CN110636771A

CN110636771A - Method and apparatus for unitary footwear construction

Info

Publication number: CN110636771A
Application number: CN201880026153.XA
Authority: CN
Inventors: P·巴斯蒂亚内利
Original assignee: BHA Altair LLC
Current assignee: Parker Hannifin Corp
Priority date: 2017-04-18
Filing date: 2018-04-18
Publication date: 2019-12-31
Also published as: EP3612051A2; EP3612051A4; WO2018195147A2; WO2018195147A3; KR20190132538A; US20180295940A1

Abstract

An upper for use in an article of footwear, a method of making the upper, and an article of footwear including the upper are provided. The upper provides an upper for an article of footwear that will enclose a foot of a wearer. The upper includes a body formed from a single air permeable, moisture vapor permeable, and waterproof sheet formed from multiple layers of material that are laminated together. The body has a bottom portion which in use is located under the foot of the wearer. The body defines an opening through which a foot of a wearer will extend in use. A single bottom seam extends substantially the entire length of the bottom portion of the body between the toe end and the heel end of the body.

Description

Method and apparatus for unitary footwear construction

Technical Field

The present invention relates generally to footwear, and more particularly to a unitary upper for footwear and a method of manufacturing a unitary upper for footwear.

Background

At least some known uppers are constructed of certain materials, including various textiles and adhesives, that have limited air permeability when assembled in layers. Similarly, commercially available waterproof and breathable footwear is constructed from multiple layers that are waterproof and permeable to moisture vapor but impermeable to air. The waterproof liner most commonly comprises a layer of air impermeable polyurethane or some other material. The lack of air permeability allows the wearer's foot to be sealed from fresh air.

Construction of conventional uppers typically involves using a pattern cut from material or cutting multiple parts from material and assembling the single or multiple parts with stitching and adhesive to form a volume shaped to cover the wearer's foot. Typically, the upper is constructed in two parts: liners and shoe shells, wherein the waterproof liner must be assembled within one or more layers of the shoe shell to complete the entire upper of the shoe. However, the method for improving the breathability of the footwear tends to reduce the waterproof ability of the footwear.

Additionally, as illustrated in fig. 3 of U.S. patent publication No. 2010/0011619 (reproduced herein as "619 publication"), the upper of a shoe tends to be permanently attached to the insole by one or more insole seams, such as insole 304 of the' 619 publication attached to upper 302 by seams 320 and 330. Having a separate insole component permanently attached to upper 302 adds additional manufacturing expense. More specifically, there is an additional cost of the additional material forming the insole. In addition, there is additional cost in forming seams 320 and 330. More specifically, the seams 320, 330 between the upper 302 and the insole 304 define the entire perimeter of the insole 304. Thus, the manufacturer is required to make substantially two seam passes between the toe and heel portions of the upper 302 along the length of the upper 302 to fully attach the insole 304 to the rest of the upper 304. Typically, these seam runs will extend between 80 percent and 100 percent of the length of the bottom of the upper between the toe and heel portions.

In addition, to prevent leakage of the upper 302 and insole 304, the' 619 publication also requires the addition of a sealing gasket 360 covering the insole 304 and seams 320, 330. This adds additional cost to the shoe.

Disclosure of Invention

Embodiments of the present invention provide improvements over the state of the art. More specifically, embodiments of the present invention provide new and improved footwear components and methods of manufacturing footwear components that provide footwear components that are water impermeable and moisture vapor permeable, particularly uppers (bootie) that form the uppers of articles of footwear.

In a particular embodiment of the invention, a method of making an article of footwear is provided. The method includes providing a single air permeable, moisture vapor permeable, and water resistant sheet formed from multiple layers of material laminated together. The method includes forming an upper from the single air permeable, moisture vapor permeable, and waterproof sheet, the upper having a bottom portion that, in use, is positioned under a foot of a wearer. Forming the upper includes stitching only a single bottom seam extending substantially an entire length of a bottom portion of the upper between a toe end and a heel end of the upper. The method comprises the following steps: the upper is attached to the outsole such that an exterior surface of the single air permeable, moisture vapor permeable, and waterproof sheet is directly exposed to the external ambient environment when used on a wearer's foot.

In an embodiment, the method includes sewing at least one cross-sewn seam extending transverse to the bottom seam.

In an embodiment, the bottom seam extends at least 80% of the length of the bottom portion between the toe end and the heel end of the upper.

In an embodiment, the method comprises applying a sealing material throughout the bottom seam.

In an embodiment, the sealing material is applied on an inner surface of the single air permeable, moisture vapor permeable and waterproof sheet.

In an embodiment, the step of forming the upper further comprises assembling a sewn seam after sewing adjacent the heel end of the upper. The rear assembly sewn seam at least partially forms an opening into the upper through which a wearer's foot will extend in use.

In an embodiment, the step of forming the upper further comprises sewing a front toe sewing seam on a (whole) curved portion of the toe end of the upper.

In an embodiment, the sole seam, the rear assembly stitch seam, and the front toe stitch seam are substantially aligned with one another.

In an embodiment, the sole seam and the front toe stitch seam are formed as a continuous seam.

In an embodiment, the single air permeable, moisture vapor permeable, and waterproof sheet comprises: a first layer comprising an air permeable, moisture vapor permeable, and water resistant film material, the first layer having a first side and a second side; a second layer including a filler, the second layer having a first side and a second side, the second layer being positioned between the first layer and an external environment when the article of footwear is completed, the second layer being configured to help protect the first layer from the external ambient environment. The first layer may be bonded to the second layer.

In an embodiment, the step of attaching the upper to the outsole covers at least a majority of the single bottom seam with the outsole.

In an embodiment, the method comprises attaching an outer support frame comprising a reinforcing material to an outer surface of the single air permeable, moisture vapor permeable, and water resistant sheet by one or more of: molding, sewing, bonding, heat welding (e.g., using a hot press), and high frequency welding.

In an embodiment, at least ten percent of the surface area of the outer surface of the single air permeable, moisture vapor permeable, and waterproof sheet is directly exposed to the external ambient environment.

In a further embodiment, an article of footwear is provided. The upper provides an upper for an article of footwear that will enclose a foot of a wearer. The upper includes a body formed from a single air permeable, moisture vapor permeable, and waterproof sheet formed from multiple layers of material that are laminated together. The body has a bottom portion which in use is located under the foot of the wearer. The body defines an opening through which a foot of a wearer will extend in use. A single bottom seam extends substantially the entire length of the bottom portion of the body between the toe end and the heel end of the body.

In an embodiment, at least one cross-stitched seam is formed in the bottom portion extending transversely to the bottom seam.

In an embodiment, the bottom seam extends at least 80% of the length of the bottom portion between the toe end and the heel end.

In an embodiment, the sealing material extends over said bottom seam to make the bottom seam waterproof. A sealing material is applied to the inner surface of the single air permeable, moisture vapor permeable and waterproof sheet.

In an embodiment, the upper includes a rear assembly stitch seam adjacent the heel end of the upper. The post-assembly sewn seam at least partially forms an opening into the upper.

In an embodiment, the upper includes a front toe sewn seam on a (entirely) curved portion of the toe end of the upper.

In an embodiment, the single air permeable, moisture vapor permeable, and waterproof sheet comprises a first layer comprising an air permeable, moisture vapor permeable, and waterproof film material, the first layer having a first side and a second side. The sheet includes a second layer having a first side and a second side. When the article of footwear is completed, the second layer is positioned between the first layer and the external environment. The second layer is configured to help protect the first layer from the external ambient environment. The first layer is bonded to the second layer.

In a further embodiment, an article of footwear is provided. The article of footwear includes an outsole and an upper coupled to the outsole as outlined above. The upper will enclose the foot of the wearer in use.

In an embodiment, an article of footwear includes an outer support frame including a reinforcing material, the outer support frame coupled to an exterior surface of an upper by one or more of: molding, sewing, bonding, heat welding (e.g., using a hot press), and high frequency welding.

In an embodiment, at least ten percent of the exterior apparent surface area of the single air permeable, moisture vapor permeable, and waterproof sheet is directly exposed to the external ambient environment.

Drawings

FIG. 1 is a perspective view of an article of footwear according to an embodiment of the invention;

FIG. 2 is an enlarged cross-section of a multi-layer laminated sheet used to form the upper shown in FIG. 1;

FIG. 3 is a perspective view of a prior art upper with the interior facing outward during construction;

FIG. 4 is a perspective view of an interior outward-facing upper during construction; and

fig. 5 is a simplified illustration of a scissors-like shape of a piece of material prior to forming the upper of fig. 4.

Detailed Description

A common limitation of waterproof and moisture vapor permeable footwear is that such footwear is impermeable to air. One example of an embodiment that does not exhibit the usual air impermeability limitations is footwear having an integral upper made of a waterproof, moisture vapor permeable, and air permeable multi-layer laminate. Embodiments described herein include such unitary uppers and methods for constructing such unitary uppers.

Fig. 1 is a perspective view of an article of footwear 100 according to an embodiment of the invention. In the example embodiment, article of footwear 100 is illustrated as an athletic shoe. In various alternative embodiments, article of footwear 100 may be another type of shoe, boot, or footwear. Article of footwear 100 includes an outsole 102 and an upper 104 configured to receive a foot (not shown) of a user (also referred to as a "wearer"). Upper 104 is formed from an upper 106 that surrounds a user's foot. As will be more fully described, upper 106 is not attached to a separate insole of upper 106. In various other embodiments, outsole 102 may be formed and coupled to upper 104 by one or more of injection molding and vulcanization/curing. Article of footwear 100 includes a front strap 108 joined to upper 104 with a plurality of fasteners 110.

In addition, article of footwear 100 includes a tongue 112, tongue 112 being configured to allow upper 104 of article of footwear 100 to contract and expand so that article of footwear 100 may accommodate the penetration and removal of a foot. Tongue 112 also provides adjustment for upper 104 so that article of footwear 100 securely contacts and attaches to the user's foot when front lace 108 is tightened. In alternative embodiments, the front strap 108 may be a strap such asThe hook and loop fastener material of (1). The tongue 112 is formed of an existing material by means of tongue stitching 114. Fastener 110 is attached to upper 104 at the edges of tongue 112. In various alternative embodiments, the firmware 110 may be one or more of the following: an eyelet, an eyelet backing, a loop fastener, and a hook.

Article of footwear 100 also basically includes exoskeleton 116, which comprises a material that is attached or molded to an outer surface of upper 104. Exoskeleton 116 provides structural support to upper 104 and helps maintain the shape of upper 104. Exoskeleton 116 also helps to distribute the strapping tension applied to fastener 110 outward through the area surrounding the attachment of exoskeleton 116, rather than isolating the forces only where fastener 110 is attached to upper 104. In the exemplary embodiment, exoskeleton 116 is attached to upper 104 by high frequency welding. In various alternative embodiments, exoskeleton 116 is attached using at least one of sewing, gluing, thermal welding (e.g., using a hot press), and high frequency welding, but is not limited to such. In the exemplary embodiment, article of footwear 100 includes a cap portion 118 that is formed by folding back a top edge 119 of upper 104 and is maintained in place using, for example (but not limited to), a cap stitch 120. In an exemplary embodiment, upper 104 is secured to outsole 102 using an attachment process, such as a gluing process. However, as noted above, other processes for securing upper 104 to outsole 102 may be used, such as one or more of injection molding and vulcanization/hardening.

The terms "waterproof" and "liquid-impermeable" are used interchangeably throughout this disclosure. As used herein, "liquid-tight" is defined as: upper 104 (including the insole) did not leak when exposed to water at a maximum pressure of 200 millibar (2.901p.s.i.g.) for one minute, where a leak is indicated by the presence of detectable liquid on the exterior of upper 104.

In an exemplary sense, the "air permeability" of upper 106 may be determined by a test method designated ASTM D737-96 by the American Society for Testing and Materials. This is preferably measured by a Frazier Air Permeability Tester, a Textest FX 3300Air Permeability Tester, or a similar type of test apparatus. The air permeability is required to provide for an air flow of at least 0.03 cubic centimeters per minute per square centimeter at a pressure of 1.27 centimeters of water (0.05 cubic feet per minute per square foot at a pressure of 0.5 inches of water) through the upper 106 portion of the upper 104. Preferably, at least 0.05 cubic centimeters per minute per square centimeter at a pressure of 1.27 centimeters of water (0.1 cubic feet per minute per square foot at a pressure of 0.5 inches of water) of airflow through upper 106. More preferably, at least 0.15 cubic centimeters per minute per square centimeter at a pressure of 1.27 centimeters of water (0.3 cubic feet per minute per square foot at a pressure of 0.5 inches of water), and most preferably, at least 0.51 cubic centimeters per minute per square centimeter at a pressure of 1.27 centimeters of water (1.0 cubic feet per minute per square foot at a pressure of 0.5 inches of water) through upper 106.

FIG. 2 is an enlarged cross-sectional view of an exemplary embodiment of a multi-layer laminate sheet 200 that may be used in the construction of an upper (shown in FIG. 1). In an exemplary embodiment, the multilayer laminated sheet 200 includes five layers. In various other embodiments, other numbers of layers may be used, including one or more of the layers outlined below. For example, it is contemplated that three or four layers of material may be used that provide sufficient breathability and water resistance.

The first layer 210 is an air permeable, moisture vapor permeable, and waterproof film material having a first side 211 and a second side 212. Second layer 220 is a waterproof filler and has been made air permeable and moisture vapor permeable by perforating the filler. The second layer 220 includes a first side 221 and a second side 222. Second layer 220 is configured to help protect first layer 210 from the surrounding environment (e.g., stone particles and other foreign objects that may puncture or otherwise physically damage first layer 210). The third layer 230 is an air permeable, moisture vapor permeable bonding material having a first side 231 and a second side 232. Additionally, the third layer 230 may be waterproof. Fourth layer 240 is an air and moisture vapor permeable material having a first side 241 and a second side 242. Fourth layer 240 is configured to help protect first layer 210 from the internal ambient environment, such as the abrasion of a wearer's foot or sock. In addition, the fourth layer 240 may be waterproof. The fifth layer 250 is an air and moisture permeable material having a first side 251 and a second side 252. Fifth layer 250 is configured to form an exterior surface of upper 104 (shown in FIG. 1). Additionally, the fifth layer 250 may be waterproof.

In an example embodiment, the first layer 210 is formed of an air permeable, moisture vapor permeable, and waterproof material including a microporous membrane. An example of such a material isFabric, a chemically treated expanded polytetrafluoroethylene (hereinafter "ePTFE") membrane commercially available from BHA Technologies, Inc.

Another exemplary commercially available material that may be used to form the multilayer laminate sheet 200 is Gore-Tex^TMXCR^TM(also known as VISI000001), FOLIOI^TM、And

in the exemplary embodiment, it is contemplated that,the second layer 220 comprises a closed cell foam, such as is commercially available under the nameThe polyester fiber foam of (1). In various alternative embodiments, the second layer 220 comprises at least one of an open cell foam or other filled material. Although the closed cell foam is waterproof in the exemplary embodiment, it is also air and water vapor impermeable without some modification. Thus, to ensure that the second layer 220 is air and moisture vapor permeable, the material is perforated prior to being laminated into the multilayer laminated sheet 200. Although the second layer 220 is perforated with a plurality of holes such that it is the layer or layers of the multi-layer laminated sheet 200 that are permeable to air and water vapor but not waterproof, at least the first layer 210 remains waterproof and thus ensures that the multi-layer laminated sheet 200 is waterproof.

Third layer 230 includes a bonding material that facilitates bonding of first layer 210 and second layer 220. The third layer 230 facilitates a strong bond, which is often unreliable if the third layer 230 is not used. In the exemplary embodiment, third layer 230 includes a textile material such as, but not limited to, a scrim, a warp knit, and a non-woven fabric.

Fourth layer 240 is configured to form an interior surface or lining of upper 104 (shown in FIG. 1), and the fourth layer is configured to help protect first layer 210 from abrasion caused by a wearer's foot (not shown). Likewise, fourth layer 220 is configured to withstand intermittent abrasion from the wearer's foot and to provide some comfort to the wearer's foot. In the exemplary embodiment, fourth layer 240 includes a woven fabric using at least one of a woven fabric, a non-woven fabric, or a knitted fabric, but is not limited to the fabric. Other exemplary fabrics that may be used for the fourth layer 240 are warp knit fabrics, including ECLIPSE 100H^TM(an abrasion resistant polyester and nylon combination fabric), ECLIPSE 200S^TM(an abrasion resistant polyester and nylon combination fabric) and ECLIPSE400H^TM(a lightweight nylon fabric) these are commercially available from Tempo Shain Corporation of Salem, Mass.

Fifth layer 250 is configured to form an exterior surface or shell (not shown) of upper 104 (shown in FIG. 1) and is visible as an exterior of footwear 100 (shown in FIG. 1) when worn by a wearer. In the exemplary embodiment, materials for fifth layer 250 include, but are not limited to, woven fabrics, non-woven fabrics, and braided fabrics.

Note that the above single-layer sheet includes five layers. However, this is an exemplary embodiment of the single-layer sheet provided

FIG. 4 is a view of a completed upper 400 according to an exemplary embodiment of the present invention. Upper 400 is illustrated with the interior facing outward prior to attaching any combination of midsole and outsole 102 (shown in fig. 1).

In an embodiment, upper 400 will enclose a user's foot, with portions that extend above and below the top of the user's foot. In addition, substantially the entire upper 400 is provided by upper 402. Additionally, the entire upper 402 is a body formed from a single piece of the multi-layer laminate sheet 200. As discussed above, upper 400 may include an exoskeleton or other material that is attached to an exterior surface (not shown) of upper 402. Additionally, a lining (e.g., a wear-resistant lining) may be attached to an interior surface of upper 402 (lining not shown).

In the exemplary embodiment, front toe sewn seam 422, rear assembly sewn seam 440, and sole sewn seam 442 form single multi-layer laminate sheet 200 (shown in fig. 2) into upper 402. To further form the shape of upper 402 from the single piece of multi-layer laminate sheet 200, one or more of heel cross-stitched seam 446 and toe cross-stitched seam 448 may be added. These cross-stitched seams 446, 448 will extend transverse to the bottom stitched seam 442 and are substantially between 80 degrees and 90 degrees relative to the bottom stitched seam 442. The cross-stitched seams 446, 448 are generally aligned with a width direction, e.g., they extend between the inside of the foot and the outside of the foot, which is generally perpendicular to the length direction in which the seam 442 is aligned. In an embodiment, the cross-stitched seams 446, 448 extend between 50 percent and 100 percent of the local width of the bottom portion of the upper 402 adjacent the corresponding cross-stitched seams 446, 448.

Unlike the prior art arrangement, upper 400 does not have a separate insole 304 (see fig. 3) attached to upper 302 as illustrated in the prior art design of fig. 3. Alternatively, a portion 449 of upper 400 that is positioned under the foot of the user (e.g., the portion that would otherwise be provided by a separate insole 304 secured to the upper or upper and counter (quarter)) is provided directly from the single sheet of multilayer laminate sheet 200. In this embodiment, only a single seam (i.e., bottom stitch seam 442) is aligned with and extends substantially the entire length of the upper bottom, for example between about 80 percent and 100 percent of the entire length from toe end 460 to heel end 470. As mentioned above, the prior art uses at least two (seam) walkers that extend substantially the entire length of the upper to secure the insole to the upper or upper and counter.

Sewn seams 422, 440, 442, 446, 448, and 450 may use any of a wide variety of thread-like materials including, but not limited to, strands or cords, and may include spun fibers coated with a liquid impermeable coating, spun fibers surrounding a core, bonded fibers, and monofilament-type materials. Sewn seams 422, 440, 442, 446, 448, and 450 may also be used in any of a wide variety of sewing patterns, including but not limited to zig-zag patterns, that do not compromise the integrity of the monolithic multilayer laminate sheet 200. In addition, adhesives and electronic die encapsulation methods may be used. It will also be appreciated that the exact location and number of seams 422, 440, 442, 446, 448, and 450 may vary depending on the type of article of footwear being produced. For example, in some embodiments, sewn seams 422, 440, and 442 may be formed by a single sewn seam rather than three separate seams. Further, although only two cross-stitched seams are illustrated, additional cross-stitched seams may be added to further define the shape of upper 402. Additionally, in some embodiments, cross-stitched seams 446, 448 may not be required.

Sewn seams 422, 440, 442, 446, 448, and 450 may be sealed with seam tape 424, 444, 451, 452, 453, and 454 positioned over sewn seams 422, 440, 442, 446, 448, and 450, respectively. Heat is then applied by applying hot air, and pressure is then applied to the top of the seam tapes 424, 444, 451, 452, 453, and 454 by nip rolls. The heat from the hot air is preselected to soften the adhesive in seam tapes 424, 444, 451, 452, 453, and 454 without adversely affecting any desired qualities present in upper 400. For most applications, the heat application preferably ranges from about 150 degrees Celsius (302 degrees Fahrenheit) to about 250 degrees Celsius (482 degrees Fahrenheit). However, the temperature may reach or exceed 750 degrees celsius. The preferred pressure application is from a gauge of about 3 kilograms per square centimeter (42.67 pounds per square inch) to a gauge of about 5 kilograms per square centimeter (71.12 pounds per square inch). However, the temperature and pressure applied depends on the type of material used for upper 400, the threads used to form seams 422, 440, 442, 446, 448, and 450, the adhesive, and the type of material used for seam tapes 424, 444, 451, 452, 453, and 454. By such a process, a solid structural weld is formed that provides at least a substantially liquid-tight quality in seams 422, 440, 442, 446, 448, and 450 that is approximately comparable to the liquid-tight quality of the remainder of upper 400.

Fig. 5 illustrates the shaped single piece multi-layer laminate sheet 200 cut prior to forming the upper 402. Referring to fig. 4 in addition to fig. 5, in one embodiment, at least a portion of the post-assembly sewn seam 440 will be formed by first securing edge portion 440A to edge portion 440B by sewing in the direction illustrated by arrow 440C. When the rear assembly sewn seam 440 is formed, the opening of the upper 402 through which the user's foot extends when wearing the finished article of footwear 100 is at least partially established.

Thereafter, in one embodiment, the front of the toe is sewn with a front toe sewing seam 422, which secures rim portion 422A to rim portion 422B in a manner that sews along the direction illustrated by arrow 422C. The stitching may extend over the top of the toe region of upper 402 and around the bend of the toe of upper 402. Preferably, sole sewing seam 442 and toe sewing seam 422 are a single continuous seam. Thus, after walking around the front of the toe as illustrated by arrow 422C, the technician will continue to sew (sew in the direction illustrated by arrow 442C) along bottom edge portion 442A to bottom edge portion 442B in a continuous sewing manner to form bottom sewing seam 442. In other embodiments, sewn seams 440, 442, and 422 are single seams. In such embodiments, the person stitching the upper will essentially start with the heel end and stitch: edge portions 440A, 440B extending along the heel; then, edge portions 442A, 442B extending along the bottom from the heel end to the toe end; then, edge portions 422A, 422B extend upwardly and over the toe and terminate adjacent the tongue (see the base of the tongue 112 in FIG. 1). Alternatively, this could be reversed starting adjacent the toe end and then ending with sewing the heel on.

At this point, upper 402 has been substantially formed into the shape of FIG. 4. However, after forming bottom sewn seam 442, the user may add heel cross-stitched seam 446 and toe cross-stitched seam 448 in a direction generally transverse (e.g., between 80-90 degrees) to bottom sewn seam 442. The cross-stitched seams 446, 448 may be utilized to provide the final shape of upper 402. These cross-stitched seams 446, 448 may be used to close the edges 422A, 442A cut from the sheet material adjacent the toe and heel portions; 422B, 442B; 442A, 440A; a choke (notch) formed between 422B and 440B.

Referring to fig. 5, portion 449 is illustrated by dashed lines and sections 449A, 449B prior to sewing. These sections 449A, 449B will fold over and lie under the wearer's foot when fully assembled and will occupy the position of the insole 304 previously.

After sewing these seams, seam tape may be applied, as previously described.

This arrangement significantly reduces the length and number of seams formed when forming an upper according to prior embodiments. This reduces potential leak paths through the monolithic multilayer laminate sheet 200. This reduces the time to form the upper. This also eliminates the need for the inner bottom sealing gasket 360.

Thereafter, a liner may be attached to upper 402 to protect the interior surface of upper 402 and, in particular, to prevent a user's foot or sock from being worn directly on the interior layer of the single piece of multilayer laminated sheet 200.

In particular embodiments, after upper 402 is formed, the upper is attached to outsole 102, as described above. The attachment of upper 402 to outsole 102 will cover bottom stitching 442. In some embodiments, outsole 102 will cover at least 80 percent of bottom sewing seam 442. Basically, if an exoskeleton (e.g., exoskeleton 116) is added, the exoskeleton will be applied to an exterior surface of the upper prior to forming the upper. In addition, a portion of the exoskeleton may extend circumferentially toward the bottom of upper 402 such that the exoskeleton is positioned between portion 449 and outsole 102 to increase the structural strength provided by the exoskeleton.

While upper 402 generally forms the entire upper, it is preferred that any exoskeleton 116 or other materials (e.g., design materials such as logos or the like applied to the exterior surface of upper 402) and, in particular, the single piece multi-layer laminate sheet 200 cover as little (a portion of) the exterior surface of upper 402 as possible when the article of footwear is fully assembled. This prevents the added material attached to the outer surface of the single piece multilayer laminate sheet 200 from inhibiting the breathability of the upper 402 and the final article of footwear. While it is preferred to have as much surface area of upper 402 directly exposed to the external ambient environment (i.e., in direct contact with the external ambient environment), at least 10% of the outer surface of monolithic multilayer laminate sheet 200 may be exposed to the ambient environment when the article of footwear is fully assembled. In other embodiments, at least 15% is exposed to the external ambient environment. More preferably, at least 20% is exposed to the external ambient environment. This percentage is measured in terms of the total surface area of upper 402 prior to outsole 102 attachment.

Exemplary embodiments of the present invention are described above in detail. The methods and components are not limited to the specific embodiments described herein, but rather, components of systems and/or steps of the methods may be utilized independently and separately from other components and/or steps described herein. For example, the methods may also be used in combination with other footwear construction methods, and are not limited to practice with only the construction methods described herein. Rather, the exemplary embodiment can be implemented and utilized in connection with many other footwear applications.

Although specific features of various embodiments may be shown in some drawings and not in others, this is for convenience only. In accordance with the principles of the invention, any feature of a drawing may be referenced and/or claimed in combination with any feature of any other drawing.

All references, including publications, patent applications, and patents, cited herein are hereby incorporated by reference to the same extent as if each reference were individually and specifically indicated to be incorporated by reference and were set forth in its entirety herein.

The use of the terms "a" and "an" and "the" and similar referents in the context of describing the invention (especially in the context of the following claims) is to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. The terms "comprising," "having," "including," and "containing" are to be construed as open-ended terms (i.e., meaning "including, but not limited to,") unless otherwise noted. Recitation of ranges of values herein are merely intended to serve as a shorthand method of referring individually to each separate value falling within the range, unless otherwise indicated herein, and each separate value is incorporated into the specification as if it were individually recited herein. All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g., "such as") provided herein, is intended merely to better illuminate the invention and does not pose a limitation on the scope of the invention unless otherwise claimed. No language in the specification should be construed as indicating any non-claimed element as essential to the practice of the invention.

Preferred embodiments of this invention are described herein, including the best mode known to the inventors for carrying out the invention. Variations of those preferred embodiments may become apparent to those of ordinary skill in the art upon reading the foregoing description. The inventors expect skilled artisans to employ such variations as appropriate, and the inventors intend for the invention to be practiced otherwise than as specifically described herein. Accordingly, this invention includes all modifications and equivalents of the subject matter recited in the claims appended hereto as permitted by applicable law. Moreover, any combination of the above-described elements in all possible variations thereof is encompassed by the invention unless otherwise indicated herein or otherwise clearly contradicted by context.

Claims

1. A method of making an article of footwear, the method comprising:

providing a single air permeable, moisture vapor permeable and waterproof sheet formed of multiple layers of material laminated together;

forming an upper from the single air permeable, moisture vapor permeable and waterproof sheet, the upper having a bottom portion that, in use, is positioned under a foot of a wearer, wherein forming the upper comprises:

sewing only a single bottom seam between a toe end and a heel end of the upper that extends substantially the entire length of the bottom portion of the upper; and

the upper is attached to the outsole such that an exterior surface of the single air permeable, moisture vapor permeable, and waterproof sheet is directly exposed to the external ambient environment when used on a wearer's foot.

2. The method of claim 1, wherein forming the upper further comprises sewing at least one cross-sewn seam extending transverse to the bottom seam.

3. The method according to claim 2, wherein the bottom seam extends at least 80% of a length of the bottom portion between a toe end and a heel end of the upper.

4. The method of claim 1, wherein forming the upper further comprises applying a sealing material throughout the bottom seam.

5. The method of claim 4, wherein the sealing material is applied on an inner surface of the single air permeable, moisture vapor permeable, and waterproof sheet.

6. The method of claim 1, wherein forming the upper further comprises: a rear assembly sewn seam is sewn adjacent the heel end of the upper, the rear assembly sewn seam at least partially forming an opening into the upper through which a wearer's foot will extend when in use.

7. The method of claim 6, wherein forming the upper further comprises sewing a front toe sewing seam on a curved portion of a toe end of the upper.

8. The method of claim 7, wherein the sole seam, rear assembly stitch seam, and front toe stitch seam are generally aligned with one another.

9. The method of claim 8, wherein the sole seam and the front toe stitch seam are formed as a continuous seam.

10. The method of claim 1, wherein the single air permeable, moisture vapor permeable, and waterproof sheet comprises:

a first layer comprising an air permeable, moisture vapor permeable, and water resistant film material, the first layer having a first side and a second side; and

a second layer including a filler, the second layer having a first side and a second side, the second layer being positioned between the first layer and an external environment when the article of footwear is completed, the second layer being configured to help protect the first layer from the external ambient environment.

11. The method of claim 1, wherein attaching the upper to the outsole covers at least a majority of the single bottom seam with the outsole.

12. The method of claim 1, further comprising

Attaching an outer support frame comprising a reinforcing material to an outer surface of the single air permeable, moisture vapor permeable and water resistant sheet by one or more of: molding, sewing, bonding, heat welding (e.g., using a hot press), and high frequency welding.

13. The method of claim 1, wherein at least ten percent of the surface area of the outer surface of the single air permeable, moisture vapor permeable, and waterproof sheet is directly exposed to the external ambient environment.

14. An article of footwear comprising:

an upper, the upper comprising:

a body formed from a single air permeable, moisture vapor permeable and waterproof sheet of multiple layers of material laminated together, the body having a bottom portion that, in use, is positioned under a wearer's foot, the body defining an opening through which the wearer's foot will extend in use;

a single bottom seam extending substantially the entire length of the bottom portion of the body between the toe end and the heel end of the body; and

an outsole attached to the upper such that an exterior surface of the single air permeable, moisture vapor permeable, and waterproof sheet is directly exposed to an external ambient environment when used on a wearer's foot.

15. The article of footwear of claim 14, further comprising at least one cross-stitched seam formed in the bottom portion extending transverse to the bottom seam.

16. The article of footwear of claim 15, wherein the bottom seam extends at least 80% of a length of the bottom portion between a toe end and a heel end.

17. The article of footwear of claim 14, further comprising a sealing material applied over the bottom seam to waterproof the bottom seam, the sealing material being applied on an interior surface of the single air permeable, moisture vapor permeable, and waterproof sheet.

18. The article of footwear of claim 14, further comprising a rear assembly stitch seam adjacent to a heel end of the upper, the rear assembly stitch seam at least partially forming an opening into the upper.

19. The article of footwear of claim 18, further comprising a front toe sewn seam attached to the curved portion of the toe end of the upper.

20. The article of footwear of claim 19, wherein the sole seam, rear assembly stitch seam, and front toe stitch seam are generally aligned with one another.

21. The article of footwear of claim 20, wherein the sole seam and the toe stitch seam are formed as a continuous seam.

22. The article of footwear of claim 14, wherein the single air permeable, moisture vapor permeable, and waterproof sheet comprises:

a first layer comprising an air permeable, moisture vapor permeable, and water resistant film material, the first layer having a first side and a second side;

a second layer having a first side and a second side, the second layer positioned between the first layer and an external environment when the article of footwear is completed, the second layer configured to help protect the first layer from the external ambient environment.

23. The article of footwear of claim 14, further comprising an outer support frame comprising a reinforcing material, the outer support frame coupled to an outer surface of the single air permeable, moisture vapor permeable, and waterproof sheet by one or more of: molding, sewing, bonding, heat welding (e.g., using a hot press), and high frequency welding.

24. The article of footwear of claim 14, wherein at least ten percent of the surface area of the outer surface of the single air permeable, moisture vapor permeable, and waterproof sheet is directly exposed to the external ambient environment.