Article of footwear having side seams manufactured from a flat pattern and method of manufacturing the same

Abstract

The present invention provides an article of footwear having side seams manufactured from a flat pattern and a method for manufacturing the same. Disclosed is an article of footwear formed from a flat pattern and including side seams and / or formed by aligning openings in multiple flat pattern pieces. In various embodiments, an article of footwear, such as an upper, is formed from a flat pattern and modified into a three-dimensional article of footwear including side closures. The side closures may include adjacent side edges of the flat pattern upper, secured to one another by securing elements to maintain the shape of the three-dimensional article of footwear. Alignment of the components can be achieved by at least partially aligning openings in the flat pattern upper with openings in the securing elements and / or other flat pattern pieces (including using multi-purpose openings), enabling streamlined processing and manufacturing of the footwear.

Description

[0001] This application is a divisional application of an application filed on May 29, 2018, with application number 201880034312.0, and the invention name is “Footwear with side seams manufactured from a flat pattern and method for manufacturing the same (formerly known as “Functional openings for manufacturing registration”)”. Technical Field

[0002] The field relates to continuous in-line manufacturing of footwear from flat patterns. Background Art

[0003] Footwear manufacturing has traditionally been a labor-intensive process involving cutting out individual pieces and attaching them together to form an article of footwear. This type of manufacturing process can be batch-like, involving a series of operations often performed by different operators at different times. This start-and-stop process can lead to inefficiencies in footwear manufacturing. Summary of the Invention

[0004] This Summary is intended to provide a high-level overview of the disclosure and to introduce a series of concepts that will be further elaborated in the detailed description section below. This Summary is not intended to identify key features or essential features of the subject matter of the present invention, nor is it intended to be used in isolation to help determine the scope of the claimed subject matter.

[0005] Briefly and generally, embodiments of the present invention relate to continuous in-line manufacturing of footwear from flat patterns to form dimensional articles of footwear including side seams. Further embodiments of the present invention relate to assembling articles of footwear from flat pattern pieces using aperture alignment for registering the pieces.

[0006] In an exemplary embodiment, a flat pattern is provided that represents a portion of an article of footwear in a pre-formed state. The flat pattern may be a shoe upper and may be formed into a three-dimensional article of footwear by adjustments during the manufacturing process. The three-dimensional article may be formed to include adjacent medial side edges or lateral side edges that may be secured using a securing element to form a medial side closing or lateral side closing portion that maintains the shape of the three-dimensional article of footwear. The securing element may be a connecting portion or a backing portion that overlaps, secures, and / or otherwise integrates with the flat pattern upper adjacent to the adjacent side edges. The securing element may include one or more openings that are at least partially alignable with one or more corresponding openings formed in the flat pattern upper to enable registration and alignment of the components during the assembly process.

[0007] In other embodiments, a flat pattern used to form an article of footwear (e.g., a flat pattern upper) may include multi-use apertures formed to provide functionality (e.g., lacing, ventilation, etc.) and also to facilitate alignment and registration of one or more flat pattern pieces (e.g., a tongue portion, a collar portion, etc.) with the flat pattern upper for assembly and attachment. Furthermore, apertures formed in the flat pattern upper for aligning and registering one flat pattern piece may also be used, at least in part, to align and register other flat pattern pieces. Thus, reusing and / or recycling apertures during the flat pattern assembly process may limit the number of apertures required to form in the pieces to assemble the article. Alignment tools having pins spaced apart to engage aligned apertures of flat pattern pieces may also be used to facilitate alignment of the flat pattern pieces.

[0008] In one embodiment herein, an article of footwear having side seams manufactured from a flat pattern is provided. The article of footwear includes a flat pattern upper having a top surface and an opposite bottom surface, a toe end and an opposite heel end, and a mesial side and an opposite lateral side. The flat pattern upper is formed into a three-dimensional article of footwear, with the top surface forming an exterior portion of the three-dimensional article of footwear. The three-dimensional article of footwear includes a side closure portion, the side closure portion comprising abutting first and second side edges of the flat pattern upper. The side closure portion also includes a connecting portion secured to the flat pattern upper adjacent to the first and second side edges, the connecting portion having one or more openings that are at least partially aligned with one or more corresponding openings formed in the flat pattern upper.

[0009] In another exemplary embodiment herein, an article of footwear having a side seam manufactured from a flat pattern is provided. The article of footwear includes a flat pattern upper having a top surface and an opposite bottom surface, a toe end and an opposite heel end, and a mesial side and an opposite lateral side. The flat pattern upper is formed into a three-dimensional article of footwear, with the top surface forming an exterior portion of the three-dimensional article of footwear. The three-dimensional article of footwear includes a side closure portion, the side closure portion comprising abutting first and second side edges of the flat pattern upper. The side closure portion includes a padded portion secured to at least the bottom surface of the flat pattern upper adjacent to the first and second side edges, the padded portion having one or more openings aligned with one or more corresponding openings formed in the flat pattern upper.

[0010] In another exemplary embodiment herein, a method for manufacturing an article of footwear having a side seam from a flat pattern is provided. The method includes forming a flat pattern upper, the flat pattern upper having a top surface and an opposite bottom surface, a toe end and an opposite heel end, and a mesial side and an opposite lateral side. The method further includes forming one or more openings in the flat pattern upper; forming the flat pattern upper into a three-dimensional article of footwear, the top surface forming an exterior portion of the three-dimensional article of footwear; and forming a side closure portion by abutting a first side edge and a second side edge of the flat pattern upper. The method also includes providing a connecting portion having one or more openings that are alignable with the one or more openings formed in the flat pattern upper; aligning the connecting portion with the side closure portion by aligning the one or more openings in the connecting portion with the one or more openings formed in the flat pattern upper; and securing the aligned connecting portion to the flat pattern upper adjacent to the first side edge and the second side edge.

[0011] This application also covers the following aspects:

[0012] 1). An article of footwear having side seams manufactured from a flat pattern, comprising:

[0013] A flat pattern upper having a top surface and an opposite bottom surface, a toe end and an opposite heel end, and a medial side and an opposite lateral side,

[0014] The flat pattern upper is formed into a three-dimensional article of footwear, the top surface forming an exterior portion of the three-dimensional article of footwear,

[0015] The three-dimensional article of footwear includes a side closure portion including a contiguous first side edge and a second side edge of the flat pattern upper.

[0016] The side closure includes a connecting portion secured to the flat pattern upper adjacent the first side edge and the second side edge, and

[0017] The connecting portion has one or more openings that are at least partially aligned with one or more corresponding openings formed in the flat pattern upper.

[0018] 2) The article of footwear according to 1), wherein the side closure portion includes a proximal side closure portion having a first side edge including a first proximal edge of the flat pattern upper and a second side edge including a second proximal edge of the flat pattern upper, and

[0019] wherein the connecting portion comprises an elongated strip of material that overlaps the flat pattern upper adjacent the first proximal edge and the second proximal edge on at least one selected from the top surface and the bottom surface of the flat pattern upper.

[0020] 3) The article of footwear according to any one of 1) to 2), wherein the flat pattern upper further comprises:

[0021] a throat edge extending from the proximal side to the lateral side of the flat pattern upper; and

[0022] A peripheral edge extends from the proximal side to the lateral side of the flat pattern upper.

[0023] 4) The article of footwear according to any one of 1) to 3), wherein the one or more openings formed in the flat pattern upper include:

[0024] a first opening extending through the flat pattern upper, the first opening being located on a first side of the proximal closure portion and spaced apart from the first proximal edge and the throat edge, and

[0025] a second opening extending through the flat pattern upper, the second opening being located on a second side of the proximal closure portion and spaced apart from the second proximal edge and the throat edge, and

[0026] wherein the one or more openings in the connecting portion include:

[0027] A first pair of openings extends through the connecting portion, and the first pair of openings are aligned with the first opening and the second opening in the flat pattern upper, respectively.

[0028] 5). The article of footwear according to any one of 1) to 4), wherein the elongated strip of material comprises a first end, a second end, and a middle portion extending between the first end and the second end, and wherein the first pair of openings are located on the middle portion.

[0029] 6) An article of footwear according to any one of 1) to 5), wherein the elongated strip of material overlaps the top surface, the throat edge and the bottom surface of the flat pattern upper so that the elongated strip of material at least partially covers the first proximal edge and the second proximal edge on each of the inner portion and the outer portion of the three-dimensional article of footwear.

[0030] 7) The footwear according to any one of 1) to 6),

[0031] wherein the one or more openings of the connecting portion further include a second pair of openings extending through the connecting portion on the intermediate portion,

[0032] The second pair of openings are aligned with the first opening and the second opening of the flat pattern upper, respectively.

[0033] wherein the first pair of openings are located on a first portion of the connecting portion that overlaps the outer portion of the three-dimensional footwear article, and

[0034] The second pair of openings is located on a second portion of the connecting portion that overlaps the interior portion of the three-dimensional footwear article.

[0035] 8). The article of footwear according to any one of 1) to 7), further comprising a throat overlap portion having a pair of throat openings, wherein the throat overlap portion is fixed to the flat pattern upper adjacent to the throat edge on at least one of the top surface and the bottom surface selected from the flat pattern upper, wherein the connecting portion at least partially overlaps with the throat overlap portion, and wherein the pair of throat openings are respectively aligned with the first opening and the second opening in the flat pattern upper.

[0036] 9). The article of footwear according to any one of 1) to 8), wherein the flat pattern upper further comprises:

[0037] a third opening extending through the flat pattern upper, the third opening being located on the first side of the proximal closure portion and spaced apart from the first proximal edge and the peripheral edge; and

[0038] a fourth opening extending through the flat pattern upper, the fourth opening being located on the second side of the proximal closure portion and spaced apart from the second proximal edge and the peripheral edge, and

[0039] wherein the connecting portion further includes a third pair of openings extending through the first end and a fourth pair of openings extending through the second end,

[0040] The first end overlaps a portion of the proximal closure portion on the top surface of the flat pattern upper so that the third pair of openings are aligned with the third opening and the fourth opening in the flat pattern upper, respectively, and

[0041] The second end overlaps a portion of the proximal closure portion on the bottom surface of the flat pattern upper such that the fourth pair of openings are aligned with the third and fourth openings in the flat pattern upper, respectively.

[0042] 10). The article of footwear according to any one of 1) to 9), wherein the connecting portion is fixed to the flat pattern upper using at least one selected from the following:

[0043] Adhesive bonding;

[0044] thermal bonding;

[0045] Pressure bonding;

[0046] sewing; and

[0047] Welding.

[0048] 11) An article of footwear having side seams manufactured from a flat pattern, comprising:

[0049] A flat pattern upper having a top surface and an opposite bottom surface, a toe end and an opposite heel end, and a medial side and an opposite lateral side,

[0050] The flat pattern upper is formed into a three-dimensional article of footwear, the top surface forming an exterior portion of the three-dimensional article of footwear,

[0051] The three-dimensional article of footwear includes a side closure portion including a contiguous first side edge and a second side edge of the flat pattern upper.

[0052] The side closure includes a padded portion secured to at least the bottom surface of the flat pattern upper adjacent the first side edge and the second side edge, and

[0053] The padded portion has one or more openings that align with one or more corresponding openings formed in the flat pattern upper.

[0054] 12) The footwear according to 11)

[0055] wherein the side closure portion includes a proximal side closure portion having a first side edge including a first proximal edge of the flat pattern upper and a second side edge including a second proximal edge of the flat pattern upper,

[0056] wherein the flat pattern upper comprises a throat edge and a perimeter edge, and

[0057] The padded portion includes a first end secured to the bottom surface of the flat pattern upper adjacent to the throat edge and a second end secured to the bottom surface of the flat pattern upper adjacent to the perimeter edge.

[0058] 13) The article of footwear according to any one of 11) to 12), wherein the one or more openings in the flat pattern upper include at least:

[0059] a first opening located on a first side of the proximal closure portion adjacent to the first proximal edge and the throat edge;

[0060] a second opening located on a second side of the proximal closure portion adjacent to the second proximal edge and the throat edge;

[0061] a third opening located on the first side of the proximal closure portion adjacent to the first proximal edge and the peripheral edge; and

[0062] a fourth opening located on the second side of the proximal closure portion adjacent to the second proximal edge and the peripheral edge,

[0063] wherein the one or more openings in the liner portion include at least:

[0064] a first pair of mating openings located at said first end of said liner portion, and

[0065] a second pair of mating openings located at said second end of said liner portion,

[0066] wherein the first pair of matching openings are at least partially aligned with the first opening and the second opening in the flat pattern upper, respectively, and

[0067] The second pair of matching openings are at least partially aligned with the third opening and the fourth opening in the flat pattern upper, respectively.

[0068] 14) The article of footwear according to any one of 11) to 13), wherein the proximal closure portion extends from the throat edge to the perimeter edge at a non-perpendicular angle relative to the throat edge and the perimeter edge, and wherein the padded portion is secured to the flat pattern upper using at least one selected from the group consisting of:

[0069] Adhesive bonding;

[0070] thermal bonding;

[0071] Pressure bonding;

[0072] sewing; and

[0073] Welding.

[0074] 15) A method of manufacturing an article of footwear having side seams from a flat pattern, comprising:

[0075] forming a flat pattern upper having a top surface and an opposite bottom surface, a toe end and an opposite heel end, and a mesial side and an opposite lateral side;

[0076] forming one or more openings in the flat pattern upper;

[0077] forming the flat patterned upper into a three-dimensional article of footwear, the top surface forming an exterior portion of the three-dimensional article of footwear;

[0078] forming a side closure by abutting a first side edge of the flat patterned upper with a second side edge;

[0079] providing a connecting portion having one or more openings that are alignable with the one or more openings formed in the flat patterned upper;

[0080] aligning the connecting portion with the side closure portion by aligning the one or more openings in the connecting portion with the one or more openings formed in the flat pattern upper; and

[0081] The aligned connecting portions are secured to the flat pattern upper adjacent to the first side edge and the second side edge.

[0082] 16). The manufacturing method according to 15), wherein the side closure portion includes a proximal side closure portion, the proximal side closure portion having the first side edge including the first proximal edge of the flat pattern upper and the second side edge including the second proximal edge of the flat pattern upper.

[0083] 17). The manufacturing method according to any one of 15) to 16),

[0084] The flat pattern upper includes a throat edge and a perimeter edge,

[0085] wherein forming the one or more openings in the flat pattern upper comprises: forming a first opening on a first side of the proximal closure portion, the first opening being spaced apart from the throat edge and the first proximal edge; and forming a second opening on a second side of the proximal closure portion, the second opening being spaced apart from the throat edge and the second proximal edge.

[0086] wherein the one or more openings in the connecting portion include a first pair of openings, the first pair of openings being respectively alignable with the first opening and the second opening in the flat pattern upper, and

[0087] Wherein aligning the connecting portion with the proximal closure portion includes at least partially aligning the first pair of openings with the first opening and the second opening in the flat pattern upper, respectively.

[0088] 18) The manufacturing method according to any one of 15) to 17),

[0089] wherein forming the one or more openings in the flat pattern upper further comprises: forming a third opening on the first side of the proximal closure portion, the third opening being spaced apart from the peripheral edge and the first proximal edge; and forming a fourth opening on the second side of the proximal closure portion, the fourth opening being spaced apart from the peripheral edge and the second proximal edge.

[0090] wherein the one or more openings in the connecting portion further include a second pair of openings, the second pair of openings being respectively aligned with the third opening and the fourth opening in the flat pattern upper, and

[0091] Aligning the connecting portion with the proximal closure portion further comprises aligning the second pair of openings with the third opening and the fourth opening of the flat pattern upper, respectively.

[0092] 19) The manufacturing method according to any one of 15) to 18), further comprising:

[0093] providing a throat overlap portion having a pair of throat openings, wherein the pair of throat openings are respectively alignable with the first opening and the second opening formed in the flat pattern upper;

[0094] aligning the throat overlap with a throat edge by aligning the pair of throat openings with the first opening and the second opening formed in the flat pattern upper; and

[0095] securing the aligned throat overlaps to the flat pattern upper,

[0096] Wherein securing the aligned connecting portions to the flat pattern upper includes at least partially covering the throat overlap with the connecting portions.

[0097] 20). A manufacturing method according to any one of 15) to 19), wherein fixing the aligned connecting portion to the flat pattern upper comprises: thermally bonding the connecting portion to the flat pattern upper, and wherein the deformation temperature of the material forming the connecting portion is lower than the deformation temperature of the material forming the flat pattern upper.

[0098] As used herein, the term "articles of footwear" includes, but is not limited to, shoes, boots, sandals, and the like, and their partial assemblies. The term "shoe" will be used herein to refer generally to articles of footwear. It should be understood that "shoe" is not limited to a specific style and may include boots, athletic shoes, sandals, running shoes, cleats, dress shoes, and other types of footwear. Generally speaking, a shoe is comprised of a ground-contacting portion, which may be referred to as a sole. The sole may be formed from a variety of materials and / or individual components. For example, a sole may include an outsole, a midsole, and / or an insole. A shoe may also include a foot-retaining portion that can be used to secure the wearer's foot to the sole. The foot-retaining portion may be referred to as a shoe upper (or simply "upper"). The upper may be formed from one or more materials and / or from one or more individual components. BRIEF DESCRIPTION OF THE DRAWINGS

[0099] The subject matter of the present invention is herein described in detail with reference to the accompanying drawings which show exemplary and non-limiting embodiments thereof, in which:

[0100] Figure 1 An exemplary in-line manufacturing process for forming an article of footwear from a flat pattern is shown according to embodiments herein.

[0101] Figure 2 An exemplary flat pattern upper is shown according to embodiments herein.

[0102] Figure 3 According to the embodiment of the present invention, a three-dimensional footwear article is formed as viewed from the medial side. Figure 2 Flat pattern upper as shown.

[0103] Figure 4A According to the embodiment herein, a device having a connecting portion fixed to a proximal closure portion is shown. Figure 3 The three-dimensional article of footwear shown.

[0104] Figure 4B According to the embodiment of this article, the Figure 4A The connection part shown.

[0105] Figure 5A According to the embodiments herein, a liner portion is shown that fits to the mesial closure portion. Figure 3 The three-dimensional article of footwear shown.

[0106] Figure 5B According to the embodiment of this article, the Figure 5A Pad portion shown.

[0107] Figure 6 According to the embodiment of this article, Figure 3 The three-dimensional article of footwear is shown wherein the connecting portion overlies the proximal closure portion and is aligned with the proximal closure portion for fit.

[0108] Figure 7 According to the embodiment of this article, Figure 3 The three-dimensional footwear article shown, wherein Figure 4B The connecting portion is fixed to the three-dimensional footwear article using a component attachment tool.

[0109] Figure 8A According to the embodiment of this article, Figure 4A A cross-sectional view of a medial closure portion of a three-dimensional article of footwear.

[0110] Figure 8B According to the embodiment of this article, Figure 5A A cross-sectional view of a medial closure portion of a three-dimensional article of footwear.

[0111] Figure 9Embodiments according to this document illustrate a three-dimensional article of footwear formed from a flat patterned upper with a fitted sole.

[0112] Figure 10 A block diagram illustrating an exemplary method of manufacturing an article of footwear from a flat pattern according to embodiments herein is shown.

[0113] Figure 11A An exploded view of a flat pattern upper and a flat pattern tongue portion aligned for assembly using a registration tool is shown according to embodiments herein.

[0114] Figure 11B According to the embodiment of the present invention, the method of aligning the registration tool for bonding is shown. Figure 11A A top-down elevation view of the flat pattern upper and flat pattern tongue portion shown.

[0115] Figure 12A An exploded view of a flat pattern upper and a flat pattern collar portion are shown aligned for assembly on another alignment tool according to embodiments herein.

[0116] Figure 12B According to the embodiment of the present invention, the method of aligning the registration tool for bonding is shown. Figure 12A A top-down elevation view of the flat pattern upper and flat pattern collar portions shown. DETAILED DESCRIPTION

[0117] The subject matter of the present invention will be specifically described herein to meet statutory requirements. However, this description is not intended to limit the scope of the invention. Specifically, the claimed subject matter can be provided in other ways and in combination with other current technologies and / or future technologies to include different features, steps and / or combinations of features and / or steps similar to the features and steps described in the present invention. The terms "step" and "block" should not be interpreted as implying any particular order between the elements of the method used, unless and except where the order of the individual steps or blocks is explicitly described and required.

[0118] In summary, the present invention generally relates to manufacturing footwear or portions thereof from a continuous line of flat patterns. The flat patterns can be formed into three-dimensional articles of footwear including fixed side closures (e.g., mesial or lateral closures). The articles of footwear can be constructed from one or more flat pattern pieces that are aligned and registered for attachment to one another using aperture alignment. In this regard, the apertures formed in the flat pattern pieces can provide functionality in the resulting article of footwear (e.g., for lacing, ventilation, etc.) and can also be reused and / or repurposed to align and register one or more flat pattern pieces for assembly and attachment.

[0119] In addition to the materials and techniques used to form such articles, other shaping, forming, and / or combining and fitting of components may be utilized to obtain the desired three-dimensional shape (e.g., a three-dimensional shoe). Traditionally, a tool known as a cobbler's last serves as a mold around which the shoe can be formed into the desired size, shape, and configuration. The term "last" as used herein refers to a tool around which a three-dimensional upper is formed. In some embodiments, the sole may be coupled (e.g., adhered, stitched, welded, etc.) to the upper while the upper is being lasted (i.e., while the last is positioned in the interior volume of the upper). The last may define the outline, shape, style, and / or other characteristics of the resulting shoe.

[0120] The "flat pattern" used in the present invention shall mean Figure 1-2 As generally shown in FIG, some substantially planar materials may be modified or shaped before being formed into a desired three-dimensional article of footwear or a portion thereof (e.g., an upper having a desired height, size, etc.). Although different materials may be coupled to one another in a manner that creates textures, bumps, embossing, protrusions, etc. on the flat pattern, some of the materials are still considered substantially planar and, therefore, "flat" even with such height and texture deviations along the surface. Once molded around a last to form a receiving cavity in which a wearer's foot may be received, the flat pattern becomes a "three-dimensional article of footwear."

[0121] In an exemplary embodiment, a three-dimensional footwear article is an article that is shaped so as to be secured to and encircle a portion of a wearer's body (e.g., a wearer's foot). In contrast to a "three-dimensional" article, a "flat" pattern is not shaped so as to be received around a portion of a wearer's body (e.g., a wearer's foot). It should be noted that a "three-dimensional footwear article" does not necessarily mean a fully shaped footwear article (e.g., a three-dimensional footwear article may simply be an upper without a fitted sole, insole, sole portion, lining, etc.).

[0122] The flat pattern concept facilitates manufacturing because many of the materials used to form the upper are rolled goods or flat goods that are originally in a substantially planar (e.g., sheet) configuration. Therefore, constructing the upper from a number of flat components in an in-line manufacturing process can be advantageous from the perspectives of material usage, construction, and assembly efficiency. Furthermore, continuous in-line manufacturing enables the strategic and efficient implementation of engineered material properties, such as tensile strength, elongation characteristics, and moisture transportation, on a flat pattern. Compared to traditional three-dimensional upper manufacturing processes, the flat pattern concept also provides greater manufacturing consistency and enhanced machine capabilities. Furthermore, within an in-line manufacturing process (including within the same in-line manufacturing process), variations in the size, style, and / or materials used in the upper can occur.

[0123] It is also contemplated that the in-line manufacturing process may be automated, such that one or more processes along the manufacturing line are performed by machines that are programmed to perform one or more specific tasks. Additionally or alternatively, it is contemplated that one or more processes in the in-line manufacturing process may be performed manually by a human operator. Thus, in exemplary embodiments, any combination of machine and human involvement may be implemented to achieve the formation of an article (e.g., a shoe upper).

[0124] Exemplary Online Manufacturing System

[0125] Figure 1 According to the embodiments herein, an exemplary in-line manufacturing process for forming an article of footwear from a flat pattern is shown. More specifically, Figure 1 A continuous in-line production system 100 is shown for forming an article of footwear using a base plate 101. Base plate 101 can serve as a foundation from which the article of footwear can be formed and can be selected to provide a degree of stretch that allows for registration and positioning of materials on base plate 101. A tracking system (e.g., including cameras, vision systems, sensors, and / or other tracking components) can be used with the production system (continuous in-line production system 100) to monitor the position of base plate 101 and / or monitor modifications to the position of base plate 101.

[0126] The substrate 101 used in the production system (continuous in-line production system 100) can have any width and / or any length. In one embodiment, the substrate 101 is a roll-like commodity having a width sufficient to form at least one, two, three, four, five, or six flat pattern uppers across the width of the substrate 101. The substrate 101 can also be wide enough to form at least two flat pattern uppers in a common operation to provide matching articles of footwear. Each of the flat footwear patterns formed in the continuous in-line manufacturing process can represent a common or different style, shape, size, and / or configuration of the upper from the next flat footwear pattern.

[0127] The substrate 101 can be made of any material, including Figure 1 The sheet material shown in the exemplary embodiment shown in . For example, substrate 101 may be a non-woven fabric, which is a sheet-like or web-like structure formed by entanglement of fibers / filaments through a mechanical, thermal, and / or chemical process. A non-woven material may be a flat, porous material that is neither woven nor knitted. A non-woven material may also be formed from recycled materials (e.g., residual materials from the on-line manufacturing process itself). Alternatively, the non-woven material may be a polymer-based material such as polyurethane (PU) or thermoplastic polyurethane (TPU). The non-woven material may be a mesh material, such as industrial felt made by needle-felt polyester fibers. In other embodiments, substrate 101 may be a knitted or woven material, or a combination of knitted / woven and / or non-woven / non-knitted materials, and may include materials obtained from the manufacturing process itself.

[0128] It is contemplated that, whether formed from a nonwoven material or another material (e.g., a woven or knitted material), substrate 101 may be formed from one or more synthetic fibers, natural fibers, or a combination thereof. In one embodiment, such fibers may be captured as part of a waste stream from the manufacturing process. For example, portions of substrate 101 not used to form an article (e.g., a shoe upper) may be collected from a waste stream following article formation, and these portions of substrate 101 not used to form the article may be recycled to be used to form substrate 101 again in a subsequent manufacturing process. In this way, recycling substrate 101 may provide economic efficiencies in the manufacturing process. This is particularly true when substrate 101 is a nonwoven material formed by randomly entangled fibers, rather than a knitted or woven material having a specifically engineered structure (e.g., interlacing, looping, etc.).

[0129] Alternatively, substrate 101 may be formed from a woven or knitted material. For example, it is contemplated that substrate 101 may be formed from an online knitted or woven material, such that substrate 101 begins with a yarn material, fiber material, thread material, or other raw material and is then formed into a sheet-like configuration as part of an online manufacturing process. Alternatively, it is contemplated that substrate 101 is formed into a sheet-like form by knitting or braiding prior to being introduced into an online manufacturing process.

[0130] Back to Figure 1 , substrate 101 is shown being processed along a series of processing stations and positioned along a production system (continuous in-line production system 100). More specifically, production system (continuous in-line production system 100) includes a conveyor system 102 that advances substrate 101 and a series of processing stations 104, 106, 108, 110, and 112, at which substrate 101 can be adjusted and / or modified during the manufacturing process. It is contemplated that production system (continuous in-line production system 100) can operate in a continuous manner, providing various modifications to each flat pattern until each flat pattern is removed from conveyor system 102. As such, it is contemplated that a portion of substrate 101 will form a portion of the removed shoe upper. Figure 1 An exemplary flat pattern upper outline 114 is shown having been extracted from base plate 101 along with waste portion 116. In certain embodiments, waste portion 116 may be recycled for use in forming other flat pattern uppers by reintegrating waste portion 116 into base plate 101.

[0131] The production system (continuous in-line production system 100) including the conveyor system 102 and the processing stations 104, 106, 108, 110 and 112 is exemplary and different processing configurations are contemplated. Figure 1An exemplary flat pattern upper outline 114 is shown, but other types of flat patterns are contemplated. It should be understood that any combination, spacing, order, and configuration of components can be used in the production system (continuous online production system 100) to achieve the embodiments provided herein. In this regard, processing stations, such as processing stations 104, 106, 108, 110, and 112, may be, but are not limited to, printing stations, liquid application stations, heat application stations, steam application stations, cutting stations, punching stations, component movement / component adjustment stations, sewing stations, adhesive application stations, welding stations, visual and component identification / analysis stations, and the like. In addition, it is contemplated that one or more stations may be combined into a common station to perform multiple operations at a common location and / or at a common time. It is also contemplated that one or more stations may be human-operated, such that humans can perform operations in the absence of the production system (continuous online production system 100) or in conjunction with the production system (continuous online production system 100).

[0132] Despite the combination Figure 1 The continuous in-line production system 100 shown in FIG. 1 shows specific components and processes, but it should be understood that any process (e.g., cutting, coupling, painting, printing, applying, forming, etc.) can be performed in any order and at any number of times. In addition, although specific components are shown, it is contemplated that any combination, shape, sequence, and / or configuration of components can be implemented by an in-line manufacturing system according to embodiments of the present invention.

[0133] Forming an article of footwear having side seams

[0134] Reference Figure 2 , according to the embodiments herein, an exemplary flat pattern upper 118 is provided. The flat pattern upper 118 may be made of, for example, Figure 1 The flat pattern upper 118 can be formed from a base material such as the base plate 101 shown in the figure or cut from the base material. The flat pattern upper 118 can be formed so that the flat pattern upper 118 can be adjusted to form a three-dimensional footwear article (for example, the three-dimensional upper can be attached to the sole, insole, bottom part of the foot, etc.). The flat pattern upper 118 includes a top surface 120 and an opposite bottom surface 122 (which is opposite to the top surface 120 and the bottom surface 122). Figure 2 lateral side 130. Figure 2 In the embodiment shown, the flat pattern upper 118 has not yet been modified into a three-dimensional article of footwear and is therefore in a lay-flat configuration. As such, the proximal side 128 is effectively separated into Figure 2, the first proximal side 132 and the second proximal side 134 are shown in a flat, planar configuration, the first proximal side 132 and the second proximal side 134 being separate and non-contiguous rather than crossing the lateral side 130 of the flat pattern upper 118. The first proximal side 132 includes a first proximal edge 136, and the second proximal side 134 includes a second proximal edge 138.

[0135] It should be understood that Figure 2 The flat pattern upper 118 can be modified and adjusted differently at different stages of the online manufacturing process. Figure 2 The flat pattern upper 118 shown in FIG is merely one example taken from one stage of the online manufacturing process and is not necessarily in its final form. Rather, additional processes such as cutting, welding, material bonding, forming and shaping, and / or other adjustment processes may be applied to the flat pattern upper 118 at other stages.

[0136] Reference Figure 3 , according to the embodiments of this article, Figure 2 The flat pattern upper 118 is shown forming a three-dimensional article of footwear 140. Figure 3 1 , top surface 120 of flat patterned upper 118 forms exterior portion 142 of three-dimensional article of footwear 140, and bottom surface 122 forms interior portion 144 of three-dimensional article of footwear 140. Furthermore, first proximal edge 136 of first proximal side 132 and second proximal edge 138 of second proximal side 134 abut or, more specifically, come within proximity of one another (e.g., within 1 inch, 1 / 2 inch, 1 / 4 inch, 1 / 8 inch, or 1 / 16 inch of one another, or are in contact with one another) to be secured thereto and thereby form proximal closure 146 in three-dimensional article of footwear 140.

[0137] The three-dimensional article of footwear 140 includes a throat portion 148 and a perimeter portion 152. The throat portion 148 has a throat edge 150 extending around the throat portion 148 from the proximal side 128 to the lateral side 130. The perimeter portion 152 has a perimeter edge 154 extending around the perimeter portion 152 from the proximal side 128 to the lateral side 130 opposite the throat edge 150. The flat pattern upper 118 also includes a plurality of openings 156. The plurality of openings 156 can be used in certain embodiments to register and align a fastening element attached to the flat pattern upper 118 to secure the first proximal side 132 to the second proximal side 134 so that the three-dimensional article of footwear 140 can at least partially maintain its shape. Figure 4A-4B and Figure 5A-5B Exemplary fixation elements (eg, connecting portions, padding portions, etc.) are discussed in further detail.

[0138] The first proximal side 132 and the second proximal side 134 each include an opening for alignment. The first proximal side 132 includes a first opening 160 extending through the flat pattern upper 118, and the second proximal side 134 includes a second opening 164 also extending through the flat pattern upper 118. Figure 3 As shown in FIG, first opening 160 is spaced apart from first proximal edge 136 and throat edge 150 such that first opening 160 is located proximal to throat edge 150 (i.e., first opening 160 is closer to throat edge 150 than first opening 160 is to perimeter edge 154). Second opening 164 is spaced apart from second proximal edge 138 and throat edge 150 such that second opening 164 is located proximal to throat edge 150 (i.e., second opening 164 is closer to throat edge 150 than second opening 164 is to perimeter edge 154).

[0139] First proximal side 132 further includes a third opening 166 that is spaced from first proximal edge 136 and perimeter edge 154 such that third opening 166 is located proximal to perimeter edge 154 (i.e., third opening 166 is closer to perimeter edge 154 than third opening 166 is to throat edge 150). Second proximal side 134 further includes a fourth opening 168 that is spaced from second proximal edge 138 and perimeter edge 154 such that fourth opening 168 is located proximal to perimeter edge 154 (i.e., fourth opening 168 is closer to perimeter edge 154 than fourth opening 168 is to throat edge 150). Throat portion 148 may also include a throat overlap that is aligned with flat pattern upper 118 during subsequent processing steps (see FIG. 1 ). Figure 4A ). Peripheral portion 152 may further include a perimeter overlap that may, for example, be a separate portion of material or may be a portion of a sole affixed to three-dimensional article of footwear 140.

[0140] In addition, although Figure 2-Figure 3 A flat pattern upper is shown formed into a three-dimensional footwear article having a proximal side closure portion, however, it is contemplated that in other embodiments, the flat pattern upper may be configured to be formed into a three-dimensional footwear article having a lateral closure portion (e.g., having adjacent and fixed lateral edges) having similarly discussed fixing elements for fixing the adjacent lateral edges.

[0141] Reference Figure 4A According to the embodiment of the present invention, there is provided a device which is shown to be fitted with a connecting portion 172 to fix the proximal closure portion 146. Figure 3 The three-dimensional footwear article 140 is shown. For greater clarity, Figure 4B Shown in isolation Figure 4A The exemplary connecting portion 172 is shown in FIG. Figure 4A , the connecting portion 172 is shown as being layered over and adhered to the flat pattern upper 118 to cover the top surface 120, the bottom surface 122, and the throat edge 150. The connecting portion 172 also at least partially covers the Figure 3 The flat pattern upper 118 is shown with the first proximal edge 136 and the second proximal edge 138 being adjacent.

[0142] exist Figure 4A-4B The connecting portion 172 of the elongated strip of material, shown as having a first end 174, a second end 176, and a middle portion 178, includes a plurality of openings positioned so that the plurality of openings can align with corresponding openings formed in the flat pattern upper 118 (e.g., Figure 3 The first opening 160, the second opening 164, the third opening 166 and the fourth opening 168 shown in FIG are aligned. Figure 4A , the adjacent first and second proximal edges 136, 138, the proximal closure portion 146, and the connecting portion 172 extend from the throat portion 148 to the peripheral portion 152 at a non-perpendicular angle to the throat edge 150 and the peripheral edge 154. It is contemplated that in different embodiments, the connecting portion 172 may be perpendicular or non-perpendicular relative to each of the throat edge 150 and the peripheral edge 154.

[0143] Reference Figure 4B , shown in isolation according to the embodiments herein Figure 4A The exemplary connecting portion 172 is shown. The connecting portion 172 includes a first pair of openings 180 that extend through a first member 182 of the connecting portion 172. Figure 4A As shown in FIG, first member 182 overlaps exterior portion 142 of three-dimensional article of footwear 140 (i.e., overlaps top surface 120 of flat pattern upper 118). Connecting portion 172 further includes a second pair of openings 184 extending through second member 186 of connecting portion 172. Figure 4A As shown in phantom in FIG, second component 186 overlaps interior portion 144 of three-dimensional article of footwear 140 (ie, overlaps bottom surface 122 of flat pattern upper 118).

[0144] Reference Figure 4A The first pair of openings 180 and the second pair of openings 184 are positioned on the connecting portion 172 so that when the connecting portion 172 is aligned with the proximal closure portion 146, the first pair of openings 180 at least partially align with the first openings 160 and the second openings 164 (shown in FIG. 1 ) formed in the flat pattern upper 118, respectively. Figure 3) and furthermore, the second pair of openings 184 are at least partially aligned with the first openings 160 and the second openings 164 formed in the flat pattern upper 118 (shown in Figure 3 The first pair of openings 180 and the second pair of openings 184 are aligned with each other. This alignment allows the connecting portion 172 to be properly positioned and registered on the flat pattern upper 118 during the manufacturing and assembly processes for attachment at the proximal medial closure portion 146. Furthermore, the portion 188 connecting the first and second members 182, 186 of the connecting portion 172 is folded over the throat edge 150.

[0145] To further facilitate component registration and alignment, the first end 174 of the connecting portion 172 includes a third pair of openings 190 that are at least partially aligned with the third openings 166 and the fourth openings 168 (shown in FIG. Figure 3 The alignment of third pair of openings 190 enables first end 174 of connecting portion 172 to be aligned with proximal closure portion 146 on exterior portion 142 of three-dimensional article of footwear 140 adjacent perimeter edge 154 (i.e., on top surface 120). Second end 176 of connecting portion 172 further includes a fourth pair of openings 192 that are at least partially aligned with third openings 166 and fourth openings 168, respectively, formed in flat patterned upper 118, enabling second end 176 of connecting portion 172 to be aligned with proximal closure portion 146 on interior portion 144 of three-dimensional article of footwear 140 adjacent perimeter edge 154 (i.e., on bottom surface 122). Thus, during the manufacturing and assembly processes, third and fourth pairs of apertures 190, 192 are aligned with corresponding third and fourth apertures 166, 168 in flat pattern upper 118 adjacent perimeter edge 154 such that first and second ends 174, 176 of connecting portion 172 are registered and aligned with proximal closure portion 146. It should be understood that the "alignment" of apertures discussed herein may refer to partial or complete alignment of corresponding apertures.

[0146] Therefore, if Figure 4A , the connecting portion 172 overlaps and adheres to the outer portion 142 along the proximal closure portion 146 (shown in solid lines), and further overlaps and adheres to the inner portion 144 along the proximal closure portion 146 (shown in dashed lines). Such alignment provides for accurate positioning of the components during assembly and, in some embodiments, may also facilitate assembly in an automated manner (e.g., using component picking tools, component placement tools, and component attachment tools to place and attach components in addition to other tools or human-based intervention).

[0147] The connecting portion 172 can be secured to the flat pattern upper 118 at the proximal closure portion 146 using heat bonding, pressure bonding, welding (e.g., ultrasonic welding), sewing, stitching, chemical or adhesive bonding, fiber entanglement, and / or any other suitable securing, connecting, and / or joining process. The securing can also be provided in an automated manner using one or more component attachment tools, or can be provided with some degree of human involvement, or can be provided by some combination of the two.

[0148] Figure 4A Further shown is a throat overlap 170 secured to the flat pattern upper 118 adjacent to the throat edge 150. The throat overlap 170 can overlap and conform to one or both of the top surface 120 and the bottom surface 122 of the flat pattern upper 118 to provide reinforcement at the throat edge 150 (e.g., to withstand forces applied when lacing the article of footwear). Additionally, the throat overlap 170 can be as Figure 4A 160 and the second opening 164 formed in the flat pattern upper 118. Figure 3 ) and the first pair of openings 180 and the second pair of openings 184 formed in the connecting portion 172. This enables the throat overlap 170 to be registered and aligned with both the flat pattern upper 118 and the connecting portion 172 during assembly of the article.

[0149] It should be noted that Figure 3 and Figure 4A The exemplary flat pattern upper 118 shown in FIG includes an exemplary number of openings located in exemplary locations, and Figure 4B The exemplary connecting portion 172 shown in FIG includes an exemplary number of openings positioned to align with the openings in the flat pattern upper 118. However, it should be understood that numerous other configurations are possible, including configurations having different numbers, sizes, arrangements, and patterns of openings. Additionally, Figure 4AThe proximal closure portion 146 shown in the embodiment of FIG is exemplary, and proximal closure portions having different sizes, lengths, angles, positioning, and / or using different aperture alignment configurations, etc., are contemplated herein. Furthermore, in various embodiments, one or more connecting portions may overlie and be secured to an exterior portion, interior portion, edge, or any combination thereof of the article, and the connecting portions may have different shapes, sizes, or aperture configurations. Additionally, in some embodiments, one or more proximal closure portions may be provided with separate or interconnected connecting portions. Alternatively, a connecting portion may not be used, and the edges may be secured to each other by any desired attachment method, including those described herein.

[0150] Reference Figure 5A According to the embodiment of the present invention, a liner portion 196 for fixing the proximal closure portion 146 is provided. Figure 3 The three-dimensional footwear article 140 shown. The padded portion 196 extends along the proximal closure portion 146 on the bottom surface 122 of the flat pattern upper 118 (or more precisely, on the inner portion 144 of the three-dimensional footwear article 140). In this way, Figure 5A The configuration shown in FIG provides a proximal closure portion 146 that has less overlapping material on the exterior portion 142 of the three-dimensional article of footwear 140. The liner portion 196 may still be secured (as with the connecting portion 172) to the flat patterned upper 118 using any desired process, material, and / or structure (e.g., using any of heat bonding, pressure bonding, adhesive or chemical bonding, welding, etc., as well as heat bonding, pressure bonding, adhesive or chemical bonding, welding, etc. using automated part attachment tools).

[0151] like Figure 5A As shown in FIG, the first and second proximal edges 136, 138 of the flat pattern upper 118 are abutted, and the padded portion 196 (shown in phantom to indicate its positioning on the interior portion 144 of the three-dimensional article of footwear 140) is aligned and affixed to the flat pattern upper 118 along the proximal side closure 146. The abutted first and second proximal edges 136, 138 form a seam 200 that, in various embodiments, may be exposed, concealed, or partially exposed and partially concealed. Additional materials and treatments may be applied to the flat pattern upper 118 to cover, obscure, blend, and / or integrate this seam 200. For example, during the continuous manufacturing process, the flat pattern upper 118 may be further modified by overlapping the covered seam 200 on the proximal side 128 to provide reinforcement, additional utility (e.g., to reduce stretch properties), or to provide additional aesthetic elements (e.g., exclusive logos, designs, etc.).

[0152] Reference Figure 5B , according to the embodiments herein, the pad portion 196 is provided in isolation. It should be noted again that, like the connecting portion 172, the size, shape, thickness, material, pore configuration, etc. of the pad portion 196 can be varied as desired, and in this way, Figure 5B The configuration shown in FIG is merely exemplary. The pad portion 196 includes a first end 202 and a second end 204. Figure 5A As shown in the figure, the first end 202 is fixed to the bottom surface 122 of the flat pattern upper 118 adjacent to the throat edge 150 (i.e., the first end 202 is closer to the throat edge 150 than the first end 202 and the peripheral edge 154), and the second end 204 is fixed to the bottom surface 122 of the flat pattern upper 118 adjacent to the peripheral edge 154 (i.e., the second end 204 is closer to the throat edge 150 than the second end 204 and the peripheral edge 154). Figure 5A Pad portion 196 is shown in phantom to illustrate its relative positioning on three-dimensional article of footwear 140.

[0153] and Figure 4A-4B Like the connecting portion 172 shown in FIG, the liner portion 196 includes openings for alignment and registration with the flat pattern upper 118. More specifically, the liner portion 196 includes a first pair of mating openings 206 located at the first end 202 and a second pair of mating openings 208 located at the second end 204. The first pair of mating openings 206 can be respectively aligned with the first openings 160 and the second openings 164 formed in the flat pattern upper 118 (as shown in FIG. Figure 3 ), the second pair of matching openings 208 can be aligned with the third opening 166 and the fourth opening 168 (as shown in FIG) formed in the flat pattern upper 118, respectively. Figure 3 As shown in Figure 4A As with the embodiments shown in , use of such aperture alignment during assembly of an article can enable more streamlined and, in some embodiments, automated placement, alignment, and fit of components.

[0154] Figure 5A The throat overlap portion 170 is further shown, and the throat overlap portion 170 includes a pair of throat openings 194, which can align with corresponding first openings 160 and second openings 164 in the flat pattern upper 118 (such as Figure 3) are aligned to allow throat overlap 170 to register and align with flat pattern upper 118. Aligning the pair of throat openings 194 allows flat pattern upper 118, padded portion 196, and throat overlap 170 to be aligned for attachment during the manufacturing process. In various embodiments, throat overlap 170 may be at least partially secured relative to flat pattern upper 118 by padded portion 196, or throat overlap 170 may overlap only exterior portion 142 of three-dimensional article of footwear 140, and padded portion 196 may overlap interior portion 144 of three-dimensional article of footwear 140. Once registration and alignment have been achieved, padded portion 196 and flat pattern upper 118 (and optionally, additional components such as throat overlap 170) may be secured to each other using one or more joining processes, such as adhesive bonding, heat bonding, pressure bonding, welding (e.g., ultrasonic welding), or another suitable method.

[0155] It should be noted that in alternative embodiments, the padded portion 196 may be attached to the flat patterned upper 118 on the exterior portion 142 of the three-dimensional article of footwear 140 to cover and secure the proximal closure 146 (see FIG. Figure 10 ). Pad portion 196 can thus be positioned to at least partially cover and / or conceal seam 200 on outer portion 142 and can additionally serve to layer other overlaps and / or materials on outer portion 142. Attachment methods similar to those described herein can be used to provide securement in this configuration.

[0156] Reference Figure 6 , according to the embodiments of this article, Figure 3 The three-dimensional footwear article 140 is shown, wherein Figure 4A-4B The connecting portion 172 is shown superimposed on the three-dimensional article of footwear 140 at the proximal closure portion 146 and aligned for securement. Figure 6 14. In the embodiment of the present invention, connecting portion 172 is positioned such that connecting portion 172 extends from interior portion 144 of three-dimensional article of footwear 140 to exterior portion 142 of three-dimensional article of footwear 140, folding over top surface 120, bottom surface 122, and throat edge 150. First and second pairs of openings 180, 184 of connecting portion 172 are aligned with first and second openings 160, 164, respectively, in flat patterned upper 118, toward the top of proximal closure portion 146 (i.e., adjacent to throat edge 150), and third and fourth pairs of openings 190, 192 are aligned with third and fourth openings 166, 168, respectively, in flat patterned upper 118, toward the bottom of proximal closure portion 146 (i.e., adjacent to perimeter edge 154). In various embodiments, such an alignment process may utilize alignment pins, a vision system, and / or other systems to facilitate achieving and confirming the desired degree of alignment of components during assembly.

[0157] Reference Figure 7 , according to the embodiments of this article, Figure 3 The three-dimensional footwear article 140 is shown, wherein Figure 4B The illustrated connecting portion 172 is positioned for attachment using a component attachment tool 210. The component attachment tool 210 may be configured to apply any one or more of pressure, heat, vibration, or the like to the aligned and stacked materials positioned within the component attachment tool 210 to attach the materials. The stacked materials may be maintained in position / alignment using pins 212, which may be aligned with corresponding openings in the component attachment tool 210. In other embodiments, the component attachment tool 210 may be configured with one or more additional component processing tools (e.g., one or more additional heat application tools, cutting tools, welding tools, adhesive application tools, etc.) provided in a combined or distributed arrangement.

[0158] In one embodiment, component attaching tool 210 may be configured to provide sufficient heat to bond connecting portion 172 to flat pattern upper 118 without reaching a temperature that degrades the material of connecting portion 172 or flat pattern upper 118. Thus, thermal bonding can be achieved without compromising the material or construction of the article of footwear. Additionally, the deformation temperature of connecting portion 172 or lining portion 196 may be lower than the deformation temperature of flat pattern upper 118 to enable bonding without deforming flat pattern upper 118.

[0159] Reference Figure 8A According to the embodiments of this article, Figure 4A The three-dimensional footwear article 140 is shown along section line 8A-8A (see Figure 4A ), which shows the connecting portion 172 superimposed on and attached to the flat pattern upper 118 at the proximal closure portion 146. Figure 8A As shown in FIG, the top surface 120, the bottom surface 122 and the throat edge 150 have been covered by the folded-over connecting portion 172, which also partially covers the throat overlap 170 located between the connecting portion 172 and the flat pattern upper 118. This provides a form of fixation at the proximal closure portion 146. In addition, as shown in FIG. Figure 8AAs shown in FIG, first opening 160 of flat pattern upper 118 is at least partially aligned with a corresponding one of the first pair of openings 180 in first component 182 of connecting portion 172, and is also partially aligned with a corresponding one of the second pair of openings 184 in second component 186 of connecting portion 172. One of throat openings 194 in throat overlap 170 is also aligned with first opening 160. This material stack configuration can be secured by utilizing adhesive bonding, heat bonding, pressure bonding, sewing, welding, and the like. For example, connecting portion 172 can be formed from a material that melts at a specific deformation temperature lower than the deformation temperature of the material forming flat pattern upper 118, such that connecting portion 172 can form a fixed bond with flat pattern upper 118 upon reaching the specific deformation temperature.

[0160] Reference Figure 8B , similarly, according to the embodiments of this invention, Figure 5A The three-dimensional footwear article 140 is shown along section line 8B-8B (see Figure 5A ) is a cross-sectional view showing the padded portion 196 attached to the flat pattern upper 118 at the proximal closure 146. Figure 8B As shown, the padded portion 196 is attached to the bottom surface 122 of the flat pattern upper 118 so as to secure the proximal closure 146. Figure 5A and Figure 8B In the embodiment shown in FIG, the throat overlap 170 is exposed on the outer portion 142. Additionally, one of the pair of throat openings 194, the first opening 160 of the flat pattern upper 118, and one of the first pair of mating openings 206 are at least partially aligned to provide a path through the laminated material.

[0161] Reference Figure 9 According to an embodiment of the present invention, a three-dimensional footwear article 214 is formed from a flat pattern upper 216. The three-dimensional footwear article 214 includes a proximal closure portion 218. A padded portion 220 is laminated on an outer portion 222 of the three-dimensional footwear article 214 along the proximal closure portion 218 and is fixed to the outer portion 222. Figure 9 , sole 221 or a portion of sole 221 has been secured to the sole portion of three-dimensional article of footwear 214. Pad portion 220 extends from throat edge 226 of flat pattern upper 216 to perimeter edge 228 of flat pattern upper 216 and is further secured at least partially by sole 221 at perimeter edge 228. As described elsewhere herein, aperture alignment may be utilized to align pad portion 220 with proximal closure portion 218. Figure 9As shown in the exemplary embodiment shown in , the liner portion 220 can be at least partially covered, concealed and / or secured by the sole 221 near the peripheral edge 228. Figure 5A and Figure 5B middle), Figure 9 The three-dimensional article of footwear 214 shown in FIG. 1 may represent an article at a location further downstream in the manufacturing and assembly process.

[0162] Exemplary Methods of Making an Article of Footwear Having Side Seams

[0163] Reference Figure 10 , a block diagram of an exemplary method 1000 for manufacturing an article of footwear having side seams from a flat pattern is provided according to embodiments herein. At block 1010, a flat pattern upper (e.g., Figure 2 ) having a top surface and an opposing bottom surface (e.g., Figure 2 , a top surface 120 and a bottom surface 122 are shown in FIG), a toe end and an opposite heel end (e.g. Figure 2 124 and heel end 126) and the mesial and opposite lateral sides (e.g. Figure 2 At block 1020, one or more openings are formed in the flat pattern upper, e.g., Figure 3 160, second opening 164, third opening 166, and fourth opening 168 are shown in FIG. At block 1030, the flat pattern upper is formed into a three-dimensional footwear article (e.g., Figure 3 ), wherein the top surface forms an exterior portion of the three-dimensional article of footwear (e.g., Figure 3 142).

[0164] At block 1040, the first side edge of the flat pattern upper (e.g. Figure 3 The first mesial edge 136 shown in FIG. 1 and the second lateral edge (eg, Figure 3 ) adjoin to form a side closure portion (e.g., Figure 4A At block 1050, a connecting portion (e.g., Figure 4B ), the connecting portion having one or more openings (e.g., Figure 4B180, a second pair of openings 184, a third pair of openings 190, and a fourth pair of openings 192 are shown in the figure, wherein the one or more openings can be aligned with the one or more openings formed in the flat pattern upper. At block 1060, the connecting portion is aligned with the side closure portion by aligning the one or more openings in the connecting portion with the one or more openings formed in the flat pattern upper. At block 1070, the aligned connecting portion is secured to the flat pattern upper adjacent to the first and second side edges, for example, using one of the methods or processes described herein.

[0165] Use the multi-purpose cutouts to align flat pattern pieces for assembly

[0166] In addition to facilitating the fixing of the element to the side closure (e.g. Figure 4A and Figure 5A In addition to aligning the proximal closure portion (as shown in FIG), the openings formed in the flat pattern upper can also provide multi-purpose functionality. For example, the flat pattern upper can include functional openings (e.g., lacing openings, ventilation openings, etc.) that can also be used to align and register the flat pattern pieces during the assembly process. In addition, the openings used to align one flat pattern piece can also be used to align other flat pattern pieces. Accordingly, such reuse and / or recycling of openings can facilitate the assembly of footwear from flat pattern pieces with fewer manufacturing-specific modifications (e.g., openings, features, and / or structures formed specifically for assembly of the components).

[0167] By using one or more registration tools, it is convenient to align and register the flat pattern pieces. Each registration tool may include pins that are spaced apart to engage with the aligned openings of the assembled flat pattern pieces. For example, the registration tool may have pins that are spaced apart to engage with the openings of the tongue portion and also engage with the corresponding openings of the flat pattern upper that are aligned with the openings of the tongue portion, so that the positioning of these pieces relative to each other can be maintained at least partially during the assembly and / or bonding process (for example, so that one or more connection processes can be applied to the aligned parts). In addition, the registration tool may have pins that are spaced apart to engage with the aligned openings of the flat pattern collar portion and the corresponding openings of the flat pattern upper, so that the positioning of these pieces relative to each other can be maintained during the assembly and / or bonding process. In this regard, different registration tools can be used to align and register different pieces with the flat pattern upper, depending on factors such as the spacing requirements of the openings.

[0168] Reference Figure 11A, according to an embodiment of the present invention, an exploded view of a flat pattern upper 230 and a flat pattern tongue portion 232 being aligned for assembly using a registration tool 234 is provided. The registration tool 234 includes a first pin 236 and a second pin 238. The first pin 236 is positioned to engage with a first tongue opening 240 in the flat pattern tongue portion 232 and a first lacing opening 244 in the flat pattern upper 230. The second pin 238 is positioned to engage with a second tongue opening 242 in the flat pattern tongue portion 232 and a second lacing opening 246 in the flat pattern upper 230.

[0169] The flat pattern upper 230 and the flat pattern tongue portion 232 can be aligned using a registration tool 234 so that further assembly processes can be applied (e.g., attaching the pieces by sewing, welding, gluing, and / or other bonding methods). The first tongue opening 240 and the second tongue opening 242 are also formed and spaced apart so that when aligned, the first tongue opening 240 and the second tongue opening 242 are aligned as shown in FIG. Figure 11B , providing an overlap of material between the flat pattern upper 230 and the flat pattern tongue portion 232. The first tongue opening 240 and the second tongue opening 242 may also be formed and / or positioned such that, when a corresponding article of footwear is assembled, the first tongue opening 240 and the second tongue opening 242 are at least partially obscured by other materials forming the article (e.g., such as the flat pattern upper in a three-dimensional state).

[0170] Reference Figure 11B According to the embodiment of the present invention, the alignment on the registration tool 234 is provided for fitting Figure 11A A top-down elevational view of the flat pattern upper 230 and the flat pattern tongue portion 232 is shown. Figure 11B , the first tongue opening 240 and the first lacing opening 244 are at least partially aligned with each other using a first pin 236, and the second tongue opening 242 and the second lacing opening 246 are at least partially aligned with each other using a second pin 238. The alignment of the first and second tongue openings 240, 242 with the corresponding first and second lacing openings 244, 246 enables a defined material overlap between the flat pattern tongue portion 232 and the flat pattern upper 230. This alignment provides a defined space 248 from the first and second tongue openings 240, 242 to a joining location 250, where the flat pattern tongue portion 232 and the flat pattern upper 230 can be secured to each other (e.g., using sewing, welding, adhesives, other bonding methods, etc.). Furthermore, due to the alignment, the exemplary fitting location 250 is spaced apart from the U-shaped throat edge 252 of the flat pattern upper 230 by a defined space 254. Thus, the flat pattern tongue portion 232 can be properly registered with the flat pattern upper 230 for fitting.

[0171] Reference Figure 12A , an exploded view of a flat pattern upper 230 and a flat pattern collar portion 256 being aligned for assembly on a registration tool 258 is provided according to an embodiment of the present invention. Figure 12A middle, Figures 11A-11B The flat pattern upper 230 is shown positioned to align with the flat pattern collar portion 256 on the registration tool 258. The registration tool 258 includes a first pin 260 and a second pin 262 spaced apart to align with the first flat pattern upper opening 264 and the second flat pattern upper opening 266, respectively, and also to align with the first collar opening 268 and the second collar opening 270, respectively, in the flat pattern collar portion 256. This again enables the components to be at least partially maintained in alignment through additional assembly processes.

[0172] To facilitate alignment of the flat pattern pieces for assembly while also limiting the number of manufacturing-specific modifications to the pieces, the first collar opening 268 and the second collar opening 270 can be formed and spaced to align with openings on the flat pattern upper that are used for other purposes. Figures 12A-12B As shown in FIG, first collar opening 268 is aligned with first flat pattern upper opening 264, which can also be used as lacing openings in a three-dimensional article of footwear formed from assembled pieces (e.g., formed along throat area 272). Second collar opening 270 is aligned with second flat pattern upper opening 266, which can be formed in flat pattern upper 230 for attaching fastening elements (e.g., such as a fastening element) used to secure a proximal closure portion of a three-dimensional article of footwear formed from assembled pieces. Figure 3 In this sense, pre-existing openings and / or multi-use openings formed in the flat pattern upper 230 can be used, at least in part, to align the flat pattern collar portion 256 or any other flat pattern piece with the flat pattern upper 230. This reuse or multi-purpose use of openings can limit the number of modifications that may need to be made to the flat pattern upper for assembly purposes.

[0173] Reference Figure 12B According to the embodiment of the present invention, the alignment on the registration tool 258 is provided for fitting Figure 12A A top-down elevational view of the flat pattern upper 230 and the flat pattern collar portion 256 is shown. Figure 12BThe alignment of first flat pattern upper openings 264 with first collar openings 268 using first pins 260 is more clearly shown, and the alignment of second flat pattern upper openings 266 with second collar openings 270 using second pins 262 is also shown. Again, aligning flat pattern collar portion 256 using openings formed for functional purposes and / or for purposes of aligning other components can facilitate assembly of an article of footwear from various flat pattern pieces while limiting the number of manufacturing-specific modifications that need to be made to the flat pattern pieces.

[0174] In addition, it should be noted that although Figures 11A-11B and Figures 12A-12B A flat pattern upper is shown being used to form a proximal closure, however the alignment and registration methods discussed herein can also be used to align flat pattern pieces in an article of footwear having a lateral closure.

[0175] In another embodiment herein, a three-dimensional article of footwear is provided, formed from a plurality of flat patterned pieces aligned and registered for attachment to one another using aperture alignment. The three-dimensional article includes a flat patterned upper having one or more apertures. The three-dimensional article further includes one or more flat patterned pieces, each including one or more apertures. At least some of the apertures in each flat patterned piece are aligned with at least some of the apertures in the flat patterned upper, thereby aligning and registering the attached flat patterned pieces with the flat patterned upper. In additional embodiments, one or more apertures in the flat patterned upper are aligned with one or more apertures in a plurality of different flat patterned pieces attached to the flat patterned upper to form the three-dimensional article of footwear, and / or one or more apertures in a flat patterned piece attached to the flat patterned upper are aligned with one or more apertures in another flat patterned piece, which is also aligned with the flat patterned upper, to form the three-dimensional article of footwear.

[0176] In another embodiment herein, a method for forming a three-dimensional article of footwear from a plurality of flat patterned pieces that are aligned and registered with one another for attachment using aperture alignment is provided. The method includes providing a flat patterned upper having one or more apertures, providing one or more flat patterned pieces, each including one or more apertures, and aligning at least some of the apertures in each of the one or more flat patterned pieces with at least some of the apertures in the flat patterned upper to align and register the flat patterned pieces. The method may further include attaching the aligned pieces to one another and forming the attached aligned pieces into a three-dimensional article of footwear. In additional embodiments, one or more apertures in the flat patterned upper may be aligned with one or more apertures in a plurality of different flat patterned pieces for attachment, and / or one or more apertures in a flat patterned piece attached to the flat patterned upper may be aligned with one or more apertures in another flat patterned piece, the other flat patterned piece also being aligned with the flat patterned upper for attachment.

[0177] In summary, it will be seen that the present invention is well adapted to attain all of the objects and goals set forth above, as well as other advantages that are obvious and inherent to the described structure. It will be understood that certain features and subcombinations have utility and can be employed without reference to other features and subcombinations. This is contemplated by and within the scope of the claims. Although the subject matter of the present invention is illustrated herein with reference to specific examples, variations are possible and contemplated that are within the scope of the claims.

Claims

1. A method for manufacturing an article of footwear, the method comprising: forming a flat pattern upper into a three-dimensional shape, wherein the flat pattern upper has an inwardly facing bottom surface and an outwardly facing top surface forming an exterior portion of the article of footwear, a toe end and an opposite heel end, and a mesial side and an opposite lateral side, and wherein the flat pattern upper is formed with a first opening; forming a side closure by abutting a first side edge of the flat patterned upper with a second side edge; During an assembly process, registering and aligning the connecting portion with the side closure portion by aligning a first opening in the connecting portion with the first opening in the flat pattern upper to secure a first side including the first side edge to a second side including the second side edge; as well as securing the aligned connecting portions to the flat pattern upper adjacent the first side edge and the second side edge, thereby coupling the first side edge and the second side edge together, wherein the first opening of the connecting portion and the first opening of the flat pattern upper are aligned to define a first functional opening in the article of footwear, and wherein the first opening of the connecting portion includes a first pair of openings extending through a first portion of the connecting portion and a second pair of openings extending through a second portion of the connecting portion, the first portion overlapping the top surface of the flat pattern upper and the second portion overlapping the bottom surface of the flat pattern upper.

2. The manufacturing method according to claim 1, wherein the side closure portion is a proximal side closure portion, the proximal side closure portion having the first side edge including the first proximal edge of the flat pattern upper and the second side edge including the second proximal edge of the flat pattern upper.

3. The manufacturing method according to claim 1, wherein the side closure portion is a lateral closure portion having the first side edge including the first outer edge of the flat pattern upper and the second side edge including the second outer edge of the flat pattern upper.

4. The manufacturing method according to claim 1, wherein the flat pattern upper is formed from one single component.

5. The manufacturing method according to claim 1, wherein the first functional opening is a lace opening. The manufacturing method according to claim 1 , wherein the first functional opening is a breathable opening. 7 . The manufacturing method according to claim 1 , wherein the connecting portion is laminated on the flat-patterned upper and adhered to the flat-patterned upper to cover the top surface, the bottom surface, and a throat edge of the flat-patterned upper.

8. A manufacturing method according to claim 1, wherein the connecting portion includes an elongated material strip, the elongated material strip includes a first end, a second end and a middle portion extending between the first end and the second end, and wherein the first opening of the connecting portion is located on the middle portion.

9. The manufacturing method according to claim 2, wherein the adjacent first proximal edge and second proximal edge, the proximal side closure portion and the connecting portion extend from the throat portion of the flat pattern upper to the perimeter portion of the flat pattern upper at a non-perpendicular angle to both the throat edge and the perimeter edge of the flat pattern upper.

10. The manufacturing method of claim 1 , wherein the first opening in the flat pattern upper comprises a pair of openings, and wherein the method further comprises providing a throat overlap having a pair of throat openings, the pair of throat openings being respectively alignable with the pair of openings in the flat pattern upper, and the method further comprises fitting the aligned throat overlap to the flat pattern upper. The manufacturing method according to claim 1 , wherein the connecting portion is fixed using an adhesive.

12. The manufacturing method according to claim 1, wherein the connecting portion is fixed using sewing.

13. The manufacturing method according to claim 1, further comprising: registering and aligning the flat pattern collar portion and the flat pattern upper for assembly and attachment by aligning first openings in the flat pattern collar portion with second openings in the flat pattern upper; as well as Fixing the aligned flat pattern shoe collar portion and the flat pattern shoe upper together, The first opening in the flat pattern collar portion and the second opening in the flat pattern upper, when aligned, define a second functional opening in the article of footwear.

14. The manufacturing method according to claim 13, further comprising forming the fixed flat pattern collar portion and the flat pattern upper into a three-dimensional article of footwear.

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