Patent Description:
Consumers desire articles of footwear that are durable, lightweight, and breathable. Durable articles of footwear function properly for an extended period of time. For example, durable articles of footwear can be both stretch and abrasive resistant. Lightweight articles of footwear minimize the weight carried by a user's feet, and breathable footwear can help wick sweat and heat away from an individual's foot. Both lightweight and breathability improve the articles of footwear's comfortability. But durable articles of footwear tend to be neither lightweight nor breathable. For example, durable articles of footwear can include a sole and an upper attached to the sole that is made of multiple materials (for example, leather or synthetic material) that add weight and decreases breathability of the article of footwear. Moreover, uppers made of multiple materials take longer to manufacture, increasing the manufacturing costs.

<CIT> discloses that a yarn or thread may include a plurality of substantially aligned filaments, with at least ninety-five percent of a material of the filaments being a thermoplastic polymer material. Various woven textiles and knitted textiles may be formed from the yarn or thread. The woven textiles or knitted textiles may be thermal bonded to other elements to form seams. A strand that is at least partially formed from a thermoplastic polymer material may extend through the seam, and the strand may be thermal bonded at the seam. The woven textiles or knitted textiles may be shaped or molded, incorporated into products, and recycled to form other products.

Further prior art is known from <CIT>, <CIT> and <CIT>.

The invention relates to a method for manufacturing an article of footwear as specified in appended independent claim <NUM>, and to an article of footwear as specified in appended independent claim <NUM>. Additional embodiments of the invention are disclosed in the dependent claims.

The accompanying drawings, which are incorporated herein and form a part of the specification, illustrate the embodiments and, together with the description, further serve to explain the principles of the embodiments and to enable a person skilled in the relevant art(s) to make and use the embodiments.

The features and advantages of the embodiments will become more apparent from the detailed description set forth below when taken in conjunction with the drawings, in which like reference characters identify corresponding elements throughout.

The disclosed embodiment(s) merely exemplify the invention. The scope of the invention is not limited to the disclosed embodiment(s). The invention is defined by the claims appended hereto.

The embodiment(s) described, and references in the specification to "an example," "for example," "one embodiment," "an embodiment," "an example embodiment," "some embodiments," "exemplary," etc., indicate that the embodiment(s) described may include a particular feature, structure, or characteristic, but every embodiment may not necessarily include the particular feature, structure, or characteristic. Further, when a particular feature, structure, or characteristic is described in connection with an embodiment, it is understood that it is within the knowledge of one skilled in the art to effect such feature, structure, or characteristic in connection with other embodiments whether or not explicitly described.

An article of footwear can be multi-functional. For example, an article of footwear can provide cushioning to a user's foot, support a user's foot, and protect a user's foot. Each of these functions, alone or in combination, provides for a comfortable article of footwear suitable for use in a variety of scenarios (e.g., during leisure activities or during exercise or sports activities). The characteristics of an article of footwear (e.g., shape and materials used to make footwear) may be altered to produce desired characteristics, for example, durability, weight, and/or breathability. Durable footwear functions properly for an extended period of time, which instills a user's trust in specific manufacture's footwear and, in turn, leading to repeat sales. Lightweight footwear is comfortable for an individual and can improve athletic performance due to the decreased weight the individual carries on his or her foot. Breathable footwear increases individual's comfort by wicking sweet and heat away from an individual's foot. Designing footwear having a high degree of one or more of these characteristics without detrimentally affecting the other characteristics of the footwear is desirable. Accordingly, an article of footwear, or a portion thereof (e.g., an upper), may be configured to provide various degrees of durability, weight, and breathability. Also the cost to manufacturing an article of footwear is another design consideration. Footwear, or a portion thereof, that can be manufactured at a relatively low cost is desirable for manufactures and consumers. Footwear that can be manufactured using a relatively small amount of resources (e.g., energy and man power), materials, and time reduces manufacturing costs and may also reduce the environmental impact of manufacturing. Accordingly, designing footwear having a manufacturing cost is also desirable.

In some embodiments, the article of footwear includes an upper made, at least in part, of fabric-a sheet material made textile monofilament yarns, multifilament yarns and/or yarns that are, for example, woven, knitted, braided, netted, felted, plaited, laid, embroidered, or otherwise bonded together to give the material mechanical strength. For example, the fabric of an upper can be a knitted fabric made by interlocking series of loops of one or more yarns. For example, the fabric of an upper can be a woven fabric made of two series of yarn-warp and filling-that are interlaced to form the fabric. For example, the fabric can be nonwoven such that the filaments may or may not be interlaced with each other depending on the means of construction of the nonwoven fabric. In the context of this application, a "yarn" is a continuous strand made of a plurality of filaments that are twisted or otherwise held together, and correspondingly, a "filament" is the fundamental component of a yarn that, for example, can be spun into a yarn.

In some embodiments, the fabric of the upper can be a mesh, which may be open with holes or closed without visible holes. In the context of this application, a "mesh" is a fabric (e.g., knitted, woven, crocheted, laced, or knotted) having open spaces between the yarns. And in some mesh embodiments, the fabric of the upper can be a sandwich mesh. In the context of this application, a "sandwich mesh" is a multilayer layer fabric that includes at least a first layer of mesh, a second layer of mesh, and spacer yarns between the first and second layers of mesh that connects the first and second layers of mesh. The spacer yarns can be, for example, monofilament or multifilament.

In some embodiments, the fabric forming at least a portion of the upper includes a portion that is fused. In the context of this application, "fused" means yarns composing the portion and filaments composing those yarns are joined by melting. "Fused," without qualification, includes both "fully fused" and "partially fused" as explained next. In the context of this application, "fully fused" means that the yarns and filaments composing the yarns are melted such that the fabric portion is transformed into a unitary layer in which the yarns and filaments are no longer individually identifiable. In the context of this application, "partially fused" means the yarns and filaments composing the yarns are fused to a degree such that the yarns and the filaments are still individually identifiable after being fused. That is, the partially fused yarns and filaments do not melt and transform into a unitary layer in which the yarns and filaments are no longer individually identifiable. In some embodiments in which the fabric comprises low-melting-temperature and higher-melting-temperature yarns, the low-melting-temperature yarns of the partially fused portion melt completely such that the yarn structure of the low-melting-temperature yarns may not be visible, but the structure of the higher-melting-temperature yarns are still identifiable.

<FIG> illustrate magnified views of knitted fabric that are (a) not fused, (b) partially fused, and (c) fully fused, respectively, according to an embodiment. As seen in <FIG>, the yarns <NUM> and the filaments <NUM> composing the yarns <NUM> are not joined by melting-not fused-and each of the yarns <NUM> and each filament <NUM> composing the yarns are identifiable. In this unfused state, yarns <NUM> are not fused together at, for example, interface <NUM> and are free to move independently relative to each other, and the filaments <NUM> composing yarns <NUM> are not fused to adjacent filaments at their respective interfaces and are free to move independently relative to each other.

As seen in <FIG>, yarns <NUM> and the filaments <NUM> are partially fused. Yarns <NUM> and filaments <NUM> composing yarns <NUM> are melted to a degree such that yarns <NUM> and the filaments <NUM> composing these yarns <NUM> are still individually identifiable after being partially fused. For example, one yarn <NUM> is fused to an adjacent yarn <NUM> at interface <NUM>, and filaments <NUM> composing yarns <NUM> are fused to adjacent filaments <NUM>. In this partially fused state, the individual yarns <NUM> cannot move independently relative to adjacent yarns <NUM>, and individual filaments <NUM> cannot move independent relative to adjacent filaments <NUM>.

Yet in this partially fused state, yarns <NUM> and filaments <NUM> retain substantially at least some of the same mechanical properties (for example, tensile strength and tear strength) as yarns <NUM> and filament <NUM> in the unfused state, which is advantageous for footwear applications. For example, partially fused fabric portions have tensile and tear mechanical properties that are advantageous for footwear applications. Particularly, a partially fused fabric portion can have a tensile strength such that the partially fused portion displaces less than <NUM> percent of the partially fused fabric portion's unstressed dimension when a <NUM> N force is applied to the fabric portion. And a partially fused fabric portion can have a tensile strength such that the partially fused fabric portion does not plastically deform when a <NUM> N force is applied to the fabric portion. Additionally, a partially fused fabric portion can have a tear strength such that the portion does not tear when a <NUM> N force is applied to the portion. Accordingly, an upper of the article of footwear having a partially fused portion can have improved stretch and support characteristics without significantly compromising tear strength.

As seen in <FIG>, yarns <NUM> and filaments <NUM> (which are not identifiable in <FIG>) are fully fused. The yarns and the filaments composing the yarns are melted to a degree such that the yarns and the filaments are transformed into a unitary layer in which the yarns and filaments are no longer individually identifiable. In the fully fused state, the yarns and the filaments have substantially degraded mechanical properties relative to the mechanical properties of the same yarns <NUM> and filaments <NUM> in an unfused state. That is, fully fused fabric tends to be too brittle and too stiff for many footwear applications.

In some embodiments, article of footwear <NUM> includes an upper that has at least one fabric portion that has yarns partially fused to adjacent yarns and filaments of the partially fused yarns that are partially fused to adjacent filaments. For example, <FIG> illustrate an article of footwear <NUM> according to one such embodiment. Article of footwear <NUM> includes an upper <NUM> and a sole <NUM> coupled to upper <NUM>.

Article of footwear <NUM> includes a forefoot region <NUM>, a midfoot region <NUM>, and a heel region <NUM>. Forefoot region <NUM> generally corresponds with the portion of article of footwear <NUM> that receives the toes and the joints that connect the metatarsals with the phalanges. Midfoot region <NUM> generally corresponds with the portion of article of footwear <NUM> that receives the arch of the foot. And heel region <NUM> generally corresponds with the portion of article of footwear <NUM> that receives the calcaneus bone. Regions <NUM>, <NUM>, and <NUM> are not intended to demarcate precise areas of article of footwear <NUM>. Rather, regions <NUM>, <NUM>, and <NUM> are intended to represent general areas of article of footwear <NUM> that provide a frame of reference. And although regions <NUM>, <NUM>, and <NUM> apply generally to article of footwear <NUM>, references to regions <NUM>, <NUM>, and <NUM> also may apply specifically to upper <NUM> or sole <NUM>, or individual components of upper <NUM> or sole <NUM>. Article of footwear <NUM> also includes a lateral side <NUM> (see <FIG> and <FIG>) and a medial side <NUM> (see <FIG> and <FIG>) that each extend from forefoot region <NUM> to heel region <NUM>.

Upper <NUM> can be made, at least in part, of a fabric having at least one partially fused portion in which yarns are partially fused to adjacent yarns and filaments of the partially fused yarns are partially fused to adjacent filaments. For example, as shown in <FIG>, upper <NUM> has three discrete partially fused portions <NUM>, <NUM>, and <NUM>. In other embodiments (not shown), upper <NUM> can have more than or less than three discrete partially portions.

As best seen in <FIG>, partially fused portion <NUM> is on lateral side <NUM> of article of footwear <NUM>. Partially fused potion <NUM> extends from forefoot region <NUM> to heel region <NUM>. In other embodiments (not shown), partially fused portion <NUM> is located at only one or two of regions <NUM>, <NUM>, and <NUM>. For example, partially fused portion <NUM> can be shaped to just be at forefoot region <NUM>, or partially fused portion <NUM> can be shaped to just be at midfoot region <NUM> and heel region <NUM>. In other embodiments (not shown), upper <NUM> can have three discrete partially fused portions at each of regions <NUM>, <NUM>, and <NUM> on lateral side <NUM>. As best seen in <FIG>, partially fused portion <NUM> has an undulated, non-linear shape. In other embodiments, partially fused portion <NUM> can have other shapes, for example, a linear shape, an arcuate shape, an oval shape, or a triangular shape.

As best seen in <FIG> and <FIG>, partially fused portion <NUM> is on medial side <NUM> and on top of forefoot region <NUM> of upper <NUM>. For example, partially fused portion <NUM> can be positioned such that it overlaps the big toe of a user's foot received within upper <NUM>. In other embodiments (not shown), partially fused portion <NUM> can extend from medial side <NUM> to lateral side <NUM>. In some embodiments (not shown), partially fused portion <NUM> extends from forefoot region <NUM> to at least midfoot region <NUM>. And in some embodiments (not shown), upper <NUM> can include more than one discrete and partially fused portions on top of forefoot region <NUM> of upper <NUM>. As best seen in <FIG>, partially fused portion <NUM> can have a substantially linear shape when viewed from above. In other embodiments, partially fused portion <NUM> can have other shapes, for example, a non-linear shape, a circular shape, a triangular shape, an undulating shape, an arcuate shape, when view from above. In some embodiments, partially fused portion <NUM> can cover substantially the entire top of forefoot region <NUM>.

As best seen in <FIG>, partially fused portion <NUM> is on medial side <NUM> of article of footwear <NUM>. Partially fused portion <NUM> extends from forefoot region <NUM> to heel region <NUM>. In other embodiments (not shown), partially fused portion <NUM> is positioned at only one or two of regions <NUM>, <NUM>, and <NUM>. For example, partially fused portion <NUM> can be shaped to just be at forefoot region <NUM>, or partially fused portion <NUM> can be shaped to just be at midfoot region <NUM> and heel region <NUM>. In other embodiments (not shown), upper <NUM> can have three discrete partially fused portions at each of portions <NUM>, <NUM>, and <NUM> on medial side <NUM>. As best seen in <FIG>, partially fused portion <NUM> has an undulated, non-linear shape. In other embodiments, partially fused portion <NUM> can have other shapes, for example, a linear shape, an arcuate shape, an oval shape, or a triangular shape.

In some embodiments, instead of three discrete portions <NUM>, <NUM>, and <NUM> covering, at least in part, lateral side <NUM> from forefoot region <NUM> to heel region <NUM>, the top of forefoot region <NUM>, and medial side <NUM> from forefoot region <NUM> to heel region <NUM>, upper can have one continuous partially fused fabric portion that covers each of these three areas. And in some embodiments, substantially the entire upper <NUM> is composed of partially fused fabric.

In some embodiments, upper <NUM> includes at least one partially fused fabric portion that is embossed. For example, one or more of partially fused portions <NUM>, <NUM>, and <NUM> can be embossed. As shown in <FIG>, each of partially fused portions <NUM>, <NUM>, and <NUM> includes a plurality of embossed portions <NUM> that are part of a repeating undulating pattern. As shown in <FIG>, embossed portions <NUM> are plurality of substantially linear ribs having a semi-circular cross-sectional shape, and embossed portions <NUM> are substantially evenly spaced apart from each other. In other embodiments, embossed portions <NUM> can be non-linear, have other cross-sectional shapes, or be part of a non-repeating or irregular pattern. Embossing portions of the partially fused fabric can provide additional structural support to upper <NUM>. Additionally, embossing can be used to provide three-dimensional aesthetic designs in upper <NUM>.

In some embodiments, upper <NUM> includes at least one partially fused fabric portion that has tensile and tear mechanical properties that are advantageous for footwear applications. For example, one or more of partially fused portions <NUM>, <NUM>, and <NUM> have tensile and tear mechanical properties that are advantageous for footwear applications. For example, each of partially fused portions <NUM>, <NUM>, and <NUM> has a tensile strength such that the respective partially fused portion displaces less than <NUM> percent of the respective partially fused fabric portion's unstressed dimension when a <NUM> N force is applied to the fabric portion. And in some embodiments, each of partially fused fabric portions <NUM>, <NUM>, and <NUM> also has a tensile strength such that the respective partially fused fabric portion does not plastically deform when a <NUM> N force is applied to the fabric portion. Additionally, each of partially fused fabric portions <NUM>, <NUM>, and <NUM> has a tear strength such that the respective portion does not tear when a <NUM> N force is applied to the portion in some embodiments. Uppers having partially fused portions with one or more of the above mechanical properties have desired compliance, breathability, and support to be used for footwear, for example, shoes for leisure, running, soccer, American football, and basketball. Uppers having partially fused portions with one or more of the above mechanical properties are not too brittle or stiff to be used in footwear applications.

Moreover, having at least one partially fused portion with one or more of the above mechanical properties allows upper <NUM> to be manufactured substantially as one unitary piece. In some one-piece embodiments, the fabric composing upper <NUM> is continuous from forefoot region <NUM> to heel region <NUM>, and upper <NUM> is continuous from lateral side <NUM> to medial side <NUM>. A one-piece upper <NUM> can reduce the total weight of article of footwear <NUM>, improving user comfort and performance. And a one-piece upper <NUM> can reduce manufacturing costs by reducing the amount of required material and manufacturing time.

In some embodiments, upper <NUM> can include a knitted fabric that comprises the partially fused portion. For example, upper <NUM> can be made of a knitted mesh fabric. The knitted mesh fabric can be a single layer mesh fabric. Or the knitted mesh fabric can be a multi-layer sandwich mesh fabric.

In some knitted mesh embodiments, upper <NUM> can be made, at least in part, of a sandwich mesh fabric including an outer layer (i.e., facing away from the foot), an inner layer (i.e., facing the foot), and spacer yarns (e.g., a monofilament spacer yarns) in between the outer layer and the inner layer that connects the outer and inner layers.

In some sandwich mesh embodiments, the outer layer comprises one or more of polyester, polyamide (for example, nylon such as PA6), and segmented polyurethane (for example, spandex); the inner layer comprises one or more of polyester, polyamide (for example, nylon such as PA6), and segmented polyurethane (for example, spandex); and the spacer yarns comprise one or more of polyamide (for example, a nylon monofilament) or polyester (for example, a polyester monofilament). In some embodiments, any one of these materials can be a thermoplastic. In the context of this application, a thermoplastic is a material that has a lower melting point than other yarns used in the fabric. For example, the thermoplastic can be a thermoplastic polyester, a thermoplastic polyurethane (for example, an ether type <NUM> shore D TPU), a thermoplastic nylon such as PA6, a thermoplastic co-polyester, or a thermoplastic co-polyamide.

In one sandwich mesh embodiment, the outer layer is made of polyester, spandex, and nylon, the spacer yarns are nylon monofilament, and the inner layer is made of nylon. In some of such sandwich mesh embodiments, the total composition of the sandwich mesh is about <NUM> percent to about <NUM> percent (for example, about <NUM> percent) polyester, about <NUM> percent to about <NUM> percent (for example, about <NUM> percent spandex), and about <NUM> percent to about <NUM> percent (for example, about <NUM> percent) nylon. (In the context of this application, the percentage of the total composition of the respective fabric or layer being discussed is by weight unless indicated otherwise. ) In other such sandwich mesh embodiments, the total composition of the sandwich mesh is about <NUM> percent to about <NUM> percent (for example, about <NUM> percent) polyester, about <NUM> percent to about <NUM> percent (for example, about <NUM> percent spandex), and about <NUM> percent to about <NUM> percent (for example, about <NUM> percent nylon).

In another sandwich mesh embodiment, the outer layer can be made of nylon and spandex, the spacer yarns can be nylon monofilament, and the inner layer can be made of polyester and spandex. In some of such sandwich mesh embodiments, the total composition of the sandwich mesh is about <NUM> percent to about <NUM> percent (for example, about <NUM> percent) nylon, about <NUM> percent to about <NUM> percent (for example, about <NUM> percent) spandex, and about <NUM> percent to about <NUM> percent (for example, about <NUM> percent) polyester.

In yet another sandwich mesh embodiment, the outer layer can be made of nylon (for example, about <NUM> percent to about <NUM> percent-for example, about <NUM> percent-of the total composition of the mesh), the spacer yarns can be nylon monofilament (for example, about <NUM> percent to about <NUM> percent-for example, about <NUM> percent-of the total composition of the mesh), and the inner layer can be made of polyester (for example, about <NUM> percent to about <NUM> percent-for example, about <NUM> percent-the total composition of the mesh).

In still another sandwich mesh embodiment, the outer layer can be made of a thermoplastic polyester; the inner layer can be made of polyester and spandex; and the spacer yarns can be made of polyester. In some of such sandwich mesh embodiments, the total composition of the sandwich mesh is about <NUM> percent to about <NUM> percent (for example, about <NUM> percent) thermoplastic polyurethane, about <NUM> percent to about <NUM> percent (for example, about <NUM> percent) spandex, and about <NUM> percent to about <NUM> percent (for example, about <NUM> percent) polyester.

In another sandwich mesh embodiment, the outer layer can be made of 210D nylon and 140D nylon; the inner layer can be made of 100D polyester and 75D polyester; and the spacer yarns can be nylon (for example, a nylon monofilament). In some of such sandwich mesh embodiments, the outer layer is about <NUM> percent to about <NUM> percent (for example, about <NUM> percent) <NUM> D nylon, and about <NUM> percent to about <NUM> percent (for example, about <NUM> percent) <NUM> D nylon; the inner layer is about <NUM> percent to about <NUM> percent (for example, about <NUM> percent) 100D polyester, and about <NUM> percent to about <NUM> percent (for example, about <NUM> percent 75D) polyester.

In one sandwich mesh embodiment, the outer layer can be polyester; the inner layer is polyester, and the spacer yarns are thermoplastic polyurethane.

In another sandwich mesh embodiment, the outer layer can be one or more of a low melt copolyamide (for example, K-<NUM> yarn manufactured by EMS-Griltech), a polyamide (for example, nylon), polyester, and spandex; the inner layer can be one or more of a low melt copolyamide (for example, K-<NUM> yarn manufactured by EMS-Griltech), a polyamide (for example, nylon), polyester, and spandex; and the spacer yarns can be one or more of polyester, polyamide (for example, nylon), and spandex. The low melt copolyamide has a low melting temperature, for example, equal to or less than about <NUM>, and in some embodiments, equal to or less than about <NUM>. In some embodiments, the low melt copolyamide has a melting peak of <NUM> degrees Celsius, and a melting range of about <NUM> to about <NUM>. In some embodiments, the copolyamide has a lower melting temperature than the polyamide, polyester, or spandex used in the mesh. In some of such sandwich mesh embodiments, the outer and inner layers each comprise about <NUM> percent to about <NUM> percent (for example, about <NUM> percent) low melt polyamide and about <NUM> percent to about <NUM> percent (for example, about <NUM> percent) polyester. In other of such sandwich mesh embodiments, the outer and inner layers each comprise about <NUM> percent to about <NUM> percent (for example, <NUM> percent) low melt copolyamide, about <NUM> percent to about <NUM> percent (for example, about <NUM> percent) nylon, and about <NUM> percent to about <NUM> percent (for example, about <NUM> percent) spandex. And the spacer yarns comprise nylon monofilament.

In some embodiments, the upper <NUM> can be made, at least in part, of core yarn in which the outer sheath is made of a material having a lower melting temperature than the melting temperature of the core of the yarn.

In some sandwich mesh embodiments, the mesh is <NUM> of upper <NUM> percent nylon or <NUM> percent polyester. In some sandwich mesh embodiments, the mesh of upper <NUM> is <NUM> percent thermoplastic polyurethane. In some sandwich mesh embodiments, the mesh of upper <NUM> includes about <NUM> percent to about <NUM> percent (for example, about <NUM> percent) low melt co-polyester coated polyester yarn, and about <NUM> percent to about <NUM> percent (for example, about <NUM> percent) polyester yarn that form, for example, a circular knit or a flat knit. In some flat knit embodiments, the mesh of upper <NUM> includes about <NUM> percent to about <NUM> percent low melt co-polyester, and about <NUM> percent to about <NUM> percent polyester yarn.

<FIG> illustrate an article of footwear <NUM> that includes an upper that has at least one fabric portion having yarns partially fused to adjacent yarns and filaments fused to adjacent filaments, according to another embodiment. Article of footwear <NUM> includes an upper <NUM> and a sole <NUM> coupled to upper <NUM>. Article of footwear <NUM> includes a forefoot region <NUM>, a midfoot region <NUM>, and a heel region <NUM>. Article of footwear <NUM> also includes a lateral side <NUM> (see <FIG> and <FIG>) and a medial side <NUM> (see <FIG> and <FIG>) that each extend from forefoot region <NUM> to heel region <NUM>.

Upper <NUM> can be made of, at least in part, a fabric having at least one partially fused portion in which yarns are partially fused to adjacent yarns and filaments of the partially fused yarns are partially fused to adjacent filaments. For example, as shown in <FIG>, upper <NUM> can have a first portion <NUM> that is partially fused. Partially fused portion <NUM> is in forefoot region <NUM> and overlaps with the distal ends of a user's toes in the forefoot region <NUM>. Fused portion <NUM> wraps around the front edge of upper <NUM> from lateral side <NUM> to medial side <NUM>. In some embodiments, fused portion <NUM> is embossed as shown.

Upper <NUM> also includes a plurality of portions <NUM> that are partially fused. Portions <NUM> are on lateral side <NUM> and spaced apart from each other. As best seen in <FIG> and <FIG>, partially fused portions <NUM> are substantially flat (not embossed) in some embodiments. In other embodiments, partially fused portions <NUM> are embossed. The partially fused portions <NUM> have a quadrilateral shape when viewed in plan. But in other embodiments, partially fused portions <NUM> can have other non-quadrilateral shape, for example, circular or oval shape.

Upper <NUM> also includes a region <NUM> that extends from forefoot region <NUM> to midfoot region <NUM> that includes a plurality of portions <NUM> that are partially fused and similarly shaped. Portions <NUM> of region <NUM> are on both lateral side <NUM> and medial side <NUM>-some of which extend from lateral side <NUM> to medial side <NUM>. As shown in <FIG>, partially fused portions <NUM> are non-linear elongated ribs that are spaced apart. In other embodiments (not shown), partially fused portions <NUM> can be linear or not elongated. As shown in <FIG>, each of partially fused portions <NUM> are positioned between a respective pair of portions <NUM>. In some embodiments, portions <NUM> are embossed.

Upper <NUM> also includes a region <NUM> at heel region <NUM> that includes a plurality of portions <NUM> that are partially fused. Partially fused portions <NUM> of region <NUM> are on both lateral side <NUM> and medial side <NUM>. As shown in <FIG>, partially fused portions <NUM> are non-linear elongated ribs that are spaced apart. In some embodiments, the shape of partially fused portions <NUM> correspond to the shape of partially fused portions <NUM> in region <NUM>. In other embodiments (not shown), portions <NUM> can be linear or not elongated. In some embodiments, partially fused portions <NUM> are embossed as shown. In other embodiments, partially fused portions <NUM> are not embossed.

Partially fused portions <NUM>, <NUM>, <NUM>, and <NUM> can have tensile and tear mechanical properties that are advantageous for footwear applications. For example, each of partially fused portions <NUM>, <NUM>, <NUM>, and <NUM> can have a tensile strength such that the respective partially fused portion displaces less than <NUM>% of the respective partially fused fabric portion's unstressed dimension when a <NUM> N force is applied to the fabric portion in some embodiments. And in some embodiments, each of partially fused fabric portions <NUM>, <NUM>, <NUM>, and <NUM> can also have a tensile strength such that the respective partially fused fabric portion does not plastically deform when a <NUM> N force is applied to the fabric portion in some embodiments. Additionally, each of partially fused fabric portions <NUM>, <NUM>, <NUM>, and <NUM> can have a tear strength such that the respective portion does not tear when a <NUM> N force is applied to the portion in some embodiments.

Uppers having partially fused portions with one or more of the above mechanical properties have desired compliance, breathability, and support to be used for footwear, for example, shoes for leisure, running, soccer, American football, and basketball. That is, uppers having partially fused portions with one or more of the above mechanical properties are not too brittle or stiff to be used in footwear applications. Moreover, having at least one partially fused portion with one or more of the above mechanical properties allows upper <NUM> to be manufactured substantially as one unitary piece. In some one-piece embodiments, the fabric composing upper <NUM> is continuous from forefoot region <NUM> to heel region <NUM>, and upper <NUM> is continuous from lateral side <NUM> to medial side <NUM>. A one-piece upper <NUM> can reduce the total weight of article of footwear <NUM>, improving user comfort and performance.

Upper <NUM> can be made of fabric and yarn as described in any one of the embodiments related to upper <NUM> above.

Now turning to embodiments of manufacturing uppers, for example, upper <NUM> and upper <NUM>, having at least one partially fused portion, the partially fused portion(s) can be generated by thermal compression molding, RF welding, ultrasonic welding, or any other suitable molding technique.

For example, a thermal compression molding apparatus (e.g., a press having top and bottom heated plates that press against at least one mold) can be used to make uppers, for example, upper <NUM> and upper <NUM>, having at least one partially fused portion. The thermal compressing molding apparatus is configured to apply heat to a fabric blank at a predetermined temperature and a predetermined pressure for a predetermined time period. In some embodiments, the fabric blank is positioned on a mold. At least a portion of the mold has raised or recessed surface portions that correspond to the partially fused portions on the upper. In some embodiments, the raised surface portions of the mold are configured to emboss the corresponding partially fused portions. The fabric blank can be single or multiple layers, have various constructions (for example, knitted or woven), and be made of various materials as described above with reference to uppers <NUM> and <NUM>. In some embodiments, the mold is a single piece mold or a two-piece mold having top and bottom halves.

The mold is then placed onto the thermal compression molding apparatus, for example, between a heated top plate and a heated bottom plate. The thermal compression molding apparatus can include at least one hydraulic cylinder that drives the top plate and the bottom plate against the mold disposed in between to apply a predetermined amount of pressure to the fabric blank in the mold. The top and bottom plates can include heating elements that heat the top and bottom plates to a predetermined temperature and, in turn, heating the mold and the fabric blank in the mold to a desired temperature. Accordingly, in some embodiments, heat and pressure are applied to the fabric blank substantially simultaneously.

In some embodiments, applying heat to the fabric blank, for example, using a thermal compression molding apparatus, at a predetermined temperature and at a predetermined pressure for a predetermined time period partially fuses yarns to adjacent yarns and partially fuses filaments of the partially fused yarns to adjacent filaments. In such embodiments, the partially fused fabric portion can have tensile and tear mechanical properties that are advantageous for footwear applications. For example, applying heat to the fabric blank at a predetermined temperature and at a predetermined pressure for a predetermined time period can partially fuse yarns to adjacent yarns and partially fuse filaments of the partially fused yarns to adjacent filaments such that the partially fused portion can have a tensile strength such that the partially fused portion displaces less than <NUM>% of the partially fused fabric portion's unstressed dimension when a <NUM> N force is applied to the fabric portion. And in some embodiments, the partially fused fabric portion can also have a tensile strength such that the partially fused fabric portion does not plastically deform when a <NUM> N force is applied to the fabric portion. Additionally, the partially fused fabric portion can have a tear strength such that the portion does not tear when a <NUM> N force is applied to the portion. In some embodiments, the partially fused portion will have one or more of these tensile and tear mechanical properties.

In some embodiments, at least one of the predetermined temperature, the predetermined pressure, and the predetermined time period is selected based on characteristics of the fabric forming fabric blank. Exemplary characteristics include the fabric construction type (e.g., woven, knitted, braided, netted, felted, plaited, single layer, multiple layer, etc.), yarn construction type (e.g., cabled yarn, core yarn, coated yarn, etc.), yarn weight (e.g., Denier), the color of the filaments forming the yarn, material content of the fabric (e.g., polyester, nylon, thermoplastic, spandex, and materials having different melting temperatures). For example, the below table illustrates the exemplary predetermined temperature ranges (in degrees Celsius) of the pressing plates for a thermal compression apparatus and time ranges (in seconds) for applying heat to a knitted fabric blank based on various characteristics (namely, material content and yarn construction):.

In some embodiments, the predetermined pressure for the knitted fabric blanks of the above table is about <NUM> kgf/cm<NUM> (where <NUM> kgf/cm2 is equivalent to <NUM> MPa) to about <NUM> kgf/cm<NUM> (for example, about <NUM> kgf/cm<NUM>).

In some embodiments, in which the fabric blank comprises a knitted fabric composed of <NUM> percent nylon and <NUM> percent spandex, the predetermined temperature is selected to be in the range from about <NUM> to about <NUM> (for example, about <NUM> to about <NUM>), the predetermined time period is in the range from about <NUM> seconds to about <NUM> seconds (for example, about <NUM> seconds), and the predetermined pressure is about <NUM> kgf/cm<NUM> to about <NUM> kgf/cm<NUM> (for example, about <NUM> kgf/cm<NUM>). The fabric blank is then than pressed at the selected parameters.

In some embodiments, in which the fabric blank comprises a knitted sandwich mesh fabric in which (a) the top layer is about <NUM> percent to about <NUM> percent (for example, about <NUM> percent) 210D nylon, and about <NUM> percent to about <NUM> percent (for example, about <NUM> percent) 140D nylon, (b) the spacer yarns are about <NUM> percent nylon monofilament, and (c) the inner layer is about <NUM> percent to about <NUM> percent (for example, about <NUM> percent) 100D polyester and about <NUM> percent to about <NUM> percent (for example, about <NUM> about percent) 75D polyester, the predetermined temperature is selected to be in the range of about <NUM> to about <NUM>, the predetermined time period is selected to be in the range of about <NUM> second to about <NUM> seconds (for example, about <NUM> seconds), and the predetermined pressure is selected to be about <NUM> kgf/cm<NUM>. The fabric blank is then than pressed at the selected parameters.

In some embodiments, in which the fabric blank comprises a knitted sandwich mesh fabric in which the top layer is polyester, the spacer yarns are thermoplastic polyurethane, and the inner layer is a polyester, the predetermined temperature is selected to be in the range of about <NUM> to about <NUM>, the predetermined time period is selected to be in the range of about <NUM> seconds, and the predetermined pressure is about <NUM> kgf/cm<NUM>. The fabric blank is then than pressed at the selected parameters.

In some embodiments in which the fabric blank is a knitted sandwich mesh in which the outer layer is a low melt copolyamide (for example, K-<NUM> yarn manufactured by EMS-Griltech), the inner layer is a low melt copolyamide (for example, K-<NUM> yarn manufactured by EMS-Griltech), and the spacer yarns are polyester, the predetermined temperature is selected to be in the range of about <NUM> to about <NUM> (for example, about <NUM>), the predetermined time period is selected to be in the range from about <NUM> seconds to about <NUM> seconds (for example, about <NUM> seconds), and the predetermined pressure is about <NUM> kgf/cm<NUM>. The fabric blank is then than pressed at the selected parameters.

In some embodiments in which the fabric blank is a knitted sandwich mesh in which (a) the outer layer is a thermoplastic polyurethane, (b) the spacer yarns are polyester, and (c) the inner layer is polyester and spandex with the total composition of the mesh being about <NUM> percent to about <NUM> percent (for example, about <NUM> percent) thermoplastic polyurethane, about <NUM> percent to about <NUM> percent (for example, about <NUM> percent) spandex, and about <NUM> percent to about <NUM> percent (for example, about <NUM> percent) polyester, the predetermined temperature is selected to be in the range of about <NUM> to about <NUM> (for example, about <NUM> or about <NUM>), the predetermined time period is selected to be in the range from about <NUM> seconds to about <NUM> seconds (for example, about <NUM> seconds), and the predetermined pressure selected to be about <NUM> kgf/cm<NUM>. The fabric blank is then than pressed at the selected parameters.

After applying heat to the fabric blank at a predetermined temperature and at a predetermined pressure for a predetermined time period, the fabric blank is removed from the mold. Then the fabric blank can be cut, for example, by die cutting, laser cutting, water jet cutting, or reciprocating knife cutting, to a desired shape. <FIG> illustrates an exemplary fabric blank <NUM> for upper <NUM> that has been cut after applying heat to the fabric blank to form partially fused portions <NUM>, <NUM>, and <NUM>. The cut fabric blank <NUM> has opposing ends <NUM> and <NUM> on medial and lateral sides <NUM>, <NUM>, respectively.

Next, the cut fabric blank is formed into an upper of the article of footwear. For example, referring to <FIG>, ends <NUM> and <NUM> of cut fabric blank <NUM> are coupled together, for example, stitched together. A back strip of material may be coupled to, for example, sewn or adhered, to the inside or outside of fabric blank <NUM> at the seam at which ends <NUM> and <NUM> are stitched together to form upper <NUM>. In some embodiments (not shown in <FIG>), fabric blank <NUM> is configured with a bellows tongue arrangement to allow for a one piece construction and thereby reducing the number of upper pieces and manufacturing steps required. In other embodiments, a tongue (not shown) in <FIG>, is coupled, for example, sewn, to fabric blank <NUM>. And then, in some embodiments, cut fabric blank <NUM> is shaped over a last (not shown), and an interlining and/or a strobel sock are coupled to fabric blank <NUM> to form the upper of the article of footwear. In some embodiments, the separate tongue is also pressed to form partially fused portions as described above.

In some embodiments, the fabric blank is embroidered before or after heat is applied to the fabric blank to partially fuse at least one portion of the fabric blank. Embroidering the fabric blank can increase the tear strength of the partially fused portion(s) of the fabric blank. In some embodiments, the predetermined temperature at which the fabric blank is heated is based on whether the fabric blank is embroidered. For example, in some embodiments, the predetermined temperature at which an embroidered fabric blank is heated can be higher than the predetermined temperature at which an unembroidered fabric blank is heated.

In some embodiments, the method of manufacturing uppers having at least one partially fused portion also includes heat transfer printing (also known as sublimation transfer printing). A design can be preprinted on transfer paper with disperse dyes that sublime onto the fabric upper. The heat transfer paper with the design is placed in the mold in contact with the fabric blank. The mold is then placed onto the thermal compression molding apparatus, and heat and pressure are applied to the transfer paper and fabric blank to transfer the design from the paper onto the fabric blank and to partially fuse a portion of the fabric blank.

In one heat transfer printing embodiment, the transfer paper and fabric blank are heated to a first temperature (for example, about <NUM> to about <NUM>, e.g., about <NUM>) to transfer the design to the fabric blank. Then the mold is removed from the compression molding apparatus and the transfer paper is removed from the mold. The mold is then placed back onto the thermal compression molding apparatus, and heated to a second temperature higher than the first temperature (for example, about <NUM> to about <NUM>, e.g., about <NUM>) to partially fuse a portion of the fabric blank. Then the mold is removed from the compression molding apparatus, and the fabric blank with a partially fused portion are removed from the mold. The fabric blank can then be formed into an upper.

In another heat transfer printing embodiment, the transfer paper and fabric blank are heated to a temperature (for example, about <NUM> to about <NUM>, e.g., about <NUM>) to both transfer the design to the fabric blank and to partially fuse a portion of the fabric blank. Then the mold is removed from the compression molding apparatus, and the transfer paper and the fabric blank with a partially fused portion are removed from the mold. The fabric blank can then be formed into an upper.

In some heat transfer printing embodiment, a portion of the design transferred from the transfer paper is positioned on the partially fused portion of the upper.

While various embodiments have been discussed herein in the context of footwear, other articles of apparel may be manufactured using fabric having at least one partially fused portion. Other articles of apparel include, but are not limited to, pants, shorts, leggings, a sock, a jacket, a coat, a hat, a sleeve, a sweater, a jersey, a bootie, and a glove. In some embodiments, the fabric on areas of apparel that are subject to excessive wear and tear can be partially fused for durability. For example, the fabric at the knee area of pants can be partially fused to provide increase durability to the knee area, and the fabric at the elbow area of shirts, jackets, and coats can be partially fused to provide increase durability to the elbow area. In some embodiments, the fabric of apparel can be partially fused and embossed with aesthetic pattern. For example, any one of pants, shorts, leggings, a sock, a jacket, a coat, a hat, a sleeve, a sweater, a jersey, a bootie, and a glove can be embossed with aesthetic pattern. And in some embodiments, any one of pants, shorts, leggings, a sock, a jacket, a coat, a hat, a sleeve, a sweater, a jersey, a bootie, and a glove can be partially fused to increase the strength of the fabric and reduce number of required layers or materials to manufacture the apparel item, decreasing both weight and manufacturing costs of the apparel item.

The present invention have been described above with the aid of functional building blocks illustrating the implementation of specified functions and relationships thereof.

Claim 1:
A method of manufacturing an article of footwear (<NUM>, <NUM>), the method comprising:
applying heat to a fabric at a temperature between <NUM> and <NUM> and a pressure between <NUM> kPa (<NUM> kgf/cm<NUM>) to <NUM> kPa (<NUM> kgf/cm<NUM>) for a time period between <NUM> to <NUM> seconds to form a partially fused portion (<NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, and <NUM>), wherein at least one of the temperature, the pressure, and the time period is selected based on a characteristic of the fabric such that, after the applying heat to the fabric, a portion of the fabric comprises (a) yarns (<NUM>) that are partially fused to adjacent yarns and (b) filaments (<NUM>) of the partially fused yarns that are partially fused to adjacent filaments, wherein the fabric is a sandwich mesh comprising a first layer, a second layer, and spacer yarns between the first layer and the second layer, and wherein the sandwich mesh comprises nylon and spandex; and
forming an upper of the article of footwear from the fabric comprising the fused portion.