CN107125833B

CN107125833B - Article of footwear with welded upper

Info

Publication number: CN107125833B
Application number: CN201710532431.6A
Authority: CN
Inventors: 托马斯·贝伦德; 道格拉斯·A·贝耶; 托尼·H·乐
Original assignee: Nike Inc
Current assignee: Nike Inc
Priority date: 2013-05-07
Filing date: 2014-05-06
Publication date: 2020-05-05
Anticipated expiration: 2034-05-06
Also published as: EP2948012A1; WO2014182651A8; CN105050442B; EP3434128A1; WO2014182651A1; CN105050442A; EP2948012B1; EP3434128B1; CN107125833A

Abstract

The present application relates to an article of footwear having a welded upper. An article of footwear includes an upper (110) including a skin layer (185) that forms at least a portion of an exterior surface of the upper (110). The upper (110) also includes a reinforcing material (190) selectively located internally and adjacent to portions of the skin (185) to define a reinforced portion (195) of the skin and an unreinforced portion (200) of the skin. The reinforcing material (190) is selectively joined to the skin layer (185) by welding at a bonded region (205), the bonded region (205) having an outer exposed surface defining a portion of an exterior surface of the upper (110). Additionally, the skin layer (185) may have a first color and the outer exposed surface of the bonded region (205) may have a second color that is different from the first color.

Description

Article of footwear with welded upper

The present application is a divisional application of the application entitled "article of footwear with welded upper" having application date 2014, year 05, month 06, application number 201480017619.1.

Cross Reference to Related Applications

This application is a part Continuation In Part (CIP) application, U.S. patent application publication No. 2012/0297643 to Schaefer et al, published on 29/11/2012, which claims priority to U.S. provisional patent application No. 61/460,776, filed 27/5/2011. The entire disclosures of both applications are hereby incorporated by reference.

Technical Field

The present invention relates generally to material structures for articles of footwear, and more particularly to material structures for uppers of articles of footwear.

Background

Conventional articles of athletic footwear include two primary elements: an upper and a sole structure. The upper provides a covering for the foot that comfortably receives the foot and securely positions the foot with respect to the sole structure. The sole structure is secured to a lower portion of the upper and is generally positioned between the foot and the ground. In addition to attenuating ground reaction forces (i.e., providing cushioning) during walking, running, and other ambulatory activities, the sole structure may affect foot motions (e.g., by resisting inversion), impart stability, and provide traction, for example. Accordingly, the upper and the sole structure operate cooperatively to provide a comfortable structure that is suited for a wide variety of athletic activities.

The upper is generally formed from multiple material elements that may be stitched or adhesively bonded together to define a void or chamber (cavity) inside the footwear for comfortably and securely receiving a foot. More specifically, the upper forms a structure that extends over the instep and toe areas of the foot, along the lateral and medial sides of the foot, and around the heel area of the foot. The upper may also incorporate a lacing system to open and close openings to the cavity or chamber and to adjust the fit of the footwear within the upper. In addition, the upper may include a tongue that extends under the lacing system to enhance adjustability and comfort of the footwear, and the upper may incorporate a heel counter or other stabilizing structure.

The upper may also include provisions for improving fit, comfort, and performance. The selection and placement of materials may be used to achieve certain desired characteristics. The design of many types of footwear is often driven by conflicting factors. As just one example, it is generally desirable for athletic footwear to have a configuration that supports and protects a wearer's foot during certain athletic efforts. However, "breathability" is also a desirable quality of many types of athletic footwear. In particular, air flowing between the interior of the shoe and the exterior of the shoe through the upper of the shoe may help to mitigate the effects of heat and perspiration that are typically generated around the foot during athletic activities. However, many materials that provide support and foot protection may block the flow of air and moisture through the upper. Conversely, many materials that assist in the flow of air and moisture provide little support or protection to the foot of the wearer.

One solution is to make shoes in which some portions are formed of supportive/protective materials and some portions are formed of breathable materials. However, this may increase the complexity of the manufacturing process and increase the cost. Additionally, material attachment techniques such as stitching and the use of adhesives may add weight to the footwear. In addition, footwear designs (including athletic footwear designs) are also aesthetically driven. Complex manufacturing processes developed for manufacturing complex footwear may potentially limit the manufacturer's ability to alter the footwear design to achieve different aesthetic effects.

Disclosure of Invention

In one aspect, the present disclosure is directed to an article of footwear having a sole structure fixedly attached to an upper configured to receive a foot of a wearer. The upper may include a skin that forms at least a portion of an exterior surface of the upper. The upper may also include a reinforcing material selectively located on an interior and adjacent to portions of the skin layer, thereby defining reinforced portions of the skin layer and unreinforced portions of the skin layer. The reinforcement material may be selectively joined with the skin layer by welding at a bond area, the bond area having an outer exposed surface that defines a portion of an exterior surface of the upper. Additionally, the skin layer may have a first color and the outer exposed surface of the bonded region may have a second color, the second color being different from the first color.

In one embodiment, the outer exposed surface of the bonding zone includes a portion of the reinforcing material, thereby providing the outer exposed surface of the bonding zone with the same color as the reinforcing material.

In one embodiment, the skin is formed from a mesh material.

In one embodiment, the unreinforced portion of the skin layer includes an outwardly exposed surface and an inwardly exposed surface.

In one embodiment, the unreinforced portion of the skin provides direct ventilation through the mesh material of the skin to a cavity defined by the upper.

In one embodiment, the bonded region includes a line of bonding material extending between components of the article of footwear.

In one embodiment, the lines of bonding material extend from the sole structure to a reinforcing band proximate to an instep region of the article of footwear.

In one embodiment, the article of footwear includes a material attachment panel welded to the skin layer.

In another aspect, the present disclosure is directed to an article of footwear having a sole structure fixedly attached to an upper that defines an interior cavity configured to receive a foot of a wearer. The upper may include a skin layer that forms at least a portion of an exterior surface of the upper, the skin layer being formed from a mesh material. In addition, the upper may include a reinforcing material selectively located interior and adjacent to the skin layer, thereby defining a reinforced portion of the skin layer and an unreinforced portion of the skin layer. The unreinforced portions of the skin may provide direct ventilation through the mesh material of the skin to the interior cavity defined by the upper. In addition, the reinforcing material may be selectively joined with the skin layer by welding at a bonded area, the bonded area having an outer exposed surface that defines a portion of an exterior surface of the upper. Also, the skin layer may have a first color and the outer exposed surface of the bonded region may have a second color, the second color being different from the first color.

In one embodiment, the article of footwear includes an additional layer of material located between a portion of the skin layer and a portion of the reinforcement material.

In one embodiment, the additional layer of material comprises a compressible foam material.

In one embodiment, the surface area of the unreinforced portion of the skin layer forms a majority of the surface area of the outer exposed surface of the skin layer; and is

Wherein, in the unreinforced portion of the skin, the upper consists essentially of the skin.

In another aspect, the present disclosure is directed to an article of footwear having a sole structure fixedly attached to an upper configured to receive a foot of a wearer. The upper may include a skin layer that forms at least a portion of an exterior surface of the upper. The upper may also include a reinforcing material selectively located on an interior and adjacent to portions of the skin layer, thereby defining reinforced portions of the skin layer and unreinforced portions of the skin layer. The reinforcement material may be selectively joined with the skin layer by welding at a bond area, the bond area having an outer exposed surface that defines a portion of an exterior surface of the upper. Additionally, the skin layer may have a first color and the reinforcing material may have a second color, the second color being different from the first color. Also, the outer exposed surface of the bonding region may include portions of the reinforcing material, thereby providing the outer exposed surface of the bonding region with substantially the same color as the reinforcing material.

In one embodiment, the additional layer of material is disposed in a tongue portion of the upper.

In one embodiment, an additional layer of compressible foam material is disposed in the pocket between the skin layer and the reinforcement material and is surrounded by the bonded region.

In another aspect, the present disclosure is directed to a method of manufacturing an article of footwear including forming an upper configured to receive a foot of a wearer. The method may include selectively attaching the inner reinforcing material to the skin layer using welding. The method may also include arranging the skin layer to form at least a portion of an exterior surface of the upper. The skin layer may have a first color and the reinforcing material may have a second color different from the first color. Welding the internal reinforcing material to the skin layer may form a bonded area having an outer exposed surface defining a portion of an exterior surface of the upper, the outer exposed surface of the bonded area including portions of the reinforcing material, thereby providing the outer exposed surface of the bonded area with a different color than the skin layer.

In one embodiment, welding the internal reinforcing material to the skin layer to form the bonded area repositions portions of the internal reinforcing material to the exterior surface of the upper at the outer exposed surface of the bonded area, thereby providing the outer exposed surface of the bonded area with the same color as the internal reinforcing material.

In one embodiment, the skin is formed from a mesh material.

In one embodiment, repositioning the portion of the internal reinforcing material to the exterior surface of the upper includes pressing the portion of the internal reinforcing material through an opening in the mesh material.

In one embodiment, selectively attaching the internal reinforcing material to the skin layer forms an unreinforced portion of the skin layer that provides direct ventilation to a lumen defined by the upper through the mesh material of the skin layer.

In one embodiment, welding the internal reinforcing material to the skin layer to form the bonded region includes forming a line of bonding material extending between components of the article of footwear.

In one embodiment, the method further includes fixedly attaching a sole structure to the upper;

wherein forming a line of bonding material includes forming a line of bonding material that extends from a sole structure of the article of footwear to a reinforcing strip proximate an instep region of the article of footwear.

In one embodiment, welding the internal reinforcing material to the skin layer includes one of ultrasonic welding and radio frequency welding.

Drawings

The invention can be better understood with reference to the following drawings and description. The components in the figures are not necessarily to scale, emphasis instead being placed upon illustrating the principles of the invention. Moreover, in the figures, like reference numerals designate corresponding parts throughout the different views.

FIG. 1 shows a perspective view of an embodiment of an article of footwear;

FIG. 2 shows an exploded view of the article of footwear shown in FIG. 1;

FIG. 3 illustrates another perspective view of the article of footwear illustrated in FIG. 1;

FIG. 4 illustrates a rear perspective view and an interior view of the article of footwear shown in FIG. 1;

FIG. 5 shows an enlarged version of a portion of the view of the article of footwear shown in FIG. 4;

FIG. 6 shows a perspective view of an enlarged portion of an article of footwear and an upper of the article of footwear;

FIG. 7 shows a cross-sectional view taken along line 7-7 of FIG. 6;

FIG. 8 shows an enlarged view of a portion of an upper of an article of footwear according to another embodiment;

9-11 illustrate an exemplary process of ultrasonically welding layers of an upper;

FIG. 12 illustrates an example tongue portion of an article of footwear;

FIG. 13 illustrates a cross-sectional view of the tongue taken along line 13-13 of FIG. 12; and

FIG. 14 illustrates a cross-sectional view of the tongue taken along line 14-14 of FIG. 12.

Detailed Description

The following discussion and accompanying figures disclose sole structures for articles of footwear. Concepts disclosed herein with respect to footwear may be applied to a variety of athletic footwear styles, including running shoes, basketball shoes, soccer shoes, baseball shoes, football shoes, and golf shoes, for example. Accordingly, the concepts disclosed herein are applicable to a variety of footwear types.

To aid and clarify the subsequent description of the various embodiments, various terms are defined herein. The following definitions apply throughout this specification, including the claims, unless otherwise indicated. Directional adjectives are used throughout this detailed description corresponding to the illustrated embodiments for consistency and convenience.

The term "longitudinal" as used throughout this detailed description and in the claims refers to a direction that extends the length of a sole structure, i.e., a direction that extends from a forefoot portion to a heel portion of a sole. The term "forward" is used to refer to the general direction in which the toes of the foot point, and the term "rearward" is used to refer to the opposite direction, i.e., the direction in which the heel of the foot faces.

The term "lateral direction" as used throughout this detailed description and in the claims refers to a side-to-side direction (side-to-side direction) that extends the width of the sole. In other words, the lateral direction may extend between a medial side and a lateral side of the article of footwear, where the lateral side of the article of footwear is the surface that faces away from the other foot and the medial side is the surface that faces toward the other foot.

The term "transverse axis" as used throughout this detailed description and in the claims refers to an axis oriented in a transverse direction.

The term "horizontal" as used throughout this detailed description and in the claims refers to any direction generally parallel to the ground, including the longitudinal direction, the lateral direction, and all directions in between. Also, the term "side" as used in the specification and claims refers to any portion of a component that generally faces in a lateral, medial, forward, or rearward direction as opposed to an upward or downward direction.

The term "vertical" as used throughout this detailed description and in the claims refers to a direction that is substantially perpendicular to both the lateral and longitudinal directions. For example, where the sole is laid flat on a ground surface, the vertical direction may extend upwardly from the ground surface. It will be understood that each of these directional adjectives may be applied to various components of the sole. The term "upward" refers to a vertical direction proceeding away from the ground, while the term "downward" refers to a vertical direction proceeding toward the ground. Likewise, the terms "top," "upper," and other similar terms refer to the portion of an object that is generally furthest from the ground in a vertical direction, while the terms "bottom," "lower," and other similar terms refer to the portion of an object that is generally closest to the ground in a vertical direction.

The "interior" of the shoe refers to the space occupied by the wearer's foot when the shoe is worn. The "medial side" of a panel or other footwear element refers to the side of the panel or element that is oriented toward (or will be oriented toward) the interior of the footwear in the finished shoe. The "lateral side" of an element refers to the side of the element that is oriented away (or will be away) from the interior of the shoe in the finished shoe. In some cases, the medial side of an element may have other elements between the medial side and the interior in a finished shoe. Similarly, the outer side of an element may have other elements between the outer side and the space outside the finished shoe. Furthermore, the terms "inwardly" and "inwardly" shall refer to a direction toward the interior of the footwear, while the terms "outwardly" and "outwardly" shall refer to a direction toward the exterior of the footwear.

For the purposes of this disclosure, when the above directional terms are used to refer to an article of footwear, it shall refer to the article of footwear when in an upright position with the sole facing the ground, that is, positioned to stand on a generally horizontal surface as the article of footwear is worn by a wearer.

Additionally, for purposes of this disclosure, the term "fixedly attached" shall mean that two components are connected in such a way that the components cannot be easily separated (e.g., without breaking one or both of the components). Exemplary forms of fixed attachment may include attachment using permanent adhesives, rivets, sutures, staples, welding or other thermal bonding or other attachment techniques. Additionally, the two components may be "fixedly attached" by being integrally formed, for example, in a molding process.

Fig. 1 depicts an embodiment of an article of footwear 100. Footwear 100 may include a sole structure 105 and an upper 110, upper 110 being secured to sole structure 105 and configured to receive a foot. For reference purposes, footwear 100 may be divided into three general regions: forefoot region 115, midfoot region 120, and heel region 125. Forefoot region 115 generally includes portions of footwear 100 corresponding with the toes and the joints connecting the metatarsals with the phalanges. Midfoot region 120 generally includes portions of footwear 100 corresponding with an arch area of the foot. Heel region 125 generally corresponds with rear portions of the foot, including the calcaneus bone. Regions 115, 120, and 125 are not intended to demarcate precise areas of footwear 10. More specifically, regions 115, 120, and 125 are intended to represent generally relevant areas of footwear 100 to facilitate the following discussion. Because various features of footwear 100 extend beyond an area of footwear 100, the terms forefoot region 115, midfoot region 120, and heel region 125 apply not only to footwear 100, but also to various features of footwear 100.

As shown in fig. 1, upper 110 may include one or more material elements (e.g., mesh, textiles, foam, leather, and synthetic leather) that may be connected to define an interior cavity 130 configured to receive a foot. The material elements may be selected and arranged to selectively impart properties such as light weight, durability, breathability, abrasion resistance, flexibility, and comfort. Upper 110 may define an opening 135, with opening 135 configured to receive a foot of a wearer into interior cavity 130. In addition, upper 110 may include lace 140, which may be used to modify the dimensions of interior cavity 130, thereby securing the foot within interior cavity 130 and facilitating entry and removal of the foot from interior cavity 130. Lace 140 may extend through lace-receiving loops 145 in upper 110. Lace-receiving loops 145 may extend from reinforcing strips 150 proximate lace region 155 of upper 110, which may be in instep region 157 of footwear 100. As further shown in fig. 1, footwear 100 may also include a tongue 800.

In some embodiments, reinforcing straps 150 may include eyelets or holes configured to receive lace 40. In addition, upper 110 may alternatively embody any of a variety of other configurations, materials, or closure mechanisms. For example, alternative closure mechanisms, such as hook and loop fasteners (e.g., straps), snaps, clasps, laces, or any other means for securing the foot within interior chamber 130 defined by upper 110.

Sole structure 105 may be fixedly attached to upper 110 (e.g., using adhesives, stitching, welding, or other suitable techniques), and may have a configuration that extends between upper 110 and the ground. Sole structure 105 may include provisions for attenuating ground reaction forces (i.e., cushioning and stabilizing the foot during vertical and horizontal loads). In addition, sole structure 105 may be configured to provide traction, impart stability, and control or limit various foot motions, such as pronation, supination, or other motions.

The configuration of sole structure 105 may vary significantly depending on the type or types of ground on which sole structure 105 may be used. For example, the disclosed concepts may be applicable to footwear configured for use on any of a variety of surfaces, including indoor surfaces or outdoor surfaces. The configuration of sole structure 105 may vary based on the nature and conditions of the surfaces on which footwear 100 is intended to be used. For example, sole structure 105 may vary depending on whether the surface is harder or softer. In addition, sole structure 105 may be customized for use in wet or dry conditions.

In some embodiments, sole structure 105 may be configured for a particular specialized surface or condition. For example, in some embodiments, footwear 100 is illustrated in the figures as a running shoe, and accordingly, sole structure 105 is shown configured to provide cushioning, stability, and traction on hard, smooth surfaces, such as a road surface. However, the proposed footwear upper configuration may be applicable to any type of footwear, such as basketball, soccer, football, and other athletic activities. Accordingly, in some embodiments, sole structure 105 may be configured to provide traction and stability on a hard indoor surface (e.g., hardwood), a soft natural turf surface, or on a hard artificial turf surface. In some embodiments, sole structure 105 may be configured for use on a plurality of different surfaces.

In some embodiments, sole structure 105 may include multiple components that may individually or collectively provide several attributes to footwear 100, such as support, rigidity, flexibility, stability, cushioning, comfort, weight reduction, or other attributes. In some embodiments, sole structure 105 may include an insole/sockliner (see fig. 4), a midsole 160, and a ground-contacting sole component 165, ground-contacting sole component 165 may have an exposed ground-contacting lower surface 170, as shown in fig. 1. However, in some cases, one or more of these components may be omitted.

The insole may be disposed within a cavity 130 defined by upper 110. An insole may extend through each of forefoot region 115, midfoot region 120, and heel region 125 of footwear 100 and between lateral side 175 and medial side 180 of footwear 100. The insole may be formed of a deformable (e.g., compressible) material, such as polyurethane foam or other polymer foam material. Thus, the insole may provide cushioning by virtue of its compressibility and may also conform to the foot to provide comfort, support, and stability.

Midsole 160 may be fixedly attached to a lower area of upper 110 (e.g., by stitching, adhesive bonding, thermal bonding (such as welding), or other techniques) or may be integral with upper 110. Midsole 160 may extend through each of forefoot region 115, midfoot region 120, and heel region 125 of footwear 100 and between lateral side 175 and medial side 180 of footwear 100. In some embodiments, portions of midsole 160 may be exposed around the perimeter of footwear 100, as shown in fig. 1. In other embodiments, midsole 160 may be completely covered by other elements, such as a layer of material from upper 110. Midsole 160 may be formed from any suitable material having the properties described above, depending upon the activity for which footwear 100 is intended to be utilized. In some embodiments, midsole 160 may include a foamed polymer material, such as Polyurethane (PU), Ethylene Vinyl Acetate (EVA), or any other suitable material that acts to attenuate ground reaction forces as sole structure 105 contacts the ground during walking, running, or other athletic activities.

In some embodiments, at least a portion of an upper of an article of footwear may be formed from a skin layer. In some embodiments, the internal reinforcement material may be welded to the skin layer in selected areas. The weld area may provide a different color change than the outer exposed skin layer. The internal reinforcing material may provide support, protection, and comfort in appropriate areas depending on the activity the footwear is intended to perform. In addition, additional layers may cover the skin in one or more areas (e.g., heel and toe areas) to provide additional durability. In some embodiments, these additional layers may also be used for decorative purposes.

The term "welding" (and variations thereof) as used herein is defined as a fixation technique between two elements that involves softening or melting the material of at least one of the elements such that the materials of the elements are fixed to each other upon cooling. Similarly, the term "weld" or variants thereof is defined as a joint, connection or structure joining two elements by a process involving softening or melting of material within at least one of the elements such that the elements are secured to one another upon cooling. In some embodiments, welding may involve melting or softening of the two components such that the materials from each component mix with each other, that is, the materials may diffuse through a boundary layer between the materials and be secured together when cooled. In some embodiments, welding may involve melting or softening of the material in the first component such that the material extends into or penetrates the structure of the second component, for example into a gap or chamber in the second component, or extends around or bonds with the wires or fibers in the second component to secure the components together as they cool. Thus, welding of the two components together may occur when material from one or both of the components melts or softens. Accordingly, weldable materials, such as polymeric materials, may be provided in one or both of the components. In addition, welding does not typically involve the use of stitching or adhesives, but involves directly bonding the components to one another by heat. However, in some cases, stitching or adhesives may be used to supplement the welds or connections of the components by welding.

Various heating techniques may be used to weld the components to each other. In some embodiments, suitable heating techniques may include conduction heating, radiation heating, high frequency heating, laser heating, or combinations of these techniques. In some embodiments, the welding process used to join portions of the upper may include a high frequency welding process, such as ultrasonic welding or Radio Frequency (RF) welding.

In embodiments where a high frequency welding process is used to form a weld in the upper, the upper material may be any material suitable for such a process. For example, materials suitable for high frequency welding may include thermoplastic materials or natural materials coated with thermoplastic materials. Examples of materials suitable for the high frequency welding process include acrylic, nylon, polyester, polylactic acid, polyethylene, polypropylene, polyvinyl chloride (PVC), urethane, natural fibers coated with one or more thermoplastic materials, and combinations of these materials. In some embodiments, natural fibers such as cotton or wool may be coated with a thermoplastic material such as ethylene vinyl acetate or thermoplastic polyurethane.

The use of welding may provide a number of advantages over the use of adhesives or stitching. For example, the use of welding may result in a lighter weight shoe due to the absence of stitching and adhesives. By eliminating stitching and adhesives, the substances that would otherwise be imparted by stitching and adhesives may be used for other structural elements that enhance performance attributes of the article of footwear, such as cushioning, durability, stability, and aesthetic properties. Another advantage relates to manufacturing efficiency and expense. Stitching and the application of adhesive can be a relatively time consuming process. By welding the components, the manufacturing time can be shortened. In addition, costs may be reduced by eliminating the expense of adhesive or stitching materials. In addition, welding (i.e., without the use of adhesives or stitching to join the materials) may protect the flexibility of the upper of the article of footwear, as adhesives and stitching may increase the stiffness of the upper material. The flexibility of the upper may conform the upper to the foot of the wearer, thereby providing an improved fit. The flexible upper may also provide improved comfort by conforming to the foot of the wearer. In some embodiments, the skin may be a mesh skin. In portions of the upper, the mesh surface layer may remain unreinforced, allowing for directional ventilation through the upper. That is, in the unreinforced portion, the skin layer may have an outwardly exposed outer surface and an inwardly exposed inner surface. Thus, in such embodiments, the openings in the unreinforced surface mesh may allow for ventilation through the upper. In addition to ventilation, the openings in the mesh skin may also provide other advantages, such as reduced weight, flexibility, and other advantages. In some embodiments, in the unreinforced portion of the skin, the upper may consist essentially of the skin, and thus may not include any additional layers. In some areas, a grid may be provided in the panels extending between the reinforcing panels, the grid and reinforcing panels being connected only at abutting edges, e.g. with minimal overlap.

Upper 110 may include a skin layer 185 that forms at least a portion of an exterior surface of upper 110. Upper 110 may also include reinforcing material 190 selectively located on an interior and proximate portions of skin layer 185, thereby defining a reinforced portion 195 of skin layer 185 and an unreinforced portion 200 of skin layer 185. As shown in fig. 1, the enhanced portion 195 may include a plurality of striped line portions (striped line portions). For example, reinforcing portion 195 may include a first reinforcing portion 301, a second reinforcing portion 302, a third reinforcing portion 303, a fourth reinforcing portion 304, a fifth reinforcing portion 305, a sixth reinforcing portion 306, and a seventh reinforcing portion 307. The arrangement of the reinforced 195 and unreinforced 200 portions is discussed in more detail below.

In some embodiments, reinforcing material 190 may be selectively coupled to skin layer 185. For example, the reinforcing material 190 may be selectively joined to the skin layer 185 at the bonding region 205 by welding. As shown in fig. 1, bonded region 205 may have an outer exposed surface that defines a portion of an exterior surface of upper 110.

The reinforcing material 190 may provide advantages with respect to various characteristics such as strength, durability, support, stability, and other attributes. In some embodiments, reinforcing material 190 may be a material having substantially the same or greater tensile or puncture strength than skin layer 185 as compared to skin layer 185. Accordingly, in some embodiments, reinforcing material 190 may provide increased strength to upper 110 at selected areas. In some embodiments, the reinforcing material 190 may be a material having a greater abrasion resistance than the skin layer 185. In such embodiments, reinforcing material 190 may provide increased durability to upper 110. In some embodiments, the reinforcing material 190 may have the same elasticity as the skin layer 185 or lower than the skin layer 185. In such embodiments, the reinforcing material 190 may provide additional support and stability to the wearer, for example by limiting the amount that the skin layer 185 may stretch in the reinforced portion 195.

In some embodiments, portions of upper 110 may include one or more additional layers/components for reinforcement, support, padding, and stability. For example, in some embodiments, upper 110 may include one or more panels affixed to an exterior of skin layer 185 or adjacent to skin layer 185. The reinforcing tape 150 is one example of such an additional layer/component. Further, as shown in fig. 1, upper 110 may include a heel panel 210. Additionally or alternatively, in some embodiments, upper 110 may include toe panel 215. In some embodiments, additional panels of material, such as heel panel 210 and toe panel 215, may be welded to skin layer 185. The heel panel 210 and the toe panel 215 may provide additional protection to the foot of the wearer. Additionally, heel panel 210 and toe panel 215 may provide additional durability to upper 110. Additionally, in some embodiments, heel panel 210 and toe panel 215 may provide additional stability to footwear 100. Additionally, the heel panel 210 and the toe panel 215 may be configured to provide an aesthetic appearance.

In some embodiments, the mesh surface layer may be a full-length layer. That is, skin layer 185 may extend throughout all or substantially all of upper 110. In such embodiments, additional layers, such as heel panel 210 and toe panel 215, may be adhered to the outer surface of skin layer 185. In other embodiments, additional weight may be saved by using skin layer 185 only in areas of footwear 100 where skin layer 185 is exposed, for example, between heel panel 210 and toe panel 215.

In some embodiments, padding may be included in one or more portions of the upper to provide comfort and a snug fit against the contours of the foot. For example, in some embodiments, ankle region 220 of upper 110 proximate opening 135 may include a compressible padding, such as a foam padding, to provide cushioning and a snug fit against the wearer's ankle.

Fig. 2 is an exploded view of footwear 100 shown in fig. 1. Figure 2 illustrates a sole structure 105 and various components that may form an upper. For example, skin 185 is shown. Skin layer 185 is shown as a full length skin layer in fig. 2.

In some embodiments, as shown in fig. 2, heel panel 210 and toe panel 215 may be fixedly attached to an outer surface of skin 185. Such fixed attachment may be by welding. However, it should be noted that, as discussed above, in some embodiments, skin layer 185 may be less than a full length layer and instead may extend between additional panel components, such as heel panel 210 and toe panel 215. In such embodiments, the heel panel 210 and the toe panel 215 may only minimally overlap the skin 185, e.g., abutting the edges of each panel at the perimeter. The shape and size of the heel panel 210 and the toe panel 215 may vary depending on desired performance characteristics such as weight, foot protection, durability, aesthetic design, and other such characteristics. In addition, the materials from which the heel panel 210 and the toe panel 215 may be formed may vary according to the same or similar desired performance characteristics.

Fig. 2 shows the strip of reinforcing material 190 in a separated state. These strips may be placed against the inner surface of the skin layer 185. The placement of the reinforcing material in footwear 100 will be discussed in more detail below.

Additional panels may also be provided around the throat opening of footwear 100. For example, an interior lining panel (lnnerline panel)191 and a reinforced collar panel 192 may be disposed inside the skin layer 185. However, in some embodiments, reinforcing collar panel 192 may be disposed on the exterior of skin layer 185. Fig. 2 also shows a foam collar piece 193 that may be disposed between the inner liner panel 191 and the reinforcing collar panel 192. Foam collar piece 193 can be a compressible member that can conform to the contours of the foot near the ankle, thereby improving fit and comfort. Such a compressible foam collar piece 193 may also provide protection for the ankle against impact and displacement of footwear 100 due to loads experienced during athletic activities.

As further illustrated in FIG. 2, the tongue 800 may include multiple components. For example, as shown in fig. 2, the tongue 800 may include a grip portion 875 that may form an outer surface of an upper portion of the tongue 800. The grip portion 875 may provide a suitable area for gripping the tongue 800 when the footwear 100 is worn on a foot. In addition, the grip portion 875 can provide a location to display indicia such as a trademark or other graphic or text. Additionally, tongue 800 may include a skin layer 885. Skin layer 885 may be formed from the same or similar materials as skin layer 185, such as a mesh material. In some embodiments, skin layer 885 may form a substantial majority of the outer surface of tongue 800. That is, the area of skin layer 885 not covered by grip portion 875 may form a substantial majority of the outer exposed surface of tongue 800. As shown in fig. 2, skin layer 885 may extend the full length of tongue 800, and thus, grip portion 875 may overlap skin layer 885. However, in some embodiments, the skin layer 885 and the grip portion 875 can be connected at their peripheral edges, and thus may not overlap or may overlap minimally. This may save weight by reducing the amount of skin material used to form tongue 800.

As shown in FIG. 2, tongue 800 may also include a plurality of foam pads 880 and a liner 890. The foam pad 880 may be disposed between the skin layer 885 (or grip portion 875) and the liner 890. Foam pad 880 may be compressible and, as a result, may provide comfort and improved fit in the instep area of footwear 100. Liner 890 may be formed from a material suitable for contacting the skin of a wearer's foot or a foot covered with a sock. Liner 890 may thus be formed from a material that enables a foot covered with a sock to slide in and out of footwear 100 with minimal effort. In addition, liner 890 may also have moisture-wicking properties that wick moisture from the foot of the wearer.

The layers of tongue 800 may be attached using one or more attachment techniques, such as welding, stitching, thermal bonding, or other suitable construction methods. Additional details of the construction of the tongue 800 will be discussed below with respect to FIGS. 12-14.

In some embodiments, the skin layer may be exposed over a relatively large area of the upper. Accordingly, the reinforcing material and the bonded regions where the reinforcing material is bonded to the skin layer may be used to enhance the span of the skin layer between other footwear components. That is, a strip of reinforcing material may extend between the shoe components. Similarly, the bonded regions may include lines of bonding material extending between components of the article of footwear. For example, the strips of reinforcing material and the lines of bonded regions may extend from a midsole of the article of footwear to the reinforcing strips proximate a lace region of the article of footwear. Such a configuration may provide structural support in a generally vertical direction. In some embodiments, however, the strands of the bands and bonded regions may be angled to strategically reinforce the upper in certain directions and orientations.

In some embodiments, first reinforcing portion 301 may extend from reinforcing band 150 to sole structure 105, e.g., to midsole 160, as shown in fig. 3. As first reinforcing portion 301 approaches midsole 160, first reinforcing portion 301 may extend not only in the vertical direction but also in the forward direction. The angle of inclination of the first reinforcing portion 301 may provide structural support in the fore-aft direction. For example, first reinforced portion 301 may act in tension to resist forces that tend to translate upper 110 in a rearward direction with respect to sole structure 105. Such forces may be generated, for example, when an athlete accelerates in a forward direction. In addition, first reinforcing portion 301 may also span between reinforcing strip 150 and toe portion 215, thereby providing further reinforcement to upper 110 by connecting the skeletal structure of upper 110.

Second reinforcing portion 302 may also extend from reinforcing band 150 to midsole 160, as shown in fig. 3. Further, second reinforced portion 302 may extend in a generally vertical direction when viewed from the side of footwear 100. Additionally, second reinforced section 302 may be connected to reinforcing strip 150 proximate to first reinforced section 301.

Third reinforcing portion 303 may extend from reinforcing band 150 to midsole 160, as shown in fig. 3. As third reinforcing portion 303 approaches midsole 160, third reinforcing portion 303 may extend not only vertically but also in a rearward direction. The angle of inclination of the second reinforcement portion 303 may provide structural support in the fore-aft direction. For example, third reinforcing portion 303 may act in tension to resist forces that tend to translate upper 110 in a forward direction relative to sole structure 105. Such forces may be generated, for example, when an athlete slows or stops their forward movement. Additionally, a third reinforcing portion 303 may be connected to reinforcing strip 150 proximate to second reinforcing portion 302.

Each of first reinforcing portion 301, second reinforcing portion 302, and third reinforcing portion 303 may be connected to reinforcing strip 150 adjacent to one another and provide supportive reinforcement in different directions (front, back, and vertical). This may aid in the stability of footwear 100 by maintaining the relative position of upper 110 with respect to sole structure 105. In some embodiments, first reinforcement portion 301, second reinforcement portion 302, and third reinforcement portion 303 may be connected to reinforcement band 150 adjacent to one another in a forefoot portion of footwear 100, for example, in a region corresponding with a first metatarsal head and a first metatarsophalangeal joint. The joint is the flexion point of the forefoot. Accordingly, it may be advantageous to maintain the positioning of upper 110 relative to sole structure 105 in this articulation region. This may promote comfort, fit, and performance of footwear 100.

First reinforced portion 301, second reinforced portion 302, and third reinforced portion 303 are strategically positioned on the lateral and medial sides of footwear 100 in the orientations discussed above to provide fore-aft stability in the first metatarsophalangeal joint region, which may allow first unreinforced region 311 in the forefoot region to relatively widely span the unreinforced skin. This may provide additional ventilation and reduce weight.

Fourth reinforcing portion 304 and fifth reinforcing portion 305 may extend from reinforcing band 150 to midsole 160, as shown in fig. 3. Additionally, fifth reinforcing portion 305 may be connected to reinforcing band 150 proximate fourth reinforcing portion 304 and may separate as fourth reinforcing portion 304 and fifth reinforcing portion 305 approach midsole 160. Also, sixth reinforcing portion 306 and seventh reinforcing portion 307 may be arranged similarly to fourth reinforcing portion 304 and fifth reinforcing portion 305, i.e., in an inverted "V" shape. This inverted "V" shape may provide structural support in a manner similar to the first reinforcing portion 301, second reinforcing portion 302, and third reinforcing portion 303 discussed above.

It should also be noted that an arrangement in which the upper ends of the reinforcing portions converge at different regions of reinforcing band 150 and diverge proximate midsole 160 may result in a structural connection between reinforcing band 150 and diverging proximal midsole 160 despite the different lengths of these two components. That is, reinforcing strips 150 have a first length that corresponds with the lace region, while midsole 160 has a second length that extends the full length of footwear 100, and thus the second length is longer than the first length of reinforcing strips 150.

In other embodiments, the reinforced portions of upper 110 may have other arrangements to provide strength, support, durability, and other performance characteristics. For example, in some embodiments, the reinforcing portions may be disposed between various components of footwear 100 in an "X" configuration, rather than an inverted "V" arrangement. Other arrangements are possible depending on where the performance advantage needs to be enhanced.

By strategically placing the reinforced portions of upper 110, a relatively large portion of the surface area of upper 110 may be formed from an unreinforced skin. For example, in addition to the first non-reinforced part 311, the second non-reinforced part 312 may be disposed between the first reinforced part 301 and the second reinforced part 302. In addition, a third unreinforced portion 313 may be disposed between the second reinforced portion 302 and the third reinforced portion 303. A fourth non-reinforced section 314 may be disposed between the third reinforced section 303 and the fourth reinforced section 304. Further, a fifth unreinforced portion 315 may be disposed between the fourth reinforced portion 304 and the fifth reinforced portion 305. Also, a sixth unreinforced portion 316 may be disposed between the fifth reinforced portion 305 and the sixth reinforced portion 306. Seventh unreinforced portion 317 may be disposed between sixth enhanced portion 306 and seventh enhanced portion 307. And eighth unreinforced portion 318 may be disposed between seventh reinforced portion 307 and ankle region 220.

Additional unreinforced portions similar to second unreinforced portion 312, third unreinforced portion 313, fourth unreinforced portion 314, fifth unreinforced portion 315, sixth unreinforced portion 316, seventh unreinforced portion 317, and eighth unreinforced portion 318 may be provided on opposite sides of footwear 100. Thus, in some embodiments, the medial and lateral sides of upper 110 may be generally mirror images according to the arrangement of the reinforcing material. In some embodiments, the common surface area of the unreinforced portions may form a substantial majority of the surface area of the exposed surface layer.

Moreover, in some embodiments, the common surface area of the unreinforced portions may make up a substantial majority of the surface area of upper 110. By providing a relatively large portion of upper 110 unreinforced, upper 110 may provide ventilation, flexibility, and weight reduction.

In some embodiments, welding may be used not only for connecting components but may also change the appearance of those components by changing the surface color of exterior portions of the footwear upper. For example, in some embodiments, the unreinforced skin layer may have a first color. As discussed in more detail below, the skin may be a mesh material, and thus, portions of the underlying reinforcing material may be revealed through openings in the mesh skin. If the reinforcing material has a second color that is different from the first color of the skin, the appearance of the reinforced portion of the skin can have a third color that is a blend of the first color of the skin and the second color of the reinforcing material. In addition, the bonded area where the reinforcing material is bonded to the skin layer may have a fourth color. This fourth color may be substantially the same as the second color of the reinforcement material, as the skin may become embedded in the reinforcement material during the welding process. However, in some embodiments, the bonded region may have a first color of the skin and a second color blended color of the reinforcement material. In addition, other portions of the footwear may have a fifth color, which may be the same as or different from other components of the footwear. The difference in color may be used for aesthetic design purposes. Further, by color arrangement, color differences may be used to show different structural aspects of footwear construction.

The unreinforced skin layer may have a first color. For example, as shown in fig. 3, the first non-enhanced portion 311, the second non-enhanced portion 312, the third non-enhanced portion 313, the fourth non-enhanced portion 314, the fifth non-enhanced portion 315, the sixth non-enhanced portion 316, the seventh non-enhanced portion 317, and the eighth enhanced portion 318 may have a first color, which is simply represented as a grid in fig. 3. Although not shown exposed in fig. 3, the reinforcing material may have a second color. For purposes of discussion, fig. 3 illustrates a configuration in which the second color of the reinforcing material is substantially the same as the fifth color of other footwear components, such as heel panel 210, toe panel 215, and reinforcing strips 150, which are shown in relatively dark stippling.

The appearance of the enhanced portion of the skin layer may have a third color blended from the first color of the skin layer and the second color of the enhancement material. For example, as shown in fig. 3, first enhancement section 301, second enhancement section 302, third enhancement section 303, fourth enhancement section 304, fifth enhancement section 305, sixth enhancement section 306, and seventh enhancement section 307 may have a third color that is intermediate between the first color of the skin layer and the second color of the enhancement material. Thus, first enhancement section 301, second enhancement section 302, third enhancement section 303, fourth enhancement section 304, fifth enhancement section 305, sixth enhancement section 306 and seventh enhancement section 307 are shown using medium-darkness stippling.

In addition, the bonded region 205 where the reinforcing material is bonded to the skin layer may have a fourth color. The fourth color may be substantially the same as the second color of the reinforcement material. Thus, the bonded regions 205 are shown in FIG. 3 as having relatively dark stippling. By welding the reinforcing material to the skin layer, the outer exposed surface of the bonded region 205 may be given a fourth color different from the first color. It should be noted that in some embodiments, the additional layers/components discussed above, such as reinforcing band 150, heel panel 210, and toe panel 215, may be formed from the same or similar materials as reinforcing material 190. For example, all of these components may be formed of a relatively lightweight fabric. In some embodiments, the lines of bonded regions 205 may match in color with other footwear components to provide various ornamental appearances. In some embodiments, one or more footwear components may have a color different than the reinforcing material and bonded regions 205 to provide a different visual appearance.

The welding process may change the apparent color of the exterior surface of upper 110 by repositioning portions of the reinforcing material to the exterior surface of upper 110. For example, the welding process may involve melting of the reinforcement material 190 such that the reinforcement material flows between the fibers of the skin layer 185 (e.g., through openings in the skin mesh material) from the inside of the skin layer 185 to the outer exposed side of the skin layer 185. Thus, the outer exposed surface of bonding region 205 may include portions of the reinforcing material, thereby providing the outer exposed surface of bonding region 205 with substantially the same color as the reinforcing material. The mechanism by which the portions of reinforcing material are repositioned will be explained in more detail below.

Although the color of footwear 100 is shown in fig. 3 as a different shade of gray, it should be understood that the components of footwear 100 may have any suitable color. Further, the difference in color between the parts may be given colors of varying shades, such as dark red and light red. In addition, blending of colors can produce not only colors of varying shades but also completely different colors. For example, in some embodiments, a yellow skin layer may be combined with a blue enhancement material to form an enhanced portion or combined area having a green appearance.

Fig. 4 shows a perspective view through opening 135 into cavity 130 within upper 110 of footwear 100. Fig. 4 shows an insole 225 and shows a strip of reinforcing material 190 extending upwardly from beneath the insole 225. As shown in fig. 4, portions of skin layer 185 are exposed inwardly between the strips of reinforcing material 190. Thus, these unreinforced portions of skin layer 185 are exposed both externally and internally. Thus, in some embodiments, when skin layer 185 may be a mesh material, unreinforced portions of skin layer 185 may provide direct ventilation through skin layer 185 to interior cavity 130 defined by upper 110.

Fig. 5 is an enlarged view of a portion of fig. 4, showing an interior surface of upper 110. As shown in fig. 5, unreinforced portion 196 (e.g., sixth unreinforced portion 316, seventh unreinforced portion 317, and eighth unreinforced portion 318) may be disposed between reinforced portions 190 (e.g., sixth reinforced portion 306 and seventh reinforced portion 307). The reinforcing portion may be welded to the skin layer, for example, in a first bonded area 321, a second bonded area 322, a third bonded area 323, and a fourth bonded area 324. It should be noted that the first, second, third and

fourth bonding areas

321, 322, 323 and 324 are shown in fig. 5 as having the same color as the reinforcing material. Because fig. 5 shows the medial side of upper 110, the skin is not shown because the skin is not internally exposed proximate the bonded area. Thus, the bonded areas may have the same color as the reinforcement material on the medial side of upper 110.

It should also be noted that in some locations, two bonded regions may be joined to form a more complex pattern. For example, as shown in fig. 5, second bonded region 322 and third bonded region 323 may converge to form an inverted "V" arrangement. This attachment of the bonded areas may provide a structural connection between the skeletal elements of upper 110. Furthermore, in some embodiments, sixth reinforcing portion 306 and seventh reinforcing portion 307 may be formed from separate strips of reinforcing material. In such an embodiment, connecting the bonded regions that secure the individual strips to the skin layer may provide a structural connection between the individual strips, creating a truss-like structure.

Fig. 6 and 7 illustrate in greater detail the structure of the reinforced portion of upper 110. The arrangement of skin layer 185, reinforcing material 190, and bonded areas 205 is shown in more detail in fig. 6, which shows an enlarged view of one of the striped areas of upper 110 created by reinforced portion 195 of skin layer 185. As shown in fig. 6, the skin layer 185 may be formed of a mesh material. As shown in the enlarged view portion of fig. 6, skin 185 may include a plurality of openings 230, which may provide weight reduction and ventilation. In unreinforced portion 200, opening 230 may provide direct ventilation to the interior of footwear 100. In certain embodiments, the mesh material may have more than 50% open area (e.g., more than 50% of the material surface area includes open spaces through which air may freely flow from one side to the other).

In a substantial portion of reinforcing portion 195, reinforcing material 190 may be visible behind skin 185 through opening 230. In a substantial portion of the reinforced portion 195, the reinforcing material 190 may remain adjacent to but separated from the skin material 185. In selected portions of reinforcing portion 195, reinforcing material 190 may be attached to skin layer 185 to form bonded regions 205. It should be noted that the unreinforced portion 200 of the surface layer 185 is presented in a generally white color, while the enhanced portion 195 is presented in a generally gray color due to the combination of the black reinforcing material 190 and the white grid of the surface layer 185. Bonded areas 205 still appear darker because no white grid lines interfere with the dark color of reinforcing material 190 in bonded areas 205.

It should be noted that in the figures the skin material is shown in a relatively simple grid representation. These grid representations are merely schematic and are provided in this manner for convenience and to avoid obscuring the drawings with excessive detail. However, the actual material used for the surface mesh, examples of which are provided below, may have a relatively simple square or rectangular grid structure, similar to that shown in the figures. The orientation of the grid may vary. Furthermore, in some embodiments, other more complex grid structures may be used for the mesh material of the skin layer. In addition, the size of the grid openings may also vary. The configuration of the surface layer mesh may be selected based on desired performance characteristics, including weight, strength, puncture resistance, ventilation, and other attributes.

In at least some embodiments, the mesh material of skin layer 185 can be a single layer warp knit fabric (or other type of woven material) having an open structure and can be formed from nylon, polyester, nylon/polyester blends, recycled polyethylene terephthalate (rePET), or other materials. However, the mesh material of the skin layer 185 may be made of any desired material, having any desired mesh opening size. Reinforcing material 190 may be any suitable material including fabrics, textiles, braids, knits, and other such materials. Reinforcing material 190 may be a material that is adhesively compatible with skin layer 185 and other materials of the footwear. In some embodiments, the reinforcing material 190 may be a material that is adhesively compatible with the skin layer 185 during welding. Suitable materials may include crystalline or semi-crystalline materials. In some embodiments, such materials may include thermoplastics. For example, suitable materials may include polyalkylenes such as polyethylene and polypropylene. Other materials may also be suitable for use as the reinforcing material, such as nylon, polyester, and other such materials. In some embodiments, the reinforcement material 190 may be configured to melt under welding and thereby flow through the openings 230 in the mesh of the skin layer 185, resulting in the skin layer 185 being embedded within the reinforcement material 190 in the bonded area. In other embodiments, the skin 185 and the reinforcing material 190 may be configured to slightly melt and adhesively attach to each other during welding (without the skin 185 becoming embedded). In some embodiments, the reinforcement material may melt slightly, causing the mesh of the skin layer 185 to become partially embedded in the reinforcement material 190 during welding. In such embodiments, the reinforcing material 190 and the skin layer 185 may rely not only on a partially embedded structure but also on an adhesive bond created by partial melting of the reinforcing material. To achieve welding, the reinforcing material may have the same melting point as the skin layer or a lower melting point than the skin layer. This may cause the reinforcing material to melt and flow through the openings in the mesh while the fibers of the mesh remain substantially intact.

As shown in fig. 6, bonded regions 205 may span one or more openings 230. Further, the amount of reinforcement 195 in which reinforcing material 190 is secured to skin layer 185 may vary. That is, the ratio of bonding region 205 to reinforcing portion 195 may vary from a lower ratio such as 1: 20 to higher levels such as 19: 20. in some exemplary embodiments, the bands on the medial and lateral sides of upper 110 may have a ratio of bonded area 205 to reinforcing portion 195 of about 1: 3. for example, as shown in fig. 6, the combined width of bonded regions 205 may be approximately one-third of the overall width of reinforcing portion 195.

Because skin layer 185 is bonded directly to reinforcing material 190, the combined strength of mesh skin layer 185 and reinforcing material 190 may obviate the need for another material on the lateral or medial surface of upper 110 to provide tensile strength, puncture strength, durability, stability, or other performance characteristics. This allows upper 110 to be lighter than various conventional shoe construction techniques that may be used.

Openings 230 in the skin 185 allow air to flow through. This air flow helps cool and dry the foot of the wearer of footwear 100. In some embodiments, skin layer 185 may be the only layer of upper 110 in certain portions of upper 110. However, in other embodiments, additional reinforcing materials may be used. For example, reinforcing material 190 may be selectively located in various portions of skin layer 185, and additional internal reinforcing material may provide more comfort and moisture control (e.g., to drain moisture away from the foot). This additional inner liner (not shown) may extend over the otherwise unreinforced portion of the skin 185 in other ways. In some embodiments, this additional inner liner may be a relatively breathable material, and thus may preserve the ventilation benefits of the mesh skin 185.

Fig. 7 is a cross-sectional view of upper 110 taken at line 7-7 in fig. 6. As shown in fig. 7, upon welding, a bond region 205 may be created by embedding the mesh fibers of the skin layer 185 into the reinforcing material 190. The fibers of the surface layer 185 may melt to a greater or lesser extent during the welding process. Thus, in some embodiments, the fibers of skin layer 185 may remain substantially intact when bonded regions 205 are formed. In other embodiments, the fibers of the skin layer 185 may be substantially melted and mixed with the reinforcing material 190. In some cases, it may be desirable for the fibers of the skin layer 185 to remain substantially intact in order to maintain the strength and durability of the skin layer 185. In some embodiments, the fibers of the skin layer 185 may be slightly deformed, as shown in fig. 7. This slight deformation, which may be due to slight melting, may improve the bond between the fibers of the skin layer 185 and the reinforcement material 190 while substantially protecting the tensile strength of the skin layer 185 as the fibers of the skin layer 185 remain substantially intact.

Fig. 7 also illustrates deformation of the reinforcing material 190 in the bonding region 205. Such deformation may be created by the heat and pressure applied by the welding process, which may compress the reinforcing material 190. In addition, fig. 7 also shows reinforced portions 195 where the reinforcing material 190 extends below the skin layer 185 and unreinforced portions 200 where the reinforcing material 190 does not extend.

Fig. 8 provides a schematic illustration of an alternative configuration of the mesh material of the skin layer. For example, fig. 8 shows a mesh skin 700 backed by a reinforcing material 705 in a reinforcing portion 730. The reinforced portion 730 extends to the edge 710 of the reinforcing material 705. In addition, reinforcing material 705 is welded to skin layer 700 in first bonded region 720 and second bonded region 725.

As shown in fig. 8, the mesh of the skin 700 may have a hexagonal structure. Such a hexagonal structure may provide improved strength and inelasticity in multiple directions compared to a square or rectangular grid structure. Meshes having grids with other geometric configurations may also be used. For example, the skin layer may be formed from a mesh material having a triangular or octagonal structure. Various shapes may be selected to provide desired performance characteristics, such as directional strength and non-elasticity.

Although the mesh of the skin layer is shown as having a substantially two-dimensional structure, in some embodiments, the mesh may have a three-dimensional structure. For example, in some embodiments, the skin layer may be comprised of a spacer grid or spacer fabric. Three-dimensional lattice structures can provide more complex and tailored performance characteristics such as oriented tensile strength and inelasticity, as well as puncture strength, abrasion resistance, and ventilation.

Some embodiments may use one or more Spacer grid or Spacer fabric Materials, discussed in U.S. patent application publication No. 2013/0266773 to Hazenberg et al, published 10/2013, entitled "Spacer Textile Materials And Methods for Manufacturing The Spacer Textile Materials," And U.S. patent application publication No. 2013/0263391 to Chao et al, published 10/2013, entitled "Methods for Manufacturing Fluid-Filled Chambers Incorporating Spacer Textile Materials. The entire disclosures of these two patent applications are incorporated herein by reference in their entirety. In some embodiments, a double needle bar raschel knit or other three-dimensional knit may be used to form the mesh material of the skin layer. Exemplary Three-dimensional knitting that may be used include double needle bar raschel knitting, which is disclosed in Bruer et al, Three-dimensional Knit Spacer Fabrics: a review of Production Techniques and Applications, journal of technology and management, summer 4, 2005, the entire disclosure of which is incorporated herein by reference.

In some embodiments, a bonded mesh composite panel of an upper may be created by assembling separate panels of material for the various layers into a flat configuration. The panels and other elements are assembled so as to have an arrangement in which the relative positions of the panels and elements correspond to the positions that those panels and elements will have in the finished shoe. After the individual panels and other elements are assembled into a suitable arrangement and the assembly is tack welded (tacking) at a plurality of locations, the assembly is subjected to a series of pressing operations to bond the assembled elements. These operations result in a flat, one-piece, unitary upper shell that can house many or all of the elements to be included in the finished upper. The edges of the one-piece upper shell may then be joined to create a three-dimensional upper body ready for further finishing and attachment with the midsole. Some embodiments may use one or more assembly procedures disclosed in U.S. patent application publication No. 2012/0297643, entitled "Shoe with composition upper and Method of Making the Same", published by Shaffer et al, 11/29/2012, the entire disclosure of which is incorporated herein by reference. Additionally, some embodiments may use one or more of the Shoe assembly methods disclosed in (a) U.S. patent application publication No. 13/029,502 to Dojan et al, entitled "Shoe with Composite Upper and foamElement and Method of Making Same," filed 2011.2.17, (b) U.S. patent application publication No. 2011/0088285 to Dojan et al, entitled "Composite Shoe Upper and Method of Making Same," filed 2011.4.21, (c) U.S. patent application publication No. 2011/0088282 to Dojan et al, entitled "Composite Shoe Upper and Method of Making Same," filed 2011.4.21. Each of these applications listed above is incorporated by reference in its entirety.

Fig. 9-11 illustrate an exemplary ultrasonic welding process in more detail. As shown in fig. 9, skin 185 and reinforcement 190 (or other components of the upper) may be ultrasonically welded on anvil (anvil) 235. The anvil 235 may be a relatively rigid body upon which the components may be ultrasonically welded. In some embodiments, the anvil 235 may be a relatively flat surface, such as a table. In other embodiments, the anvil 235 may be a last on which the article of footwear may be assembled. The schematic illustrations of fig. 9-11 are intended to encompass the general use of an anvil, and thus are not specific to any particular anvil configuration.

As further shown in fig. 9, an ultrasonic horn 240 may be provided to effect ultrasonic welding. As shown in fig. 10, the ultrasonic horn 240 can compress the skin 185 and the reinforcement material 190 against the anvil 235. In addition, the ultrasonic horn 240 may vibrate at ultrasonic frequencies, as represented by vibration lines 245. This ultrasonic vibration may generate friction, which may generate heat that, along with the pressure of the ultrasonic horn 240, presses against the anvil 235, which may at least partially melt a portion of the reinforcement material 190. As a result of this melting, the fibers of skin layer 185 may become embedded within reinforcing material 190, effectively repositioning portions of reinforcing material 190 to the exterior surface of the upper, thereby forming bonded areas 205, as shown in fig. 11.

Using the techniques schematically illustrated in fig. 9-11, a method of manufacturing an article of footwear may be presented. The method may include forming an upper configured to receive a foot of a wearer. Forming the upper may include selectively attaching interior reinforcing material 190 to skin layer 185 using ultrasonic welding. (in some embodiments, other welding techniques may be used.) the method may also include positioning skin layer 185 to form at least a portion of an exterior surface of the upper. Ultrasonic welding of interior reinforcing material 190 to skin layer 185 may form a bonded region 205 having an outer exposed surface that defines a portion of the exterior surface of the upper. In certain embodiments, skin layer 185 may have a first color and reinforcing material 190 may have a second color different from the first color.

The outer exposed surface of bonding area 205 may form a portion that includes reinforcing material 190, thereby providing the outer exposed surface of bonding area 205 with a different color than skin layer 185. For example, ultrasonic welding of interior reinforcing material 190 to skin layer 185 to form bonded regions 205 may reposition portions of reinforcing material 190 to the exterior surface of the upper at the outer exposed surface of bonded regions 205, thereby providing the outer exposed surface of bonded regions 205 with the same color as reinforcing material 190. In some embodiments, repositioning portions of reinforcing material 190 to the exterior surface of the upper may include pressing portions of reinforcing material 190 through the openings in the mesh material of skin layer 185. Further, selectively attaching the internal reinforcing material 190 to certain portions of the skin layer 185 may form reinforced portions of the skin layer 185, leaving unreinforced portions of the skin layer 185 to provide direct ventilation to the interior cavity defined by the upper through the mesh material of the skin layer 185.

Ultrasonically welding inner reinforcing material 190 to skin layer 185 to form bonded regions 205 may include forming lines of bonding material extending between components of the article of footwear. For example, forming the line of bonding material may include forming a line of bonding material that extends from a sole structure of the article of footwear to a reinforcing strip proximate an instep region of the article of footwear.

To form the bonded material lines, a needle-shaped ultrasonic horn 240 may be moved in a desired pattern. In other embodiments, the ultrasonic horn 240 may be an elongated structure formed in a desired pattern. Such an elongate ultrasonic horn may simply extrude material to be welded and ultrasonically vibrationally activated. Some embodiments may use one or more ultrasonic welding techniques of the elongated horn discussed in U.S. patent application publication No. ________ to Beye et al (U.S. patent application No. 13/741,428 (attorney docket No. 51-2687) entitled "Spacer Textile Material with Textile Strand and living multiple entry and Exit Points," filed 2013, 1, 15, and the entire disclosure of which is incorporated herein by reference) published at ________.

In some embodiments, an example article of footwear may include an additional layer of material located between a portion of the skin layer and a portion of the reinforcement material. For example, additional layers of material may include compressible foam materials that may provide comfort, protection, and a snug fit. Such a compressible foam layer may be provided, for example, in a tongue portion of an upper of an article of footwear. The lines of bonded regions may enclose a pocket between the skin and the reinforcing material, and a compressible foam layer may be disposed in the pocket. In some embodiments, a plurality of compressible foam pads may be provided adjacent to one another. For example, a plurality of compressible foam pads may be separated by lines of bonded areas. Such an arrangement may create a quilted structure (a quilted configuration) that may provide comfort to an instep region of the footwear.

Fig. 12 shows a view of footwear 100 with tongue 800 generally exposed. As shown in fig. 12, upper 110 may include a tongue 800, and tongue 800 may be formed from multiple layers that may be joined using welds or stitching. For example, a plurality of bonded regions 805 may be provided in the form of lines for selectively attaching reinforcing material 190 to skin layer 885. Additionally, stitching 840 may secure reinforcing material 190 to skin layer 885 in certain portions of tongue 800, such as peripheral edges, as shown in fig. 12.

As further shown in fig. 12, in some embodiments, footwear 100 may include an additional layer of material located between a portion of skin layer 885 and a portion of reinforcing material 190. For example, the additional layer of material may comprise a compressible foam material. As shown in fig. 12, first pocket 810 between skin 885 and reinforcing material 190 may house first foam pad 815. First pocket 810 may be surrounded by a plurality of bonded area lines defining a polygonal pocket. For example, as shown in fig. 12, first bonded area line 820, second bonded area line 825, third bonded area line 830, and fourth bonded area line 835 may enclose first pocket 810.

Additionally, at least one additional foam pad may be provided in tongue 800. For example, a second foam pad 845 may be disposed in second pocket 850. Second pocket 850 may be surrounded by fifth bonded area line 855, sixth bonded area line 860, seventh bonded area line 865, and fourth bonded area line 835. First foam pad 815 and second foam pad 845 may be disposed generally adjacent to one another, thereby forming a generally quilted configuration.

Fig. 13 shows a cross-sectional view taken along line 13-13 of fig. 12. As shown in fig. 13, first foam pad 815 may be disposed within first pocket 810 between skin 885 and reinforcing material 190. Likewise, foam pad 845 may be disposed within second pocket 850. As shown in fig. 12, second bonded area line 825 and third bonded area line 830 define the boundary of first pocket 810. Likewise, sixth bonded area line 860 and seventh bonded area line 865 define boundaries of second pocket 850.

Fig. 14 shows a cross-sectional view taken along line 14-14 of fig. 12, line 14-14 being generally perpendicular to line 13-13 along which the cross-section in fig. 13 is taken. As shown in fig. 14, tongue 800 may include, in addition to first foam pad 815, a third foam pad 846 and a fourth foam pad 847 disposed between liner 890 and skin layer 885. In some embodiments, liner 890 may be formed from reinforcing material 190. Thus, liner 890 may provide structural support to tongue 800.

As shown in fig. 14, reinforcing material 190 may be attached to skin layer 885 to form a plurality of bonded regions. For example, reinforcing material 190 may be welded to skin layer 885 to form eighth bonded area line 901 and ninth bonded area line 902. Eighth bonded area line 901 and ninth bonded area line 902 may separate third foam pad 846 from first foam pad 815. Additionally, fourth bonded area line 835 and tenth bonded area line 904 may separate first foam pad 815 and fourth foam pad 847. Further, the upper edge 905 may be formed using a welding or other bonding process. Upper edge 905 may form at least one side of a pouch within which third foam pad 846 is disposed. Likewise, lower edge 906 may be formed using welding or other bonding processes. Lower edge 906 may form at least one side of a pocket in which fourth foam pad 847 is disposed.

While various embodiments of the invention have been described, the description is intended to be exemplary, rather than limiting and it will be apparent to those of ordinary skill in the art that many more embodiments and implementations are possible that are within the scope of the invention. Although many possible combinations of features are shown in the drawings and discussed in this detailed description, many other combinations of the disclosed features are possible. Thus, it should be understood that any features shown and/or discussed in this disclosure may be implemented together in any suitable combination. Accordingly, the invention is not to be restricted except in light of the attached claims and their equivalents. Further, various modifications and changes may be made within the scope of the appended claims.

Claims

1. An article of footwear including a sole structure fixedly attached to an upper configured to receive a foot of a wearer, the upper comprising:

a skin layer forming at least a portion of an exterior surface of the upper; and

a reinforcing material selectively located internally and adjacent to portions of the skin layer, thereby defining reinforced portions of the skin layer and unreinforced portions of the skin layer;

wherein the reinforcement material is selectively joined with the skin layer by welding at a bond area, the bond area having an outer exposed surface that defines a portion of the exterior surface of the upper, and the bond area including a compressed reinforcement material that deforms from heat and pressure during welding; and is

Wherein the skin layer has a first color and the outer exposed surface of the bonded region has a second color, the second color being different from the first color.

2. The article of footwear of claim 1, wherein the skin layer is formed from a mesh material.

3. The article of footwear of claim 2, wherein the unreinforced portion of the skin layer includes an outwardly exposed surface and an inwardly exposed surface.

4. The article of footwear recited in claim 2, wherein the unreinforced portion of the skin layer provides direct ventilation through the mesh material of the skin layer to an interior cavity defined by the upper.

5. The article of footwear according to claim 1, wherein the bonded region includes a line of bonding material extending between components of the article of footwear.

6. The article of footwear recited in claim 5, wherein the lines of bonding material extend from the sole structure to a reinforcing strip proximate an instep region of the article of footwear.

7. The article of footwear of claim 1, wherein the article of footwear includes a material add-on panel that is welded to the skin layer.

8. An article of footwear including a sole structure fixedly attached to an upper, the upper defining an interior cavity configured to receive a foot of a wearer, the upper comprising:

a skin layer forming at least a portion of an exterior surface of the upper, the skin layer being formed from a mesh material; and

a reinforcing material selectively located internally and adjacent to the skin layer, thereby defining a reinforced portion of the skin layer and an unreinforced portion of the skin layer;

wherein the unreinforced portion of the skin provides direct ventilation, through the mesh material of the skin, to the interior cavity defined by the upper;

9. The article of footwear according to claim 8, wherein the bonded region includes a line of bonding material extending between components of the article of footwear.

10. The article of footwear of claim 9, wherein the lines of bonding material extend from the sole structure to a reinforcing strip proximate an instep region of the article of footwear.

11. The article of footwear of claim 8, wherein the article of footwear includes an additional layer of material located between a portion of the skin layer and a portion of the reinforcement material.

12. The article of footwear of claim 11, wherein the additional layer of material comprises a compressible foam material.

13. The article of footwear of claim 8, wherein a surface area of the unreinforced portion of the skin layer forms a majority of a surface area of an outer exposed surface of the skin layer; and is

14. An article of footwear including a sole structure fixedly attached to an upper configured to receive a foot of a wearer, the upper comprising:

wherein the reinforcement material is selectively joined with the skin layer by welding at a bond area, the bond area having an outer exposed surface that defines a portion of the exterior surface of the upper, and the bond area including a compressed reinforcement material that deforms from heat and pressure during welding, the bond area being smaller than the reinforced portion of the skin layer; and is

15. The article of footwear of claim 14, wherein the skin layer is formed from a mesh material.

16. The article of footwear of claim 15, wherein the unreinforced portion of the skin layer includes an outwardly exposed surface and an inwardly exposed surface.

17. The article of footwear recited in claim 15, wherein the unreinforced portion of the skin layer provides direct ventilation through the mesh material of the skin layer to an interior cavity defined by the upper.

18. The article of footwear according to claim 14, wherein the bonded region includes a line of bonding material extending between components of the article of footwear.

19. The article of footwear recited in claim 18, wherein the lines of bonding material extend from the sole structure to a reinforcing strip proximate an instep region of the article of footwear.

20. The article of footwear of claim 14, wherein the article of footwear includes an additional panel of material that is welded to the skin layer.

21. An article of footwear including a sole structure fixedly attached to an upper, the upper defining an interior cavity configured to receive a foot of a wearer, the upper comprising:

wherein the reinforcement material is selectively directly joined with the skin layer by welding at a bond area, the bond area having an outer exposed surface that defines a portion of the exterior surface of the upper, and the bond area including a compressed reinforcement material that deforms from heat and pressure during welding;

wherein the skin layer has a first color and the outer exposed surface of the bonded region has a second color, the second color being different from the first color;

wherein the upper includes an additional layer of material located between a portion of the skin layer and a portion of the reinforcement material; and is

Wherein the additional layer of material comprises a compressible foam material.

22. The article of footwear according to claim 21, wherein the bonded region includes a line of bonding material extending between components of the article of footwear.

23. The article of footwear recited in claim 22, wherein the lines of bonding material extend from the sole structure to a reinforcing strip proximate an instep region of the article of footwear.

24. The article of footwear of claim 21, wherein the unreinforced portion of the skin layer includes an outwardly exposed surface and an inwardly exposed surface.

25. The article of footwear recited in claim 21, wherein a surface area of the unreinforced portion of the skin layer forms a majority of a surface area of an outer exposed surface of the skin layer; and is

26. An article of footwear including a sole structure fixedly attached to an upper configured to receive a foot of a wearer, the upper comprising:

wherein the reinforcement material is selectively joined with the skin layer by welding at a bonded region, the bonded region having an outer exposed surface that defines a portion of the exterior surface of the upper, and the bonded region including a compressed reinforcement material that deforms during welding due to heat and pressure, the bonded region being smaller than the reinforced portion of the skin layer such that the reinforced portion of the skin layer includes the bonded region and an unbonded region in which the reinforcement material is unattached to the skin layer;

wherein the skin layer has a first color and the outer exposed surface of the bonded region has a second color, the second color being different from the first color; and is

Wherein the outer exposed surface of the bonding zone comprises a portion of the reinforcing material, thereby providing the outer exposed surface of the bonding zone with substantially the same color as the reinforcing material.

27. The article of footwear according to claim 26, wherein the upper includes an additional layer of material located between at least one of the reinforced portions of the skin layer and a portion of the reinforcing material;

wherein the additional layer of material comprises a compressible foam material; and is

Wherein the compressible foam material is disposed in a pocket between the skin layer and the reinforcement material and is surrounded by the bonded region.

28. The article of footwear of claim 26, wherein the skin layer is formed from a mesh material.

29. The article of footwear of claim 28, wherein the unreinforced portion of the skin layer includes an outwardly exposed surface and an inwardly exposed surface.

30. The article of footwear recited in claim 28, wherein the unreinforced portion of the skin layer provides direct ventilation through the mesh material of the skin layer to an interior cavity defined by the upper.

31. The article of footwear according to claim 26, wherein the bonded region includes a line of bonding material extending between components of the article of footwear.

32. The article of footwear recited in claim 31, wherein the lines of bonding material extend from the sole structure to a reinforcing strip proximate an instep region of the article of footwear.

33. The article of footwear of claim 26, wherein the article of footwear includes an additional panel of material that is welded to the skin layer.

34. An article of footwear including a sole structure fixedly attached to an upper, the upper defining an interior cavity configured to receive a foot of a wearer, the upper comprising:

wherein the upper includes an additional layer of material located between at least one of the reinforced portions of the skin layer and a portion of the reinforcing material;

35. The article of footwear of claim 34, wherein the bonded region includes a line of bonding material extending between components of the article of footwear.

36. The article of footwear recited in claim 35, wherein the lines of bonding material extend from the sole structure to a reinforcing strip proximate an instep region of the article of footwear.

37. The article of footwear of claim 34, wherein one or more of the unreinforced portions of the skin layer include an outwardly exposed surface and an inwardly exposed surface.

38. The article of footwear of claim 34, wherein the article of footwear includes an additional panel of material that is welded to the skin layer.

39. The article of footwear recited in claim 34, wherein a surface area of the unreinforced portion of the skin layer forms a substantial majority of a surface area of an outer exposed surface of the skin layer.

40. An article of footwear including a sole structure fixedly attached to an upper configured to receive a foot of a wearer, the upper comprising:

wherein the skin layer has a first color and the reinforcing material has a second color, the second color being different from the first color;

wherein the outer exposed surface of the bonding zone comprises a portion of the reinforcing material, thereby providing the outer exposed surface of the bonding zone with substantially the same color as the reinforcing material;

wherein the upper includes at least two padded portions, each padded portion including an additional layer of material located between a portion of the skin layer and a portion of the reinforcement material;

wherein the additional layer of material comprises a compressible foam material;

wherein the at least two filled portions are separated from each other by a portion of the bonded area connecting the reinforcing material and the skin layer; and is

41. The article of footwear recited in claim 40, wherein the bonded regions include lines of bonding material that extend between components of the article of footwear.

42. The article of footwear recited in claim 41, wherein the lines of bonding material extend from the sole structure to a reinforcing strip proximate an instep region of the article of footwear.

43. The article of footwear of claim 40, wherein one or more of the unreinforced portions of the skin layer include an outwardly exposed surface and an inwardly exposed surface.

44. The article of footwear recited in claim 40, wherein the skin layer is formed from a mesh material, and wherein one or more of the unreinforced portions of the skin layer provide direct ventilation through the mesh material of the skin layer to an interior cavity defined by the upper.

45. The article of footwear recited in claim 40, wherein the additional layer of material is disposed in a tongue portion of the upper.

46. The article of footwear of claim 40, wherein the article of footwear includes an additional panel of material that is welded to the skin layer.

47. An article of footwear including a sole structure fixedly attached to an upper configured to receive a foot of a wearer, the upper comprising:

Wherein the outer exposed surface of the bonding zone comprises a visible portion of the reinforcement material, thereby providing the outer exposed surface of the bonding zone with substantially the same color as the reinforcement material.

48. The article of footwear according to claim 47, wherein the upper includes an additional layer of material located between at least one of the reinforced portions of the skin layer and a portion of the reinforcing material;

49. The article of footwear of claim 47, wherein the skin layer is formed from a mesh material that includes a plurality of openings, and wherein the reinforcing material is exposed and visible through the plurality of openings of the mesh material at a majority of the reinforced portion of the skin layer.

50. The article of footwear recited in claim 49, wherein a surface area of the mesh material of the skin layer constitutes at least 50% open area defined by the plurality of openings.

51. The article of footwear of claim 49, wherein the mesh material of the skin layer is embedded in the reinforcement material at the bonded region.

52. The article of footwear of claim 47, wherein the bonded region includes a line of bonding material extending between components of the article of footwear.

53. The article of footwear recited in claim 52, wherein the lines of bonding material extend from the sole structure to a reinforcing strip proximate an instep region of the article of footwear.

54. The article of footwear of claim 47, wherein the article of footwear includes an additional panel of material that is welded to the skin layer.

55. An article of footwear including a sole structure fixedly attached to an upper, the upper defining an interior cavity configured to receive a foot of a wearer, the upper comprising:

a skin layer forming at least a portion of an exterior surface of the upper, the skin layer being formed from a mesh material, the mesh material including a plurality of openings; and

wherein the unreinforced portions of the skin provide direct ventilation to the interior cavity defined by the upper through the plurality of openings of the mesh material of the skin;

wherein the skin layer has a first color and the outer exposed surface of the bonded region includes visible portions of the reinforcement material exposed through the plurality of openings of the mesh material to provide a second color to the outer exposed surface of the bonded region that is different from the first color;

56. The article of footwear of claim 55, wherein the bonded region includes a line of bonding material extending between components of the article of footwear.

57. The article of footwear recited in claim 56, wherein the lines of bonding material extend from the sole structure to a reinforcing strip proximate an instep region of the article of footwear.

58. The article of footwear recited in claim 55, wherein a surface area of the mesh material of the skin layer constitutes at least 50% open area defined by the plurality of openings.

59. The article of footwear recited in claim 55, wherein the mesh material of the skin layer is embedded in the reinforcing material at the bonded regions.

60. The article of footwear recited in claim 55, wherein a surface area of the unreinforced portion of the skin layer forms a substantial majority of a surface area of an outer exposed surface of the skin layer.

61. An article of footwear including a sole structure fixedly attached to an upper configured to receive a foot of a wearer, the upper comprising:

wherein the outer exposed surface of the bonding zone comprises a visible portion of the reinforcement material, thereby providing the outer exposed surface of the bonding zone with substantially the same color as the reinforcement material;

62. The article of footwear of claim 61, wherein the bonded region includes a line of bonding material extending between components of the article of footwear.

63. The article of footwear recited in claim 62, wherein the lines of bonding material extend from the sole structure to a reinforcing strip proximate an instep region of the article of footwear.

64. The article of footwear recited in claim 61, wherein the skin layer is formed from a mesh material that includes a plurality of openings, and wherein the reinforcing material is exposed and visible through the plurality of openings of the mesh material at a majority of the reinforced portion of the skin layer.

65. The article of footwear recited in claim 64, wherein a surface area of the mesh material of the skin layer constitutes at least 50% open area defined by the plurality of openings.

66. The article of footwear recited in claim 61, wherein the additional layer of material is disposed in a tongue portion of the upper.

67. The article of footwear recited in claim 61, wherein the skin layer is formed from a mesh material, and wherein the mesh material of the skin layer is embedded in the reinforcing material at the bonded regions.