Patent Description:
Footwear typically includes an upper and a sole structure underlying and secured to the upper. An upper may have a specific material, color, or design for function, for aesthetic appearance, or both. Consumers may select footwear at least in part based on the aesthetic appearance of the footwear.

<CIT> relates to a shoe upper for a shoe, in particular a sports shoe, comprising (a. ) a first layer; (b. ) a second layer connected to the first layer in a fixed way, wherein (c. ) the second layer comprises at least two regions separated from each other, and wherein (d. ) the first layer comprises a higher elasticity in a region not covered by the at least two regions of the second layer than the second layer.

An article of footwear and a method of manufacturing an article of footwear disclosed herein enable aesthetic and/or functional aspects of a footwear upper to remain a surprise to the wearer until the wearer decides to reveal the aspects. Additionally, the configuration of the upper allows the aspects to be revealed one at a time and in any order.

An article of footwear includes an upper having a plurality of discrete sections secured to one another. Each discrete section includes a base layer and a cover layer. Each cover layer is secured to and covers the outer side of a corresponding one of the base layers. Each cover layer is configured to be selectively removable from the base layer independently of each other cover layer to expose the outer side of the base layer. Stated differently, when a cover layer is removed, each other cover layer may remain secured to and covering the outer side of its corresponding base layer until it is independently selectively removed.

Each base layer has a peripheral edge and the cover layer secured to the base layer has a portion wrapped around and covering the peripheral edge. For example, the cover layer may include a portion wrapped over the peripheral edge and adhered to an inner side of the base layer. In some embodiments, the cover layers may be opaque. Accordingly, the cover layers may hide the underlying base layers from view, even covering the peripheral edges, until the cover layers are selectively and individually removed. A wearer may choose to keep all of the base layers hidden by the cover layers or may choose to reveal the outer side of any one or more of the base layers by removing the respective cover layer(s).

The cover layers are configured so that selective removal of one or more cover layers may be in any order or combination and may occur at any time during possession of the footwear. The wearer thus may enjoy many different and surprising appearances from a single article of footwear. Additionally, the outer side of at least one of the base layers may comprise a different material or may have a different color, texture, or pattern than at least one other of the base layers. At least one of the cover layers may be entirely on a lateral side of the upper. Additionally, at least one of the cover layers may be entirely on a medial side of the upper. Accordingly, a different material, color, texture, or pattern of an underlying base layer may be present only at the lateral side or only at the medial side of the upper in some embodiments.

In another aspect, each cover layer may be secured to its corresponding base layer by stitches extending through the cover layer and the base layer. Each of the base layers may be bordered by at least two other of the base layers. The stitches may extend through a pair of bordering base layers and the respective cover layers may cover the base layers.

In an aspect, at least one of the cover layers may define an integral pull tab disposed at an edge of the corresponding base layer to which the cover layer is secured. For example, the cover layer defining the integral pull tab may be disposed on a throat portion of the upper with the integral pull tab extending forward over a toe region of the upper. In this position, the pull tab is relatively protected so that scuffs and bumps against the footwear will not unintentionally pull on the pull tab. One or more different cover layers may include an integral pull tab instead of or in addition to the cover layer located on the throat portion. For example, cover layers at either or both of the medial and lateral side portions may include integral pull tabs.

The base layer and the cover layers may be a variety of different materials. For example, one or more of the base layers may be leather or a synthetic leather. One or more of the cover layers may be a nonwoven textile.

A method of manufacturing an article of footwear such as the article of footwear disclosed herein includes providing a plurality of base layers of an upper and providing a plurality of cover layers. The method further includes securing the cover layers to the base layers, each cover layer secured to a different corresponding one of the base layers so that the cover layer covers an outer side of the base layer. After securing the cover layers to the base layers, the method then includes securing the base layers to one another to define a foot-receiving cavity with each cover layer selectively removable from the corresponding base layer independently of each other cover layer to expose the outer side of the base layer with each other cover layer remaining secured to and covering the outer side of its corresponding base layer until independently selectively removed. Securing the cover layers to the base layers includes wrapping the cover layers around peripheral edges of the base layers. In an aspect, securing the cover layers to the base layers further includes securing the cover layers to inner sides of the base layers. Securing the cover layers to inner sides of the base layers may include adhering the cover layers to the inner sides of the base layers. Furthermore, securing the base layers to one another may include stitching adjacent ones of the base layers to one another with a series of stitches, the series of stitches extending through the adjacent ones of the base layers and through the cover layers secured to the adjacent ones of the base layers.

In one example, at least one of the cover layers may include a pull tab. The method may include, prior to securing the cover layers to the base layers, disposing the pull tab at a peripheral edge of the corresponding base layer to which the at least one of the cover layers is to be secured.

The method enables different articles of footwear manufactured in the same manner to have the same initial look (e.g., when the base layers are covered by the cover layers) but different appearances once one or more of the base layers are revealed by removal of the corresponding cover layers. More specifically, the base layer and the cover layers discussed above may be of a first upper of a first article of footwear, and the method further comprising manufacturing a second article of footwear by providing a second plurality of base layers of a second upper. The second plurality of base layers may correspond in shape and dimension to the plurality of base layers of the first article of footwear. However, at least one of the second plurality of base layers may comprise a different material or may have a different color, texture, or pattern than a corresponding one the base layers of the first article of footwear. The method may further comprise providing a second plurality of cover layers and securing the second plurality of cover layers to the second plurality of base layers. Each cover layer of the second plurality of cover layers may be secured to and may cover an outer side of a different corresponding one of the base layers of the second plurality of base layers. After securing the second plurality of cover layers to the second plurality of base layers, the method may include securing the second plurality of base layers to one another with each cover layer of the second plurality of cover layers selectively removable from the different corresponding one of the second plurality of base layers independently of each other cover layer of the second plurality of cover layers to expose the outer side of the base layer with each other cover layer of the second plurality of cover layers remaining secured to and covering the corresponding one of the base layers of the second plurality of base layers until independently selectively removed. Because at least one of the second plurality of base layers may comprise a different material or may have a different color, texture, or pattern than a corresponding one the base layers of the first article of footwear, the second article of footwear will have a different appearance than the first article of footwear when the cover layer of that base layer is removed.

Referring to the drawings, wherein like reference numbers refer to like components throughout the views, <FIG> is a lateral side view of an article of footwear <NUM> that has a sole structure <NUM> and an upper <NUM> secured to the sole structure <NUM>. The upper <NUM> forms a foot-receiving cavity <NUM> configured to receive a foot. The upper <NUM> may be a variety of materials, such as leather, textiles, polymers, cotton, foam, composites, etc., and is shown with a lace <NUM> for tightening the upper <NUM> around a foot (not shown). As discussed further herein, the upper <NUM> is configured to have many different appearances than that shown in <FIG>, any one of which results from the optional selective removal of one or more discrete cover layers 20A-<NUM> described herein.

The footwear <NUM> illustrated herein is depicted as an athletic shoe configured for sports or for wear as a leisure shoe, but the footwear <NUM> is not limited to athletic or leisure shoes. The footwear <NUM>, including its components described herein, may be an athletic shoe, a leisure shoe, a dress shoe, a work shoe, a sandal, a slipper, a boot, or any other category of footwear. As indicated in <FIG>, the footwear <NUM> may be divided into a forefoot region <NUM>, a midfoot region <NUM>, and a heel region <NUM>, which are also the forefoot region, the midfoot region, and the heel region, respectively, of the sole structure <NUM> and the upper <NUM>. The forefoot region <NUM> generally includes portions of the article of footwear <NUM> corresponding with the toes and the joints connecting the metatarsals with the phalanges. The midfoot region <NUM> generally includes portions of the article of footwear <NUM> corresponding with the arch area and instep of the foot, and the heel region <NUM> corresponds with rear portions of the foot, including the calcaneus bone. The forefoot region <NUM>, the midfoot region <NUM>, and the heel region <NUM> are not intended to demarcate precise areas of the footwear <NUM> but are instead intended to represent general areas of the footwear <NUM> to aid in the following discussion.

The sole structure <NUM> includes a midsole <NUM> and an outsole <NUM> which are integrated as a unitary component in the embodiment shown and may be referred to as a unisole. An insole (not shown) may rest on the sole structure <NUM> in the foot-receiving cavity <NUM>. The midsole <NUM> attenuates ground reaction forces (e.g., provides cushioning) when compressed between the foot and the ground during walking, running, or other ambulatory activities. The outsole <NUM> establishes the ground-engaging surface of the article of footwear <NUM> and may be one-piece or may be several discrete outsole components. In one example, the outsole <NUM> may be formed from a wear-resistant material that may be textured to impart traction. For example, the outsole <NUM> may comprise a natural or synthetic rubber.

When the foot is positioned within the foot-receiving cavity <NUM> of the footwear <NUM>, it is supported on a foot-facing surface of the midsole <NUM>. The foot-facing surface of the midsole <NUM> may be covered by a strobel (not shown) secured to a lower region 14C of the upper <NUM>. Also, an insole (not shown) may rest on the strobel or directly on the sole structure <NUM> in embodiments without a strobel, in which case the foot is supported by both the sole structure <NUM> and the insole.

The footwear <NUM> has a lateral side <NUM> (shown in <FIG>) and a medial side <NUM> (best shown in <FIG>). The lateral side <NUM> and the medial side <NUM> extend through each of the forefoot region <NUM>, the midfoot region <NUM>, and the heel region <NUM>, each falling on an opposite side of a longitudinal midline LM of the article of footwear <NUM>, as is understood by those skilled in the art. The medial side <NUM> is thus considered opposite to the lateral side <NUM>.

The upper <NUM> includes a plurality of base layers 32A-<NUM> secured to one another. The base layers 32A-<NUM> are individually revealed in <FIG> as the respective cover layers 20A-<NUM> are selectively and individually removed. Each base layer 32A-<NUM> has a respective outer side 36A-<NUM> that is viewable from the exterior of the article of footwear <NUM> when the respective cover layer 20A-<NUM> is removed. In the embodiments shown, adjacent ones of the base layers 32A-<NUM> are secured to one another with stitching <NUM> as discussed herein. For example, <FIG> shows two adjacent base layers 32E and 32F secured to one another with stitching <NUM>. Cover layer 20E covers an outer side 36E of its corresponding base layer 32E. Additionally, a portion 20E1 of the cover layer 20E is wrapped around a peripheral edge 38E1 of the base layer 32E to cover the peripheral edge 38E1 and is secured to an inner side 40E of the base layer 32E with adhesive <NUM>. Similarly, cover layer 20F covers an outer side 36F of its corresponding base layer 32F. Additionally, a portion 20F1 of the cover layer 20F is wrapped around a peripheral edge 38F1 of the base layer 32F to cover the peripheral edge 38F1 and is secured to an inner side 40F of the base layer 32F with adhesive <NUM>. The stitching <NUM> extends through each of the adjacent base layers 32E, 32F as well as through their respective cover layers 20E, 20F.

Each cover layer 20A-<NUM> corresponds generally in shape and size to the respective base layer 32A-<NUM> to which it is secured so that it can cover the entire outer side of the base layer, wrap around the peripheral edges of the base layer, and secure to the inner side of the respective base layer. The cover layers 20A-<NUM> are secured to the respective base layers 32A-<NUM> only at the stitching <NUM> indicated in <FIG>, <FIG> and <FIG>. Accordingly, although the cover layers 20A-<NUM> cover the outer sides 36A-<NUM> of the base layers 32A-<NUM>, they are not adhered to the outer sides 36A-<NUM>. The lower region 14C of the upper <NUM> shown in <FIG> and <FIG> is not covered by any cover layer and is not considered one of the base layers.

Each cover layer 20A-<NUM> is configured to be selectively removable from the respective base layer 32A-<NUM> independently of each other cover layer to expose the outer side 36A-<NUM> of the base layer. Stated differently, when one cover layer is removed, each other cover layer may remain secured to and covering the outer side of its different corresponding base layer until it is independently selectively removed. The cover layers 20A-<NUM> may be a relatively thin and flexible material, such as a nonwoven textile. Generally, a nonwoven textile or fabric is a sheet or web structure made from fibers and/or yarns that are bonded together. The bond can be a chemical and/or mechanical bond, and can be formed using heat, solvent, adhesive or a combination thereof Exemplary nonwoven fabrics are flat or tufted porous sheets that are made directly from separate fibers, molten plastic and/or plastic film. They are not made by weaving or knitting and do not necessarily require converting the fibers to yarn, although yarns can be used as a source of the fibers. Nonwoven textiles are typically manufactured by putting small fibers together in the form of a sheet or web (similar to paper on a paper machine), and then binding them either mechanically (as in the case of felt, by interlocking them with serrated or barbed needles, or hydro-entanglement such that the inter-fiber friction results in a stronger fabric), with an adhesive, or thermally (by applying binder (in the form of powder, paste, or polymer melt) and melting the binder onto the web by increasing temperature). A nonwoven textile can be made from staple fibers (e.g., from wetlaid, airlaid, carding/crosslapping processes), or extruded fibers (e.g., from meltblown or spunbond processes, or a combination thereof), or a combination thereof Bonding of the fibers in the nonwoven textile can be achieved with thermal bonding (with or without calendering), hydro-entanglement, ultrasonic bonding, needle punching (needle felling), chemical bonding (e.g., using binders such as latex emulsions or solution polymers or binder fibers or powders), meltblown bonding (e.g., fiber is bonded as air attenuated fibers intertangle during simultaneous fiber and web formation). In one example, the cover layers 20A-<NUM> may be made of TYVEK®, a nonwoven textile made of high density polyethylene fibers and available from E. du Pont de Nemours and Company of Wilmington, Delaware USA. Although the material of the cover layers 20A-<NUM> is not limited to a nonwoven textile, such a material may make each cover layer 20A-<NUM> relatively easy to remove (e.g., cut or tear away) from the base layers 32A-<NUM> to expose the outer sides 36A-<NUM> of the base layers.

In some embodiments, one or more of the cover layers 20A-<NUM> may be opaque so that the color, texture, and material of the corresponding base layer 32A-<NUM> remains hidden until revealed by removal of the cover layer 20A-<NUM>. Accordingly, the footwear <NUM> could be sold to a consumer without the consumer knowing these characteristics of the base layers 32A-<NUM>. Alternatively, the consumer may know the characteristics of one or more of the base layers 32A-<NUM> when purchasing the footwear <NUM> such as if the footwear <NUM> is packaged with a description of the characteristics of the underlying base layer 32A-<NUM>. In either case, the outer sides 36A-<NUM> of the base layers 32A-<NUM> remain hidden from view until the respective cover layers 20A-<NUM> are separately and individually removed, if they are removed at all. Because even the peripheral edges of the base layers 32A-<NUM> are covered by the cover layers 20A-<NUM>, the underlying base layers 32A-<NUM> are totally and completely concealed.

Removal of the cover layers 20A-<NUM> can be in any order and in any combination. <FIG> depict just one order and combination of selective removal of the cover layers 20A-<NUM> (e.g., removal of all eleven cover layers 20A-<NUM> in the order indicated from <FIG>). In other possibilities, no cover layers 20A-<NUM> are removed, any one of the cover layers 20A-<NUM> is removed, and two of the cover layers 20A-<NUM> are removed, and three of the cover layers 20A-<NUM> are removed, any four of the cover layers 20A-<NUM> are removed, any five of the cover layers 20A-<NUM> are removed, any six of the cover layers 20A-<NUM> are removed, any seven of the cover layers 20A-<NUM> are removed, any eight of the cover layers 20A-<NUM> are removed, any nine of the cover layers 20A-<NUM> are removed, or any ten of the cover layers 20A-<NUM> are removed.

Accordingly, the footwear <NUM> may have many different appearances over the course of use depending upon which of the cover layers 20A-<NUM> have been removed and in what order. As further discussed herein, the outer side 36A-<NUM>, respectively, of at least one of the base layers 32A-<NUM> may comprise a different material or may have a different color, texture, and/or pattern than the outer side of at least one other of the base layers. The cover layers 20A-<NUM> may be a variety of different materials. For example, one or more of the base layers 32A-<NUM> may be leather or a synthetic leather. One or more of the cover layers 20A-<NUM> may be a nonwoven textile. The cover layers 20A, 20E, and 20F and their respective underlying base layers 32A, 32E, and 32F are entirely on the lateral side <NUM> of the upper <NUM>. Cover layers 20I, 20J, and <NUM> and their respective underlying base layers 32I, 32J, and <NUM> are entirely on the medial side <NUM> of the upper <NUM>. Accordingly, once any of these cover layers are removed, the lateral and medial sides may have different appearances as any of the base layers 32A, 32E, and 32F may comprise a different material or may have a different color, texture, and/or pattern than at least one of the base layers 32I, 32J, and <NUM>.

<FIG> and <FIG> show that each cover layer 20A-<NUM> is secured to the different corresponding one of the base layers 32A-<NUM> (all of which are covered in <FIG> but shown in <FIG>) by stitches <NUM> extending through the cover layer and the base layer. Each of the cover layers 20A-<NUM> and the corresponding base layers 32A-<NUM> are bordered by at least two other of the cover layers 20A-<NUM> and corresponding base layers 32A-<NUM>. The stitches <NUM> extend through a pair of bordering base layers 32A-<NUM> and the respective cover layers 20A-<NUM> covering the pair of bordering base layer 32A-<NUM>. For example, <FIG> shows cover layer 20A bordered by cover layers 20D, 20E, and 20F. Cover layer 20B is shown bordered by cover layers 20F, 20C, <NUM> and <NUM> (see <FIG>). Cover layer 20C is bordered by cover layers 20E, 20F, 20B, <NUM>, <NUM>, and 20J. Cover layer 20D is bordered by cover layers 20A, 20I, 20E, <NUM>, and 20J. Cover layer 20E is bordered by cover layers 20D, <NUM>, 20F, and 20C. Cover layer 20F is bordered by cover layers 20A, 20E, 20B, and 20C. Cover layer <NUM> is bordered by cover layers 20B and 20C. Cover layer <NUM> is bordered by cover layers 20D, 20E, and 20J (see <FIG>, <FIG>, and <FIG>). Cover layer 20I is bordered by cover layers <NUM>, 20J, and 20D (see <FIG>). Cover layer 20J is bordered by cover layers 20C, <NUM>, 20I, 20D and <NUM>. Cover layer <NUM> is bordered by cover layers 20B, 20C, 20I, and 20J. The base layers 32A-<NUM> border one another in the same manner as the corresponding cover layers 20A-<NUM>. Stitches <NUM> are shown extending through bordering ones of the cover layers 20A-<NUM> and the corresponding bordering ones of the base layers 32A-<NUM>.

The cover layers 20A-<NUM> may be selectively individually removed in various different ways. <FIG> shows that the cover layer 20C includes an integral pull tab <NUM> disposed at a peripheral edge <NUM> of the corresponding base layer 32C to which the cover layer 20C is secured by stitching <NUM>. For example, the cover layer 20C defining the integral pull tab <NUM> is disposed on a throat portion 14A of the upper <NUM> with the integral pull tab <NUM> extending forward over a toe region 14B of the upper <NUM>. In this position, the pull tab <NUM> is relatively protected so that scuffs and bumps against the footwear <NUM> will not pull on the pull tab <NUM> and tear the cover layer 20C. However, if the consumer desires to remove the cover layer 20C, the pull tab <NUM> may be lifted slightly and pulled straight rearward to tear the cover layer 20C off of the underlying base layer 32C (see <FIG>). In <FIG>, the cover layer 20C is marked "TEAR HERE" with an arrowhead indicating the pull tab <NUM> to direct the user as to how to remove the cover layer 20C. One or more of the other cover layers 20A-20B or 20D-<NUM> may also have an integral pull tab. For example, either or both of the cover layers 20A and 20I at the lateral and medial sides <NUM>, <NUM> of the footwear <NUM> may include an integral pull tab like pull tab <NUM> at a forward edge of the cover layer 20A or 20I, to be pulled rearward to remove the cover layer 20A or 20I.

Instead of removal by pulling a pull tab, one or more of the cover layers 20A-<NUM> may be removed by cutting the cover layer 20A-<NUM>. As shown in <FIG>, a small scissors icon is printed on the cover layer 20A to indicate that it can be cut with scissors to remove it from the underlying base layer 32A. Cover layer 20I also has a scissors icon (see <FIG>). The cover layers 20A-<NUM> are secured to the outer sides 36A-<NUM> of the base layers 32A-<NUM> only by the stitching <NUM> and are secured to the inner sides of the base layers 32A-<NUM> by adhesive <NUM> (see, e.g., <FIG>). Because the cover layers 20A-<NUM> are not adhered to the outer sides 36A-<NUM> of the underlying base layers 32A-<NUM>, the cover layers 20A-<NUM> can be removed (such as by tearing or cutting) without affecting the surface of the outer side 36A-<NUM> of the base layers 32A-<NUM>.

<FIG> show one example order in which the cover layers 20A-<NUM> can be removed. <FIG> shows the footwear <NUM> with only the cover layer 20A removed to reveal the outer side 36A of the base layer 32A. A1l other cover layers 20B-<NUM> remain intact covering the respective discreet sections 32B-<NUM> over which they lie and to which they are secured. Due to the securement of the cover layer 20A under the stitching <NUM>, frayed remnants <NUM> of the cover layer 20A may remain at the stitching <NUM> when the cover layer 20A is removed. All frayed remnants <NUM> of various cover layers 20A-<NUM> are indicated in the drawings with reference numeral <NUM>. The remnants <NUM> provide a unique look, evidencing that the footwear <NUM> once included an intact cover layer such as cover layer 20A overlying the base layer 32A.

<FIG> indicates that cover layer 20B has been removed second in order, revealing the outer side 36B of base layer 32B. <FIG> indicates that cover layer 20C has been removed third in order, revealing the outer side 36C of base layer 32C. <FIG> indicates that cover layer 20D has been removed fourth in order, revealing the outer side 36D of base layer 32D. <FIG> indicates that cover layer 20E has been removed fifth in order, revealing the outer side 36E of base layer 32E. Because the base layer 32A overlays the cover layer 20E of the base layer 32E, the portion of the cover layer 20E above the base layer 32A may need to be removed separately from the portion of the cover layer 20E below the base layer 32A. A portion of the cover layer 20E sandwiched between the base layer 32A and the base layer 32E (e.g., over outer side of base layer 32E but under base layer 32A) may or may not remove when the upper and lower portions of the cover layer 20E are removed but is hidden under the base layer 32E in any event.

<FIG> indicates that cover layer 20F has been removed sixth in order, revealing the outer side 36F of base layer 32F. <FIG> indicates that cover layer <NUM> has been removed seventh in order, revealing the outer side <NUM> of base layer <NUM>. <FIG> indicates that cover layer <NUM> has been removed eighth in order, revealing the outer side <NUM> of base layer <NUM>. <FIG> shows the medial side <NUM> of the article of footwear <NUM> without any additional cover layers removed than are removed in <FIG>. <FIG> indicates that cover layer 20I has been removed ninth in order, revealing the outer side 36I of base layer 32I. <FIG> indicates that cover layer 20J has been removed tenth in order, revealing the outer side 36J of base layer 32J. Because the base layer 32I overlays the cover layer 20J of the base layer 32J, the portion of the cover layer 20J above the base layer 32I may need to be removed separately from the portion of the cover layer 20J below the base layer 32I. A portion of the cover layer 20J sandwiched between the base layer 32I and the base layer 32J (e.g., over outer ide of base layer 32J but under base layer 32I) may or may not remove when the upper and lower portions of the cover layer 20J are removed but is hidden under the base layer 32I in any event. <FIG> indicates that cover layer <NUM> has been removed eleventh in order, revealing the outer side <NUM> of base layer <NUM>. Accordingly, in <FIG>, all cover layers 20A-<NUM> have been removed.

Some or all of base layers 32A-<NUM> may have different aesthetic or functional aspects. In the embodiment of the article of footwear <NUM>, many of the base layers 32A-<NUM> have a different appearance due to different colors, materials, patterns, or textures such as of their respective outer sides. The following description of the colors, materials, patterns, and textures of the base layers 32A-<NUM> is one nonlimiting example. In the example of the article of footwear <NUM> shown, base layers 32F and <NUM> are a felted material, base layer 32C is suede, base layer 32E is a pebbled leather material, and any or all of the remaining base layers 32A-32B, 32D, <NUM>-32J may be a natural or artificial leather of any type including pebbled or patent leather or suede, a vinyl material, a woven or nonwoven material with thermoplastic polyurethane threads, for example, a felt, a denim, or another type of material. Base layers 32A, <NUM>, and 32J have a decorative cross-hatch pattern. Base layer 32B has a pattern of stars. Base layer 32C is a solid color. Base layer 32D is a speckled pattern. Base layers 32E and 32J have a pebbled texture. Base layers 32F and <NUM> are solid colors. Base layer <NUM> is a perforated material of a solid color.

Some of the materials may be selected to provide a specific function in addition to the general function of forming a discrete section of a durable upper <NUM>. For example, the perforated material of base layer <NUM> has the function of increasing ventilation of the footwear <NUM>. The suede of base layer 32C has a relatively high coefficient of friction and may decrease slip of the lace <NUM> in comparison to a material of a lesser coefficient of friction. The pebbled leather of the base layers 32E and 32J as well as the felted material of the base layers 32F and <NUM> may be relatively flexible in comparison to a stiffer material and may enable better conformance of the base layers 32E, 32F, 32J, and <NUM> to the shape of the foot when the lace <NUM> tightens the upper <NUM>. Any or all of the base layers 32A-<NUM> may have different colors or the same color. Accordingly, at least some of the base layers 32A-<NUM> are different in appearance or function.

<FIG> shows a second article of footwear <NUM> with a second upper <NUM> alike in all aspects to the first upper <NUM> of the first article of footwear <NUM> except that the base layer 132B that underlies the cover layer 20B (removed in <FIG>) has a different material than base layer 32B of the footwear <NUM>. For example, base layer 32B of the first article of footwear <NUM> may be white leather with stars as shown and base layer 132B of the second article of footwear <NUM> may be black patent leather at its outer side 136B. Accordingly, the configuration of the footwear <NUM>, <NUM> enables two articles of footwear <NUM>, <NUM> that each have cover layers 20A-<NUM> and corresponding base layers as described to be manufactured with at least one of the base layers of one of the articles of footwear having a different material or color, texture, or pattern than the corresponding base layer of the other article of footwear (e.g., than the base layer disposed in the same relative location on the other article of footwear). The two articles of footwear <NUM>, <NUM> will have the same appearance when all of the cover layers 20A-<NUM> are intact but different appearances when the corresponding base layers (e.g., 32B, 132B) having the different material or color, texture, or pattern are uncovered. This differentiation may be applied to a pair of footwear (e.g., between a right foot article of footwear and a left foot article of footwear) and/or between different pairs of footwear. Because there are so many permutations of appearances that are possible by varying the material, color, texture, and/or pattern of one or more of the base layers during manufacture of the footwear, each pair of footwear may be made even more unique in appearance.

<FIG> show one example of how a cover layer and its corresponding base layer is assembled prior to stitching together to another base layer and its cover layer as in <FIG>. Although described with respect to cover layer 20F and base layer 32F, the same process is used to join each cover layer 20A-<NUM> to its corresponding respective base layer 32A-<NUM>. In <FIG>, the cover layer 20F is shown placed on a work table <NUM> with its outer side <NUM> laying against the work table <NUM> and its inner side <NUM> facing upward. In <FIG>, the corresponding base layer 32F is shown placed on the inner side <NUM> of the cover layer 20F with its outer side 36F against the cover layer 20F and its inner side 40F facing upward. It is apparent in <FIG> that the cover layer 20F and the base layer 32F correspond in shape and dimension. As used herein, a cover layer and a base layer correspond in shape and dimension when the cover layer can be wrapped around the peripheral edges of the base layer and then be adhered to the inner side of the base layer, covering all peripheral edges and all of the outer side of the base layer, with the portions wrapped around to the inner side hidden under the base layer. For example, the cover layer 20F is wider and longer than the base layer 32F, leaving portions 20F1, 20F2, 20F3, and 20F4 of the cover layer 20F along each respective peripheral edge 38F1, 38F2, 38F3, and 38F4 of the base layer 32F. The portions 20F1, 20F2, 20F3, and 20F4 can be wrapped around the respective peripheral edges and then can be adhered to the inner side 40F of the base layer 32F. Adhesive <NUM> is placed on the inner side 40F of the base layer 32F bordering the peripheral edges 38F1, 38F2, 38F3, and 38F4 in preparation for adherence to the cover layer 20F. <FIG> shows the process of wrapping the portions 20F1-20F4 of the cover layer 20F around the peripheral edges and securing the portions 20F1-20F4 to the inner side 40F of the base layer 32F. In <FIG>, two of the portions 20F1 and 20F2 have been wrapped around the peripheral edges 38F1 and 38F2, respectively, and secured with the adhesive <NUM>, while two of the portions 20F3 and 20F4 not yet been wrapped around the respective peripheral edges 38F3 and 38F4. Once each of the base layers and corresponding cover layers have been secured to one another in this manner, adjacent ones of the base layers can be secured to one another with the stitching, as shown and described in detail with respect to base layers 32E, 32F in <FIG>.

<FIG> is a flowchart of a method of manufacturing <NUM> an article of footwear such as the article of footwear <NUM> or <NUM> disclosed herein. The method <NUM> may start at step <NUM>, providing a plurality of base layers 32A-<NUM> of an upper <NUM>, and step <NUM>, providing a plurality of cover layers 20A-<NUM>. Each of the cover layers 20A-<NUM> corresponds in shape and dimension to a respective one of the base layers 32A-<NUM> and together with the base layer forms a discrete section of the upper <NUM>. The base layers 32A-32F and the cover layers 20A-<NUM> may be provided already cut or otherwise formed to their final shapes and dimensions or may be cut or otherwise formed to their final shapes and dimensions as part of the method steps <NUM>, <NUM>, respectively.

If any of the cover layers 20A-<NUM> include a pull tab such as pull tab <NUM> of <FIG>, the method <NUM> may include in step <NUM>, prior to securing the cover layers 20A-<NUM> to the base layers 32A-<NUM>, disposing the pull tab <NUM> at a peripheral edge of the corresponding base layer to which the cover layer is to be secured. For example, as discussed with respect to <FIG>, the pull tab <NUM> is disposed at the peripheral edge <NUM> of base layer 32C.

Next, in step <NUM>, the method <NUM> may include securing the cover layers 20A-<NUM> to the corresponding base layers 32A-<NUM> with each cover layer secured to a different corresponding one of the base layers so that the cover layer covers an outer side of the base layer. For example, as shown in <FIG> and <FIG>, the cover layer 20F covers the outer side 36F of the base layer 32F.

Next, the method <NUM> moves to step <NUM>, securing the cover layers 20A-<NUM> to the respective base layers 32A-<NUM>. Step <NUM> may include substep <NUM>, wrapping the cover layers 20A-<NUM> around peripheral edges of the base layers 32A-<NUM> as discussed with respect to portions 20F1-20F4 of cover layer 20F wrapping around the peripheral edges 38F1-38F4 of base layer 32F in <FIG> and <FIG>.

Step <NUM>, securing the cover layers 20A-<NUM> to the base layers 32A-<NUM>, may also include substep <NUM>, securing the cover layers 20A-<NUM> to inner sides of the base layers 32A-<NUM>. For example, securing the cover layers 20A-<NUM> to inner sides of the base layers 32A-<NUM> in substep <NUM> may include adhering the cover layers 20A-<NUM> to the inner sides of the base layers 32A-<NUM> with adhesive <NUM> as discussed with respect to <FIG> and <FIG>.

After securing the cover layers 20A-<NUM> to the base layers 32A-<NUM> in step <NUM>, the method <NUM> may move to step <NUM>, securing the base layers 32A-<NUM> to one another to define a foot-receiving cavity <NUM> with each cover layer 20A-<NUM> selectively removable from the different corresponding one of the base layers 32A-<NUM> independently of each other cover layer to expose the outer side 36A-<NUM> of the base layers 32A-<NUM> while each other cover layer remains secured to and covering the outer side of a different corresponding base layer until independently selectively removed.

Step <NUM>, securing the base layers 32A-<NUM> to one another, may include substep <NUM>, stitching adjacent ones of the base layers 32A-<NUM> to one another with a series of stitches <NUM>, the series of stitches extending through the adjacent ones of the base layers 32A-<NUM> and through the cover layers 20A-<NUM> secured to the adjacent ones of the base layers 32A-<NUM>. Substep <NUM> is illustrated in <FIG> with respect to the stitches <NUM> extending through the adjacent base layers 32E and 32F and their corresponding cover layers 20E and 20F, respectively.

After substep <NUM>, the method <NUM> may end with respect to the article of footwear <NUM>. Because the method <NUM> enables different articles of footwear manufactured in the same manner to have the same initial look (e.g., when the base layers are covered by the cover layers) but different appearances once one or more of the base layers are revealed, the method <NUM> may be repeated to manufacture a second article of footwear such as footwear <NUM>. For example, after step <NUM>, the method <NUM> may again move to step <NUM>, which may include providing a second plurality of base layers 32A, 32C-<NUM> and 132B of a second upper <NUM>, the second plurality of base layers 32A, 32C-<NUM> and 132B corresponding in shape and dimension to the plurality of base layers 32A-<NUM> of the first upper <NUM> of the first article of footwear <NUM> but at least one of the second plurality of base layers 132B comprising a different material or having a different color, texture, or pattern than a corresponding one the base layers 32B of the first article of footwear <NUM>. The method <NUM> may repeat step <NUM>, this time providing a second plurality of cover layers 20A-<NUM>. Step <NUM> may be repeated if any of the cover layers of the second plurality have a pull tab <NUM>. Step <NUM> may be repeated, securing the second plurality of cover layers 20A-<NUM> to the second plurality of base layers, including substeps <NUM> and <NUM>. Next, the method <NUM> may include step <NUM>, but this time securing the second plurality of base layers 32A, 32C-<NUM> and 132B to one another with each cover layer 20A-<NUM> of the second plurality of cover layers selectively removable from the different corresponding one of the second plurality of base layers independently of each other cover layer of the second plurality of cover layers to expose the outer side of the base layer with each other cover layer of the second plurality of cover layers remaining secured to and covering the corresponding one of the base layers until independently selectively removed. Because at least one of the second plurality of base layers 132B may comprise a different material or may have a different color, texture, or pattern than a corresponding one the base layers 32B of the first article of footwear <NUM>, the second article of footwear <NUM> will have a different appearance than the first article of footwear when the cover layer of that base layer is removed. More specifically, the second upper <NUM> will have a different appearance.

The term "longitudinal" refers to a direction extending a length of a component. For example, a longitudinal direction of a shoe extends between a forefoot region and a heel region of the shoe. The term "forward" or "anterior" is used to refer to the general direction from a heel region toward a forefoot region, and the term "rearward" or "posterior" is used to refer to the opposite direction, i.e., the direction from the forefoot region toward the heel region. In some cases, a component may be identified with a longitudinal axis as well as a forward and rearward longitudinal direction along that axis. The longitudinal direction or axis may also be referred to as an anterior-posterior direction or axis.

The term "transverse" refers to a direction extending a width of a component. For example, a transverse direction of a shoe extends between a lateral side and a medial side of the shoe. The transverse direction or axis may also be referred to as a lateral direction or axis or a mediolateral direction or axis.

The term "vertical" refers to a direction generally perpendicular to both the lateral and longitudinal directions. For example, in cases where a sole is planted flat on a ground surface, the vertical direction may extend from the ground surface upward. It will be understood that each of these directional adjectives may be applied to individual components of a sole. The term "upward" or "upwards" refers to the vertical direction pointing towards a top of the component, which may include an instep, a fastening region and/or a throat of an upper. The term "downward" or "downwards" refers to the vertical direction pointing opposite the upwards direction, toward the bottom of a component and may generally point towards the bottom of a sole structure of an article of footwear.

The "interior" of an article of footwear, such as a shoe, refers to portions at the space that is occupied by a wearer's foot when the shoe is worn. The "inner side" of a component refers to the side or surface of the component that is (or will be) oriented toward the interior of the component or article of footwear in an assembled article of footwear. The "outer side" or "exterior" of a component refers to the side or surface of the component that is (or will be) oriented away from the interior of the shoe in an assembled shoe. In some cases, other components may be between the inner side of a component and the interior in the assembled article of footwear. Similarly, other components may be between an outer side of a component and the space external to the assembled article of footwear. Further, the terms "inward" and "inwardly" refer to the direction toward the interior of the component or article of footwear, such as a shoe, and the terms "outward" and "outwardly" refer to the direction toward the exterior of the component or article of footwear, such as the shoe. In addition, the term "proximal" refers to a direction that is nearer a center of a footwear component, or is closer toward a foot when the foot is inserted in the article of footwear as it is worn by a user. Likewise, the term "distal" refers to a relative position that is further away from a center of the footwear component or is further from a foot when the foot is inserted in the article of footwear as it is worn by a user. Thus, the terms proximal and distal may be understood to provide generally opposing terms to describe relative spatial positions.

Claim 1:
An article of footwear (<NUM>) comprising:
an upper (<NUM>) having a plurality of discrete sections secured to one another, each of the discrete sections including a cover layer (20A-<NUM>) and a corresponding base layer (32A-<NUM>), the cover layer (20A-<NUM>) secured to and covering an outer side (36A-<NUM>) of the corresponding base layer (32A-<NUM>) and selectively removable independently of each other cover layer (20A-<NUM>) to expose the outer side (36A-<NUM>) of the corresponding base layer (32A-<NUM>) without exposing the outer side (36A-<NUM>) of any other corresponding base layer (32A-<NUM>) of any other discrete section,
wherein each base layer (32A-<NUM>) has a peripheral edge and the cover layer (20A-<NUM>) secured to the corresponding base layer (32A-<NUM>) has a portion wrapped around and covering the peripheral edge.