Patent Description:
Manufacturing of footwear has traditionally been a labor-intensive process that involves cutting individual pieces and attaching them together to form an article of footwear. This type of manufacturing process may be batch-like, involving a series of operations that are performed at different times, often by different operators. This start-and-stop-type process can produce inefficiencies in the manufacturing of footwear.

Document <CIT> describes an article of footwear including a knitted component formed of multiple knitted component portions. The knitted component includes a body portion and a heel portion. The body portion is formed of unitary knit construction and extends through a forefoot region, a midfoot region, and at least partially into a heel region of the article of footwear. The heel portion is formed of unitary knit construction and extends through the heel region and includes a cuff that defines a throat opening of the upper for receiving a foot. The body portion and the heel portion are joined along adjacent edges to form the knitted component. Knitting directions of the knitted component portions vary along the adjacent edges. An overlay element may also be provided to cover a seam attaching the adjacent edges of the knitted component portions.

Document <CIT> describes an upper for article of footwear that includes one or more skin layers attached to a base layer, wherein the skin layers overlap with one another in varying ways, e.g., with a first skin layer over-laying a second skin layer at some locations and the second skin layer overlaying the first skin layer at other locations. At least one of the skin layers may be at least partially transparent or translucent. The skin layers may be applied over other elements of the upper, e.g., other skin layers, base layers, reinforcing layers.

The claimed invention is defined by the features set forth in the appended independent claims.

In brief, and at a high level, examples of this disclosure relate to continuous in-line manufacturing of footwear from a flat pattern to form a dimensional article of footwear that includes a side seam. Further examples of this disclosure relate to assembling articles of footwear from flat pattern pieces using aperture alignment for registration of the pieces.

In some examples, a flat pattern is provided that represents a portion of an article of footwear in a pre-formed state. The flat pattern may be an upper, and may be formed into a dimensional article of footwear through manipulation during a manufacturing process. The dimensional article may be formed to include adjoining medial or lateral side edges that can be secured using a securing element to form a medial or lateral side closing that holds the dimensional article of footwear in its shape. The securing element may be a connecting or backing portion that is overlaid, secured, and/or otherwise integrated with the flat pattern upper adjacent the adjoined side edges. The securing element may include one or more apertures that are at least partially alignable with one or more corresponding apertures formed in the flat pattern upper to allow for registration and alignment of the parts during the assembly process.

In additional examples, a flat pattern used to form an article of footwear (e.g., a flat pattern upper) may include multi-use apertures formed to provide functionality (e.g., lacing, ventilation, etc.) and also to provide for alignment and registration of one or more flat pattern pieces (e.g., a tongue portion, a collar portion, etc., with the flat pattern upper) for assembly and attachment. Additionally, apertures formed in a flat pattern upper used for alignment and registration of one flat pattern piece may also, at least in part, be useable for alignment and registration of other flat pattern pieces. As such, the re-use and/or repurposing of apertures in a flat pattern assembly process may limit the number of apertures that need to be formed in the pieces to assemble the article. The alignment of flat pattern pieces may also be facilitated using registration tools having pins spaced to engage aligned apertures of the flat pattern pieces.

As used herein, the term "article of footwear" includes, but is not limited to, shoes, boots, sandals, and the like, as well as partial assemblies thereof. The term "shoe" will be used herein to generically refer to an article of footwear. It is to be understood that "shoe" is not limited to a certain style, and may include boots, athletic shoes, sandals, running shoes, cleats, dress shoes, and/or other types of footwear. Generally, a shoe is comprised of a ground-contacting portion, which may be referred to as a sole. The sole may be formed from a variety of materials and/or from a variety of individual components. For example, a sole may include an outsole, a midsole, and/or an insole. A shoe may also include a foot-securing portion that can be used to secure a wearer's foot to the sole. The foot-securing portion may be referred to as a shoe upper, or just an upper. An upper may be formed from one or more materials and/or from one or more individual components.

The subject matter of this disclosure is described in detail herein with reference to the attached figures, which depict exemplary and non-limiting aspects hereof, in which:.

The subject matter of this disclosure is described with specificity herein to meet statutory requirements. However, the description is not intended to limit the scope of this disclosure. Rather, the claimed subject matter may be provided in other ways, to include different features, steps, and/or combinations of features and/or steps, similar to the ones described in this disclosure, and in conjunction with other present and/or future technologies. The terms "step" and "block" should not be interpreted as implying any particular order among the elements of methods employed herein unless and except when the order of individual steps or blocks is explicitly described and required.

At a high level, this disclosure relates generally to continuous in-line manufacturing of footwear, or portions thereof, from a flat pattern. The flat pattern may be formed into a dimensional article of footwear that includes a secured side closing (e.g., a medial or lateral side closing). The article of footwear may be constructed from one or more flat pattern pieces aligned and registered for attachment to each other using aperture alignment. In this respect, apertures formed in flat pattern pieces may provide functionality in a formed article of footwear (e.g., for lacing, ventilation, etc.) and also may be re-used and/or re-purposed for alignment and registration of one or more flat pattern pieces for assembly and attachment.

In addition to the materials and techniques used to form such articles, additional shaping, forming, and/or combining and attaching of components may be used to obtain a desired three-dimensional shape (e.g., a dimensional shoe). Traditionally, a tool known as a cobbler's last serves as a shape about which a shoe may be formed to a desired size, shape, and construction. As used herein, the term "last" refers to a tool about which a dimensional shoe upper may be formed. In some aspects, a sole may be coupled (e.g., adhered, stitched, welded, etc.) to the upper as the upper is lasted (i.e., while the last is positioned in an interior volume of the upper). The last may define the contours, shape, style, and/or other characteristics of a resulting shoe.

As used in this disclosure, "flat pattern" shall mean a substantially planar collection of materials, as generally depicted in <FIG>, that may be modified or shaped before being formed into a desired dimensional article of footwear, or portion thereof (e.g., an upper with a desired height, size, etc.). While different materials may be coupled to one another in a manner that forms textures, bumps, embossing, protrusions, and the like on the flat pattern, the collection of materials is still considered substantially planar, and therefore is considered "flat" even with such deviations in height and texture along the surface. The flat pattern, once formed about a last to create a receiving cavity in which a wearer's foot may be received, becomes a "dimensional article of footwear.

A dimensional article of footwear is one that is formed so that it can be secured to and around a portion of a wearer (e.g., a wearer's foot). A "flat" pattern, in contrast to a "dimensional" article, is not formed to be received about a portion of a wearer (e.g., the wearer's foot). It should be noted that a "dimensional article of footwear" does not necessarily mean a fully formed article of footwear (e.g., a dimensional article of footwear may only be an upper without an attached sole, sockliner, underfoot portion, interior liner, etc.).

The concept of a flat pattern is conducive to manufacturing, as many materials used to form a shoe upper are rolled or flat goods that are in a substantially planar (e.g., sheet-like) configuration in their raw state. Accordingly, construction of a shoe upper from a collection of flat components in an in-line manufacturing process may be advantageous from a material use, construction, and assembly efficiency standpoint. Furthermore, continuous in-line manufacturing allows for strategic implementation of engineered material properties, such as tensile strength, elongation characteristics, and moisture transportation, in an efficient manner on a flat pattern. The flat pattern concept may also provide greater consistency in manufacturing and greater ability to implement machines relative to a traditional dimensional upper manufacturing process. Additionally, variations in size, style, and/or materials used in shoe uppers are possible with an in-line manufacturing process, including within the same in-line manufacturing process.

It is also contemplated that an in-line manufacturing process may be automated so that one or more processes along the manufacturing line are performed by machines that are programmed to complete one or more specific tasks. Additionally, or alternatively, it is contemplated that one or more processes of the in-line manufacturing process may be performed manually by a human operator. Accordingly, any combination of machine and human involvement may be implemented to achieve the formation of an article (e.g., a shoe upper).

<FIG> depicts an exemplary in-line manufacturing process used to form the article of footwear from a flat pattern according to the claimed invention. More specifically, <FIG> depicts a continuous in-line production system <NUM> that utilizes a substrate <NUM> to form an article of footwear. The substrate <NUM> may be used as a foundation from which the article of footwear may be formed, and may be selected to provide a level of stretch that allows for registration and positioning of materials on the substrate <NUM>. A tracking system (e.g., that includes cameras, vision systems, sensors, and/or other tracking components) may be used with the production system <NUM> to monitor the location of the substrate <NUM> and/or monitor the modifications to the same.

The substrate <NUM> used in the production system <NUM> may be of any width and/or of any length. In one example, the substrate <NUM> is a rolled good that has a width sufficient to form at least one, two, three, four, five, or six flat pattern uppers across the width of the substrate <NUM>. The substrate <NUM> may also have a width sufficient to form at least two flat pattern uppers in a common operation to provide matching articles of footwear. Each of the footwear flat patterns formed in the continuous in-line manufacturing process may represent a common, or different, style, shape, size, and/or configuration of a shoe upper from the next footwear flat pattern.

The substrate <NUM> may be of any material, including, as shown in the example depicted in <FIG>, a sheet material. For example, the substrate <NUM> may be a non-woven fabric that is a sheet or web-like structure formed through entanglement of fibers/filaments by mechanical, thermal, and/or chemical processes. The non-woven material may be a flat and porous material that is non-woven or non-knit. The non-woven material may also be formed from recycled materials, such as scrap materials generated from the in-line manufacturing process itself. Additionally, a non-woven material may be a polymer-based material, such as polyurethane ("PU") or thermoplastic polyurethane ("TPU"). The non-woven material may be a web material, such as an industrial felt that is fabricated by a needle felting of polyester fibers. The substrate <NUM> may also, in other examples, be a knitted or woven material, or may be a combination of knitted/woven materials and/or non-woven/non-knitted materials, and may include the same that is retrieved from the manufacturing process itself.

It is contemplated that the substrate <NUM>, whether formed from a non-woven material or another material (e.g., a woven or knitted material), may be formed from one or more synthetic fibers, natural fibers, or a combination of the same. In one example, such fibers may be captured from the manufacturing process as part of a waste stream. For example, portions of the substrate <NUM> not used to form an article (e.g., a shoe upper) may be collected from the waste stream following the formation of the article, and may be recycled to once again form the substrate <NUM> for a subsequent manufacturing process. As such, recycling the substrate <NUM> may provide economic efficiencies in the manufacturing process. This is particularly true when the substrate <NUM> is a non-woven material formed from a random entanglement of fibers, rather than a knit or a woven material with specific engineered structures (e.g., interlacing, looping, etc.).

The substrate <NUM> may alternatively be formed from a woven or knit material. For example, it is contemplated that the substrate <NUM> may be formed from an in-line knit or in-line woven material such that the substrate <NUM> begins as a yarn, fiber, thread, or other raw material, and then is formed into a sheet-like construction as part of the in-line manufacturing process. Alternatively, it is contemplated that the substrate <NUM> is formed into a sheet-like format by knitting or weaving prior to being introduced to the in-line manufacturing process.

Returning to <FIG>, the substrate <NUM> is depicted progressing along a series of processing stations positioned along the in-line production system <NUM>. More specifically, the production system <NUM> includes a conveyor system <NUM> that advances the substrate <NUM> and a series of processing stations <NUM>, <NUM>, <NUM>, <NUM>, and <NUM> at which the substrate <NUM> may be manipulated and/or modified during the manufacturing process. It is contemplated that the production system <NUM> may run in a continuous fashion, providing various modifications to each flat pattern until it is removed from the conveyor system <NUM>. As such, it is contemplated that a portion of the substrate <NUM> will form a portion of a removed upper. <FIG> depicts an exemplary flat pattern upper outline <NUM> that has been extracted from the substrate <NUM>, along with a waste portion <NUM>. In certain examples, the waste portion <NUM> may be recycled for use in forming other flat pattern uppers by reintegrating the waste portion <NUM> into the substrate <NUM>.

The production system <NUM>, including the conveyor system <NUM> and the processing stations <NUM>, <NUM>, <NUM>, <NUM>, and <NUM>, are exemplary in nature and different processing configurations are contemplated. Similarly, an exemplary flat pattern upper outline <NUM> is depicted in <FIG>, but other types of flat patterns are contemplated. It should be understood that any combination, spacing, sequence, and configuration of components may be used in the production system <NUM>. In this respect, the processing stations, such as the processing stations <NUM>, <NUM>, <NUM>, <NUM>, and <NUM>, may be, but are not limited to, printing stations, liquid application stations, heat application stations, steam application stations, cutting stations, punching stations, part-moving/part-adjusting stations, sewing stations, adhesive application stations, welding stations, vision and part-recognition/analysis stations, and the like. Furthermore, it is contemplated that one or more stations may be combined into a common station that performs multiple operations at a common location and/or at a common time. It is also contemplated that one or more stations may be human occupied so that an operation may be performed by a human absent or in connection with the production system <NUM>.

While specific components and processes are depicted in connection with the system <NUM> depicted in <FIG>, it is to be understood that any processes (e.g., cutting, coupling, painting, printing, applying, forming, and the like) may be performed in any sequence and in any number. Additionally, while specific components are depicted, it is contemplated that any combination, shape, ordering, and/or configuration of components may be implemented with the in-line manufacturing system.

Referring to <FIG>, an exemplary flat pattern upper <NUM> is provided, in accordance with an aspect of the claimed invention. The flat pattern upper <NUM> may be formed or cut from a base material such as, for example, the substrate <NUM> depicted in <FIG>. The flat pattern upper <NUM> may be formed so as to enable it to be manipulated into a dimensional article of footwear (e.g., a dimensional upper that can be attached to a sole, sockliner, underfoot portion, etc.). The flat pattern upper <NUM> includes a top surface <NUM> and an opposite bottom surface <NUM> (which is opposite to the side depicted in <FIG>), a toe end <NUM> and an opposite heel end <NUM>, and a medial side <NUM> and an opposite lateral side <NUM>. In <FIG>, the flat pattern upper <NUM> has not yet been modified into a dimensional article of footwear, and is therefore in a lay-flat configuration. As such, the medial side <NUM> is actually separated into a first medial side <NUM> and a second medial side <NUM> that are, in the lay-flat configuration shown in <FIG>, separated and non-adjoined other than across the lateral side <NUM> of the flat pattern upper <NUM>. The first medial side <NUM> includes a first medial edge <NUM>, and the second medial side <NUM> includes a second medial edge <NUM>.

It should be understood that, with respect to <FIG> and the flat pattern upper <NUM>, different modifications and manipulations of the flat pattern upper <NUM> may occur at different stages of an in-line manufacturing process. As such, the flat pattern upper <NUM> depicted in <FIG> is but one example, taken from one stage of an in-line manufacturing process, and is not necessarily in a final form. Rather, additional processes, such as cutting, welding, attaching of materials, forming and shaping, and/or other manipulative processes may be applied to the flat pattern upper <NUM> at other stages.

Referring to <FIG>, the flat pattern upper <NUM> depicted in <FIG> is shown formed into a dimensional article of footwear <NUM>, in accordance with an aspect of the claimed invention. In <FIG>, the top surface <NUM> of the flat pattern upper <NUM> forms an exterior portion <NUM> of the dimensional article of footwear <NUM>, and the bottom surface <NUM> forms an interior portion <NUM> of the dimensional article of footwear <NUM>. Additionally, the first medial edge <NUM> of the first medial side <NUM> and the second medial edge <NUM> of the second medial side <NUM> have been adjoined, or rather, brought within proximity of each other (e.g., have been brought within <NUM> inch, ½ inch, ¼ inch, <NUM>/<NUM> inch, or <NUM>/<NUM> inch of each other, or are directly abutting each other in contact) for securement in order to form a medial side closing <NUM> in the dimensional article of footwear <NUM>.

The dimensional article of footwear <NUM> includes a throat portion <NUM> having a throat edge <NUM> that extends around the throat portion <NUM> from the medial side <NUM> to the lateral side <NUM>, and a perimeter portion <NUM> having a perimeter edge <NUM> that extends around the perimeter portion <NUM> from the medial side <NUM> to the lateral side <NUM> opposite to the throat edge <NUM>. The flat pattern upper <NUM> also includes a plurality of apertures <NUM> which may, in certain examples, be used for registration and alignment of a securing element that is attached to the flat pattern upper <NUM> to secure the first medial side <NUM> to the second medial side <NUM> so that the dimensional article of footwear <NUM> can, at least partially, retain its shape. Exemplary securing elements (e.g., a connecting portion, a backing portion, etc.) are discussed in further detail with respect to <FIG> and <FIG>.

The first medial side <NUM> and the second medial side <NUM> each include apertures for alignment. The first medial side <NUM> includes a first aperture <NUM> that extends through the flat pattern upper <NUM>, and the second medial side <NUM> includes a second aperture <NUM> that extends through the flat pattern upper <NUM> as well. As shown in <FIG>, the first aperture <NUM> is spaced from the first medial edge <NUM> and the throat edge <NUM>, such that it is located adjacent the throat edge <NUM> (i.e., is located closer to the throat edge <NUM> than to the perimeter edge <NUM>). The second aperture <NUM> is spaced from the second medial edge <NUM> and the throat edge <NUM>, such that it is located adjacent the throat edge <NUM> (i.e., is located closer to the throat edge <NUM> than to the perimeter edge <NUM>).

The first medial side <NUM> further includes a third aperture <NUM> spaced from the first medial edge <NUM> and the perimeter edge <NUM>, such that it is located adjacent the perimeter edge <NUM> (i.e., is located closer to the perimeter edge <NUM> than to the throat edge <NUM>). The second medial side <NUM> further includes a fourth aperture <NUM> spaced from the second medial edge <NUM> and the perimeter edge <NUM>, such that it is located adjacent the perimeter edge <NUM> (i.e., is located closer to the perimeter edge <NUM> than to the throat edge <NUM>). The throat portion <NUM> may also include, during later processing steps, a throat overlay (see the exemplary throat overlay <NUM> depicted in <FIG>) that aligns with the flat pattern upper <NUM>. The perimeter portion <NUM> may further include a perimeter overlay which may, for example, be a discrete portion of material, or which may be a portion of a sole attached to the dimensional article of footwear <NUM>.

Additionally, although <FIG> depict a flat pattern upper formed into a dimensional article of footwear with a medial side closing, it is contemplated in additional aspects of the claimed invention that a flat pattern upper may be configured to be formed into a dimensional article of footwear with a lateral side closing (e.g., having adjoined and secured lateral side edges) with similarly discussed securing elements used for securing the adjoined lateral side edges.

Referring to <FIG>, the dimensional article of footwear <NUM> of <FIG>, depicted with a connecting portion <NUM> attached to secure the medial side closing <NUM>, is provided, in accordance with an aspect of the claimed invention. The connecting portion <NUM> depicted in <FIG> is shown in isolation in <FIG> for greater clarity. In <FIG>, the connecting portion <NUM> is shown layered over and attached to the flat pattern upper <NUM> to cover the top surface <NUM>, the bottom surface <NUM>, and the throat edge <NUM>. The connecting portion <NUM> also at least partially covers the adjoined first and second medial edges <NUM>, <NUM> of the flat pattern upper <NUM> shown in <FIG>.

The connecting portion <NUM>, which is depicted in <FIG> as an elongated strip of material having a first end <NUM>, a second end <NUM>, and an intervening portion <NUM>, includes a plurality of apertures positioned such that they are alignable with corresponding apertures formed in the flat pattern upper <NUM> (e.g., the first, second, third, and fourth apertures <NUM>, <NUM>, <NUM>, and <NUM> shown in <FIG>). In the aspect of the claimed invention depicted in <FIG>, the adjoined first and second medial edges <NUM>, <NUM>, the medial side closing <NUM>, and the connecting portion <NUM> extend from the throat portion <NUM> to the perimeter portion <NUM> at an angle that is non-perpendicular to both the throat edge <NUM> and the perimeter edge <NUM>. It is contemplated that the connecting portion <NUM> may be perpendicular or non-perpendicular with respect to each of the throat edge <NUM> and the perimeter edge <NUM> in different aspects of the claimed invention.

Referring to <FIG>, the connecting portion <NUM> of <FIG> is depicted in isolation. The connecting portion <NUM> includes a first pair of apertures <NUM> extending through a first part <NUM> of the connecting portion <NUM>. As shown in <FIG>, the first part <NUM> overlays the exterior portion <NUM> of the dimensional article of footwear <NUM> (i.e., overlays the top surface <NUM> of the flat pattern upper <NUM>). The connecting portion <NUM> further includes a second pair of apertures <NUM> extending through a second part <NUM> of the connecting portion <NUM>. As shown in <FIG>, in dotted lines, the second part <NUM> overlays the interior portion <NUM> of the dimensional article of footwear <NUM> (i.e., overlays the bottom surface <NUM> of the flat pattern upper <NUM>).

Referring to <FIG>, the first pair of apertures <NUM> and the second pair of apertures <NUM> are positioned on the connecting portion <NUM> such that when the connecting portion <NUM> is aligned with the medial side closing <NUM>, the first pair of apertures <NUM> respectively align, at least partially, with the first and second apertures <NUM>, <NUM> formed in the flat pattern upper <NUM> (shown in <FIG>), and also, the second pair of apertures <NUM> respectively align, at least partially, with the first and second apertures <NUM>, <NUM> formed in the flat pattern upper <NUM> (shown in <FIG>). The first and second pairs of apertures <NUM>, <NUM> are therefore also aligned with each other. This alignment allows the connecting portion <NUM> to be appropriately positioned and registered on the flat pattern upper <NUM> for attachment at the medial side closing <NUM> during the manufacturing and assembly process. In addition, the portion <NUM> joining the first and second parts <NUM>, <NUM> of the connecting portion <NUM> is folded over the throat edge <NUM>.

To further provide registration and alignment of the parts, the first end <NUM> of the connecting portion <NUM> includes a third pair of apertures <NUM> that respectively align, at least partially, with the third and fourth apertures <NUM>, <NUM> in the flat pattern upper <NUM> (shown in <FIG>) adjacent the perimeter edge <NUM>. The alignment of the third pair of apertures <NUM> allows the first end <NUM> of the connecting portion <NUM> to be aligned with the medial side closing <NUM> on the exterior portion <NUM> of the dimensional article of footwear <NUM> (i.e., on the top surface <NUM>) adjacent the perimeter edge <NUM>. The second end <NUM> of the connecting portion <NUM> further includes a fourth pair of apertures <NUM> that respectively align, at least partially, with the third and fourth apertures <NUM>, <NUM> formed in the flat pattern upper <NUM>, allowing the second end <NUM> of the connecting portion <NUM> to be aligned with the medial side closing <NUM> on the interior portion <NUM> of the dimensional article of footwear <NUM> (i.e., on the bottom surface <NUM>) adjacent the perimeter edge <NUM>. Accordingly, the alignment of the third and fourth pairs of apertures <NUM>, <NUM> with the respective third and fourth apertures <NUM>, <NUM> in the flat pattern upper <NUM> adjacent the perimeter edge <NUM> allows for registration and alignment of the first and second ends <NUM>, <NUM> of the connecting portion <NUM> with the medial side closing <NUM> during the manufacturing and assembly process. It should be understood that "alignment" of apertures as discussed herein may refer to partial alignment, or complete alignment, of the corresponding apertures.

As a result, as depicted in <FIG>, the connecting portion <NUM> overlays and is attached to the exterior portion <NUM> along the medial side closing <NUM> (as shown in solid lines), and also, overlays and is attached to the interior portion <NUM> along the medial side closing <NUM> (as shown in dotted lines). This alignment provides for correct positioning of the parts during assembly, and may also facilitate assembly in an automated fashion (e.g., placement and attachment of parts using part pickup, placement, and attachment tools, in addition to other tools or human-based manipulation).

The connecting portion <NUM> may be secured to the flat pattern upper <NUM> at the medial side closing <NUM> using thermal bonding, pressure bonding, welding (e.g., ultrasonic welding), stitching, sewing, chemical or adhesive bonding, fiber entanglement, and/or any other suitable securing, joining, and/or bonding process. The securement may also be provided in an automated fashion using one or more part-attachment tools, or may be provided through some level of human involvement, or by some combination of the same.

<FIG> further depicts the throat overlay <NUM> secured to the flat pattern upper <NUM> adjacent to the throat edge <NUM>. The throat overlay <NUM> may overlay and be attached to one or both of the top surface <NUM> and the bottom surface <NUM> of the flat pattern upper <NUM> to provide reinforcement at the throat edge <NUM> (e.g., to resist forces applied from lacing the article of footwear). In addition, the throat overlay <NUM> may be positioned, as shown in <FIG>, so that the connecting portion <NUM> at least partially covers and secures the throat overlay <NUM> against the flat pattern upper <NUM>. The throat overlay <NUM> includes a pair of throat apertures <NUM> that are respectively alignable with the first and second apertures <NUM>, <NUM> formed in the flat pattern upper <NUM> (as shown in <FIG>), as well as with the first and second pairs of apertures <NUM>, <NUM> formed in the connecting portion <NUM>. This allows for registration and alignment of the throat overlay <NUM> with both the flat pattern upper <NUM> and the connecting portion <NUM> during assembly of the article.

It should be noted that the exemplary flat pattern upper <NUM> depicted in <FIG> and <FIG> includes an exemplary number of apertures in exemplary locations, and the connecting portion <NUM> shown in <FIG> includes an exemplary number of apertures positioned to align with the apertures in the flat pattern upper <NUM>. However, it should be understood that numerous other configurations are possible, including those with differing numbers, sizes, arrangements, and patterns of apertures. Additionally, the medial side closing <NUM> shown in the aspect of the claimed invention in <FIG> is exemplary, and a medial side closing of a different size, length, angle, position, and/or utilizing a different configuration of aperture alignments, etc., is contemplated herein. Furthermore, one or more connecting portions may be overlaid and secured to an exterior portion, an interior portion, edges, or any combination of the same of an article in different aspects, and a connecting portion may be of different shapes, sizes, or aperture configurations. Additionally, one or more medial side closings with separate or interconnected connecting portions may be provided. Alternatively, in an exemplary not-claimed arrangement, no connecting portion may be used, and the edges may instead be secured to each other with any desired attachment method, including those described herein.

Referring to <FIG>, the dimensional article of footwear <NUM> of <FIG> with a backing portion <NUM> securing the medial side closing <NUM> is provided, in accordance with the claimed invention. The backing portion <NUM> extends along the medial side closing <NUM> on the bottom surface <NUM> of the flat pattern upper <NUM>, or rather, on the interior portion <NUM> of the dimensional article of footwear <NUM>. As such, the configuration depicted in <FIG> provides a medial side closing <NUM> with less overlaying material on the exterior portion <NUM> of the dimensional article of footwear <NUM>. The backing portion <NUM> may still be secured, like the connecting portion <NUM>, to the flat pattern upper <NUM> using any desired process, material, and/or structure (e.g., using thermal bonding, pressure bonding, adhesive or chemical bonding, welding, etc., as well as any of the same using an automated part-attachment tool).

As shown in <FIG>, the first and second medial edges <NUM>, <NUM> of the flat pattern upper <NUM> are adjoined, and the backing portion <NUM>, shown in dotted lines to represent its position on the interior portion <NUM> of the dimensional article of footwear <NUM>, is aligned and attached to the flat pattern upper <NUM> along the medial side closing <NUM>. The adjoined first and second medial edges <NUM>, <NUM> form a seam <NUM> which may be exposed, concealed, or partially exposed and concealed. Additional materials and treatments may be applied to the flat pattern upper <NUM> that cover, obscure, blend, and/or integrate this seam <NUM>. For example, during the continued manufacturing process, the flat pattern upper <NUM> may be further modified with an overlay on the medial side <NUM> that covers the seam <NUM>, whether to provide reinforcement, additional utility (e.g., reduction in stretch properties), or to provide an additional aesthetic element (e.g., a proprietary logo, design, etc.).

Referring to <FIG>, the backing portion <NUM> is provided in isolation, in accordance with the claimed invention. It should be noted that, once again, the size, shape, thickness, material, aperture configuration, etc., of the backing portion <NUM>, like the connecting portion <NUM>, may be varied as desired, and as such, the configuration shown in <FIG> is merely exemplary. The backing portion <NUM> includes a first end <NUM> and a second end <NUM>. As shown in <FIG>, the first end <NUM> is secured to the bottom surface <NUM> of the flat pattern upper <NUM> adjacent to the throat edge <NUM> (i.e., closer to the throat edge <NUM> than to the perimeter edge <NUM>) and the second end <NUM> is secured to the bottom surface <NUM> of the flat pattern upper <NUM> adjacent to the perimeter edge <NUM> (i.e., closer to the perimeter edge <NUM> than to the throat edge <NUM>). The backing portion <NUM> is depicted in <FIG> with dotted lines to show its relative positioning on the dimensional article of footwear <NUM>.

Like the connecting portion <NUM> shown in <FIG>, the backing portion <NUM> includes apertures for alignment and registration with the flat pattern upper <NUM>. More specifically, the backing portion <NUM> includes a first pair of mating apertures <NUM> located at the first end <NUM> that are respectively alignable with the first and second apertures <NUM>, <NUM> formed in the flat pattern upper <NUM> (as shown in <FIG>), and a second pair of mating apertures <NUM> located at the second end <NUM> that are respectively alignable with the third and fourth apertures <NUM>, <NUM> formed in the flat pattern upper <NUM> (as shown in <FIG>). As with the aspect of the claimed invention depicted in <FIG>, utilization of this aperture alignment during assembly of the article may allow for a more streamlined automated placement, alignment, and attachment of components.

<FIG> further depicts a throat overlay <NUM> that includes a pair of throat apertures <NUM> that are alignable with the corresponding first and second apertures <NUM>, <NUM> in the flat pattern upper <NUM> (as shown in <FIG>) to allow for registration and alignment of the throat overlay <NUM> with the flat pattern upper <NUM>. Alignment of the pair of throat apertures <NUM> may allow, during the manufacturing process, the flat pattern upper <NUM>, the backing portion <NUM>, and the throat overlay <NUM> to be aligned for attachment. The throat overlay <NUM> may be secured against the flat pattern upper <NUM> at least partially by the backing portion <NUM>, or the throat overlay <NUM> may only overlay the exterior portion <NUM> of the dimensional article of footwear <NUM>, and the backing portion <NUM> may overlay the interior portion <NUM> of the dimensional article of footwear <NUM>, in aspects of the claimed invention. Once registration and alignment have been obtained, the backing portion <NUM> and the flat pattern upper <NUM> (and optionally, additional components, such as the throat overlay <NUM>) may be secured to each other using one or more joining processes, such as adhesive bonding, thermal bonding, pressure bonding, welding (e.g., ultrasonic welding), or another suitable method.

It should be noted that, in alternative examples, the backing portion <NUM> may instead be attached to the flat pattern upper <NUM> on the exterior portion <NUM> of the dimensional article of footwear <NUM> to cover and secure the medial side closing <NUM> (see <FIG>). The backing portion <NUM> may therefore be positioned to at least partially cover and/or obscure the seam <NUM> on the exterior portion <NUM>, and may be used in addition to other overlays and/or materials layered on the exterior portion <NUM>. Attachment methods similar to those described herein may be used to provide securement in this configuration.

Referring to <FIG>, the dimensional article of footwear <NUM> of <FIG> with the connecting portion <NUM> of <FIG> being layered over and aligned for securement at the medial side closing <NUM> is provided, in accordance with an aspect of the claimed invention. In <FIG>, the connecting portion <NUM> has been placed such that it extends from the interior portion <NUM> to the exterior portion <NUM> of the dimensional article of footwear <NUM>, being folded over the top surface <NUM>, the bottom surface <NUM>, and the throat edge <NUM>. The first and second pairs of apertures <NUM>, <NUM> of the connecting portion <NUM> are each respectively aligned with the first and second apertures <NUM>, <NUM> in the flat pattern upper <NUM> towards the top of the medial side closing <NUM> (i.e., adjacent the throat edge <NUM>), and the third and fourth pairs of apertures <NUM>, <NUM> are each respectively aligned with the third and fourth apertures <NUM>, <NUM> in the flat pattern upper <NUM> towards the bottom of the medial side closing <NUM> (i.e., adjacent the perimeter edge <NUM>). In various examples, this aligning process may utilize aligning pins, vision systems, and/or other systems to facilitate and confirm a desired level of alignment of the parts during assembly.

Referring to <FIG>, the dimensional article of footwear <NUM> of <FIG> with the connecting portion <NUM> of <FIG> positioned for attachment using a part-attachment tool <NUM> is provided, in accordance with an aspect of the claimed invention. The part-attachment tool <NUM> may be configured to apply any one or more of pressure, heat, vibration, or the like to the aligned and stacked materials positioned within the part-attachment tool <NUM> to attach them. The stacked materials may be maintained in position/alignment using pins <NUM>, which may be alignable with corresponding apertures in the part-attachment tool <NUM>. In other examples, the part-attachment tool <NUM> may be configured with one or more additional part-processing tools provided in a combined or distributed arrangement (e.g., one or more additional heat application tools, cutting tools, welding tools, adhesive application tools, etc.).

In one example, the part-attachment tool <NUM> may be configured to provide heat sufficient to bond the connecting portion <NUM> to the flat pattern upper <NUM> without reaching a temperature that degrades the materials of the connecting portion <NUM> or the flat pattern upper <NUM>. As a result, thermal bonding may be achieved without compromising the materials or construction of an article of footwear. Additionally, the temperature of deformation of the connecting portion <NUM> or the backing portion <NUM> may be lower than the temperature of deformation of the flat pattern upper <NUM> to allow bonding to occur without deforming the flat pattern upper <NUM>.

Referring to <FIG>, a cross-section view of the dimensional article of footwear <NUM> of <FIG> showing the connecting portion <NUM> layered over and attached to the flat pattern upper <NUM> at the medial side closing <NUM> is provided, in accordance with an aspect of the claimed invention. As depicted in <FIG>, the top surface <NUM>, the bottom surface <NUM>, and the throat edge <NUM> have been overlaid by the folded-over connecting portion <NUM>, which also partially covers the throat overlay <NUM> that is positioned between the connecting portion <NUM> and the flat pattern upper <NUM>. This provides a secured format at the medial side closing <NUM>. Additionally, as shown in <FIG>, the first aperture <NUM> of the flat pattern upper <NUM> is at least partially aligned with a corresponding one of the first pair of apertures <NUM> in the first part <NUM> of the connecting portion <NUM>, and also, with a corresponding one of the second pair of apertures <NUM> in the second part <NUM> of the connecting portion <NUM>. One of the throat apertures <NUM> in the throat overlay <NUM> is also aligned with the first aperture <NUM>. This stacked configuration of materials may be secured through use of adhesive bonding, heat bonding, pressure bonding, stitching, welding, and the like. For example, the connecting portion <NUM> may be formed from a material that melts at a particular temperature of deformation that is lower than the temperature of deformation of a material that forms the flat pattern upper <NUM>, allowing the connecting portion <NUM> to form a secure bond with the flat pattern upper <NUM> when the particular temperature of deformation is achieved.

Referring to <FIG>, similarly, a cross-section view of the dimensional article of footwear <NUM> of <FIG>, showing the backing portion <NUM> attached to the flat pattern upper <NUM> at the medial side closing <NUM>, is provided, in accordance with an aspect of the claimed invention. As shown from <FIG>, the backing portion <NUM> is attached to the bottom surface <NUM> of the flat pattern upper <NUM>, allowing the medial side closing <NUM> to be secured. In the aspect of the claimed invention depicted in <FIG> and <FIG>, the throat overlay <NUM> is exposed on the exterior portion <NUM>. Additionally, one of the pair of throat apertures <NUM>, the first aperture <NUM> of the flat pattern upper <NUM>, and one of the first pair of mating apertures <NUM> are at least partially aligned to provide a path through the layered materials.

Referring to <FIG>, a dimensional article of footwear <NUM> formed from a flat pattern upper <NUM> is provided, in accordance with an aspect of the claimed invention. The dimensional article of footwear <NUM> includes a medial side closing <NUM>. A backing portion <NUM> is layered over and secured to an exterior portion <NUM> of the dimensional article of footwear <NUM> along the medial side closing <NUM>. Additionally, as shown in <FIG>, a sole <NUM>, or a portion thereof, has been secured to the underfoot portion of the dimensional article of footwear <NUM>. The backing portion <NUM> extends from a throat edge <NUM> of the flat pattern upper <NUM> to a perimeter edge <NUM> of the flat pattern upper <NUM>, being further secured at least partially by the sole <NUM> at the perimeter edge <NUM>. As noted elsewhere herein, aperture alignment may be used to align the backing portion <NUM> with the medial side closing <NUM>. The backing portion <NUM> may be at least partially covered, obscured, and/or secured by the sole <NUM> near the perimeter edge <NUM>, as shown in the aspect of the claimed invention depicted in <FIG>. In comparison to other aspects of the claimed invention depicted herein (e.g., as in <FIG>), the dimensional article of footwear <NUM> shown in <FIG> may represent an article at a position further downstream in a manufacturing and assembly process.

Referring to <FIG>, a block diagram of an exemplary method <NUM> of manufacturing an article of footwear having a side seam from a flat pattern is provided, in accordance with an aspect of the claimed invention. At a block <NUM>, a flat pattern upper, such as the flat pattern upper <NUM> depicted in <FIG>, having a top surface and an opposite bottom surface, such as the top surface <NUM> and the bottom surface <NUM> depicted in <FIG>, a toe end and an opposite heel end, such as the toe end <NUM> and the heel end <NUM> depicted in <FIG>, and a medial side and an opposite lateral side, such as the medial side <NUM> and the lateral side <NUM> depicted in <FIG>, is formed. At a block <NUM>, one or more apertures are formed in the flat pattern upper, such as the first, second, third, and fourth apertures <NUM>, <NUM>, <NUM>, <NUM> depicted in <FIG>. At a block <NUM>, the flat pattern upper is formed into a dimensional article of footwear, such as the dimensional article of footwear <NUM> depicted in <FIG>, with the top surface forming an exterior portion, such as the exterior portion <NUM> shown in <FIG>, of the dimensional article of footwear.

At a block <NUM>, a side closing, such as the medial side closing <NUM> depicted in <FIG>, is formed by adjoining a first side edge, such as the first medial edge <NUM> depicted in <FIG>, and a second side edge, such as the second medial edge <NUM> depicted in <FIG>, of the flat pattern upper. At a block <NUM>, a connecting portion, such as the connecting portion <NUM> depicted in <FIG>, having one or more apertures, such as the first, second, third, and fourth pairs of apertures <NUM>, <NUM>, <NUM>, <NUM> depicted in <FIG>, that are alignable with the one or more apertures formed in the flat pattern upper is provided. At a block <NUM>, the connecting portion is aligned with the side closing by aligning the one or more apertures in the connecting portion with the one or more apertures formed in the flat pattern upper. At a block <NUM>, the aligned connecting portion is secured to the flat pattern upper adjacent the first side edge and the side medial edge, such as using one of the methods or processes described herein.

In addition to facilitating the alignment of a securing element with a side closing (e.g., a medial side closing as shown in <FIG> and <FIG>), apertures formed in a flat pattern upper may provide multi-purpose functionality. For example, a flat pattern upper may include apertures that are functional (e.g., lacing apertures, ventilation apertures, etc.) that are also useable for alignment and registration of flat pattern pieces during the assembly process. Additionally, apertures used for alignment with one flat pattern piece may also be used for alignment with other flat pattern pieces. Accordingly, this re-using and/or re-purposing of apertures may facilitate assembly of an article of footwear from flat pattern pieces with fewer manufacturing-specific modifications (e.g., apertures, features, and/or structures formed specifically for assembly of the parts).

The alignment and registration of the flat pattern pieces may be facilitated through use of one or more registration tools. Each registration tool may include pins spaced for engagement with aligned apertures of flat pattern pieces being assembled. For example, a registration tool may have pins spaced to engage apertures of a tongue portion and also corresponding apertures of a flat pattern upper that are aligned with the apertures of the tongue portion, allowing the position of those pieces relative to each other to be at least partially maintained in the assembly and/or attachment process (e.g., allowing one or more joining processes to be applied to the aligned parts). Additionally, a registration tool may have pins spaced to engage aligned apertures of a flat pattern collar portion and corresponding apertures of a flat pattern upper, allowing the position of those pieces relative to each other to be maintained in the assembly and/or attachment process. In this respect, different registration tools may be used for the alignment and registration of different pieces with a flat pattern upper, depending on spacing requirements of the apertures, among other factors.

Referring to <FIG>, an exploded view of a flat pattern upper <NUM> and a flat pattern tongue portion <NUM> aligned for attachment using a registration tool <NUM> is provided, in accordance with an example hereof. The registration tool <NUM> includes first and second pins <NUM>, <NUM>. The first pin <NUM> is positioned for engagement with a first tongue aperture <NUM> in the flat pattern tongue portion <NUM> and with a first lacing aperture <NUM> in the flat pattern upper <NUM>. The second pin <NUM> is positioned for engagement with a second tongue aperture <NUM> in the flat pattern tongue portion <NUM> and a second lacing aperture <NUM> in the flat pattern upper <NUM>.

Using the registration tool <NUM>, the flat pattern upper <NUM> and the flat pattern tongue portion <NUM> may be brought together in alignment so that further assembly processes may be applied (e.g., attachment of the pieces by stitching, welding, adhering, and/or other bonding, etc.). The first and second tongue apertures <NUM>, <NUM> are also formed and spaced such that they provide an overlay of material between the flat pattern upper <NUM> and the flat pattern tongue portion <NUM> as shown in <FIG> when in alignment. The first and second tongue apertures <NUM>, <NUM> may also be formed and/or positioned such that, upon assembly of the corresponding article of footwear, the first and second tongue apertures <NUM>, <NUM> are at least partially obscured by other materials forming the article (e.g., such as the flat pattern upper in the dimensional state).

Referring to <FIG>, a top-down elevation view of the flat pattern upper <NUM> and the flat pattern tongue portion <NUM> of <FIG> aligned for attachment on the registration tool <NUM> is provided, in accordance with an example hereof. In <FIG>, the first tongue aperture <NUM> and the first lacing aperture <NUM> are at least partially aligned with each other using the first pin <NUM>, and the second tongue aperture <NUM> and the second lacing aperture <NUM> are at least partially aligned with each other using the second pin <NUM>. The alignment of the first and second tongue apertures <NUM>, <NUM> with the respective first and second lacing apertures <NUM>, <NUM> allows for a defined overlap of material between the flat pattern tongue portion <NUM> and the flat pattern upper <NUM>. This alignment provides a defined spacing <NUM> from the first and second tongue apertures <NUM>, <NUM> to an attachment location <NUM> at which the flat pattern tongue portion <NUM> and the flat pattern upper <NUM> can be secured to each other (e.g., using stitching, welding, adhesive, other bonding, etc.). Also due to the alignment, the exemplary attachment location <NUM> is spaced from a U-throat edge <NUM> of the flat pattern upper <NUM> by a defined spacing <NUM>. As a result, proper registration of the flat pattern tongue portion <NUM> with the flat pattern upper <NUM> for attachment can be provided.

Referring to <FIG>, an exploded view of the flat pattern upper <NUM> and a flat pattern collar portion <NUM> aligned for attachment on a registration tool <NUM> is provided, in accordance with an example hereof. In <FIG>, the flat pattern upper <NUM> of <FIG> is shown positioned for alignment with the flat pattern collar portion <NUM> on the registration tool <NUM>. The registration tool <NUM> includes first and second pins <NUM>, <NUM> that are spaced for respective alignment with first and second flat pattern upper apertures <NUM>, <NUM>, and also, for respective alignment with first and second collar apertures <NUM>, <NUM> in the flat pattern collar portion <NUM>. This once again allows alignment of the parts to be at least partially maintained through additional assembly processes.

To facilitate alignment of the flat pattern pieces for assembly while also limiting a number of manufacturing-specific modifications made to the pieces, the first and second collar apertures <NUM>, <NUM> may be formed and spaced to align with apertures on the flat pattern upper used for other purposes. For example, as shown in <FIG>, the first collar aperture <NUM> aligns with the first flat pattern upper aperture <NUM>, which may also be used as a lacing aperture in a dimensional article of footwear formed from the assembled pieces (e.g., formed along the throat area <NUM>). The second collar aperture <NUM> aligns with the second flat pattern upper aperture <NUM>, which may be formed in the flat pattern upper <NUM> for alignment of a securing element used to secure a medial side closing of the dimensional article of footwear formed from the assembled pieces (e.g., such as the second aperture <NUM> shown in <FIG>). In this sense, alignment of the flat pattern collar portion <NUM>, or any other flat pattern piece, with the flat pattern upper <NUM> may use, at least in part, pre-existing apertures and/or multi-use apertures formed in the flat pattern upper <NUM>. This re-use or multi-use of apertures may limit a number of modifications that may need to be made to flat pattern uppers for assembly purposes.

Referring to <FIG>, a top-down elevation view of the flat pattern upper <NUM> and the flat pattern collar portion <NUM> of <FIG> aligned for attachment on the registration tool <NUM> is provided, in accordance with an example hereof. <FIG> more clearly depicts the alignment of the first flat pattern upper aperture <NUM> and the first collar aperture <NUM> using the first pin <NUM>, and also, the alignment of the second flat pattern upper aperture <NUM> and the second collar aperture <NUM> using the second pin <NUM>. Once again, the alignment of the flat pattern collar portion <NUM> using apertures formed for functional purposes and/or for alignment of other parts may facilitate the assembly of an article of footwear from various flat pattern pieces while limiting the number of manufacturing-specific modifications that need to be made to the flat pattern pieces.

Furthermore, it should be noted that although <FIG> and <FIG> depict a flat pattern upper configured to form a medial side closing, the alignment and registration methods discussed herein may also be used to provide alignment of flat pattern pieces in an article of footwear having a lateral side closing.

In another example hereof, a dimensional article of footwear formed from multiple flat pattern pieces aligned and registered for attachment to each other using aperture alignment is provided. The dimensional article includes a flat pattern upper with one or more apertures. The dimensional article further includes one or more flat pattern pieces that each include one or more apertures. At least some of the apertures of each flat pattern piece are aligned with at least some of the apertures of the flat pattern upper, providing alignment and registration of the attached flat pattern pieces with the flat pattern upper. In additional examples, one or more apertures of the flat pattern upper are aligned with one or more apertures of multiple different flat pattern pieces attached to the flat pattern upper to form the dimensional article of footwear, and/or one or more apertures of a flat pattern piece attached to the flat pattern upper are aligned with one or more apertures of another flat pattern piece also aligned with the flat pattern upper to form the dimensional article of footwear.

In another example hereof, a method of forming a dimensional article of footwear from multiple flat pattern pieces that are aligned and registered with each other for attachment using aperture alignment is provided. The method includes providing a flat pattern upper with one or more apertures, providing one or more flat pattern pieces that each include one or more apertures, aligning at least some of the apertures of each of the one or more flat pattern pieces with at least some of the apertures of the flat pattern upper to provide alignment and registration of the flat pattern pieces. The method may further comprise attaching the aligned parts to each other and forming the attached aligned parts into a dimensional article of footwear. In additional aspects, one or more apertures in the flat pattern upper may be aligned with one or more apertures of multiple different flat pattern pieces for attachment, and/or one or more apertures in a flat pattern piece attached to the flat pattern upper may be aligned with one or more apertures of another flat pattern piece also aligned with the flat pattern upper for attachment.

Claim 1:
An article of footwear (<NUM>) with a side seam manufactured from a flat pattern, comprising:
a flat pattern upper (<NUM>) having a top surface (<NUM>) and an opposite bottom surface (<NUM>), a toe end (<NUM>) and an opposite heel end (<NUM>), and a medial side (<NUM>) and an opposite lateral side (<NUM>), wherein the flat pattern upper (<NUM>) is formed from one individual component,
the flat pattern upper (<NUM>) formed into a dimensional article of footwear (<NUM>) with the top surface (<NUM>) forming an exterior portion of the dimensional article of footwear (<NUM>),
the dimensional article of footwear (<NUM>) including a side closing (<NUM>) comprising an adjoined first side edge (<NUM>) and second side edge (<NUM>) of the flat pattern upper (<NUM>),
the side closing (<NUM>) including a connecting portion (<NUM>) that is secured to the flat pattern upper (<NUM>) adjacent the first side edge (<NUM>) and the second side edge (<NUM>), and the connecting portion (<NUM>) having one or more apertures (<NUM>, <NUM>, <NUM>, <NUM>) that are at least partially aligned with one or more corresponding apertures (<NUM>, <NUM>, <NUM>, <NUM>, <NUM>) formed in the flat pattern upper (<NUM>), and
wherein the connecting portion (<NUM>) comprises an elongated strip of material that overlays the top surface (<NUM>), a throat edge (<NUM>), and the bottom surface (<NUM>) of the flat pattern upper (<NUM>), such that the elongated strip of material at least partially covers the first side edge (<NUM>) and the second side edge (<NUM>) on each of an interior portion and the exterior portion of the dimensional article of footwear (<NUM>).