Footwear article and method of manufacture

Abstract

A footwear item and a method of manufacturing the same are provided. The item includes an upper fixedly attached to a sole structure. The upper may include a wall that includes an inner layer and an outer layer coupled to the inner layer such that the inner layer and the outer layer define a closed bag therebetween. A layer of waste particulate material is disposed within the closed bag. The method includes dividing waste material into a plurality of discrete pieces of waste particulate material via a grinding process or a shredding process and inserting a layer of the discrete pieces of waste particulate material into a closed bag formed between an inner layer and an outer layer of a wall of the upper. The outer layer may be formed of a material that is sufficiently transparent such that the layer of waste particulate material is at least partially visible through the outer layer.

Description

[0001] Priority Claims and Cross - References to Related Applications

[0002] This application is an international (PCT) application of U.S. Patent Application No. 16 / 788,589, filed on February 12, 2020. Technical Field

[0003] The present disclosure generally relates to articles of footwear and methods of manufacturing articles of footwear.

[0004] Background

[0005] Footwear typically includes many components of many different materials. An article of footwear generally includes an upper and a sole structure. The upper is operable to receive a foot, and the sole structure is configured to be located beneath a wearer's foot to space the foot apart from the ground. The sole structure typically includes a rubber or foamed elastomer material that is suitable for attenuating ground impact forces.

[0006] It is estimated that more than 300 million pairs of shoes are thrown away globally each year. In the past, it was common for waste materials from these shoes to simply be discarded. Additionally, the footwear manufacturing process generates surplus materials in the initial formation of an article of footwear, such as offcuts or scraps that are also often discarded.

[0007] Recently, technologies have been developed to incorporate recycled waste and formed surplus materials into new shoes. These technologies generally involve breaking the waste and / or excess surplus materials into pieces, commonly referred to as "regrind".

[0008] Summary

[0009] The techniques of the present disclosure employ a sustainable and environmentally conscious approach in footwear manufacturing. The approach contemplates that waste materials from discarded shoes can be ground and recycled to form reusable "green regrind material", and excess surplus materials (such as offcuts or waste materials) generated during the initial shoe formation can be ground and recycled to form reusable "grey regrind material". These reusable "green regrind material" and "grey regrind material" can be further incorporated into new shoes or footwear applications.

[0010] More specifically, the technology of the present disclosure relates to a construction of a footwear article in which waste particulate matter is incorporated into an outer wall of a shoe upper. The waste particulate matter can include at least one of "green regrind material" (i.e., recycled and ground scrap material from a previous footwear application) or "grey regrind material" (i.e., ground trimmings and / or waste material generated during the manufacturing process of a previous footwear application). As described below, using waste particulate matter or regrind material can provide a unique visual effect while also improving the cushioning and / or ventilation properties of the shoe upper.

[0011] Generally, a footwear article can include a sole structure and a shoe upper fixedly attached to the sole structure. The shoe upper can include a wall that at least partially encloses an interior volume that is operable to receive a wearer's foot. The wall can also include an inner layer and an outer layer coupled to the inner layer such that the inner layer and the outer layer define a closed bag therebetween. A layer of waste particulate matter is disposed between the inner layer and the outer layer and dispersed throughout the closed bag. The waste particulate matter can be formed of at least one of green regrind material and grey regrind material, or a combination of green regrind material and grey regrind material. The outer layer can be formed of a sufficiently transparent material such that the waste particulate matter or regrind material is at least partially visible through the outer layer.

[0012] A method of manufacturing a footwear article is designed to be an environmentally friendly and sustainable process in which recycled or surplus material from at least one of a shoe upper and a sole structure of another footwear article is used to form a newly formed shoe to reduce material waste. That is, waste material can be obtained or received; regrind material (particularly green regrind material or grey regrind material) is formed by dividing the waste material into a plurality of discrete pieces of waste particulate matter via at least one of a grinding process or a shredding process; the discrete pieces of waste particulate matter are combined with a resin binder to form a mixture; the mixture is thermoformed to form a layer of waste particulate matter; and the layer of waste particulate matter is inserted into a closed bag formed between an inner layer of a wall of the shoe upper of the footwear article and an outer layer of the wall of the shoe upper. Brief Description of the Drawings

[0014] The drawings described herein are for illustrative purposes only, are schematic in nature, and are intended to be exemplary and not limiting of the scope of the present disclosure.

[0015] Figure 1 is a schematic perspective view of a lateral side of a footwear article in which a layer of waste particulate matter is disposed in a closed bag formed between an inner layer and an outer layer of a shoe upper and is positioned in a vamp portion of the shoe upper.

[0016] Figure 2Is a schematic perspective view of the outer side of a footwear item, wherein a layer of waste particulate matter is disposed within a closed bag formed between an inner layer and an outer layer of the footwear upper and is positioned within the midfoot region of the footwear upper.

[0017] Figure 3 Is a schematic perspective view of the outer side of a footwear item, wherein a layer of waste particulate matter is disposed within a closed bag formed between an inner layer and an outer layer of the footwear upper and is positioned within the heel region of the footwear upper.

[0018] Figure 4 Is a schematic perspective view of the medial side of a footwear item, wherein a layer of waste particulate matter is disposed within a closed bag formed between an inner layer and an outer layer of the footwear upper and is positioned within the toe box portion of the footwear upper.

[0019] Figure 5 Is a schematic perspective view of the medial side of a footwear item, wherein a layer of waste particulate matter is disposed within a closed bag formed between an inner layer and an outer layer of the footwear upper and is positioned within the midfoot region of the footwear upper.

[0020] Figure 6 Is a schematic perspective view of the medial side of a footwear item, wherein a layer of waste particulate matter is disposed within a closed bag formed between an inner layer and an outer layer of the footwear upper and is positioned within the heel region of the footwear upper.

[0021] Figure 7 Is a schematic perspective partially exploded view of an exemplary footwear item.

[0022] Figure 8 Is a schematic perspective plan view of an exemplary footwear item.

[0023] Figure 9 Is for manufacturing Figures 1-8 Flowchart of an exemplary method of manufacturing a footwear item.

[0024] Figure 10 Is for further detailing Figure 9 Flowchart of step 103.

[0025] Describes in detail

[0026] Although the present disclosure may be described with respect to a particular application or industry, those skilled in the art will recognize the broader applicability of the present disclosure.

[0027] The terms "a", "an", "the", "at least one", and "one or more" are used interchangeably to indicate the presence of at least one item among the items. Unless the context clearly indicates otherwise, there may be more than one such item. Unless the context clearly indicates otherwise, all numerical values of parameters (e.g., amounts or conditions) in this specification (including the appended claims) should be understood to be modified in all cases by the term "about", whether or not "about" actually appears before the numerical value. "About" indicates that the stated numerical value allows some slight imprecision (somewhat close to the accuracy of the value; approximately or moderately close to the value; nearly). If the imprecision provided by "about" is not otherwise understood in the art in this ordinary meaning, then "about" as used herein indicates at least the variations that may be caused by the ordinary methods of measuring and using these parameters. Additionally, the disclosure of a range should be understood to specifically disclose all values within the range and further divided ranges.

[0028] The terms "comprising", "including", and "having" are inclusive and thus specify the presence of the stated features, steps, operations, elements, or components, but do not preclude the presence or addition of one or more other features, steps, operations, elements, or components. The order of steps, processes, and operations may be changed when possible, and additional or alternative steps may be employed. As used in this specification, the term "or" includes any and all combinations of the related listed items. The term "any" is understood to include any possible combination of the recited items, including "any one" of the recited items. The term "any" is understood to include any possible combination of the recited claims of the appended claims, including "any one" of the recited claims.

[0029] The features shown in one figure may be combined with, substituted for, or modified by the features shown in any figure. Unless otherwise stated, no feature, element, or limitation is mutually exclusive with any other feature, element, or limitation. Additionally, no feature, element, or limitation is absolutely required for operation. Any particular configuration shown in the figures is illustrative only, and the particular configuration shown is not a limitation on the claims or the description.

[0030] For consistency and convenience, directional adjectives are used throughout this detailed description corresponding to the illustrated embodiments. Those of ordinary skill in the art will recognize that terms such as "above", "below", "upward", "downward", "top", "bottom", etc. may be used descriptively with respect to the figures and do not represent a limitation on the scope of the invention as defined by the claims. Any numerical designations such as "first" or "second" are merely illustrative and are not intended to limit the scope of the disclosure in any way.

[0031] As used throughout this detailed description and in the claims, the term "longitudinal" refers to the direction extending along the length of an elongate member. For example, the longitudinal direction of a shoe extends between the toe region and the heel region of the shoe. The terms "forward" or "anterior" are used to refer to the general direction from the heel region toward the toe region of the shoe, and the terms "rearward" or "posterior" are used to refer to the opposite direction, i.e., from the toe region toward the heel region of the shoe. In some cases, a member may be identified with a longitudinal axis and a forward longitudinal direction and a rearward longitudinal direction along that axis. The longitudinal direction or longitudinal axis may also be referred to as the anterior-posterior direction or anterior-posterior axis.

[0032] As used throughout this detailed description and in the claims, the term "transverse" refers to the direction extending along the width of an elongate member. For example, the transverse direction of a shoe extends between the outer side and the inner side of the shoe. The transverse direction or transverse axis may also be referred to as the lateral direction or lateral axis or the medial-lateral direction or medial-lateral axis.

[0033] As used throughout this detailed description and in the claims, the term "vertical" refers to a direction generally perpendicular to both the lateral direction and the longitudinal direction. For example, in the case where the sole is flat on a ground surface, the vertical direction may extend upward from the ground surface. It should be understood that each of these directional adjectives may be applied to the various components of the sole. The terms "upward" or "upwards" refer to the vertical direction pointing toward the top of a member, which may include the vamp, fastening zone, and / or throat of the upper. The terms "downward" or "downwards" refer to the vertical direction opposite the upward direction, pointing toward the bottom of a member and may generally point toward the bottom of the sole structure of the footwear item.

[0034] Additionally, the term "proximal" refers to the direction that is closer to the center of the footwear component or closer to the foot when the foot is inserted into the footwear article while the footwear article is being worn by a user. Similarly, the term "distal" refers to the relative position that is further away from the center of the footwear component or further away from the foot when the foot is inserted into the footwear article while the footwear article is being worn by a user. Thus, the terms proximal and distal can be understood as providing generally opposite terms to describe relative spatial positions.

[0035] To aid and clarify the subsequent description of the various embodiments, various terms are defined herein. Unless otherwise indicated, the following definitions apply throughout this specification (including the claims). "Footwear article", "footwear product", and "footwear" can be considered both a machine and a manufactured article. An assembled and ready-to-wear footwear article (such as a shoe, sandal, boot, etc.) and discrete components of a footwear article (such as a midsole, outsole, upper component, etc.) are considered herein and optionally referred to in the singular or plural as "footwear article" before being finally assembled into a ready-to-wear footwear article.

[0036] The following discussion and figures disclose various footwear configurations and methods related to manufacturing the footwear configurations. Although the footwear article 10 is depicted in the associated figures as being configured as athletic footwear (such as a sports shoe) for sports, the concepts associated with the configurations and methods can be applied to various other types of athletic footwear articles, such as hiking boots and shoes, soccer shoes, football shoes, running shoes, cross-training shoes, rugby shoes, basketball shoes, etc. However, the footwear article 10 is not limited to athletic shoes or other shoes for sports. In some embodiments, the disclosed arrangements can be configured for use with various types of non-sports-related footwear, including but not limited to boots, casual shoes, dress shoes, work shoes, sandals, slippers, or any other category of footwear that can also incorporate the concepts discussed herein.

[0037] In a general sense, the footwear article 10 of the present disclosure is designed to be manufactured via an environmentally friendly and sustainable process. In this way, waste materials, manufacturing surplus materials, or materials recovered or recycled from discarded or unsellable shoes are utilized in the formation of the newly formed shoe to reduce material waste. More specifically, recycled materials from at least one of the upper and sole structures of another footwear article or surplus materials formed from at least one of the upper and sole structures of another footwear article are divided into multiple discrete pieces (also referred to as "regrind") of waste particulate matter 22 via a grinding process or a shredding process. By definition, regrind material is material that has undergone at least one processing method, and subsequent runners, gates, flash, or scrap parts are ground or shredded.

[0038] In addition, the regrind 22 is defined herein as a mixture of at least one of cured rubber particles, foam particles, pieces of textile and fibers, pieces of leather, and pieces of polymer. The regrind can include ground waste from used, discarded, or unsellable footwear and / or ground surplus material or recycled waste from footwear manufacturing.

[0039] In one example, the regrind 22 is a "gray regrind material" which is defined as ground / shredded / cut / truncated pieces of surplus material from footwear manufacturing, such surplus material being, for example, ground waste or discarded rubber from footwear manufacturing, ground waste or discarded foam from footwear manufacturing, ground or shredded waste or discarded textile fibers (e.g., string, thread, yarn) from footwear manufacturing, or combinations thereof. In another example, the regrind 22 is a recycled or "green regrind material", where the green regrind material consists of ground / shredded / cut / truncated pieces of recycled, discarded, or unsellable footwear, such as ground cured rubber from footwear, ground foam from footwear, ground or shredded textile fibers from footwear, or combinations thereof. In such an example, the green regrind material is obtained from ground post-consumer waste (e.g., footwear waste, recycled post-consumer shoes, and / or the ground portion of unsellable footwear). Unless otherwise specified, the term "regrind" is not meant to imply any particular process, but is intended to generically refer to truncated pieces of post-consumer waste and / or post-manufacture waste.

[0040] Then, the waste particulate matter or regrind 22 is formed into a layer of the waste particulate matter 22 and inserted between an inner layer 18 and an outer layer 20 of a wall 15 of the upper 12 of the newly formed footwear article 10. To provide a unique visual effect, the outer layer 20 can be formed of a material that is sufficiently transparent or translucent such that the regrind 22 is at least partially visible through the outer layer 20.

[0041] Referring to the drawings, in which like reference numerals refer to like components throughout the several views, there is provided a footwear article 10. As Figures 1-8 shown, the footwear article 10 includes an upper 12 fixedly attached to a sole structure 14.

[0042] The upper 12 is part of a footwear item 10 and defines an interior volume or interior cavity 16 adapted to receive a wearer's foot. The upper 12 in the present disclosure also includes a wall 15 that at least partially surrounds the interior volume or interior cavity 16. For purposes of consistency and clarity, the "interior" of the footwear item 10 refers to the space occupied by the wearer's foot when the footwear item 10 is being worn. The "inner side" of the wall 15 or other shoe element refers to the face of the piece of material or element that faces (or will face) the interior orientation of the completed footwear item 10. The "outer side" or "exterior" of an element refers to the face of the element that is remote from (or will be remote from) the interior orientation of the completed footwear item 10.

[0043] As Figures 1-6 indicated, the footwear item 10 can be divided into a forefoot region 34, a midfoot region 36, and a heel region 38, which are also the forefoot region 34, midfoot region 36, and heel region 38 of the sole structure 14 and the upper 12, respectively. The forefoot region 34 generally includes the portion of the footwear item 10 corresponding to the toes and the joints connecting the metatarsals and phalanges. The midfoot region 36 generally includes the portion of the footwear item 10 corresponding to the arch region and the instep of the foot. The heel region 38 corresponds to the posterior portion of the foot including the calcaneus. The forefoot region 34, midfoot region 36, and heel region 38 are not intended to demarcate precise regions of the footwear 10, but rather are intended to represent approximate regions of the footwear 10 to facilitate the following discussion.

[0044] The footwear item 10 also has an outer side portion 24 ( Figures 1-3 ) and an inner side portion 26 ( Figures 4-6 ). The outer side portion 24 and the inner side portion 26 extend through each of the forefoot region 34, midfoot region 36, and heel region 38 and correspond to opposite sides of the footwear item 10, with the outer side portion 24 and the inner side portion 26 each falling on opposite sides of the longitudinal midline LM of the footwear item 10 (partially indicated in Figure 8 ). Thus, the inner side portion 26 is considered to be opposite the outer side portion 24.

[0045] The sole structure 14 may include provisions for attenuating ground reaction forces (i.e., cushioning and stabilizing the foot during vertical and horizontal loading). Additionally, the sole structure 14 may be configured to provide traction friction, impart stability, and control or limit various foot movements (such as pronation, supination, or other movements). For example, the disclosed concepts may be applicable to footwear configured for use on any of a variety of surfaces, including indoor or outdoor surfaces. In some embodiments, the sole structure 14 may be configured to provide traction friction and stability on hard indoor surfaces (such as hardwood), soft natural turf surfaces, or hard artificial turf surfaces.

[0046] In different embodiments, the sole structure 14 may include different components that may individually or jointly provide several attributes for the article, such as support, stiffness, flexibility, stability, cushioning, comfort, reduced weight, or other attributes. For example, the sole structure 14 may include a midsole, an outsole, and a cushioning layer and / or an insole. The compressible polymer elements of the sole structure 14 attenuate ground reaction forces (i.e., provide cushioning) when compressed between the foot and the ground during walking, running, or other locomotive activities, and may be formed of compressible polymer elements such as thermosetting or thermoplastic materials, such as crosslinked thermosetting plastics, crosslinked thermosetting resins, or crosslinked thermosetting elastomers (such as rubber), polyurethane foam, ethylene vinyl acetate (EVA) foam, ionomer polymer foam, or the like. In additional configurations, the midsole may contain fluid-filled chambers, plates, regulators, or other elements that further attenuate forces, enhance stability, or influence foot movement.

[0047] The midsole may be a single one-piece midsole, or may be multiple components that are integral as a unit. In some embodiments, the midsole may be integral with the outsole as a unisole. The outsole may be one-piece, or may be several outsole components, and may be formed of a wear-resistant rubber material that may be textured to impart traction friction and / or may include traction friction elements such as cleats fixed to the midsole.

[0048] When the foot is located within the foot-receiving interior cavity 16 of the footwear article 10, the foot is supported on the foot-facing surface of the midsole. Optionally, the foot-facing surface of the midsole may be covered by a strobel that is fixed to the lower region of the upper 12. Additionally, optionally, the insole may rest on the strobel or, in embodiments without a strobel, directly on the sole structure 14, in which case the foot is supported by both the sole structure 14 and the insole.

[0049] However, it is understood that the sole structure 14 is not limited to including conventional sole components and can include various different types of elements disposed at the outermost, innermost, and intermediate "layers" or positions of the sole. Thus, the sole structure 14 can include an outer sole member or element, which may or may not coincide with a conventional "outsole". Similarly, the sole structure 14 can include an inner sole member or element, which may or may not be an "insole". In addition, the sole structure 14 can include any number of intermediate and / or midsole members or elements, which may or may not be a "midsole".

[0050] The sole structure 14 can be permanently and / or fixedly attached to one or more portions of the upper 12 (e.g., using adhesives, stitching, welding, and / or other suitable techniques) and can have a configuration that extends between the upper 12 and the ground. For the purposes of this disclosure, the term "permanently attached" shall mean that two components are joined in such a way that the components cannot be easily separated (e.g., without breaking one or both of the components). Additionally, two components can be "permanently attached" by being integrally formed, for example, through a molding process.

[0051] Generally, the upper 12 includes provisions for reducing any tendency for the foot to be pulled away from the sole structure 14 during use. In some embodiments, the upper 12 can be a conventional upper that defines and at least partially encloses an interior volume or interior cavity 16 for receiving the wearer's foot. The upper 12 can include a wall 15 that at least partially encloses the interior volume or interior cavity 16 and the wearer's foot. The wall 15 is formed from a variety of materials (such as leather, textiles, polymers, cotton, foam, composite materials, etc.). The wall 15 can include an inner layer 18 of a material having elasticity, breathability, or both elasticity and breathability to assist with foot insertion and comfort. For example, the inner layer 18 can be a polymeric material or textile material capable of providing elasticity and can have a braided construction, a knitted (e.g., warp-knitted) construction, or a woven construction.

[0052] The wall 15 at least partially defines an outer side portion 24 and an inner side portion 26 of the upper 12 such that the upper 12 can further define a front panel 46 of the shoe, which extends into the toe region 34 and the midfoot region 36 on each of the outer side 24 and the inner side 26 of the upper 12. The wall 15 of the upper 12 can form at least a part of the front panel 46 of the shoe.

[0053] The wall 15 also defines a throat opening 28 disposed between the outer side portion 24 ( Figures 1-3 ) and the inner side portion 26 ( Figures 4-6 ). The throat opening 28 can permit a wearer's foot to extend into the inner cavity 16 of the upper 12. The throat opening 28 can be defined or surrounded by an eyestay reinforcement 48. The throat opening 28 can also be configured to receive a closure system 32, such as a shoelace 35 or the like, which can selectively span the throat opening 28 to couple the outer side 24 and the inner side 26 while providing the ability to adjust the girth of the upper 12. The closure system 32 generally can include an integral closure sheet or a tongue portion 30 and a plurality of shoelaces 35, each shoelace extending between the outer side portion 24 and the inner side portion 26 of the wall 15. The tongue portion 30 can be integral with the wall 15 or fixedly attached to the wall 15 separately. The tongue portion 30 can extend over the dorsal region of the foot.

[0054] In other embodiments, the upper 12 can be configured to provide a "tension fit" with respect to the wearer's foot. As used herein, the term tension fit refers to a fit that ensures that the upper is pulled against the foot at all times, including at the underside where the sole of the foot contacts the bottom portion of the upper 12. In some cases, a tension fit upper can be configured such that when there is no foot in the inner cavity 16, the inner cavity 16 has a volume smaller than the volume after the foot is inserted. In other words, the upper 12 can be configured to stretch or expand when the foot is inserted. Such a configuration can provide an upper 12 that "stays" with the foot, and particularly with the sole of the foot, during any activity (e.g., running, jumping, walking, etc.). A tension fit may or may not require stretching in the upper 12. In certain cases, the upper 12 can be configured to stretch significantly when the foot is inserted. However, in other cases, the upper 12 may simply fit very closely to the foot without significant expansion.

[0055] In the present disclosure, the shoe upper 12 may include a wall 15 that at least partially encloses an interior volume or interior cavity 16 and the wearer's foot. The wall 15 may also include an inner layer 18 that defines the interior cavity 16 adapted to receive the wearer's foot. In some embodiments, the inner layer 18 may include a plurality of discrete layers. Thus, the inner layer 18 has an inner surface 21 and an outer surface 25 that contact the wearer's foot.

[0056] The shoe upper 12 may also include an outer layer 20 formed of a transparent or translucent material (such as a transparent or translucent textile, polymer, mesh, or the like). As used herein, a component is "sufficiently transparent" if it has a light transmittance of at least 80% (i.e., the percentage of incident light transmitted) and a haze of no more than 56% (i.e., the percentage of transmitted light scattered). Those skilled in the art will readily understand the various methods for determining the light transmittance and haze of an object (such as the outer layer 20).

[0057] The outer layer 20 also defines a surface 31, where the surface 31 is the outermost surface of the shoe upper 12. The outer layer 20 may be coupled to the inner layer 18 such that a closed pouch 33 is formed between the inner layer 18 and the outer layer 20 of the wall 15. In the present disclosure, the closed pouch 33 is defined as an enclosed void space between the inner layer 18 and the outer layer 20. The closed pouch 33 is not an open pouch in which inserts can be freely interchanged to change the external appearance of the footwear item 10. The closed pouch 33 is sealed such that after the final shaping of the footwear item 10 is completed, the inner layer 18 and the outer layer 20 are permanently attached, i.e., joined in such a way that the components are not likely to be easily separated (e.g., without breaking one or both of the components).

[0058] The outer layer 20 may be further coupled to and permanently attached to the inner layer 18 at a plurality of bonding area lines 42. The plurality of bonding area lines 42 may be arranged in a predetermined pattern such that the closed pouch 33 is divided into a plurality of closed pouches 33a, 33b ( Figures 7-8 ).

[0059] The multiple bonding region lines 42 can be defined in a variety of ways. In one example, the multiple bonding region lines 42 can be defined as multiple pocket boundary sutures. In this way, the inner layer 18 and the outer layer 20 can be permanently attached by stitching at the bonding region lines 42 such that the entirety of each of the multiple pockets 33a, 33b is bounded by the stitching along its respective outer boundary. In another example, the multiple bonding region lines 42 can be defined as multiple pocket boundary welding joints. In this way, the inner layer 18 and the outer layer 20 can be permanently attached by welding, i.e., the inner layer 18 is welded to the outer layer 20 at the multiple bonding region lines 42 such that the entirety of each of the multiple pockets 33a, 33b is bounded by the welding joints along its respective outer boundary. In yet another example, the multiple bonding region lines 42 can be defined as multiple pocket boundary barriers. In this way, the inner layer 18 and the outer layer 20 can be permanently attached by the barriers at the multiple bonding region lines 42 such that the entirety of each of the multiple pockets 33a, 33b is bounded by the barriers extending between the inner layer 18 and the outer layer 20. In such an example, the pocket boundary barriers can include the same material as the outer layer 20.

[0060] The upper 12 can also include a plurality of auxiliary sutures 44 that couple or permanently attach the inner layer 18 to the outer layer 20. In this way, each of the auxiliary sutures 44 extends between the inner layer 18 and the outer layer 20. The auxiliary sutures 44 are generally an aesthetic feature of the footwear item 10 and are thus arranged on the upper 12 in a predetermined pattern. In each predetermined pattern, at least one of the auxiliary sutures 44 crosses at least one of the closed pockets 33a, 33b.

[0061] In the past, it has been common for scrap materials from discarded post-consumer shoes or unsellable footwear to be simply discarded. Additionally, the footwear manufacturing process generates leftover materials during the initial formation of the footwear item, such as offcuts or waste that are also routinely discarded. Therefore, it is desirable to incorporate these recycled, regenerated, or repurposed materials into the manufacture of new footwear. Thus, the reuse or repurposing of recycled or leftover waste materials is beneficial both in terms of the design of the item 10 and in terms of the sustainability of the manufacturing operations.

[0062] As discussed herein, in a general sense, the article of footwear 10 of the present disclosure is designed to be manufactured in an environmentally friendly and sustainable process 100 that includes techniques for incorporating multiple discrete pieces of waste particulate material 22 or "regrind" into the upper 12 of a new article of footwear 10. The "regrind" material can be one of "gray regrind material" (derived from ground or shredded excess leftover material (such as trim or scrap) generated during initial shoe formation) or "green regrind material" (derived from ground or shredded recycled or discarded post-consumer shoes or other unsellable footwear).

[0063] Thus, as detailed in the manufacturing method 100 disclosed herein and as shown by the example in Figures 1-10 waste or leftover materials from footwear manufacturing and / or recycled waste materials from recycled or discarded post-consumer shoes or unsellable footwear can be used to form the newly formed article of footwear 10 to reduce material waste. In this way, at step 101 as shown in Figure 9 waste materials can be obtained. More specifically, at step 101, waste materials are obtained or harvested from leftover materials (such as trim or scrap) generated during initial shoe formation and / or from recycled or discarded waste materials from post-consumer shoes or unsellable footwear.

[0064] At step 102, the waste materials can then be separated into multiple discrete pieces of waste particulate material 22 or regrind material. As discussed herein, by definition, regrind material is material that has undergone at least one processing method and subsequent runners, sprues, flash, or scrap parts are ground or shredded. Thus, in one example, separating the waste materials into discrete pieces of waste particulate material 22 can be accomplished via a grinding process, i.e., inserting the waste materials into a grinder to produce multiple discrete pieces of waste particulate material 22. In another example, separating the waste materials into multiple discrete pieces of waste particulate material 22 can be accomplished via a shredding process, i.e., inserting the waste materials into a shredder to produce multiple discrete pieces of waste particulate material 22.

[0065] Assume that in step 102, discrete pieces of waste particulate matter 22 or reground material are formed via a grinding process or a shredding process. The shredded or ground nature of the reground material may cause each discrete piece of waste particulate matter 22 or reground particles to have a different shape. In other words, the discrete pieces of waste particulate matter 22 or reground particles do not have a regular or normalized shape because when the waste material travels through a grinder or shredder, it is possible to obtain a wide range of particle sizes, including but not limited to fine, small dust-like particles, up to material pieces 0.25 inches or larger. In other words, the discrete pieces of waste particulate matter 22 or reground particles do not have a regular or normalized shape and each discrete piece of waste particulate matter 22 or reground particle can have a unique and different shape. Alternative ways of forming discrete pieces of waste particulate matter 22 or reground material include the techniques described in U.S. Patent No. 9,132,430, which is incorporated by reference in its entirety.

[0066] As shown herein, waste material is obtained or harvested from the remaining material (such as trim or scrap) generated in the initial shoe formation and / or from recycled or discarded post-consumer shoes or other unsellable footwear. In one example, waste material is obtained or harvested from the remaining material (such as trim or scrap generated during the initial shoe formation of another footwear item) such that the reground material 22 generated at step 102 is defined as "grey reground material". The grey reground material can include at least one of the following: leather material, textile material, polymer material, foam material, or elastomeric material in the form of ground or shredded pieces of remaining material (such as trim or other waste from at least one of the upper and sole structures of another footwear item). In an example where the grey reground material includes pieces of remaining material from the upper of another footwear item (such as yarn, thread, label, textile, upper foam, leather, or polymer trim and the like), the grey reground material can include at least one of leather material, textile material, and foam material. In an example where the grey reground material includes pieces of remaining material from the sole structure of another footwear item, the grey reground material can include at least one of a foamed thermoplastic material or a thermosetting material. Additionally, the grey reground material can include pieces of remaining material from each of the upper and sole structures of another footwear item.

[0067] In another example, the waste material is obtained or harvested from recycled or discarded post-consumer shoes or unsellable footwear such that the reground material 22 produced at step 102 is defined as "green reground material". The green reground material can include at least one of the following: leather material, textile material, polymer material, foam material, or elastomeric material in the form of ground or shredded chunks of recycled or discarded post-consumer shoes or unsellable footwear. In an example where the green reground material includes chunks from the upper of recycled or discarded post-consumer shoes or unsellable footwear (such as yarn, thread, labels, textiles, upper foam, leather, or polymer chunks and the like), the green reground material can include at least one of leather material, textile material, and foam material. In an example where the green reground material includes chunks of the sole structure of recycled or discarded post-consumer shoes or unsellable footwear, the green reground material can include at least one of a foamed thermoplastic material or a thermosetting material. Suitable examples of foamed thermoplastic materials can include polyurethane foam material, ethylene-vinyl acetate (EVA) foam material, ionomer foam material, or the like. Examples of thermosetting polymer materials can include crosslinked thermosetting plastics, crosslinked thermosetting resins, or crosslinked thermosetting elastomers, such as rubber.

[0068] In addition, the green reground material can include chunks from each of the upper and sole structure of recycled or discarded post-consumer shoes or unsellable footwear. The waste particulate matter 22 or reground material can also be formed by a combination of green reground material and grey reground material.

[0069] At step 103, discrete chunks of the waste particulate matter 22 (such as grey reground material, green reground material, or a combination thereof) are inserted between an inner layer 18 and an outer layer 20 of the wall 15 of the upper 12 and are further dispersed throughout an enclosed pocket 33 formed between the inner layer 18 and the outer layer 20. In an example where the enclosed pocket 33 is a plurality of enclosed pockets 33a, 33b, the discrete chunks of the waste particulate matter 22 are dispersed in each of the enclosed pockets 33a, 33b. The discrete chunks of the waste particulate matter 22 can be inserted between the inner layer 18 and the outer layer 20 and are also dispersed throughout the enclosed pocket 33 via various processes.

[0070] In one example, the reground 22 can be sprayed or blown into the pocket 33 via a filling machine such that each of the discrete chunks of the waste particulate matter 22 or reground particles freely floats within the pocket 33.

[0071] In another example, as Figure 10As shown in steps 201 - 204, the waste particulate matter 22 can be adhered together and then inserted into the closed bag 33 in the form of a layer. More specifically, at step 201, discrete pieces of the waste particulate matter 22 are mixed with a resin binder to form a mixture. The discrete pieces of the waste particulate matter 22 can account for from about 3% to about 15% of the mixture, such that the discrete pieces of the waste particulate matter can be easily seen from the mixture. The mixture of the resin binder and the discrete pieces of the waste particulate matter 22 can be placed in a mixing container, and then the mixing container can be placed inside a mixer and thoroughly mixed to coat all the outer surfaces of the discrete pieces of the waste particulate matter 22 with the resin binder. The mixture can then be removed from the mixer and formed into a sheet-like formation having a thickness 52.

[0072] At step 202, the sheet-like formation of the mixture can be placed in a dryer at, for example, 80 degrees Celsius for 30 minutes. Once dried, the sheet-like formation can be compression molded or thermoformed to produce a layer 54 of the waste particulate matter having a thickness 52, as Figure 7 shown.

[0073] At step 203, the layer 54 of the waste particulate matter can be placed on and in contact with the outer layer 20. At step 204, the inner layer 18 can be positioned over the layer 54 of the waste particulate matter and the outer layer 20 such that the inner layer 18 and the outer layer 20 form a closed bag 33 around the perimeter or outer boundary of the layer 54 of the waste particulate matter, such that the layer 54 of the waste particulate matter is disposed within the closed bag 33.

[0074] At step 104, the outer layer 20 can be further joined to and permanently attached to the inner layer 18 at a plurality of bonding area lines 42. The plurality of bonding area lines 42 can be arranged in a predetermined pattern such that the closed bag 33 and the layer 54 of the waste particulate matter are enclosed by the bonding area lines 42.

[0075] The plurality of bonding area lines 42 can be defined in a variety of ways. In one example, the plurality of bonding area lines 42 can be defined as a plurality of bag boundary sutures such that joining the inner layer 18 of the wall 15 of the upper 12 to the outer layer 20 of the wall 15 of the upper includes suturing the inner layer 18 to the outer layer 20 at each of the plurality of bonding area lines 42 such that each of the bonding area lines is defined as a suture, and each of the plurality of bags 33a, 33b is bounded in its entirety along the respective outer boundary by the sutures.

[0076] In another example, a plurality of bonding region lines 42 may be defined as a plurality of bag boundary adhesive joints such that joining the inner layer 18 of the wall 15 of the upper 12 to the outer layer 20 of the wall 15 of the upper 12 includes applying an adhesive to one of the inner layer 18 and the outer layer 20 at the bonding region lines 42 and joining the inner layer 18 and the outer layer 20 at the bonding region lines 42.

[0077] In another example, a plurality of bonding region lines 42 may be defined as a plurality of bag boundary weld joints. In this manner, the inner layer 18 and the outer layer 20 may be permanently attached via welding, i.e., the inner layer 18 is welded to the outer layer 20 at the plurality of bonding region lines 42 such that the entirety of each of the plurality of bags 33 is bounded by the weld joints along their respective outer boundaries. As used herein, the term "welding" or variations thereof (such as "thermal bonding") is defined as a technique for securing two elements to each other that involves softening or melting a polymeric material within at least one of the elements such that the materials of the elements are secured to each other when cooled. Similarly, the term "weld" or variations thereof (e.g., "thermal bond") is defined as a joint, connection, or structure that joins two elements by a process that involves softening or melting a polymeric material within at least one of the elements such that the materials of the elements are secured to each other when cooled.

[0078] Welding typically creates a heat affected zone in which the materials of the two joined components are intermixed. Such a heat affected zone may be considered a "weld" or "thermal bond". Additionally, welding may involve (a) melting or softening two layers including polymeric materials such that the polymeric materials from each layer are intermixed with each other (e.g., diffusing across the boundary layer between the polymeric materials) and are secured together when cooled, and (b) melting or softening the polymeric material in the first layer such that the polymeric material extends into or penetrates the structure of the second layer (e.g., penetrating into cracks or cavities formed in the second layer, or extending around filaments or fibers in the second layer, or bonding to filaments or fibers in the second layer) so as to secure the two layers together when cooled. Further, welding may occur when only one layer includes a polymeric material, when both layers include a polymeric material, or when a polymeric material or resin is disposed between the respective layers.

[0079] In one embodiment, to effect a weld, a resin binder is applied to the inner layer 18 at each of the bonding region lines 42, the resin binder is heated to a viscous state such that the resin binder penetrates the inner layer 18 and the outer layer 20 at each of the plurality of bonding region lines 42, and the resin binder is cooled to a solid state.

[0080] In another embodiment, one of the inner layer 18 and the outer layer 20 is formed of a thermoplastic material. To achieve a weld, the corresponding layer 18, 20 formed of the thermoplastic material is heated to a viscous state such that the thermoplastic layer penetrates the other of the inner layer 18 and the outer layer 20 at a plurality of bonding area lines 42, and the thermoplastic layer is cooled to a solid state.

[0081] A layer 54 of waste particulate matter is disposed between the inner layer 18 and the outer layer 20 and is dispersed throughout the closed bag 33. In this way, the layer 54 of waste particulate matter is positioned in the position of the corresponding closed bag 33 on the upper 12. As Figures 1-6 shown, the closed bag 33 can be disposed in any one or each of the toe region 34, the midfoot region 36, the heel region 38, and the tongue portion 30 of the upper 12.

[0082] In one example, the closed bag 33 can be disposed in the toe region 34 ( Figure 1 , Figure 4 , Figure 7 and Figure 8 ). In another example, the closed bag 33 can be disposed in the midfoot region 36 ( Figure 2 and Figure 5 ). In another example, the closed bag 33 can be disposed in the heel region 38 ( Figure 3 and Figure 6 ). In another example, the closed bag 33 can be disposed in the tongue portion 30 ( Figure 8 ).

[0083] In a particular exemplary embodiment ( Figure 1 , Figure 4 , Figure 7 and Figure 8 ), the wall 15 of the upper 12 at least partially defines a toe front piece 46 that extends into the toe region 34 and the midfoot region 36 on each of the outer side 24 and the inner side 26 of the upper 12. In such an example, the closed bag 33 can be positioned or disposed in the toe front piece 46. In a similar example, where the closed bag 33 is a plurality of closed bags ( Figures 7-8 ), each of the plurality of closed bags 33a, 33b is disposed in the toe front piece 46.

[0084] Regardless of where the closed pocket 33 is positioned on the upper 12, due to the transparent and / or translucent nature of the exterior layer 20, the layer 54 of waste particulate matter, once positioned between the interior layer 18 and the exterior layer 20, is at least partially visible through the exterior layer 20. In other words, the exterior layer 20 is formed of a sufficiently transparent material such that the layer 54 of waste particulate matter is at least partially visible through the exterior layer 20. In this manner, the waste particulate matter 22 (e.g., gray regrind, green regrind, or a combination thereof) can be easily seen by an observer or wearer of the article of footwear 10 to showcase not only the desired and unique aesthetic design, but also the sustainable and environmentally conscious manufacturing method 100, in which waste materials, manufacturing surplus materials, or recycled or regenerated materials from discarded or unsalable footwear applications are used in the formation of newly formed shoes to reduce material waste.

[0085] In addition to providing a way to recycle and reuse materials from post-consumer shoes and regenerate leftover materials from initial shoe manufacturing, this technology also provides an upper with a more breathable and cushioning structure. In other words, rather than simply acting as a solid foam cushion, the granular gray regrind or granular green regrind allows air and / or evaporated sweat to pass between the discrete particles, which can improve the comfort of the upper. Furthermore, because the gray regrind and green regrind can each be derived from materials of different colors, this technology allows each shoe to have a unique visual appearance. This uniqueness is due to the random dispersion of the regrind throughout the closed bag 33. More specifically, each shoe 10 can exhibit a different appearance based on the available color of the regrind during manufacturing, as part of the dispersion process. This can contribute to the increasing consumer demand for shoes with aesthetically pleasing or unique designs, or with creative patterns or colors.

[0086] The detailed description and accompanying drawings or figures support and describe the present teachings, but the scope of the present teachings is limited only by the claims. Although some best modes and other embodiments for implementing the present teachings have been described in detail, there are various alternative designs and embodiments for practicing the present teachings defined in the appended claims.

[0087] Although a number of embodiments have been described, this description is intended to be illustrative rather than restrictive, and it will be apparent to those skilled in the art that more embodiments and implementations within the scope of the embodiments are possible. Any feature of any embodiment may be used in combination with or replace any other feature or element in any other embodiment, unless otherwise specified. Therefore, the embodiments are not limited except in accordance with the appended claims and their equivalents. Moreover, various modifications and variations may be made within the scope of the appended claims.

[0088] However, a benefit, other advantage, or solution to a problem, and any element or elements that may cause any benefit, advantage, or solution to occur or become more pronounced should not be construed as a critical, required, or essential feature or element of any or all of the claims, unless such benefit, advantage, solution, or element is expressly recited in such claims.

[0089] The following articles provide example configurations of the footwear disclosed herein.

[0090] Article 1. A footwear item comprising a sole structure and an upper fixedly attached to the sole structure, wherein the upper comprises a wall at least partially surrounding an interior volume operable to receive a wearer's foot, and wherein the wall comprises: an inner layer; an outer layer coupled to the inner layer such that the inner layer and the outer layer define a closed pouch therebetween; a layer of waste particulate material comprising at least one of gray regrind material or green regrind material, wherein the layer of waste particulate material is disposed between the inner layer and the outer layer and dispersed throughout the closed pouch; and wherein the outer layer is formed of at least partially transparent material such that the waste particulate material is at least partially visible through the outer layer.

[0091] Article 2. The footwear item according to Article 1, wherein the layer of waste particulate material comprises a plurality of discrete pieces of waste particulate material, and the discrete pieces of waste particulate material are defined as at least one of ground pieces of waste particulate material or shredded pieces of waste particulate material.

[0092] Article 3. The footwear item according to Article 2, wherein each discrete piece of waste particulate material has a different shape.

[0093] Article 4. The footwear item according to any one of Articles 2-3, wherein the discrete pieces of waste particulate material are discrete pieces of gray regrind material, and wherein the discrete pieces of gray regrind material comprise remaining material from forming the upper of another footwear item, and wherein the discrete pieces of gray regrind material comprise at least one of leather material, textile material, polymer material, or foam material.

[0094] Article 5. The footwear item according to Article 4, wherein the gray regrind material comprises leather material.

[0095] Article 6. The footwear item according to Article 4, wherein the gray regrind material comprises textile material.

[0096] Article 7. The footwear item according to Article 4, wherein the gray regrind material comprises polymer material.

[0097] Clause 8. The footwear article according to Clause 4, wherein the grey regrind material comprises a foam material.

[0098] Clause 9. The footwear article according to any one of Clauses 2-3, wherein the discrete pieces of the waste particulate material are discrete pieces of the grey regrind material, wherein the discrete pieces of the grey regrind material comprise residual material from the sole structure of another footwear article, and wherein the discrete pieces of the grey regrind material are formed of at least one of a foamed thermoplastic material or a thermosetting material.

[0099] Clause 10. The footwear article according to Clause 9, wherein the grey regrind material comprises a foamed thermoplastic material, and wherein the foamed thermoplastic material is ethylene-vinyl acetate (EVA) foam.

[0100] Clause 11. The footwear article according to Clause 9, wherein the grey regrind material comprises a foamed thermoplastic material, and wherein the foamed thermoplastic material is an ionomer polymer foam.

[0101] Clause 12. The footwear article according to Clause 9, wherein the grey regrind material comprises a thermosetting polymer material, and wherein the thermosetting polymer material is a crosslinked thermosetting plastic.

[0102] Clause 13. The footwear article according to Clause 9, wherein the grey regrind material comprises a thermosetting polymer material, and wherein the thermosetting polymer material is a crosslinked thermosetting elastomer.

[0103] Clause 14. The footwear article according to Clause 13, wherein the crosslinked thermosetting elastomer is rubber.

[0104] Clause 15. The footwear article according to any one of Clauses 2-3, wherein the discrete pieces of the waste particulate material are discrete pieces of the green regrind material, wherein the discrete pieces of the green regrind material comprise recycled material from the upper of another footwear article, and wherein the discrete pieces of the green regrind material comprise discrete pieces of at least one of a leather material, a textile material, a polymer material or a foam material.

[0105] Clause 16. The footwear article according to Clause 15, wherein the green regrind material comprises a leather material.

[0106] Clause 17. The footwear article according to Clause 15, wherein the green regrind material comprises a textile material.

[0107] Clause 18. The footwear article according to Clause 15, wherein the green regrind material comprises a polymer material.

[0108] [[ID=(33)]]Clause 19. The footwear article according to Clause 15, wherein the grey regrind material comprises a foam material.

[0109] Clause 20. The footwear article according to any one of Clauses 2 - 3, wherein the discrete blocks of waste particulate material are discrete blocks of green regrind material, wherein the discrete blocks of green regrind material comprise recycled material from the sole structure of another footwear article, and wherein the discrete blocks of green regrind material comprise at least one of a foamed thermoplastic material or a thermosetting material.

[0110] Clause 21. The footwear article according to Clause 20, wherein the green regrind material comprises a foamed thermoplastic material, and wherein the foamed thermoplastic material is ethylene - vinyl acetate (EVA) foam.

[0111] Clause 22. The footwear article according to Clause 20, wherein the green regrind material comprises a foamed thermoplastic material, and wherein the foamed thermoplastic material is an ionomer polymer foam.

[0112] Clause 23. The footwear article according to Clause 20, wherein the green regrind material comprises a thermosetting polymer material, and wherein the thermosetting polymer material is a cross - linked thermosetting plastic.

[0113] Clause 24. The footwear article according to Clause 23, wherein the green regrind material comprises a thermosetting polymer material, and wherein the thermosetting polymer material is a cross - linked thermosetting elastomer.

[0114] Clause 25. The footwear article according to Clause 24, wherein the cross - linked thermosetting elastomer is rubber.

[0115] Clause 26. The footwear article according to any one of Clauses 2 - 25, wherein the layer of waste particulate material further comprises a resin binder, and wherein each of the discrete blocks of waste particulate material is fixed to each other via the resin binder.

[0116] Clause 27. The footwear article according to any one of Clauses 1 - 26, wherein the outer layer is joined to the inner layer at a plurality of bonding region lines, and wherein the plurality of bonding region lines are defined as a plurality of pocket - boundary suture lines, a plurality of pocket - boundary welded joints, or a plurality of pocket - boundary barriers extending between the inner layer and the outer layer.

[0117] Clause 28. The footwear article according to Clause 27, wherein the plurality of bonding region lines are defined as a plurality of pocket - boundary suture lines.

[0118] Clause 29. The footwear article according to Clause 27, wherein the plurality of bonding region lines are defined as a plurality of pocket - boundary welded joints, and wherein the inner layer is welded to the outer layer at each pocket - boundary welded joint.

[0119] Clause 30. The footwear article according to Clause 27, wherein a plurality of bonding region lines are defined as a plurality of pocket boundary barriers extending between the inner layer and the outer layer, and wherein the pocket boundary barriers comprise the same material as the outer layer.

[0120] Clause 31. The footwear article according to any one of Clauses 1-30, wherein the upper has an outer side and an inner side, and also defines a toe region, a midfoot region, and a heel region; each of the outer side and the inner side extends into the toe region, the midfoot region, and the heel region; the upper also defines a toe cap that extends into the toe region and the midfoot region on each of the outer side and the inner side; a wall forms at least a part of the toe cap; and a closed pocket is provided in the toe cap.

[0121] Clause 32. The footwear article according to any one of Clauses 1-31, wherein a plurality of auxiliary stitching lines extend between the inner layer and the outer layer; wherein the plurality of auxiliary stitching lines are arranged in a predetermined pattern; and wherein one of the auxiliary stitching lines crosses the closed pocket.

[0122] Clause 33. A method of manufacturing a footwear article, the method comprising: inserting a plurality of discrete pieces of waste particulate material into a closed pocket formed between an inner layer of a wall of the upper of the footwear article and an outer layer of the wall of the upper; wherein the outer layer is formed of at least partially transparent material such that the discrete pieces of waste particulate material are at least partially visible through the outer layer.

[0123] Clause 34. The method according to Clause 33, further comprising: receiving waste material; and dividing the waste material into a plurality of discrete pieces of waste particulate material via at least one of a grinding process and a shredding process such that each discrete piece of waste particulate material has a different shape.

[0124] Clause 35. The method according to any one of Clauses 33-34, further comprising: mixing the discrete pieces of waste particulate material with a resin binder to form a mixture; and thermoforming the mixture to form a layer of waste particulate material.

[0125] Clause 36. The method according to Clause 35, wherein inserting the plurality of discrete pieces of waste particulate material into the closed pocket formed between the inner layer and the outer layer further comprises: placing the layer of waste particulate material on the outer layer and in contact with the outer layer; and positioning the inner layer over the layer of waste particulate material and the outer layer such that the inner layer and the outer layer form a closed pocket around the perimeter of the layer of waste particulate material such that the layer of waste particulate material is disposed within the closed pocket.

[0126] Clause 37. The method according to any one of Clauses 33 - 36 further includes: joining an inner layer of the wall of the shoe upper to an outer layer of the wall of the shoe upper at a plurality of joining area lines surrounding the closed bag and the layer of waste particulate matter such that the closed bag is enclosed by the joining area lines; and wherein joining the inner layer of the wall of the shoe upper to the outer layer of the wall of the shoe upper is performed by thermally pressing the inner layer to the outer layer.

[0127] Clause 38. The method according to Clause 37, wherein joining the inner layer of the shoe upper to the outer layer of the shoe upper at the plurality of joining area lines further includes stitching the inner layer to the outer layer at each of the plurality of joining area lines such that each of the joining area lines is defined as a stitching line.

[0128] Clause 39. The method according to Clause 37, wherein joining the inner layer of the shoe upper to the outer layer of the shoe upper at the plurality of joining area lines further includes applying an adhesive to at least one of the inner layer or the outer layer at the joining area lines and joining the inner layer and the outer layer at the joining area lines.

[0129] Clause 40. The method according to Clause 37, wherein joining the inner layer of the shoe upper to the outer layer of the shoe upper at the plurality of joining area lines further includes welding the inner layer to the outer layer at each of the plurality of joining area lines such that each of the joining area lines is defined as a welding joint.

[0130] Clause 41. The method according to Clause 40, wherein a resin binder is applied to the inner layer at each of the joining area lines.

[0131] Clause 42. The method according to Clause 41, wherein welding the inner layer to the outer layer at each of the plurality of joining area lines further includes heating the resin binder to a viscous state such that the resin binder penetrates the inner layer and the outer layer at each of the plurality of joining area lines; and cooling the resin binder to a solid state.

[0132] Clause 43. The method according to Clause 41, wherein at least one of the inner layer or the outer layer is formed of a thermoplastic polymer material.

[0133] Clause 44. The method according to Clause 43, wherein welding the inner layer to the outer layer at each of the plurality of joining area lines further includes heating the thermoplastic layer to a viscous state such that the thermoplastic layer penetrates the other of the inner layer and the outer layer at the plurality of joining area lines; and cooling the thermoplastic layer to a solid state.

[0134] Clause 45. The method according to any one of Clauses 33 - 44, wherein the discrete blocks of the waste particulate matter are discrete blocks of grey regrind material, wherein the discrete blocks of grey regrind material comprise the remaining material from the formation of the upper of another footwear item, and wherein the discrete blocks of grey regrind material comprise at least one of leather material, textile material, polymer material or foam material.

[0135] Clause 46. The method according to any one of Clauses 33 - 44, wherein the discrete blocks of the waste particulate matter are discrete blocks of grey regrind material, wherein the discrete blocks of grey regrind material comprise the remaining material from the formation of the sole structure of another footwear item, and wherein the discrete blocks of grey regrind material are formed of at least one of a foamed thermoplastic material or a thermosetting material.

[0136] Clause 47. The method according to any one of Clauses 33 - 44, wherein the discrete blocks of the waste particulate matter are discrete blocks of green regrind material, wherein the discrete blocks of green regrind material comprise recycled material from the upper of another footwear item, and wherein the discrete blocks of green regrind material comprise discrete blocks of at least one of leather material, textile material, polymer material or foam material.

[0137] Clause 48. The method according to any one of Clauses 33 - 44, wherein the discrete blocks of the waste particulate matter are discrete blocks of green regrind material, wherein the discrete blocks of green regrind material comprise recycled material from the sole structure of another footwear item, and wherein the discrete blocks of green regrind material comprise at least one of a foamed thermoplastic material or a thermosetting material.

Claims

1. An article of footwear, comprising: a sole structure; and an upper that is fixedly attached to the sole structure, the upper including a wall that at least partially encloses an interior volume that is operable to receive a wearer's foot, wherein the wall includes: an inner layer; an outer layer that is coupled to the inner layer such that the inner layer and the outer layer define a closed pouch therebetween; a layer of waste particulate material, the waste particulate material including one or more of ground, shredded, cut, or truncated discrete pieces of yarn, thread, label, textile, leather, or fiber disposed between the inner layer and the outer layer and dispersed throughout the closed pouch; and a plurality of bonding area lines that couple the inner layer to the outer layer such that the closed pouch is enclosed by the bonding area lines and subdivided into a plurality of closed pouches, wherein the waste particulate material is disposed between the inner layer and the outer layer in each of the plurality of closed pouches, and each of the discrete pieces of the waste particulate material freely floats within the closed pouch; wherein the outer layer is formed of at least partially transparent material such that the layer of waste particulate material is at least partially visible through the outer layer, wherein the upper further includes a plurality of auxiliary stitching lines that couple the inner layer to the outer layer, wherein the auxiliary stitching lines are disposed in a predetermined pattern and at least one of the auxiliary stitching lines traverses at least one of the plurality of closed pouches.

2. The article of footwear according to claim 1, wherein the layer of waste particulate material includes a plurality of discrete pieces of waste particulate material.

3. The article of footwear according to claim 2, wherein each discrete piece of waste particulate material has a different shape.

4. The article of footwear according to any one of claims 2-3, wherein the plurality of discrete pieces of waste particulate material includes remaining material from the upper of another article of footwear.

5. The article of footwear according to any one of claims 2-3, wherein the plurality of discrete pieces of waste particulate material includes recycled material from the upper of another article of footwear.

6. The article of footwear according to any one of claims 2-5, wherein the layer of waste particulate material further includes a resin binder, wherein each of the discrete pieces of the waste particulate material is fixed to one another via the resin binder.

7. The article of footwear according to any one of claims 1-6, wherein: the upper has an outer side and an inner side and further defines a toe region, a midfoot region, and a heel region of the shoe; each of the outer side and the inner side extends into the toe region, the midfoot region, and the heel region of the shoe; the upper further defines a toe cap that extends into the toe region and the midfoot region on each of the outer side and the inner side; [[ID=L19]]the wall forms at least a portion of the toe cap; and the closed pouch is disposed within the toe cap.

8. The footwear article according to claim 7, wherein the plurality of bonding region lines are defined as at least one of a plurality of pocket boundary sutures, a plurality of pocket boundary welded joints, or a plurality of pocket boundary barriers extending between the inner layer and the outer layer.

9. The footwear article according to claim 8, wherein the plurality of auxiliary sutures extend between the inner layer and the outer layer.

10. A method of manufacturing a footwear article, the method comprising: Inserting a plurality of discrete pieces of waste particulate material into a closed pocket formed between an inner layer of a wall of the upper of the footwear article and an outer layer of the wall of the upper, such that each of the discrete pieces of waste particulate material freely floats within the closed pocket; wherein the outer layer is formed of at least partially transparent material such that the discrete pieces of waste particulate material are at least partially visible through the outer layer; Joining the inner layer of the wall of the upper to the outer layer of the wall of the upper at a plurality of bonding region lines, wherein the plurality of bonding region lines are arranged in a predetermined pattern such that the closed pocket is enclosed by the bonding region lines and divided into a plurality of closed pockets; wherein the waste particulate material comprises one or more of ground, shredded, cut, or truncated pieces of yarn, thread, label, textile, leather, or fiber disposed between the inner layer and the outer layer and dispersed throughout the closed pocket, wherein the upper further comprises a plurality of auxiliary sutures joining the inner layer to the outer layer, wherein the auxiliary sutures are arranged in a predetermined pattern and at least one of the auxiliary sutures traverses at least one of the plurality of closed pockets.

11. The method according to claim 10, further comprising: Receiving waste material; and Dividing the waste material into a plurality of discrete pieces of waste particulate material via at least one of a grinding process and a shredding process such that each discrete piece of waste particulate material has a different shape.

12. The method according to any one of claims 10 - 11, further comprising: Mixing the discrete pieces of waste particulate material with a resin binder such that the discrete pieces of waste particulate material and the resin binder jointly define a mixture; and Thermoforming the mixture into a layer of waste particulate material.

13. The method according to claim 12, wherein inserting the plurality of discrete pieces of waste particulate material into the closed pocket defined between the inner layer and the outer layer further comprises: Placing the layer of waste particulate material on the outer layer and in contact with the outer layer; and Positioning the inner layer over the layer of waste particulate material and the outer layer such that the inner layer and the outer layer define the closed pocket around the perimeter of the layer of waste particulate material such that the layer of waste particulate material is disposed within the closed pocket.

14. The method according to claim 13, further comprising: The bonding region lines enclose the closed pocket and the layer of waste particulate material; and Wherein, joining the inner layer of the wall of the upper to the outer layer of the wall of the upper is performed by thermally pressing the inner layer to the outer layer.

15. The method according to claim 14, wherein: The waste particulate material includes residual material from forming the upper of another footwear item.

16. The method according to claim 14, wherein: The plurality of discrete pieces of the waste particulate material include recycled material from the upper of another footwear item.

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