM> may be engaged over a base support <NUM> for further shaping (e.g., using thermoplastic or thermosetting properties, using shape memory materials, etc., the shape of at least some portion(s) of the upper component may be temporarily or permanently modified). As further shown in <FIG>, the sole member <NUM> in this illustrated example wraps around the side and rear heel areas <NUM> to provide additional support for the heel (e.g., akin to a type of heel counter construction) and extends upward at the forward toe area <NUM> to provide additional stiffness or structure around the toe area. If desired, at least some areas of the sole member <NUM> may be somewhat thicker (e.g., include a foam material), e.g., to provide impact force attenuation properties.

The combined upper base member <NUM>, upper support(s) <NUM> (if any), and sole structure <NUM> may be worn directly as an article of footwear, for example, if exterior surfaces of at least some of the pod areas <NUM> of the sole structure <NUM> are formed to include a material suitable for use as a ground-contacting surface (e.g., having sufficient wear resistance, traction characteristics, and the like to function in a desired manner for contacting the ground). Alternatively, if desired, other sole components may be engaged with one or more of the pod areas <NUM> of the sole structure <NUM>, such as one or more outsole components (e.g., rubber, thermoplastic polyurethanes, etc.); one or more traction elements (e.g., cleats or spikes, bases for mounting cleats or spikes, etc.); etc. The additional sole component(s), when present, may be engaged with the sole structure <NUM> or other footwear component(s) in conventional manners as are known or used in the art, such as by bonding (using adhesives or cements), by mechanical connectors, by sewing or stitching, etc..

The processes described above in conjunction with <FIG> utilized a substantially flat jig <NUM>, <NUM> to which a single piece upper base member <NUM> (e.g., a sock or sock-type structure) was applied. At least one single piece support member <NUM>, <NUM>, <NUM> was wrapped around a bottom 120c of the upper base member <NUM> (akin to a taco shell) to lie adjacent the opposing flat sides of the upper base member <NUM>. Other options are possible. For example, for at least some materials, after pressing, a permanent crease is formed at the bottom of the upper base member <NUM> and/or the support member <NUM>, <NUM>, <NUM> (at the location of the fold). This crease can be undesirable (e.g., aesthetically displeasing, uncomfortable feeling to the bottom of the foot, adversely impacting bonding with other footwear components, etc.). Various ways of avoiding the issues created by this crease may be used in some methods according to this disclosure. For example, if possible, additional heat and/or pressure may be applied to the creased area over a flat or rounded surface to eliminate or reduce the severity of the crease (e.g., akin to ironing out the crease). As other examples, the underlying sole component (e.g., midsole foam) may be formed to include a sufficiently soft plantar support surface and/or with a corresponding groove in the plantar support surface (to accommodate the fold line) so that the crease is not substantially felt by the wearer. If desired, an underlying sole component of this type (with a soft plantar support surface and/or groove) could be used to moderate the feel of inelastic strands (if any) that extend beneath the foot, like those shown in <FIG>, and particularly looped inelastic strands like those shown in <FIG>.

Alternatively, rather than a wrapped "taco-like" configuration, one or more separate support members <NUM>, <NUM>, <NUM> may be applied to each side of the upper base member <NUM> in a manner so that none of the support members extends continuously around the bottom edge of the jig <NUM>, <NUM> and/or the upper base member <NUM>. For example, <FIG> illustrates an alternative configuration of a two-piece support member <NUM> in broken lines in which the bottom area <NUM> of support member <NUM> is separated or cut to form a lateral side of the support member <NUM> (including free edge <NUM> at the bottom area <NUM>) separated from a medial side of the support member <NUM> (including free edge <NUM> at the bottom area).

Then, returning to the processes described in conjunction with <FIG>, rather than folding and positioning a support member <NUM>, <NUM>, <NUM> to lie along and extend continuously across the top surface of the jigs in the orientation shown in <FIG>, separate support members can be used. More specifically, as one example, the lateral side of support member <NUM> and the separate medial side of support member <NUM> shown in <FIG>), with their bonding or adhesive material containing sides oriented upward, may be releasably and temporarily fixed to the exposed surfaces 402a of pressure plates <NUM>. This releasable and temporary engagement of the support members <NUM> to the pressure plate surfaces 402a may be accomplished in any desired manner, for example, using a light adhesive, electrostatic charge, vacuum attachment, or the like (e.g., any method providing sufficient holding force to hold the support members <NUM> in position with respect to the pressure plate surface 402a during transport (e.g., from Station <NUM> to Station <NUM>) and/or while the pressure plates <NUM> move to engage against the sides of upper base member <NUM>). In this manner, because the support members <NUM> do not extend continuously and wrap around the bottom edge of the upper base member <NUM> and the jig, the heating and pressure applying steps will not produce a crease or fold line on the support member(s) <NUM>. In such constructions, the upper base member <NUM> may be made from a material (such as a fabric or textile) such that the crease can be removed (e.g., by steaming or ironing) and/or such that the fold line is sufficiently flexible and thin that it does not produce an adverse feel on the bottom of the foot. Also, if the support members <NUM> extend to locations close to this central line of the bottom edge, the elevation provided by the closely adjacent support members <NUM> along the central line of the bottom edge may accommodate the crease and negate the feel of the fabric crease (if any) in the bottom of the upper base member <NUM>.

In this example production process, the lateral side support member and the medial side support member (e.g., the opposite sides of two-piece support member <NUM>) may be oriented with respect to the upper base member <NUM> and/or jig <NUM>, <NUM> so that at least a portion of their edges <NUM> and <NUM> are positioned close to the bottom edge 120c of the upper base member <NUM> and/or close to the bottom edge of jig <NUM>, <NUM>. As some more specific examples, the separate sides of the support member <NUM> may be positioned such that, when the composite upper base member <NUM> and support member <NUM> is formed, at least a portion of lateral edge <NUM> will be located a distance of <NUM> inch or less from at least a portion of the medial edge <NUM> (and in some examples, this edge separation distance may be ½ inch or less or even ¼ or less) over at least some portion of the bottom plantar support surface of the upper base member <NUM>.

As noted above, some aspects of this disclosure relate to footwear components made from lightweight textile structures that are selectively supported at various areas to provide desired local characteristics, as well as to methods of making such components. The embodiments of the disclosure described in <FIG> describe various pressing methods of making footwear components using a sock or sock-type structure as an upper base member. The use of a sock or sock-type structure as the upper base member is advantageous because of the soft, flexible, and conforming fit and feel provided by conventional sock and sock-type structures (e.g., circular knitted fabric components made from natural and/or synthetic fiber containing materials, optionally having a closed toe end and an open end for inserting the foot) and because such structures eliminate various other processing steps, such as engagement of the upper with a strobel or bottom, plantar support surface and/or other sewing steps (e.g., to close the bottom and/or heel area of the upper).

Additional aspects of the claimed invention relate to other ways of providing a footwear component using sock and sock-type structures as an upper base member. One specific example relates to the use of certain reactive polymeric materials to provide shape, support, hardness, and/or stiffness to one or more predetermined localized areas of a sock or sock-type upper base member. For example, as shown in <FIG> and <FIG>, starting with a sock or sock-type upper base member <NUM>, a reactive polymeric material <NUM> may be applied to a surface (e.g., the exterior surface) of the upper base member <NUM>. This may be accomplished, for example, with the upper base member <NUM> in a flat condition (<FIG>, e.g., on a flat jig type structure <NUM>) or in a more shaped, three-dimensional condition (<FIG>, e.g., on a base support <NUM>, optionally a base support having an exterior surface shaped as the desired shape of at least a portion of the final footwear component).

Any desired curable, reactive polymeric materials <NUM> may be used without departing from the claimed invention. The reactive polymeric materials <NUM> will be used that exhibit the following characteristics: the reactive polymeric material(s) <NUM> will have thermoplastic properties as long as it is maintained below a certain temperature (e.g., the material will become soft, pliable, and easily deformable when heated), but after it is heated above a certain temperature optionally for a sufficient time period, the reactive polymeric material will "cure" and harden in an irreversible manner (e.g., by forming cross links, such as ester bond cross links). As some more specific examples, the reactive polymeric material(s) <NUM> may include a water-based reactive polymer solution, and in some examples, the reactive polymeric material(s) <NUM> may include an acrylic acid copolymer and a cross-linking agent. In some embodiments of this invention, the reactive polymeric material(s) <NUM> will include a polymeric binder material free of formaldehyde, phenols, and isocyanates. As a specific example, reactive polymeric materials <NUM> that may be used in at least some examples of this invention are available from BASF Corporation under the trademark ACRODUR®.

The reactive polymeric material <NUM> are selectively applied only to local areas of the upper base member <NUM> where stiffening, hardening, and/or additional support is desired in the upper base member <NUM>. The reactive polymeric material <NUM> is applied to the upper base member <NUM> as a series of relatively small dots (of any desired shape) or segments (e.g., straight or curved line segments) at predetermined areas of the upper base member <NUM> by a printing process (as shown by the movable print head <NUM> member in <FIG> and <FIG>). Any desired process may be used to selectively apply the reactive polymeric material <NUM> to areas of the upper base member <NUM>, such as printing (e.g., screen printing, jet printing, etc.); by masking techniques (e.g., masking areas of the upper base member <NUM> to apply the reactive polymeric material only to desired locations); by spraying techniques; by coating techniques; etc..

In the example of <FIG> and <FIG>, the print head <NUM> moves to selected areas of the upper base member <NUM> (shown by arrow <NUM>) and applies small "dots" or "segments" of reactive polymeric material <NUM> to the predetermined desired areas at a predetermined desired "application density level" (e.g., a predetermined amount of reactive polymeric material (e.g., grams) per unit area (e.g., cm<NUM>) or volume (cm<NUM>) of the upper base member <NUM>). While the applied dots or segments may overlap one another, this is not a requirement. <FIG> shows an example upper base member <NUM> with both dots (e.g., at the heel area) and segments (at the midfoot area) of reactive polymeric material <NUM> applied to it (the combination of an upper base member <NUM> with one or more areas of uncured reactive polymeric material <NUM> applied to it is represented by reference number <NUM> in <FIG>). Spacing between dots and/or segments, dot and/or segment dimensions, and/or the like, also may be used to control the application density level. Reactive polymeric material applications processes in accordance with examples of this invention may coat individual fibers of the textile upper base member <NUM> (or portions thereof) and/or fill interstitial areas between fibers of the textile base member with the reactive polymeric material <NUM>.

Also, as is apparent from <FIG>, any desired number of separated areas of reactive polymeric material <NUM> may be applied to an upper base member <NUM> without departing from this invention. As some more specific examples, the reactive polymeric material <NUM> may be applied (and eventually cured): over at least a portion of a bottom surface of the upper base member (e.g., to form a support plate for supporting all or some portion(s) of the plantar surface of a wearer's foot and/or for supporting a cleat or other sole component); at an area around one or more sides and/or rear heel area of a wearer's foot (e.g., to provide a heel counter type structure); at an area around the sides or instep of a wearer's foot (e.g., to provide shape support to the upper); at a toe area (e.g., to provide a more defined toe box); along the instep area to provide supports for a shoe lace (e.g., extending in a top-to-bottom direction of the upper base member at a medial or lateral side of the instep area); etc. The same or different reactive polymeric materials <NUM> and/or application density levels may be used on different areas of a single upper base member <NUM> (e.g., optionally with different reactive polymeric materials at different areas) without departing from this invention.

If desired, once the reactive polymeric material <NUM> is applied to the upper base member <NUM>, the so-treated upper base member/uncured reactive polymeric material combination <NUM> can be removed from any support member (e.g., element <NUM> or <NUM>) and stored until further processing is desired (e.g., footwear production as will be explained in more detail below). If desired, uncured, reactive polymeric material treated upper base members <NUM> (e.g., as shown in <FIG>, after any necessary drying) may be stored for an extended period of time (days, weeks, months, etc.). In this manner, a large bulk of footwear components (e.g., uncured, reactive polymeric material treated upper base members <NUM>) may be produced and stored, and these components can then be available for further production as desired or needed. A single "uncured" component of this type may be produced and used for producing a wide variety of different finally "cured" component parts (e.g., depending on the upper properties desired, depending on user preferences, depending on commercial demand, etc.), including component parts over a range of sizes (e.g., due to stretchability of the textile portion of component <NUM>). For example, because the treated upper base member <NUM> may have some flexibility and stretchability (e.g., because of the sock-type construction of the upper base member <NUM>), a single sized treated upper base member <NUM> may be used for a range of final footwear sizes (e.g., for a range of <NUM>-<NUM> conventional shoe sizes in length and/or for a range of <NUM>-<NUM> conventional shoe sizes in width, and in some examples, for a range of <NUM>-<NUM> conventional shoe sizes in length and/or for a range of <NUM>-<NUM> conventional shoe sizes in width).

When production of a footwear component is desired, as one step, an uncured, reactive polymeric material treated upper base member <NUM> (e.g., as shown in <FIG>) may be applied to a support base <NUM> having a desired shape for the final footwear component. At some point during this step, if necessary, the assembly shown in <FIG> may be heated to a temperature sufficient to take advantage of the thermoplastic properties of the reactive polymeric material <NUM> and allow the component <NUM> to be manipulated to a desired shape. The temperature at this shaping stage should be sufficient to allow the component <NUM> to be shaped due to its thermoplastic properties but insufficient to finally cure the reactive polymeric component, as will be described in more detail below. This type of shaping can occur in any desired manner, for example, by pressing, by pushing/pulling the component <NUM> against the surface of the support base <NUM> using vacuum pressure, by hand, etc. Optionally, after this shaping step, the shaped component <NUM> may be removed from the support base <NUM> and optionally stored again (with the shaped component <NUM> retaining its shape and its thermoplastic properties (which can allow the shaped component <NUM> to be heated, re-shaped, or further shaped in the future, if desired)). Alternatively (or optionally after this additional storing step), during or after any desired shaping step in the thermoplastic condition (if any is needed), the reactive polymeric material <NUM> may be cured (e.g., by raising the temperature of the finally shaped component <NUM> above the reactive polymer curing temperature). Curing of this type causes cross linking, e.g., formation of ester cross linking bonds, which converts the reactive polymeric material to a cured, thermoset state (at which the shapes of any cured parts are irreversibly fixed).

As noted above, when an upper base member <NUM> includes reactive polymeric material <NUM> in more than one area, the reactive polymeric materials <NUM> may be the same or different in the different areas. Varying the stiffness and/or hardness properties on different areas of a single upper base member may be accomplished in various manners in accordance with some aspects of this invention. For example, the use of different reactive polymeric materials <NUM> at different areas may provide varying hardness and/or stiffness at the different areas of the upper base member <NUM>. Different concentrations of reactive polymeric materials <NUM> in aqueous solutions are applied at different areas of the upper base member <NUM>. Optionally also, different "dot" or "segment" spacings and/or sizes may be used at different areas of the upper base member (to thereby alter the "application density levels" (e.g., in g/cm<NUM> and/or g/cm<NUM>) of the reactive polymeric material <NUM> on the upper base member <NUM>.

The above description of <FIG> relates to constructions and methods in which the reactive polymeric material <NUM> is applied to predetermined, targeted areas of an upper base member <NUM> and then all (or substantially all) of the reactive polymeric material <NUM> on the upper base member <NUM> may be exposed to curing conditions and cured to a hardened or stiffened (thermoset) state (thereby forming a finally and irreversibly hardened footwear component that may be further processed to a final article of footwear product). Other footwear component production methods and techniques are possible. For example, if desired, the final footwear component may have both cured and uncured reactive polymeric material(s) <NUM> in or on it. In other words, a greater proportion of the upper base member <NUM> surface and/or volume may have reactive polymeric material <NUM> applied to it than the proportion thereof having reactive polymeric material <NUM> that is eventually cured. This will leave some portion of the reactive polymeric material <NUM> on the upper base member <NUM> with thermoplastic properties (and potentially capable of being altered in shape, e.g., upon heating to a temperature below the curing temperature) and some portion of the reactive polymeric material <NUM> cured and thermoset (and not capable of being altered in shape upon reheating). The remaining thermoplastic portion also could be cured at a later time, in a separate curing step, if desired.

As some more specific examples, the reactive polymeric material(s) <NUM> may be applied (e.g., by coating, spraying, printing, etc.) to at least <NUM>% of an overall surface area and/or volume of the upper base member <NUM> and then only one or more selected portions of this surface area and/or volume (e.g., less than <NUM>% of the overall surface area and/or volume in some examples) will be exposed to effective curing/thermosetting conditions. In some other examples of this invention, at least <NUM>%, at least <NUM>%, at least <NUM>%, at least <NUM>%, or even up to <NUM>% of the surface area and/or volume of the upper base member <NUM> may have reactive polymeric material applied to it, but less than <NUM>%, less than <NUM>%, less than <NUM>%, less than <NUM>%, or even less than <NUM>% of this overall surface area and/or volume with reactive polymeric material applied to it will then be cured/thermoset. In other words, assume: (a) X is a total exterior surface area and/or volume of the upper base member <NUM>, (b) Y is a total exterior surface area and/or volume of the upper base member <NUM> to which the reactive polymeric material <NUM> is applied, and (c) Z is a total exterior surface area and/or volume of the upper base member <NUM> including reactive polymeric material <NUM> that is cured/thermoset. Then, X ≥ Y ≥ Z, and any one or more of the following relationships also may exist: (a) Y = <NUM>. 1X to X, (b) Y = <NUM>. 25X to X, (c) Y = <NUM>. 5X to X, (d) Y = <NUM>. 65X to X, (e) Y = <NUM>. 75X to X, (f) Y = <NUM>. 9X to X, (g) Z = <NUM>. 1Y to Y, (h) Z = <NUM>. 25Y to Y, (i) Z = <NUM>. 5Y to Y, (j) Z = <NUM>. 65Y to Y, (k) Z = <NUM>. 75Y to Y, and/or (<NUM>) Z = <NUM>.

Systems and methods according to examples of this invention may accomplish this "selective exposure" to curing/thermosetting conditions in various ways, such as: by applying an insulative "mask" over areas of the surface at which curing is not desired (so that insufficient heat transfers through the insulative mask during the curing process to cure any reactive polymeric material(s) <NUM> located behind the mask); by applying a heat conductive "mask" over areas of the surface at which curing is desired (so that sufficient heat quickly transfers through the heat conductive mask to the areas where curing of the reactive polymeric material(s) <NUM> is desired and completed before the reactive polymeric material <NUM> in the "unmasked areas" reaches the curing conditions); by using a heated die for heating that selectively applies heat only at desired locations; by selectively heating areas of the surface 850d where curing is desired using laser radiation (such as the scanning laser source <NUM> shown in <FIG>, a heat gun, or other targeted heat applying source); by selectively activating portions of an array of heat elements provided on a base member <NUM> that supports the treated upper base member <NUM>; by providing a base member <NUM> having heat elements located at predetermined areas for heating the footwear component <NUM>; etc..

The base member <NUM> may be shaped so as to hold at least the portions of the footwear component <NUM> (including the upper base member <NUM> with the reactive polymeric material <NUM> applied to it as described above) to be cured in a final desired shape for the curing process (i.e., during curing, the portion of the reactive polymeric material <NUM> exposed to effective curing conditions will be thermoset and irreversibly maintained in this shape). If necessary or desired, this type of shaping can be assisted, for example, by pressing, by pushing/pulling the component <NUM> against the surface of the support base <NUM> using vacuum pressure, etc. Curing may take place in multiple steps, if desired (e.g., with one area of the component <NUM> cured in one step and one or more other areas of the component <NUM> cured in one or more other steps).

Similar to the discussion above with respect to <FIG>, selectively curing one or more areas of a footwear component <NUM> in the manner described above with respect to <FIG> may cure at any desired number of separated areas on an individual footwear component. As some more specific examples, the reactive polymeric material <NUM> may be selectively cured: over at least a portion of a bottom surface of the upper base member (e.g., to form a support plate for supporting all or some portion(s) of the plantar surface of a wearer's foot and/or for supporting a cleat or other sole structure component); at an area around one or more sides and/or rear heel area of a wearer's foot (e.g., to provide a heel counter type structure); at an area around the sides or instep of a wearer's foot (e.g., to provide shape support to the upper); at a toe area (e.g., to provide a more defined toe box); along the instep area to provide supports for a shoe lace (e.g., extending in a top-to-bottom direction of the upper base member at a medial or lateral side of the instep area); etc. In some examples of this invention, holes may be formed in and/or hardware may be attached at one or more cured areas of the reactive polymeric material <NUM> (e.g., in the instep area), and these holes and/or hardware may be used to engage a lace or other footwear securing structure.

Once at least some portion(s) of the footwear component <NUM> is cured, the footwear component <NUM> may be used directly as a footwear product in at least some examples of this invention. Alternatively, if desired, the at least partially cured footwear component <NUM> may be engaged with a sole component for an article of footwear, such as one or more midsole components (e.g., foam midsole components, fluid-filled bladder midsole components, foam column type midsole components, mechanical impact force absorbing structures, etc.); one or more outsole components (e.g., rubber, thermoplastic polyurethanes, etc.); one or more traction elements (e.g., cleats or spikes, bases for mounting cleats or spikes, etc.); etc. These sole component(s) may be engaged with the other footwear component <NUM> in conventional manners as are known or used in the art, such as by bonding (using adhesives or cements), by mechanical connectors, by sewing or stitching, etc., including by the various methods described above (e.g., in conjunction with <FIG>).

Claim 1:
A process for forming a component for an article of footwear, the process comprising:
applying a first series of small dots or segments of a first reactive polymeric material (<NUM>) to a first portion of an outer or exterior surface of an upper base member (<NUM>, <NUM>), the upper base member (<NUM>, <NUM>) comprising a textile component to which the reactive polymeric material is applied, and wherein the first reactive polymeric material (<NUM>) exhibits a first set of thermoplastic properties as long as it is not exposed to thermoset curing conditions and thermosetting properties after it is exposed to thermoset curing conditions;
applying a second series of small dots or segments of a second reactive polymeric material (<NUM>) to a second portion of the outer or exterior surface of the upper base member (<NUM>, <NUM>), wherein the second reactive polymeric material (<NUM>) exhibits a second set of thermoplastic properties as long as it is not exposed to thermoset curing conditions and thermosetting properties after it is exposed to thermoset curing conditions;
exposing the first reactive polymeric material (<NUM>) on the first portion of the upper base member (<NUM>, <NUM>) to thermoset curing conditions after the first reactive polymeric material (<NUM>) is applied to the upper base member (<NUM>, <NUM>) so as to convert the first reactive polymeric material (<NUM>) at the first portion of the upper base member (<NUM>, <NUM>) to a thermoset condition; and
exposing the second reactive polymeric material (<NUM>) on the second portion of the upper base member (<NUM>, <NUM>) to thermoset curing conditions after the second reactive polymeric material (<NUM>) is applied to the upper base member (<NUM>, <NUM>) so as to convert the second reactive polymeric material (<NUM>) at the second portion of the upper base member (<NUM>, <NUM>) to a thermoset condition,
wherein the first reactive polymeric material is different from the second reactive polymeric material, or wherein the first and second reactive polymeric materials are applied to the upper base member at different application density levels.