Shoe with composite upper and method of making the same

Patent metadata

Field	Value
Publication number	US-10645998-B2
Application number	US-201213467499-A
Country	US
Kind code	B2
Filing date	May 9, 2012
Priority date	May 27, 2011
Publication date	May 12, 2020
Grant date	May 12, 2020

Abstract

Uppers for article of footwear may include one or more skin layers attached to a base layer, wherein at least one of the skin layers is at least partially transparent or translucent. The transparent or translucent skin layer may be applied over other elements of the upper (e.g., other skin layers, base layers, reinforcing layers, etc.) to provide interesting color change options and color palettes for the upper. Additional aspects of this invention relate to production of curved tongue composite structures and/or footwear having a bonded (hot melt) side seam for forming the upper (and optionally do not include a rear heel seam).

First claim

The invention claimed is:

1. An upper for an article of footwear, comprising:
a base layer, wherein the base layer has a first color;
an intermediate layer partially covering an exterior surface of the base layer, wherein the intermediate layer has a second color, and wherein the intermediate layer includes a first eye stay reinforcing element, the first eye stay reinforcing element including a first opening defined through it; and
a first skin layer partially covering and bonded to the exterior surface of the base layer and at least partially covering an exterior surface of the intermediate layer, wherein the first skin layer covers an exterior surface of the first eye stay reinforcing element, wherein the first skin layer includes a second opening defined through it that is axially aligned with the first opening defined through the first eye stay reinforcing element, wherein the first skin layer has a third color and is partially transparent or translucent, and wherein the upper includes: (a) a first color appearance at a first portion where the first skin layer is absent, (b) a second color appearance different from the first color appearance at a second portion where the first skin layer partially covers the exterior surface of the base layer and the intermediate layer is absent, wherein the second color appearance includes a blend of the first color and the third color, and (c) a third color appearance different from the first color appearance and the second color appearance at a third portion where the first skin layer at least partially covers the exterior surface of the intermediate layer, wherein the third color appearance includes a blend of the second color and the third color.

2. An upper according to claim 1 , wherein the intermediate layer is partially transparent or translucent.

3. An upper according to claim 1 , wherein the intermediate layer further includes a second eye stay reinforcing element.

4. An upper according to claim 1 , wherein the intermediate layer further includes a toe reinforcing element.

5. An upper according to claim 1 , wherein the intermediate layer further includes a heel reinforcing element.

6. An upper according to claim 1 , wherein the first skin layer is fuse bonded to the base layer by application of heat and pressure.

7. An upper according to claim 1 , wherein the first skin layer is fuse bonded to the base layer and the intermediate layer by application of heat and pressure.

8. An article of footwear, comprising:
an upper according to claim 1 ; and
a sole structure engaged with the upper.

9. An upper according to claim 1 , wherein the first eye stay reinforcing element is located on a first side of an instep opening of the upper, wherein the intermediate layer further includes a second eye stay reinforcing element located on the first side of the instep opening, wherein the second eye stay reinforcing element includes a third opening defined through it, and wherein the first skin layer includes a fourth opening defined through it that is axially aligned with the third opening defined through the second eye stay reinforcing element.

10. An upper according to claim 1 , wherein the first eye stay reinforcing element is located on a first side of an instep opening of the upper, wherein the intermediate layer further includes a second eye stay reinforcing element located on a second side of the instep opening, wherein the second eye stay reinforcing element includes a third opening defined through it, and wherein the first skin layer includes a fourth opening defined through it that is axially aligned with the third opening defined through the second eye stay reinforcing element.

11. An upper according to claim 1 , wherein the base layer includes a mesh layer.

12. An upper according to claim 1 , wherein the base layer includes a support layer and a mesh layer at least partially overlaying the support layer.

13. An upper according to claim 1 , wherein the first skin layer is a hot melt film material.

14. An upper according to claim 1 , wherein the first skin layer is a polyurethane hot melt film material.

15. An upper according to claim 1 , wherein the first eye stay reinforcing element includes openings for more than one lace engaging eye stay.

16. An article of footwear, comprising:
a sole structure; and
an upper engaged with the sole structure, wherein the upper includes:
a base layer, wherein the base layer has a first color;
a first eye stay reinforcing element partially covering an exterior surface of the base layer, wherein the first eye stay reinforcing element has a second color, and wherein the first eye stay reinforcing element includes a first opening defined through it; and
a first skin layer partially covering and bonded to the exterior surface of the base layer and covering an exterior surface of the first eye stay reinforcing element, wherein the first skin layer includes a second opening defined through it that is axially aligned with the first opening defined through the first eye stay reinforcing element, wherein the first skin layer has a third color and is partially transparent or translucent, and wherein the upper includes: (a) a first color appearance at a first portion where the first skin layer is absent, (b) a second color appearance different from the first color appearance at a second portion where the first skin layer partially covers the exterior surface of the base layer and the first eye stay reinforcing element is absent, wherein the second color appearance includes a blend of the first color and the third color, and (c) a third color appearance different from the first color appearance and the second color appearance at a third portion where the first skin layer covers the exterior surface of the first eye stay reinforcing element, wherein the third color appearance includes a blend of the second color and the third color.

17. An article of footwear according to claim 16 , wherein the first skin layer is fuse bonded to the base layer by application of heat and pressure.

18. An article of footwear according to claim 16 , wherein the first eye stay reinforcing element is located on a first side of an instep opening of the upper, wherein the upper further includes a second eye stay reinforcing element located on the first side of the instep opening, wherein the second eye stay reinforcing element includes a third opening defined through it, and wherein the first skin layer includes a fourth opening defined through it that is axially aligned with the third opening defined through the second eye stay reinforcing element.

19. An article of footwear according to claim 16 , wherein the first eye stay reinforcing element is located on a first side of an instep opening of the upper, wherein the upper further includes a second eye stay reinforcing element located on a second side of the instep opening, wherein the second eye stay reinforcing element includes a third opening defined through it, and wherein the first skin layer includes a fourth opening defined through it that is axially aligned with the third opening defined through the second eye stay reinforcing element.

20. An article of footwear according to claim 16 , wherein the first skin layer is a hot melt film material.

Assignees

• Shaffer Benjamin A
• Hoffer Kevin W
• Le Tony H
• Kang Yunmi
• Nike Inc

Inventors

• Shaffer Benjamin A
• Hoffer Kevin W
• Le Tony H
• Kang Yunmi

Classifications

• A43B23/0245

  characterised by the constructive form · CPC title

• A43B1/0027

  made at least partially from a material having special colours · CPC title

• A43B23/0235 Primary

  Different layers of different material · CPC title

• A43B1/0072

  made at least partially of transparent or translucent materials · CPC title

• A43B23/026

  Laminated layers · CPC title