Composite footwear upper and method of manufacturing a composite footwear upper
First Claim
1. A method of manufacturing a footwear upper having a three-dimensional geometry, the method comprising:
- forming a composite sheet from two or more layers; and
shaping the composite sheet into the three-dimensional geometry of the footwear upper.
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Accused Products
Abstract
A method of manufacturing a multi-layer, composite footwear upper having a three-dimensional geometry includes forming a substantially planar composite sheet from two or more layers, heating the composite sheet, and shaping the composite sheet into the three-dimensional geometry of the footwear upper. The composite sheet can be formed by laminating a first layer of thermoplastic foam to a second layer of thermoplastic urethane (TPU). A third layer of mesh fabric can be interposed between the first and second layers. The composite sheet can be shaped by compression molding in a mold cavity or by lasting to achieve the desired three-dimensional geometry.
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Citations
59 Claims
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1. A method of manufacturing a footwear upper having a three-dimensional geometry, the method comprising:
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forming a composite sheet from two or more layers; and
shaping the composite sheet into the three-dimensional geometry of the footwear upper. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 40, 41, 42, 43, 49)
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27. A method of manufacturing a footwear upper having a three-dimensional geometry, the method comprising:
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forming a composite sheet from two or more layers;
positioning the composite sheet on a last to shape the composite sheet into the three-dimensional geometry of the footwear upper, and attaching a lasting board to the composite sheet.
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39. A method of manufacturing footwear comprising the steps of:
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constructing an upper having a three-dimensional geometry by forming composite sheet from two or more layers, positioning the composite sheet on a last to shape the composite sheet into the three-dimensional geometry of the footwear upper, and attaching a lasting board to the composite sheet, and attaching the upper to a sole.
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44. A method of manufacturing a footwear upper having a three-dimensional geometry, the method comprising:
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forming a composite sheet from two or more layers;
positioning the composite sheet on a last to shape the composite sheet into the three-dimensional geometry of the footwear upper, and attaching a lasting sock to the composite sheet. - View Dependent Claims (45, 46, 47, 48, 50, 51, 52, 53, 54)
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55. A method of manufacturing footwear comprising the steps of:
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constructing an upper having a three-dimensional geometry by forming composite sheet from two or more layers, positioning the composite sheet on a last to shape the composite sheet into the three-dimensional geometry of the footwear upper, and attaching a lasting sock to the composite sheet, and attaching the upper to a sole. - View Dependent Claims (56, 57, 58, 59)
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Specification