Multi-layer extruded uppers for footwear and other foot-supporting devices

Abstract

This application relates to multilayer extruded uppers for footwear articles and other foot-accommodating devices. Upper components (2002, 3002) for footwear (2000, 3000) include: (a) a first upper component (1210, 3002b) comprising a first layer (300, 350, 400, 500, 600, 700, 800, 900), the first layer having a first material as a first filament, the first filament comprising a first plurality of non-intersecting spaced path segments (100a-100e) (wherein the first filament has a length of less than 3m). (a) a width dimension of m (and in some examples, less than 2 mm, less than 1.5 mm, less than 1 mm, or even less than 0.75 mm); and (b) a second upper component (1110, 1120, 3002a) comprising a fabric element at least partially formed of a fusible material (1124, 1134, 1144), wherein the fusible material (e.g., in a binder-free manner) is melted into the first material of the first upper component. Additional material layers including additional layers may be included in the upper, these additional layers comprising, for example, filaments and / or fabric elements of the type described above.

Description

[0001] This application is a divisional application of the application filed on April 10, 2019, with application number 201980038497.7 and invention title "Multi-layer extruded upper for footwear articles and other foot-accommodating devices".

[0002] Relevant application data

[0003] This application claims priority based on (a) U.S. Provisional Patent Application No. 62 / 655,519, filed April 10, 2018, and (b) U.S. Provisional Patent Application No. 62 / 655,539, filed April 10, 2018. Each of U.S. Provisional Patent Application No. 62 / 655,519 and U.S. Provisional Patent Application No. 62 / 655,539 is incorporated herein by reference in its entirety. Technical Field

[0004] This invention relates to the field of footwear and other foot-enclosing devices. More specifically, aspects of the invention relate to uppers for footwear articles and other foot-enclosing devices, and methods of manufacturing such uppers. Background Technology

[0005] Traditional athletic footwear comprises two main components: the upper and the sole structure. The upper provides coverage for the foot, which securely houses and positions the foot relative to the sole structure. Furthermore, the upper may have configurations that protect the foot and provide ventilation, allowing the foot to stay cool and wick away sweat. The sole structure is attached to the underside of the upper and is typically located between the foot and any contact surfaces. In addition to damping ground reaction forces and absorbing energy, the sole structure also provides traction and controls potentially harmful foot movements, such as overpronation. The general characteristics and configurations of the upper and sole structures will be discussed in more detail below.

[0006] The upper forms a cavity within the footwear to accommodate the foot. This cavity has a general shape of the foot and an entrance to it via an ankle opening or foot insertion opening. Therefore, the upper extends along the medial and lateral sides of the foot and around the heel area of ​​the foot, across the instep and toe areas. A lacing system is typically integrated into the upper to selectively change the size of the ankle opening and allow the wearer to modify certain dimensions of the upper, particularly the girth, to accommodate different foot proportions. Furthermore, the upper may include a tongue that extends below the lacing system to enhance footwear comfort (e.g., to adjust the pressure exerted on the foot by the lacing), and the upper may also include a heel stabilizer to restrict or control heel movement.

[0007] The sole construction typically comprises multiple layers, commonly referred to as the "insole," "midsole," and "outsole." The insole (which can also form the insole) is a thin component located inside the upper and adjacent to the sole (lower) surface of the foot to enhance comfort, such as by wicking away moisture. The midsole, traditionally attached to the entire length of the upper, forms the middle layer of the sole construction and serves multiple purposes, including controlling foot movement and dampening impact. The outsole forms the ground contact element of the footwear and is typically made of durable, abrasion-resistant materials that include textures or other features to improve traction.

[0008] Terminology / General Information

[0009] First, some general terminology and information are provided to aid in understanding the various parts of this specification and the invention described herein. As stated above, the present invention relates to the field of footwear and other foot-accommodating devices. "Foot-accommodating device" refers to any device used by a user to place at least a portion of his or her foot. In addition to various types of footwear (described below), foot-accommodating devices include, but are not limited to: straps and other devices for securing the foot to skis, cross-country skis, water skis, snowboards, etc.; straps, clamps, or other devices for securing the foot to pedals for use with bicycles, sports equipment, etc.; straps, clamps, or other devices for accommodating the foot during video games or other games, etc. A "foot-accommodating device" may include one or more "foot covering members" (e.g., similar to footwear upper components) that facilitate positioning of the foot relative to other components or structures; and one or more "foot support members" (e.g., similar to footwear sole structural components) that support at least one or more portions of the sole surface of the user's foot. A "fixation system" can help position and / or securely hold the user's foot in place relative to the foot covering members and / or foot support members. "Footwear" means any type of clothing used for the feet, and the term includes, but is not limited to: all types of shoes, boots, athletic shoes, sandals, flip-flops, slippers, slippers, sleepwear, casual shoes, athletic shoes (such as cross-country running shoes, golf shoes, tennis shoes, baseball shoes, football or rugby shoes, ski boots, basketball shoes, cross-training shoes, track and field shoes, track and field shoes (e.g., for high jump, long jump, etc.)), etc. "Foot support components" can include components used for and / or as midsoles and / or outsoles in footwear articles (or components that provide corresponding functionality in non-footwear foot-accommodating devices).

[0010] Unless otherwise stated or clear from the context, the terms "forward" or "forward direction" as used herein refer to the orientation or direction toward the forefoot area of ​​the footwear or foot-receiving structure or component. Unless otherwise stated or clear from the context, the terms "backward" or "backward direction" as used herein refer to the orientation or direction toward the rearfoot area of ​​the footwear or foot-receiving structure or component. Unless otherwise stated or clear from the context, the terms "outer" or "outer side" as used herein refer to the outer side or "little toe" side of the footwear or foot-receiving structure or component. Unless otherwise stated or clear from the context, the terms "inner" or "inner side" as used herein refer to the inner side or "big toe" side of the footwear or foot-receiving structure or component.

[0011] As used in this paper, the term "Moiré effect" refers to the visual perception that occurs when observing a set of lines or points overlapping another set of lines or points, where the two sets differ in relative size, angle, or spacing. In some cases, the "Moiré effect" can be seen when two sets of lines (e.g., path segments) of equal thickness and spacing overlap, but one set is at an angle (e.g., several degrees) relative to the other. In this case, the "Moiré effect" can be perceived as a set of thick, indistinct stripes. Summary of the Invention Attached Figure Description

[0012] The following detailed description will be better understood when read in conjunction with the accompanying drawings, in which similar reference numerals indicate the same or similar elements appearing in all the various views.

[0013] Figure 1 An example of a multilayer shoe upper blank made of multilayer extruded filaments according to the present invention is shown;

[0014] Figures 2A to 2F Various features of filament paths and filament path segments in the upper layer according to some examples of the present invention are shown;

[0015] Figures 3A to 3W The illustration shows the layers of the extruded filament according to an example of the present invention, the steps of manufacturing a multilayer shoe upper component from the extruded filament, and various features / properties of the multilayer shoe upper component;

[0016] Figures 4A to 4C Various features of a filament-based upper component bonded to another upper component by an adhesive are shown;

[0017] Figures 5A to 5F Various features of a filament-based upper component that is bonded to another upper component in an adhesive-free manner are shown;

[0018] Figures 6A to 6EThe illustration shows example steps for joining a filament-based upper component to another upper component;

[0019] Figures 7A to 7C The illustration shows a footwear article comprising a multilayer extruded filament component according to an example of the present invention;

[0020] Figures 8A to 8B The illustration shows a footwear article comprising a multilayer extruded filament component according to another example of the invention; and

[0021] Figure 9 The illustration shows a multi-layered shoe upper blank integrally formed with a stud component according to some examples of the present invention.

[0022] Readers should understand that the accompanying drawings are not necessarily drawn to scale. Detailed Implementation

[0023] In the following description of various examples of footwear and foot-accommodating device structures and components according to the invention, reference is made to the accompanying drawings, which form part of the invention, and in which various exemplary structures and environments in which aspects of the invention can be implemented are illustrated. It should be understood that other structures and environments can be used, and structural and functional modifications can be made from the specifically described structures and functions without departing from the scope of the invention.

[0024] I. Detailed description of exemplary shoe uppers or other foot covering components according to the invention

[0025] Referring to the accompanying drawings and the following discussion, various footwear articles / foot housings and their features according to aspects of the invention are disclosed. The footwear depicted and discussed is athletic footwear (e.g., cross-country, running, or track shoes), but the concepts disclosed regarding this type of footwear can be applied to a wide range of athletic footwear types, including but not limited to: walking shoes, tennis shoes, soccer shoes, rugby shoes, basketball shoes, running shoes, track shoes, shoes for track and field sports (e.g., high jump, long jump, etc.), and cross-training shoes. Furthermore, the concepts of the invention can be applied to a wide range of non-athletic footwear, including work boots, sandals, loafers, and dress shoes, as well as other foot housings.

[0026] An upper for footwear articles (or a foot covering component for other foot-accommodating devices) according to at least some examples and aspects of the present invention may include: an upper component having: (A) a first layer comprising a first filament comprising a first plurality of non-intersecting spaced path segments, wherein the first filament has a width dimension of less than 3 mm (and in some examples, less than 2 mm, less than 1.5 mm, less than 1 mm, or even less than 0.75 mm); and (b) a second layer comprising a second filament comprising a second plurality of non-intersecting spaced path segments, wherein the second filament has a width dimension of less than 3 mm (and in some examples, less than 2 mm, less than 1.5 mm, less than 1 mm, or even less than 0.75 mm). The second layer may at least partially cover the first layer and may be fused to the first layer at the location where the second layer contacts the first layer. An additional material layer comprising, for example, an additional filament layer of the type described above may be included in the upper. The filament materials in different layers can be the same or different from each other (e.g., thermoplastic materials, thermoplastic polyurethane materials, hydrophobic materials, waterproof materials, non-absorbent materials, etc.), and they can be extruded, for example, formed in a solid deposition modeling process. The filament materials can include any material conventionally known and used as a meltable material in solid deposition modeling techniques (e.g., including thermoplastics such as acrylonitrile butadiene styrene (ABS), polylactic acid (PLA), high-impact polystyrene (HIPS), thermoplastic polyurethane (TPU), aliphatic polyamide (nylon), and / or other materials conventionally known and used in solid deposition modeling techniques). As used herein, the term "solid deposition modeling" includes processes referred to in the art as "molten filament fabrication" and "fused deposition modeling."

[0027] According to at least some examples and aspects of the present invention, an upper blank for footwear articles (or a foot cover component for other foot receiving devices) may include: (a) a first layer comprising a first filament formed as a first path (e.g., a first continuous path) of extruded filaments, wherein the first path (e.g., the first continuous path) of the first filaments forms a first lateral heel portion, a first lateral midfoot portion, a first forefoot portion, a first medial midfoot portion, and a first medial heel portion of the first layer, and wherein the first filament has a width of less than 3 mm (and in some examples, less than 2 mm, less than 1.5 mm, less than 1 mm, or even less). (a) a width dimension of less than 0.75 mm; and (b) a second layer comprising a second filament formed as a second path (e.g., a second continuous path) of extruded filaments, wherein the second path (e.g., a second continuous path) of the second filaments forms a second lateral heel portion, a second lateral midfoot portion, a second forefoot portion, a second medial midfoot portion, and a second medial heel portion, wherein the second filament has a width dimension of less than 3 mm (and in some examples, less than 2 mm, less than 1.5 mm, less than 1 mm, or even less than 0.75 mm), and wherein the second layer is fused to the first layer at the location where the second layer contacts the first layer. Additional material layers including, for example, additional filament layers of the type described above may be included in the upper blank. The filament materials in different layers may be the same or different from each other (e.g., as described above). The filament layers may be extruded, for example, in a solid deposition molding process.

[0028] An upper for footwear articles (or a foot covering component for other foot-accommodating devices) according to at least some examples and aspects of the invention may include: (a) a first upper component comprising a first layer comprising a first material as a first filament comprising a first plurality of non-intersecting spaced path segments, wherein the first filament has a width dimension of less than 3 mm (and in some examples, less than 2 mm, less than 1.5 mm, less than 1 mm, or even less than 0.75 mm); and (b) a second upper component comprising a fabric element at least partially formed of a fusible material, wherein the fusible material of the second upper component (e.g., in a binder-free manner) is melted into the first material of the first upper component. Additional material layers comprising, for example, additional filament layers and / or additional fabric elements of the type described above may be included in the upper. The filaments or fabric materials in different layers may be the same as or different from each other (e.g., as described above).

[0029] A method of forming an upper for footwear articles (or a foot covering component for other foot-accommodating devices) according to at least some examples and aspects of the present invention (and / or the types described above) may include: (a) extruding a first material to form a first layer comprising a first extruded filament comprising a first plurality of non-intersecting spaced path segments, wherein the first extruded filament has a width dimension of less than 3 mm (and in some examples, less than 2 mm, less than 1.5 mm, less than 1 mm, or even less than 0.75 mm); and (b) extruding a second material to form a second layer comprising a second extruded filament comprising a second plurality of non-intersecting spaced path segments, wherein the second extruded filament has a width dimension of less than 3 mm (and in some examples, less than 2 mm, less than 1.5 mm, less than 1 mm, or even less than 0.75 mm), and wherein the step of extruding the second material includes melting the second layer to the first layer at a location where the second layer contacts the first layer. The second layer at least partially overlaps the first layer. Filaments can be deposited in solid deposition molding processes.

[0030] A method of forming an upper (or foot covering component for other foot-accommodating devices) for footwear articles according to at least some examples and aspects (and / or the types described above) of the present invention may include: (a) extruding a first material to form a first layer comprising a first extruded filament as a first path (e.g., a first continuous path), wherein the first path (e.g., a first continuous path) of the first extruded filament forms a first lateral heel portion, a first lateral midfoot portion, a first forefoot portion, a first medial midfoot portion, and a first medial heel portion of the first layer, and wherein the first extruded filament has a width of less than 3 mm (and in some examples, less than 2 mm, less than 1.5 mm, less than 1 mm, or even less than 0 mm). (a) A width dimension of 0.75 mm; and (b) extruding a second material to form a second layer comprising a second extruded filament as a second path (e.g., a second continuous path), wherein the second path (e.g., a second continuous path) of the second extruded filament forms a second lateral heel portion, a second lateral midfoot portion, a second forefoot portion, a second medial midfoot portion, and a second medial heel portion of the second layer, wherein the second extruded filament has a width dimension of less than 3 mm (and in some examples, less than 2 mm, less than 1.5 mm, less than 1 mm, or even less than 0.75 mm), and wherein the step of extruding the second material includes melting the second layer to the first layer at the location where the second layer contacts the first layer. The second layer at least partially covers the first layer, and these layers can be deposited in a solid deposition molding process. If desired, additional layers of extruded filaments may be included in the upper.

[0031] A method of forming an upper (or foot covering component for other foot-accommodating devices) for footwear articles according to at least some examples and aspects of the present invention (and / or the types described above) may include: (a) extruding a first material to form a first layer comprising a first extruded filament comprising a first plurality of non-intersecting spaced path segments, wherein the first extruded filament has a width dimension of less than 3 mm (and in some examples, less than 2 mm, less than 1.5 mm, less than 1 mm, or even less than 0.75 mm), and wherein the first layer of the first extruded filament forms at least a portion of a first upper component; and (b) melting a second upper component to the first upper component, wherein the second upper component comprises a fabric element at least partially formed of a fusible material, wherein the fusible material of the second upper component is melted to the first material of the first upper component, for example by applying heat and / or pressure, optionally in a binder-free manner. The first upper component may comprise a multilayer filament material. The extruded filament layer may be deposited in a solid deposition molding process.

[0032] A method of forming an upper (or foot covering component for other foot-accommodating devices) for footwear articles according to at least some examples and aspects of the present invention (and / or the types described above) may include: (a) extruding a first material to form a first layer comprising a first extruded filament comprising a first plurality of non-intersecting spaced path segments, wherein the first extruded filament has a width dimension of less than 3 mm (and in some examples, less than 2 mm, less than 1.5 mm, less than 1 mm, or even less than 0.75 mm), and comprising the first layer of the first extruded filament forming at least a portion of a first upper component; (b) covering a portion of the first layer (e.g., a portion of the first layer extending inward from the outer periphery of the first layer) with a release liner; (c) extruding a second material to form a second layer comprising a second extruded filament comprising a second plurality of non-intersecting spaced path segments, wherein the second extruded filament has a width dimension of less than 3 mm ( And in some examples, it has a width dimension of less than 2 mm, less than 1.5 mm, less than 1 mm, or even less than 0.75 mm, wherein the step of extruding the second material includes: (i) applying a first portion of the second layer to a release liner such that the release liner extends between the first portion of the first layer and the first portion of the second layer, and (ii) melting a second portion of the second layer to the second portion of the first layer at a location where the second layer contacts the first layer (e.g., at a location away from the release liner), and wherein the second layer forms part of the first upper component; (d) removing the release liner from between the first portion of the first layer and the first portion of the second layer; (e) optionally, placing a portion of the second upper component between the first portion of the first layer and the first portion of the second layer, wherein the portion of the second upper component optionally includes a fabric element formed at least partially of a fusible material; and (f) optionally, joining the second upper component to the first upper component. In examples where the second upper component includes a fabric element at least partially formed of a fusible material, the fusible material of the second upper component may be melted, for example, into a first material of the first upper component and / or a second material of the first upper component in a binder-free manner. If desired, a multilayer of filament material may be provided on either side or both sides of the release liner (and the second upper component). The filament material layer may be deposited in a solid deposition molding process.

[0033] The two or more layers of molten filament material in the footwear upper according to examples of the present invention can provide designers with several options to control the characteristics and / or performance features of the footwear upper, and / or provide designers with several options to control the characteristics and / or performance features in different areas or zones of a single upper. Many features or properties of the upper can be controlled or altered, including one or more of the following: (a) the filament size (e.g., extrusion diameter, extrusion width, or extrusion thickness) in one or more filament layers of the upper and / or in one or more sections or regions of a single layer of the upper; (b) the filament material (e.g., elasticity, tensile strength, etc.) in one or more filament layers of the upper and / or in one or more sections or regions of a single layer of the upper; (d) the degree of filament overlap between layers of the upper (e.g., overlap in the filament width direction and / or filament axial direction); (e) the filament arrangement layers in the layers of the upper; (f) the number of filament path segments in one or more filament layers of the upper and / or in one or more sections or regions of a single layer of the upper; (g) the filament path orientation in one or more filament layers of the upper and / or in one or more sections or regions of a single layer of the upper, etc. Compared to the bonding between strands or yarns in knitted or woven fabrics, the melting at the intersections of filament layers provides a different kind of bonding and interaction between layers. Typically, filaments extending in the inner-outer direction of the upper (e.g., from one side to the other and / or from the top edge (e.g., through the foot-accommodating opening and / or instep opening) to the bottom edge (e.g., where the upper will join the sole)) will provide an enhanced “locking” effect on the foot (e.g., holding the foot more firmly to the sole). Fibers arranged in more curved and / or serpentine patterns and / or in rhomboid or parallelogram shapes can provide directional stretching characteristics (e.g., more stretch in one direction compared to the opposite direction). Closer filament spacing in one or more layers and / or within a single layer of the upper will tend to provide reduced flexibility, reduced stretchability, reduced permeability (e.g., for air, water, or other materials), and / or reduced breathability for that layer and / or section (and larger filament spacing will tend to increase these properties of that layer and / or section).

[0034] Having given the background and general description of various aspects and examples of the invention, the following is a more detailed description of specific examples of shoe uppers, shoe upper components, shoe upper blanks and / or footwear articles according to at least some examples of the invention.

[0035] II. Detailed description of specific examples of shoe uppers, shoe upper components, shoe upper blanks, and footwear articles according to the present invention.

[0036] Figure 1The illustration shows an upper blank 1000 for forming an upper (or foot cover part of another type of foot receiving device) of a footwear article according to an example of the present invention. The upper blank 1000 of this example is formed from multiple layers of extruded filaments. One or more filament layers of the upper blank 1000 (and optionally each individual layer in the filament layers) can be extruded as a continuous path of extruded filaments, although in some examples of the invention, one or more (or even all) of the individual layers need not be extruded as a continuous path. The extruded filament paths in any one or more layers of the upper blank 1000 can extend to form one or more (and optionally all) of the following: a lateral heel portion 1002 (e.g., extending along the lateral side 1002s of the ankle / foot opening 1014 of the upper blank 1000); a lateral midfoot portion 1004 (e.g., adjacent to the lateral side 1004s of the instep opening 1012 of the upper blank 1000, the lateral midfoot portion 1004 may include one or more structures to receive... (lacing); forefoot portion 1006 (e.g., bridging from the outer side to the inner side of the upper blank 1000 in front of the midfoot portion); inner midfoot portion 1008 (e.g., adjacent to the inner side 1008s of the instep opening 1012 of the upper blank 1000, the inner midfoot portion 1008 may include one or more structures to engage the lacing); and inner heel portion 1010 (e.g., extending along the inner side 1010s of the ankle / foot opening 1014 of the upper blank 1000). Figure 1 The vertical dashed lines shown typically define and divide the upper blank 1000 into three parts or regions: (a) the rear third (including the lateral heel portion 1002 and the medial heel portion 1010), (b) the middle third (including the lateral midfoot portion 1004 and the medial midfoot portion 1008), and (c) the front third (including the forefoot portion 1006). In some examples of the invention, the upper blank 1000 will consist substantially of a multilayered filament structure, or even more. For this example upper blank 1000 Figure 1 The visible blank spaces in the design constitute the open spaces between the filament path segments (for example, where one can see the shoe upper blank 1000 completely).

[0037] Now we will combine Figures 2A to 2F The example features of a single layer of the multi-layered shoe upper blank 1000 are described in more detail. Figure 2A and Figure 2DThe figures generally show extrusion path segments 100, which can be laid by an extruder 102 during upper forming processes according to some examples of the invention (e.g., in solid deposition modeling or fused deposition modeling processes). As shown in these figures, individual path segments 100 of the extruded filament will typically have an axial length L much greater than the width W and / or thickness T of the individual filament path segment. As some more specific examples, an individual filament (and / or at least one or more path segments 100 thereof) may have an extrusion width dimension W less than 3 mm, and in some examples, it may have an extrusion width dimension W less than 2 mm, less than 1.5 mm, less than 1 mm, or even less than 0.75 mm. Additionally or alternatively, an individual filament (and / or at least one or more path segments 100 thereof) may have an extrusion thickness dimension T less than 3 mm, and in some examples, it may have an extrusion thickness dimension T less than 2 mm, less than 1.5 mm, less than 1.25 mm, less than 1 mm, or less than 0.75 mm, or even less than 0.5 mm. For at least some path segments 100 (and optionally all path segments 100 in the upper layer and / or upper blank 1000), the width dimension W may be greater than the thickness dimension T. The path segment length dimension L and / or the entire continuous path length may be at least 10 times larger than the width dimension W and / or thickness dimension T of the filament / filament path (and in some examples, at least 20 times, at least 50 times, at least 75 times, at least 100 times, or even at least 150 times larger). Moreover, as described above, a single layer of the upper component may include multiple non-intersecting, spaced-apart path segments. As further examples, as shown in the figures, a single layer may include at least 5 non-intersecting path segments over a path segment length of at least 25 mm, and in some examples, it may include at least 5 non-intersecting path segments over path segment lengths of at least 50 mm, at least 75 mm, at least 100 mm, at least 150 mm, or even longer. As an additional example, a single layer may include at least 10 non-intersecting path segments on any of the aforementioned path segment length dimensions, at least 15 non-intersecting path segments on any of the aforementioned path segment length dimensions, or even at least 20 non-intersecting path segments on any of the aforementioned path segment length dimensions.

[0038] like Figure 2DAs shown, material 108 for forming the filament path segment 100 can be forced onto a substrate 106, which can be formed of glass or other suitable material, via nozzle 104 of extruder 102. For example, the diameter of nozzle 104 can be slightly narrower than the final extruded width W of the path segment 100 because the heated filament material 108 may tend to flatten after deposition as the path segment 100 (or may even be pushed downward by nozzle 104 of extruder 102). Generally, increasing the temperature of the extruded material 108 can make the deposited path segment 100 flatter (and generally increase the width W and decrease the thickness T). In a more specific example, the diameter of nozzle 104 can be about 0.4 mm, although the diameter of nozzle 104 can range, for example, from 0.25 mm to 2.5 mm (and in some examples, from 0.3 mm to 2 mm). The surface 106s of the substrate 106 may be smooth or textured, and the features of the bottom surface 100s of the filament path segment 100 may be formed and take the shape of the surface 106s of the substrate 106 (e.g., smooth or textured features), the bottom surface 100s of the filament path segment 100 contacting and forming on the surface 106s of the substrate 106.

[0039] Figure 2B The illustration shows a portion of an upper preform 1000 containing two layers of filaments. First, a first filament path segment 100 (e.g., having any one or more of the aforementioned filament dimensions and / or structural features) is extruded, and then a second filament path segment 200 (e.g., as a second layer of the upper / upperform preform 1000) is extruded along a direction intersecting or intersecting with the first filament path segment 100. The second filament path segment 200 may directly contact the first filament path segment 100 during its extrusion (at contact area 202). During the extrusion of the second filament path segment 200, heat (and / or another heat source) from the material of the second filament path segment 200 causes the second filament path segment 200 and the first filament path segment 100 to melt together at their contact point 202 (e.g., the material of the second filament path segment 200 can polymerize and seamlessly bond with the material of the first filament path segment 100, and the heat from the extruded second filament path segment 200 during deposition can support this melting feature). In this way, the first layer (including the first filament path segment 100) of the upper blank 1000 can be fixedly bonded to the second layer (including the second filament path segment 200) of the upper blank 1000 at the contact position 202 without adhesive.

[0040] Figure 2C and Figure 2E This illustrates another method in which two (or more) layers of the upper blank 1000 can be joined together. It is not a simple intersection (as shown in the diagram). Figure 2BAs shown), a second extrusion path segment 200 can be extruded at a location that generally overlaps with (and optionally extends parallel to) the first extrusion path segment 100 over at least a portion of their respective axial length L. This action creates an axially extending contact area 202 between path segments 200 and 100. However, other options are also possible; after extruding the first path segment 100, the second path segment 200 can be extruded at a location slightly offset from the extrusion path of the first path segment 100 (optionally formed in a second layer of the upper blank 1000). Figure 2E As shown, when the first path segment 100 is extruded, the center of the nozzle 104 is located at line 120a. Then, when the second path segment 200 is extruded (e.g., having a second upper blank layer), the nozzle 104 moves an offset distance D to the center at line 120b. This offset distance D can be any desired amount, and in some examples of the invention, it can be 0.5D. N up to 0.9D N Between, and in some cases, it can be 0.625D N up to 0.85D N Between, or even up to about 0.75D N D N This indicates the diameter of nozzle 104.

[0041] Figure 2C and Figure 2E The overlapping (and generally parallel) contact areas 202 of the type shown can extend to any desired axial length L without departing from the invention. In some examples, the second path segment 200 of the second filament (or second layer) can extend parallel to and / or partially overlap with the first path segment of the first filament (or first layer) over a path segment length 100 of at least 25 mm, and in some examples, it can extend parallel to and / or partially overlap with the first path segment of the first filament (or first layer) over a path segment length 100 of at least 50 mm, at least 75 mm, at least 100 mm, at least 150 mm, or even longer. The overlapping contact areas 202 can also extend along curved path segments. Additionally or alternatively, the entire layer path of the second layer (including the second path segment 200) may: (a) extend parallel to and / or partially overlap with the entire layer path of the first layer (including the first path segment 100) for at least 10%, at least 25%, at least 50%, at least 75%, at least 85%, at least 90%, or even at least 95% of the total path length of the second layer; and / or (b) extend parallel to and / or partially overlap with the entire layer path of the first layer (including the first path segment 100) for at least 10%, at least 25%, at least 50%, at least 75%, at least 85%, at least 90%, or even at least 95% of the total path length of the first layer.

[0042] In at least some embodiments of this aspect of the invention, the second path segment 200 of the second filament overlaps with the first path segment 100 of the first filament by an overlap width WO, which is 5% to 50% of the total combined width WC of the second and first filaments at the overlap location. See also Figure 2C In some examples, the overlap width WO can be 10% to 45% or even 15% to 40% of the total combined width WC at the overlap location. When a single filament layer is formed as a plurality of non-intersecting spaced path segments, a plurality of second plurality of non-intersecting spaced path segments of the second filament (e.g., path segment 200) can overlap with a plurality of first plurality of non-intersecting spaced path segments of the first filament (e.g., path segment 100) by an overlap width WO of 5% to 50% (or 10% to 45% or even 15% to 40%) of the total combined width WC at the locations of the overlapping path segments: (a) the second plurality of non-intersecting spaced path segments and (b) the first plurality of non-intersecting spaced path segments. Additionally or alternatively, if desired, the overlap width WO of the second path segment 200 with one or more filaments of the corresponding first path segment 100 may be within 10% to 75%, 15% to 60%, or even 25% to 50% of the width W of the second path segment 200 (or the width W of the first path segment 100) at the overlap location. Thus, WO = 0.1W to 0.75W, or even 0.15W to 0.6W or 0.25W to 0.5W, where W is the width of path segment 100 or path segment 200.

[0043] Although Figure 2C and Figure 2E Two layers of path segments 100 and 200 are shown, overlapping if needed, but a third layer and / or additional layers can be deposited to partially overlap with the first segment 100 and / or the second segment 200 at or near the point where the first segment 100 and the second segment 200 overlap. This feature is in Figure 2C and Figure 2E The third layer path segment 300 is represented by a dashed line. The third layer path segment 300 may overlap with the first layer path segment 100 and / or the second layer path segment 200 in any of the aforementioned overlap width and / or length ranges. Overlapping and substantially parallel path segments, for example... Figure 2C and Figure 2E Each of the path segments 100, 200, and / or 300 shown may have the same or different colors. In some examples, two or more overlapping and generally parallel path segments may have the same general color but different shades of that color. These color features can contribute to interesting aesthetic features of the upper components if desired.

[0044] Figure 2F Additional path segments and / or path layers according to aspects of the invention are shown that can be disposed in at least some upper blanks 1000 and / or uppers. As described above, one or more of the filament layers of the upper or upper blank 1000 can be formed by an extruder 102 (optionally as a continuous path). This filament path can form one or more of the outer heel portion, outer midfoot portion, forefoot portion, medial midfoot portion, and / or medial heel portion of the upper, layers, and / or upper blank 1000. When these portions of the upper / upper blank 1000 are manufactured from thin extruded filaments, in some areas of the upper / upper blank 1000, path segments 100 of individual layers can be extruded to positions relatively close to each other, optionally extending parallel to each other. Figure 2F As shown, in a layer, the filament can be extruded into multiple non-intersecting, spaced-apart path segments, which include at least three first non-intersecting path segments (such as...). Figure 2F (As shown in the illustration, 100a-100e). In this example, each non-intersecting path segment (100a-100e) in a single layer of non-intersecting path segment groups is spaced apart from each directly adjacent non-intersecting path segment in the same layer by a distance of less than 10mm over a length dimension L of at least 25mm. Figure 2F (S1 to S4 in the example). In some examples, the spacing S can be less than 8 mm, less than 6 mm, less than 5 mm, or even less than 3 mm, and / or the length L can be at least 15 mm, at least 50 mm, at least 75 mm, at least 100 mm, or even at least 150 mm. Figure 2F The widths W1 to W5 of the path segments 100a to 100e shown in the figure can have, for example, the combinations described above. Figure 2A and Figure 2D Any of the width features. In some examples of the invention, the second layer (or even the third or more layers) of the path segment will be with Figure 2F The segments 100a-100e shown are deposited overlapping and / or parallel to, for example, as... Figure 2C and Figure 2E The overlap shown.

[0045] The spacing S, width W, and / or overlap length L in a given layer can be constant or vary throughout the layer of the path segment. As some more specific examples, the filaments in the layer (and optionally the continuous paths of the filaments) can have a first thickness in a first region of the upper or upper blank 1000 and a second thickness in a second region of the upper or upper blank 1000, wherein the first thickness is different from the second thickness (and optionally can be within the range described above). Additionally or alternatively, if desired, the filaments in the layer (and optionally the continuous paths of the filaments) can have a first diameter and / or a first width in the first region of the upper or upper blank 1000 and a second diameter and / or a second width in the second region of the upper or upper blank 1000, wherein the first diameter and / or the first width is different from the second diameter and / or the second width (and optionally can be within the range described above). The varying thicknesses, widths, and / or diameters of the filaments within the layers can help control the properties of the upper and / or upper blank 1000 (e.g., strength, durability, flexibility, stretchability, breathability, support, etc.).

[0046] The following is combined Figures 3A to 3W A more detailed description of, for example, similar to Figure 1 Various features and examples of shoe uppers or shoe upper blanks 1000 made of multi-layered filament materials, as well as methods of manufacturing them. Figure 3A An example first layer 300 is shown, consisting of a first filament (e.g., having any of the aforementioned filament features and characteristics), formed by, for example, extruding a first material into a plurality of path segments (e.g., having any of the aforementioned path and / or path segment characteristics) via a solid deposition molding process. Optionally, the first layer 300 may be extruded as a first continuous path. In the illustrated example, the first path of the first filament (optionally as a continuous path) forms the following portions of the first layer 300: (a) a first lateral heel portion 302 (e.g., extending along and / or adjacent to the lateral side 302s of the ankle / foot opening 314 of the first layer 300); (b) a first lateral midfoot portion 304 (e.g., extending along and / or adjacent to the lateral side 304s (or inner edge) of the instep opening 312 of the first layer 300); (c) a first forefoot portion 306 (e.g., bridging from the outer side to the inner side of the first layer 300 in front of the midfoot portion); (d) a first medial midfoot portion 308 (e.g., extending along and / or adjacent to the inner side 308s (or inner edge) of the instep opening 312 of the first layer 300); and (e) a first medial heel portion 310 (e.g., extending along and / or adjacent to the inner side 310s of the ankle / foot opening 314 of the first layer 300). Figure 3AThe vertical dashed lines shown typically define and divide the first layer 300 into three parts: (a) the posterior third (including the lateral hind heel portion 302 and the medial hind heel portion 310), (b) the middle third (including the lateral midfoot portion 304 and the medial midfoot portion 308), and (c) the anterior third (including the forefoot portion 306). In at least some embodiments of the invention, the first layer 300 will consist substantially of this filamentary structure, or even entirely of this filamentary structure (optionally shaped as a continuous path and / or a monolithic construction). For this example of the first layer 300 Figure 3A The visible blank spaces in the middle constitute the open spaces between the filamentary path segments (for example, where one can have a complete view of the first layer 300).

[0047] While the path segments of the first layer 300 can be extruded in any desired order without departing from the invention, in some embodiments of the invention, the outer periphery (e.g., 300P) can be extruded first, and then the remainder of layer 300 can be extruded, for example, in a “grating” manner, to fill the area within periphery 300P. In the illustrated example, the entire path of the extrusion of the first layer 300 lays out a first plurality of non-intersecting, spaced path segments over a large portion of the entire surface area of ​​the first layer 300, which extend in a generally inside-outside direction of the first layer 300. This type of inside-outside oriented and / or extending filament can help enhance the “locking” characteristics of the upper (e.g., help hold the foot firmly to the sole structure) and can help control / reduce stretchability. Along the lateral heel region 302 and the medial heel region 310, the first filament path segment typically extends from the ankle opening 302s / 310s of the first layer 300 to the bottom peripheral portion 302t / 310t (e.g., here the first layer 300 will connect to the sole structure in the final footwear structure), wherein adjacent path segments of layer 300 extend generally parallel. Similarly, along the lateral midfoot region 304 and the medial midfoot region 308, the first filament path segment typically extends from the inner edge 304s / 308s of the instep opening 312 of the first layer 300 to the bottom peripheral portion 304t / 308t (outer edge) (e.g., here the first layer 300 will connect to the sole structure in the final footwear structure), wherein adjacent path segments of layer 300 extend generally parallel. In the forefoot region 306, the first filament path segment typically extends from the outer bottom edge 306s of the first layer 300 to the inner bottom edge 306t (e.g., where the first layer 300 will connect to the sole structure in the final footwear structure), wherein adjacent path segments of the layer 300 extend substantially parallel to each other. The path segments in these different regions 302, 304, 306, 308, and 310 may have the aforementioned features for… Figures 2A to 2F Any of the features and / or options of the path segment shown.

[0048] In the first layer 300, a path segment in one area does not need to have a constant interval with a directly adjacent path segment in other areas of the first layer 300. For example, as Figure 3A As shown, compared to the multiple non-intersecting spaced path segments in the heel regions 302 / 310 of the first layer 300, the multiple non-intersecting spaced path segments in the forefoot region 306 and / or midfoot region 304 / 308 of the first layer 300 are spaced closer together. The path segment spacing can be selected (e.g., Figure 2E (S1 to S4) to provide the required features (e.g., required stretchability, breathability, etc.) for individual areas of layer 300, upper, and / or upper blank 1000.

[0049] After the first layer 300 is extruded (e.g., on the substrate 106), a second layer 350 of the entire upper or upper blank 1000 can then be applied onto the first layer 300. Figure 3B This example shows a single path segment of the second layer 350, and Figure 3C The illustration schematically shows the production of the second layer 350 on top of the previously prepared first layer 300 to produce the combined first and second layers 380 of the upper or upper blank 1000. More specifically, Figure 3B A second layer 350 is shown, which is formed from a second filament (e.g., having any of the aforementioned filament features and characteristics) and is formed by, for example, extruding the second material into a plurality of path segments (e.g., having any of the aforementioned path and / or path segment characteristics) via a solid deposition molding process. Optionally, the second layer 350 can be extruded as a second continuous path. In the illustrated example, the second path of the second filament (optionally as a continuous path) forms the following portions of the second layer 350: (a) a second lateral heel portion 352 (e.g., extending along and / or adjacent to the lateral side 352s of the ankle / foot opening 364 of the second layer 350); (b) a second lateral midfoot portion 354 (e.g., extending along and / or adjacent to the lateral side 354s of the instep opening 362 (or inner edge) of the second layer 350); (c) a second forefoot portion 356 (e.g., bridging from the lateral side to the medial side of the second layer 350 in front of the midfoot portion); (d) a second medial midfoot portion 358 (e.g., extending along and / or adjacent to the medial side 358s of the instep opening 362 (or inner edge) of the second layer 350); and (e) a second medial heel portion 360 (e.g., extending along and / or adjacent to the medial side 360s of the ankle / foot opening 364 of the second layer 350). Figure 3BThe vertical dashed lines shown generally define the second layer 350 and divide it into three parts: (a) the posterior third (including the lateral hind heel portion 352 and the medial hind heel portion 360), (b) the middle third (including the lateral midfoot portion 354 and the medial midfoot portion 358), and (c) the anterior third (including the forefoot portion 356). In at least some examples of the invention, the second layer 350 will consist substantially of this filamentary structure, or even entirely of this filamentary structure (optionally shaped as a continuous path and / or a monolithic construction). For this example of the second layer 350 Figure 3B The visible blank spaces in the middle form open spaces between the filamentary path segments (for example, where one can fully see through the second layer 350).

[0050] While the path segments of the second layer 350 can be extruded in any desired order without departing from the invention, in some embodiments of the invention, the outer periphery (e.g., 350P) can be extruded first, and then the remainder of layer 350 can be extruded, for example, in a “grating” manner, to fill the area within periphery 350P. In the illustrated example, the entire path of the extrusion of the second layer 350 lays out the second filament over a large portion of the entire surface area of ​​the second layer 350 as a second plurality of non-intersecting, spaced-apart path segments that extend in a generally inside-outside direction of the second layer 350 (e.g., to help provide the aforementioned “locking” or other features for layer 300). Along the lateral heel region 352 and the medial heel region 360, the second filament path segment typically extends from the ankle opening 352s / 360s of the second layer 350 to the bottom peripheral portion 352t / 360t (e.g., here the second layer 350 will connect to the sole structure in the final footwear structure), wherein adjacent path segments of layer 350 extend generally parallel. Similarly, along the lateral midfoot region 354 and the medial midfoot region 358, the second filament path segment typically extends from the inner edge 354s / 358s of the instep opening 362 of the second layer 350 to the bottom peripheral portion 354t / 358t (outer edge) (e.g., here the second layer 350 will connect to the sole structure in the final footwear structure), wherein adjacent path segments of layer 350 extend generally parallel. In the forefoot region 356, the second filament path segment typically extends from the outer bottom edge 356s of the second layer 350 to the inner bottom edge 356t (e.g., here the second layer 350 will connect to the sole structure in the final footwear structure), wherein adjacent path segments of layer 350 extend substantially parallel to each other. The path segments in these different regions 352, 354, 356, 358, and 360 may have the aforementioned features for… Figures 2A to 2F Any of the features and / or options of the path segment shown.

[0051] In the second layer 350, a path segment in one area does not need to have a constant interval with a path segment directly adjacent to it in other areas of the second layer 350. For example, as Figure 3B As shown, compared to the multiple non-intersecting, spaced-apart path segments in the forefoot region 356 and / or midfoot region 354 / 358 of the second layer 350, the path segments are more closely spaced. The path segment spacing can be selected (e.g., Figure 2E (S1 to S4) to provide the required features (e.g., required stretchability, breathability, etc.) for individual areas of layer 350, upper, and / or upper blank 1000.

[0052] from Figure 3A and Figure 3B The comparison clearly shows that the path segments of the first layer 300 and the second layer 350 extend in a generally parallel manner over most of their entire paths. Therefore, the path segments of the second layer 350 can be arranged as follows: Figure 2C and Figure 2E The manner shown typically involves extruding and / or being extruded in parallel to overlap with the path segments of the first layer 300 over a large portion of their entire path length. If necessary: ​​(a) at least 25% of the entire path length of the second layer 350 (and in some examples, at least 40%, at least 50%, at least 60%, at least 75%, at least 85%, or even at least 90%) will be extruded. Figure 2C and Figure 2E The manner shown overlaps with the path segments of the first layer 300, and / or (b) at least 25% (and in some examples, at least 40%, at least 50%, at least 60%, at least 75%, at least 85%, or even at least 90%) of the total path length of the first layer 300 will be... Figure 2C and Figure 2E The arrangement shown overlaps with the path segments of the second layer 350. Therefore, when the second layer 350 is extruded, the filaments of the second layer 350 will directly contact the filaments of the first layer 300 (at the overlapping contact area 202). When the second layer 350 is extruded, heat (and / or another heat source) from the second layer 350 causes the second filament path segments to melt together with the first filament path segments at the contact point 202 (e.g., the filament material of the second layer 350 can polymerize and seamlessly bond with the filament material of the first layer 300). In this way, the first layer 300 of the upper or upper blank 1000 can be fixedly bonded to the second layer 350 of the upper or upper blank 1000 at the contact point 202 without adhesive, to form... Figure 3CThe combined first and second layers 380. An upper component or intermediate comprising the combined first and second layers 380 constitutes an integral structure, wherein the first layer 300 and the second layer 350 are fixed together only by a non-adhesive fusion method. An upper component or intermediate comprising the combined first and second layers 380 may consist substantially of the first layer 300 and the second layer 350, or even solely of the first layer 300 and the second layer 350.

[0053] After the second layer 350 is extruded (e.g., on the first layer 300 and / or substrate 106), the third layer 400 of the entire upper or upper blank 1000 can then be applied to the combined first and second layers 380. Figure 3D This example shows a single path segment of layer 400 in the third layer, and... Figure 3E The schematic illustration shows the production of the third layer 400 on top of the previously prepared combined first and second layers 380 to produce the combined first to third layers 440 of the upper or upper blank 1000. More specifically, Figure 3D A third layer 400 is shown, which is formed from a third filament (e.g., having any of the aforementioned filament features and characteristics) and is formed by, for example, extruding the third material into a plurality of path segments (e.g., having any of the aforementioned path and / or path segment characteristics) via a solid deposition molding process. Optionally, the third layer 400 can be extruded as a third continuous path. In the illustrated example, the third path of the third filament (optionally as a continuous path) forms the following portions of the third layer 400: (a) a third lateral heel portion 402 (e.g., extending along and / or adjacent to the lateral side 402s of the ankle / foot opening 414 of the third layer 400); (b) a third lateral midfoot portion 404 (e.g., extending along and / or adjacent to the lateral side 404s (or inner edge) of the instep opening 412 of the third layer 400); (c) a third forefoot portion 406 (e.g., bridging from the lateral side to the medial side of the third layer 400 in front of the midfoot portion); (d) a third medial midfoot portion 408 (e.g., extending along and / or adjacent to the medial side 408s (or inner edge) of the instep opening 412 of the third layer 400); and (e) a third medial heel portion 410 (e.g., extending along and / or adjacent to the medial side 410s of the ankle / foot opening 414 of the third layer 400). Figure 3DThe vertical dashed lines shown generally define the third layer 400 and divide it into three parts: (a) the posterior third (including the lateral hind heel portion 402 and the medial hind heel portion 410), (b) the middle third (including the lateral midfoot portion 404 and the medial midfoot portion 408), and (c) the anterior third (including the forefoot portion 406). In at least some examples of the invention, the third layer 400 will consist substantially of this filamentary structure, or even entirely of this filamentary structure (optionally shaped as a continuous path and / or a monolithic construction). For this example of the third layer 400 Figure 3D The visible blank spaces in the middle constitute the open spaces between the filamentary path segments (for example, where one can have a complete view of the third layer 400).

[0054] While the path segments of the third layer 400 can be extruded in any desired order without departing from the invention, in some embodiments of the invention, the outer periphery (e.g., 400P) can be extruded first, and then the remainder of the third layer 400 can be extruded, for example, in a "grating" manner, to fill the area within the periphery 400P. In the illustrated example, the entire path of the extruded third layer 400 lays out a third plurality of non-intersecting, spaced path segments over a large portion of the entire surface area of ​​the third layer 400, these third plurality of non-intersecting, spaced path segments extending in a generally front-to-back direction of the third layer 400. Figure 3D As shown, in the lateral hind heel portion 402, the lateral midfoot portion 404, the forefoot portion 406, and the medial hind heel portion 410, the third plurality of non-intersecting path segments of the third layer 400 extend in a gently curving manner in the direction forward from the hind heel portions 402 / 410. However, in the medial midfoot portion 408, at least some of the third plurality of non-intersecting spaced path segments extend in a serpentine configuration including at least two peaks (408P) and at least two valleys (408V). The path segments in these different regions 402, 404, 406, 408, and 410 may have the aforementioned features for... Figures 2A to 2F Any of the features and / or options of the path segment shown.

[0055] like Figure 3DAs further shown, the third path of the filament defines a first inner edge at the outer instep opening edge 404s, a first outer edge 404t at the outer midfoot region 404, a second inner edge at the inner instep opening edge 408s, and a second outer edge 408t at the inner midfoot region 408. The instep opening 412 of the third layer 400 is defined between the first inner edge at 404s and the second inner edge at 408s. The third path of the filament in the example layer 400 includes: (a) a first plurality of non-intersecting spaced path segments located between a first inner edge and a first outer edge 404t at 404s, wherein the first plurality of non-intersecting spaced path segments of the third path are linear and / or curved without defining a plurality of peaks and valleys, and / or (b) a second plurality of non-intersecting spaced path segments located between a second inner edge and a second outer edge 408t at 408s, wherein the plurality of second plurality of non-intersecting spaced path segments of the third continuous path located between the second inner edge and the second outer edge 408t at 408s extend in a serpentine configuration and have at least two peaks 408P and at least two valleys 408V. Figure 3D The third layer 400 may include at least 4 path segments, at least 6 path segments, at least 8 path segments, at least 10 path segments, or even at least 12 path segments, which extend generally in parallel and / or have the serpentine configuration described above.

[0056] In the third layer 400, a path segment within a zone does not need to have a constant interval with directly adjacent path segments in other zones of the third layer 400. For example, as Figure 3D As shown, compared to the multiple non-intersecting spaced path segments in the midfoot region 404 / 408, the multiple non-intersecting spaced path segments in the forefoot region 406 of the third layer 400 are more closely spaced, and / or compared to the multiple non-intersecting spaced path segments in the heel region 402 / 410 of the third layer 400, the multiple non-intersecting spaced path segments in the forefoot region 406 and / or the midfoot region 404 / 408 are more closely spaced.

[0057] from Figure 3D and Figure 3A and Figure 3B The comparison clearly shows that the path segments of the third layer (400) will intersect the path segments of the first layer (300) and the second layer (350) over most of their entire paths. The intersecting path segments form a grid or a typical matrix pattern, which can be observed... Figure 3EThis is seen in the combined first to third layers 440 shown. The path segments of the third layer 400 can intersect with the path segments of the first layer 300 and / or the second layer 350 at any desired angle, for example, from 5° to 175°, and in some examples, from 15° to 165°, from 25° to 155°, from 35° to 145°, from 45° to 135°, from 55° to 125°, from 60° to 120°, from 65° to 90°, etc. In at least some examples of the present invention: (a) the third path of the third layer 400 will overlap with the first path of the first layer 300 for less than 50% of the entire length of the third path (and in some examples, less than 40%, less than 30%, less than 20%, or even less than 10%); (b) the third path of the third layer 400 will overlap with the second path of the second layer 350 for less than 50% of the entire length of the third path (and in some examples, less than 40%, less than 30%, less than 20%, or even less than 10%); (c) the third path of the third layer 400 will overlap with the first path of the first layer 300 for less than 50% of the entire length of the first path (and in some examples, less than 40%, less than 30%, less than 20%, or even less than 10%); and / or (d) the third path of the third layer will overlap with the second path of the second layer 350 for less than 50% of the entire length of the second path (and in some examples, less than 40%, less than 30%, less than 20%, or even less than 10%).

[0058] Therefore, when the third layer 400 is extruded, the filaments of the third layer 400 will directly contact the filaments of the first layer 300 and the second layer (at the intersecting contact area 202). During extrusion, heat (and / or another heat source) from the third layer 400 causes the third filament path segment to melt together with any one or two of the first and / or second filament path segments at the location 202 where the third filament path segment contacts any one or two of the first and / or second filament path segments (e.g., the filament material of the third layer 400 can polymerize and seamlessly bond with the filament material of the first layer 300 and / or the second layer 350). In this way, the third layer 400 of the upper or upper blank 1000 can be fixedly bonded to the first layer 300 and the second layer 350 of the upper or upper blank 1000 at the contact location 202 without adhesive, forming the combined first to third layers 440. The upper component or intermediate comprising the combined first to third layers 440 constitutes an integral structure, wherein the first layer 300, the second layer 350, and the third layer 400 are fixed together only by a non-adhesive fusion method. The upper component or intermediate comprising the combined first and third layers 440 may consist substantially of the first layer 300, the second layer 350, and the third layer 400, or even consist of the first layer 300, the second layer 350, and the third layer 400.

[0059] After the third layer 400 is extruded (e.g., on the first layer 300, the second layer 350 and / or the substrate 106), the fourth layer 500 of the entire upper or upper blank 1000 can then be applied to the combined first to third layers 440. Figure 3F This example shows a single path segment of layer 500 in level 4, and... Figure 3G The schematic illustration shows the production of the fourth layer 500 on top of the previously prepared combined first to third layers 440 to produce the combined first to fourth layers 540 of the upper or upper blank 1000. More specifically, Figure 3F A fourth layer 500 is shown, which is formed from a fourth filament (e.g., having any of the aforementioned filament features and characteristics) and is formed by, for example, extruding the fourth material into a plurality of path segments (e.g., having any of the aforementioned path and / or path segment characteristics) via a solid deposition molding process. Optionally, the fourth layer 500 can be extruded as a fourth continuous path. In the illustrated example, the fourth path of the fourth filament (optionally as a continuous path) forms the following portions of the fourth layer 500: (a) a fourth lateral heel portion 502 (e.g., extending along and / or adjacent to the lateral side 502s of the ankle / foot opening 514 of the fourth layer 500); (b) a fourth lateral midfoot portion 504 (e.g., extending along and / or adjacent to the lateral side 504s (or inner edge) of the instep opening 512 of the fourth layer 500); (c) Fourth forefoot portion 506 (e.g., bridging from the lateral side to the medial side of the fourth layer 500 in front of the midfoot portion); (d) Fourth medial midfoot portion 508 (e.g., extending along and / or adjacent to the medial side 508s (or inner edge) of the instep opening 512 of the fourth layer 500); and (e) Fourth medial heel portion 510 (e.g., extending along and / or adjacent to the medial side 510s of the ankle / foot opening 514 of the fourth layer 500). Figure 3F The vertical dashed lines shown generally define the fourth layer 500 and divide it into three parts: (a) the posterior third (including the lateral hind heel portion 502 and the medial hind heel portion 510), (b) the middle third (including the lateral midfoot portion 504 and the medial midfoot portion 508), and (c) the anterior third (including the forefoot portion 506). In at least some examples of the invention, the fourth layer 500 will consist substantially of this filamentary structure, or even entirely of this filamentary structure (optionally shaped as a continuous path and / or a monolithic construction). For this example of the fourth layer 500 Figure 3F The visible blank spaces in the middle constitute the open spaces between the filamentary path segments (for example, where one can have a complete view of the fourth layer 500).

[0060] While the path segments of the fourth layer 500 can be extruded in any desired order without departing from the invention, in some embodiments of the invention, the outer periphery (e.g., 500P) can be extruded first, and then the remainder of the fourth layer 500 can be extruded, for example, in a "grating" manner, to fill the area within the periphery 500P. In the illustrated example, the entire path of the extruded fourth layer 500 lays out a fourth plurality of non-intersecting, spaced path segments over a large portion of the entire surface area of ​​the fourth layer 500, these fourth plurality of non-intersecting, spaced path segments extending in a generally front-to-back direction of the fourth layer 500. Figure 3F As shown, in the lateral hind heel portion 502, the lateral midfoot portion 504, the forefoot portion 506, and the medial hind heel portion 510, a fourth plurality of non-intersecting path segments extend in a gently curving manner in the direction forward from the hind heel portions 502 / 510. However, in the medial midfoot portion 508, at least some of the fourth plurality of non-intersecting spaced path segments of the fourth layer 500 extend in a serpentine configuration including at least two peaks (508P) and at least two valleys (508V). The path segments in these different regions 502, 504, 506, 508, and 510 may have the aforementioned features for... Figures 2A to 2F Any of the features and / or options of the path segment shown.

[0061] like Figure 3F As further shown, the fourth path of the filament defines a first inner edge at the outer instep opening edge 504s, a first outer edge 504t at the outer midfoot region 504, a second inner edge at the inner instep opening edge 508s, and a second outer edge 508t at the inner midfoot region 508. The instep opening 512 of the fourth layer 500 is defined between the first inner edge at 504s and the second inner edge at 508s. The fourth path of the filament in the example layer 500 includes: (a) a first plurality of non-intersecting spaced path segments located between a first inner edge and a first outer edge 504t at 504s, wherein the first plurality of non-intersecting spaced path segments of the fourth path are linear and / or curved without defining a plurality of peaks and valleys, and / or (b) a second plurality of non-intersecting spaced path segments located between a second inner edge and a second outer edge 508t at 508s, wherein the plurality of second plurality of non-intersecting spaced path segments of the fourth path located between the second inner edge and the second outer edge 508t at 508s extend in a serpentine configuration and have at least two peaks 508P and at least two valleys 508V. Figure 3F The fourth layer 500 may include at least 4 path segments, at least 6 path segments, at least 8 path segments, at least 10 path segments, or even at least 12 path segments, which extend generally in parallel and / or have the serpentine configuration described above.

[0062] from Figure 3D and Figure 3F The comparison clearly shows that the path segments of the third layer (400) and the fourth layer (500) extend in a generally parallel manner over most of their entire paths. Therefore, the path segment of the fourth layer (500) can be arranged as follows: Figure 2C and Figure 2E The manner shown typically involves extruding and / or being extruded in parallel to overlap with the path segments of the third layer 400 over a large portion of their entire path length. If necessary: ​​(a) at least 25% of the entire path length of the fourth layer 500 (and in some examples, at least 40%, at least 50%, at least 60%, at least 75%, at least 85%, or even at least 90%) will be extruded. Figure 2C and Figure 2E The manner shown overlaps with the path segment of the third layer 400, and / or (b) at least 25% (and in some examples, at least 40%, at least 50%, at least 60%, at least 75%, at least 85%, or even at least 90%) of the total path length of the third layer 400 will be... Figure 2C and Figure 2E The method shown overlaps with the path segment of the fourth layer 500. In at least some examples of the present invention: (a) the fourth path of the fourth layer 500 will overlap with the first path of the first layer 300 for less than 50% of the entire length of the fourth path (and in some examples, less than 40%, less than 30%, less than 20%, or even less than 10%), (b) the fourth path of the fourth layer 500 will overlap with the second path of the second layer 350 for less than 50% of the entire length of the fourth path (and in some examples, less than 40%, less than 30%, less than 20%, or even less than 10%), (c) the fourth path of the fourth layer 500 will overlap with the first path of the first layer 300 for less than 50% of the entire length of the first path (and in some examples, less than 40%, less than 30%, less than 20%, or even less than 10%), and / or (d) the fourth path of the fourth layer 500 will overlap with the second path of the second layer 350 for less than 50% of the entire length of the second path (and in some examples, less than 40%, less than 30%, less than 20%, or even less than 10%).

[0063] Therefore, when the fourth layer 500 is extruded, the filaments of the fourth layer 500 will directly contact the filaments of the third layer 400 (at the overlapping contact area 202). During extrusion, heat from the fourth layer 500 (and / or another heat source) causes the fourth filament path segment and the third filament path segment to melt together at their contact point 202 (e.g., the filament material of the fourth layer 500 can polymerize and seamlessly bond with the filament material of the third layer 400). In this way, the third layer 400 of the upper or upper blank 1000 can be securely bonded to the fourth layer 500 of the upper or upper blank 1000 at the contact point 202 without adhesive.

[0064] from Figure 3F and Figure 3A and Figure 3B The comparison also clearly shows that the path segments of the fourth layer (500) will intersect the path segments of the first layer (300) and the second layer (350) roughly over most of their entire paths. The intersecting path segments form a grid or a typical matrix pattern, which can be seen in... Figure 3G This is seen in the combined first to fourth layers 540 shown. The path segments of the fourth layer 500 can intersect the path segments of the first layer 300 and / or the second layer 350 at any desired angle, for example, from 5° to 175°, and in some examples, from 15° to 165°, from 25° to 155°, from 35° to 145°, from 45° to 135°, from 55° to 125°, from 60° to 120°, from 65° to 90°, etc. Therefore, when the fourth layer 500 is extruded, the filaments of the fourth layer 500 will directly contact the filaments of the first layer 300 and the filaments of the second layer 350 (at the intersecting contact area 202). When the fourth layer 500 is extruded, the heat (and / or another heat source) from the fourth layer 500 causes the fourth filament path segment to melt together with any one or two of the first filament path segments and / or the second filament path segments at location 202 where the fourth filament path segment contacts any one or two of the first filament path segments and / or the second filament path segments (e.g., the filament material of the fourth layer 500 can polymerize and seamlessly bond with the filament material of the first layer 300 and / or the second layer 350).

[0065] In these ways, the fourth layer 500 of the upper or upper blank 1000 can be fixedly bonded to the first layer 300, second layer 350, and third layer 400 of the upper or upper blank 1000 at the contact location 202 without adhesive, to form the combined first to fourth layers 540. The upper component or intermediate comprising the combined first to fourth layers 540 constitutes an integral structure, wherein the first layer 300, second layer 350, third layer 400, and fourth layer 500 are fixed together only by a non-adhesive melting method. The upper component or intermediate comprising the combined first to fourth layers 540 can consist substantially of the first layer 300, second layer 350, third layer 400, and fourth layer 500, or even solely of the first layer 300, second layer 350, third layer 400, and fourth layer 500.

[0066] In layer 4, 500, a path segment within a zone does not need to have a constant interval with directly adjacent path segments in other zones of layer 4, 500. For example, as Figure 3F As shown, compared to the multiple non-intersecting spaced path segments in the midfoot regions 504 / 508, the multiple non-intersecting spaced path segments in the forefoot region 506 of the fourth layer 500 are more closely spaced, and / or compared to the multiple non-intersecting spaced path segments in the heel regions 502 / 510 of the fourth layer 500, the multiple non-intersecting spaced path segments in the forefoot region 506 and / or the midfoot region 504 / 508 are more closely spaced.

[0067] After the fourth layer 500 is extruded (e.g., on the first layer 300, the second layer 350, the third layer 400 and / or the substrate 106), the fifth layer 600 of the entire upper or upper blank 1000 can then be applied to the combined first to fourth layers 540. Figure 3H This example shows a single path segment of layer 5, 600, and... Figure 3I The illustration schematically shows the production of the fifth layer 600 on top of the previously prepared combined first to fourth layers 540 to produce the combined first to fifth layers 640 of the upper or upper blank 1000. More specifically, Figure 3HA fifth layer 600 is shown, which is formed from a fifth filament (e.g., having any of the aforementioned filament features and characteristics) and is formed by, for example, extruding the fifth material into a plurality of path segments (e.g., having any of the aforementioned path and / or path segment characteristics) via a solid deposition molding process. Optionally, the fifth layer 600 can be extruded as a fifth continuous path. In the illustrated example, the fifth path of the fifth filament (optionally as a continuous path) forms the following portions of the fifth layer 600: (a) a fifth lateral heel portion 602 (e.g., extending along and / or adjacent to the lateral side 602s of the ankle / foot opening 614 of the fifth layer 600); (b) a fifth lateral midfoot portion 604 (e.g., extending along and / or adjacent to the lateral side 604s (or inner edge) of the instep opening 612 of the fifth layer 600); (c) Fifth forefoot portion 606 (e.g., bridging from the lateral side to the medial side of the fifth layer 600 in front of the midfoot portion); (d) Fifth medial midfoot portion 608 (e.g., extending along and / or adjacent to the medial side 608s of the instep opening 612 of the fifth layer 600); and (e) Fifth medial heel portion 610 (e.g., extending along and / or adjacent to the medial side 610s (or inner edge) of the ankle / foot opening 614 of the fifth layer 600). Figure 3H The vertical dashed lines shown generally define the fifth layer 600 and divide it into three parts: (a) the posterior third (including the lateral hind heel portion 602 and the medial hind heel portion 610), (b) the middle third (including the lateral midfoot portion 604 and the medial midfoot portion 608), and (c) the anterior third (including the forefoot portion 606). In at least some examples of the invention, the fifth layer 600 will consist substantially of this filamentary structure, or even entirely of this filamentary structure (optionally shaped as a continuous path and / or a monolithic construction). For this example of the fifth layer 600 Figure 3H The visible blank spaces in the middle form open spaces between the filamentary path segments (for example, where one can have a complete view of the fifth layer 600).

[0068] While the path segments of the fifth layer 600 can be extruded in any desired order without departing from the invention, in some embodiments of the invention, the outer periphery (e.g., 600P) can be extruded first, and then the remainder of the fifth layer 600 can be extruded, for example, in a "grating" manner, to fill the area within the periphery 600P. In the illustrated example, the entire path of the extruded fifth layer 600 lays out the fifth filament over a large portion of the entire surface area of ​​the fifth layer 600 as a fifth plurality of non-intersecting, spaced path segments extending in a generally front-to-back direction of the fifth layer 600. Figure 3HAs shown, in the lateral hind heel portion 602, the lateral midfoot portion 604, the forefoot portion 606, and the medial hind heel portion 610, the fifth plurality of non-intersecting path segments of the fifth layer 600 extend in a gently curving manner in the direction forward from the hind heel portions 602 / 610. However, in the medial midfoot portion 608, at least some of the fifth plurality of non-intersecting spaced path segments extend in a serpentine configuration including at least two peaks (608P) and at least two valleys (608V). The path segments in these different regions 602, 604, 606, 608, and 610 may have the aforementioned features for... Figures 2A to 2F Any of the features and / or options of the path segment shown.

[0069] like Figure 3H As further shown, the fifth path of the filament defines a first inner edge at the outer instep opening edge 604s, a first outer edge 604t at the outer midfoot region 604, a second inner edge at the inner instep opening edge 608s, and a second outer edge 608t at the inner midfoot region 608. The instep opening 612 of the fifth layer 600 is defined between the first inner edge at 604s and the second inner edge at 608s. The fifth path of the filament in the example layer 600 includes: (a) a first plurality of non-intersecting spaced path segments located between a first inner edge and a first outer edge 604t at 604s, wherein the first plurality of non-intersecting spaced path segments of the fifth path are linear and / or curved without defining a plurality of peaks and valleys, and / or (b) a second plurality of non-intersecting spaced path segments located between a second inner edge and a second outer edge 608t at 608s, wherein the plurality of second plurality of non-intersecting spaced path segments of the fifth path located between the second inner edge and the second outer edge 608t at 608s extend in a serpentine configuration and have at least two peaks 608P and at least two valleys 608V. Figure 3H The fifth layer 600 may include at least 4 path segments, at least 6 path segments, at least 8 path segments, at least 10 path segments, or even at least 12 path segments, which extend generally in parallel and / or have the serpentine configuration described above.

[0070] from Figure 3D , Figure 3F and Figure 3H The comparison clearly shows that the path segments of the third layer (400), the fourth layer (500), and the fifth layer (600) extend in a generally parallel manner over most of their entire paths. Therefore, the path segment of the fifth layer (600) can be arranged as follows: Figure 2C and Figure 2EThe manner shown typically involves extruding and / or being extruded in parallel to overlap with path segments of the third layer 400 and / or the fourth layer 500 over a large portion of their entire path length. If necessary: ​​(a) at least 25% of the entire path length of the fifth layer 600 (and in some examples, at least 40%, at least 50%, at least 60%, at least 75%, at least 85%, or even at least 90%) will be extruded. Figure 2C and Figure 2E The manner shown overlaps with path segments of at least one of the third layer 400 and / or the fourth layer 500, and / or (b) at least 25% (and in some examples, at least 40%, at least 50%, at least 60%, at least 75%, at least 85%, or even at least 90%) of the total path length of the third layer 400 and / or the fourth layer 500. Figure 2C and Figure 2E The method shown overlaps with the path segment of the fifth layer 600. In at least some examples of the present invention: (a) the fifth path of the fifth layer 600 will overlap with the first path of the first layer 300 for less than 50% of the entire length of the fifth path (and in some examples, less than 40%, less than 30%, less than 20%, or even less than 10%), (b) the fifth path of the fifth layer 600 will overlap with the second path of the second layer 350 for less than 50% of the entire length of the fifth path (and in some examples, less than 40%, less than 30%, less than 20%, or even less than 10%), (c) the fifth path of the fifth layer 600 will overlap with the first path of the first layer 300 for less than 50% of the entire length of the first path (and in some examples, less than 40%, less than 30%, less than 20%, or even less than 10%), and / or (d) the fifth path of the fifth layer 600 will overlap with the second path of the second layer 350 for less than 50% of the entire length of the second path (and in some examples, less than 40%, less than 30%, less than 20%, or even less than 10%).

[0071] Therefore, when the fifth layer 600 is extruded, the filaments of the fifth layer 600 will directly contact the filaments of the third layer 400 and / or the fourth layer 500 (at the overlapping contact area 202). When the fifth layer 600 is extruded, heat (and / or another heat source) from the fifth layer 600 causes the fifth filament path segment to melt together with any one or two of the third and / or fourth filament path segments at the location 202 where the fifth filament path segment contacts any one or two of the third and / or fourth filament path segments (e.g., the filament material of the fifth layer 600 can polymerize and seamlessly bond with the filament material of the third layer 400 and / or the fourth layer 500). In this way, the third layer 400 and / or the fourth layer 500 of the upper or upper blank 1000 can be fixedly bonded to the fifth layer 500 of the upper or upper blank 1000 at the contact location 202 without adhesive.

[0072] from Figure 3H and Figure 3A and Figure 3B The comparison also clearly shows that the path segments of the fifth layer (600) will intersect the path segments of the first layer (300) and the second layer (350) over most of their entire paths. The intersecting path segments form a grid or a typical matrix pattern, which can be seen in... Figure 3I This is seen in the combined first to fifth layers 640 shown. The path segments of the fifth layer 600 can intersect the path segments of the first layer 300 and / or the second layer 350 at any desired angle, for example, from 5° to 175°, and in some examples, from 15° to 165°, from 25° to 155°, from 35° to 145°, from 45° to 135°, from 55° to 125°, from 60° to 120°, from 65° to 90°, etc. Therefore, when the fifth layer 600 is extruded, the filaments of the fifth layer 600 will directly contact the filaments of the first layer 300 and the second layer 350 (at the intersecting contact area 202). When the fifth layer 600 is extruded, the heat (and / or another heat source) from the fifth layer 600 causes the fifth filament path segment to melt together with any one or two of the first filament path segments and / or the second filament path segments at location 202 where the fifth filament path segment contacts any one or two of the first filament path segments and / or the second filament path segments (e.g., the filament material of the fifth layer 600 can polymerize and seamlessly bond with the filament material of the first layer 300 and / or the second layer 350).

[0073] In these ways, the fifth layer 600 of the upper or upper blank 1000 can be fixedly bonded to the first layer 300, second layer 350, third layer 400, and fourth layer 500 of the upper or upper blank 1000 at the contact location 202 without adhesive, to form the combined first to fifth layers 640. The upper component or intermediate comprising the combined first to fifth layers 640 constitutes an integral structure, wherein the first layer 300, second layer 350, third layer 400, fourth layer 500, and fifth layer 600 are fixed together only by a non-adhesive melting method. The upper component or intermediate comprising the combined first to fifth layers 640 can consist substantially of the first layer 300, second layer 350, third layer 400, fourth layer 500, and fifth layer 600, or even solely of the first layer 300, second layer 350, third layer 400, fourth layer 500, and fifth layer 600.

[0074] In layer 5, 600, a path segment within a zone does not need to have a constant interval with directly adjacent path segments in other zones of layer 5, 600. For example, as Figure 3H As shown, compared to the multiple non-intersecting spaced path segments in the midfoot region 604 / 608, the multiple non-intersecting spaced path segments in the forefoot region 606 of the fifth layer 600 are more closely spaced, and / or compared to the multiple non-intersecting spaced path segments in the heel region 602 / 610 of the fifth layer 600, the multiple non-intersecting spaced path segments in the forefoot region 606 and / or the midfoot region 604 / 608 are more closely spaced.

[0075] After the fifth layer 600 is extruded (e.g., on the first layer 300, the second layer 350, the third layer 400, the fourth layer 500 and / or the substrate 106), the sixth layer 700 of the entire upper or upper blank 1000 can then be applied to the combined first to fifth layers 640. Figure 3J This example shows a single path segment of layer 6, 700, and... Figure 3K The illustration schematically shows the production of the sixth layer 700 on top of the previously prepared combined first to fifth layers 640 to produce the combined first to sixth layers 740 of the upper or upper blank 1000. More specifically, Figure 3JA sixth layer 700 is shown, which is formed from a sixth filament (e.g., having any of the aforementioned filament features and characteristics) and is formed by, for example, extruding the sixth material into a plurality of path segments (e.g., having any of the aforementioned path and / or path segment characteristics) via a solid deposition molding process. Optionally, the sixth layer 700 can be extruded as a sixth continuous path. In the illustrated example, the sixth path of the sixth filament (optionally as a continuous path) forms the following portions of the sixth layer 700: (a) a sixth lateral heel portion 702 (e.g., extending along and / or adjacent to the lateral side 702s of the ankle / foot opening 714 of the sixth layer 700); (b) a sixth lateral midfoot portion 704 (e.g., extending along and / or adjacent to the lateral side 704s (or inner edge) of the instep opening 712 of the sixth layer 700); (c) a sixth forefoot portion 706 (e.g., which bridges from the outer side to the inner side of the sixth layer 700 in front of the midfoot portion); (d) a sixth medial midfoot portion 708 (e.g., extending along and / or adjacent to the inner side 708s (or inner edge) of the instep opening 712 of the sixth layer 700); and (e) a sixth medial heel portion 710 (e.g., extending along and / or adjacent to the inner side 710s of the ankle / foot opening 714 of the sixth layer 700). Figure 3J The vertical dashed lines shown generally define the sixth layer 700 and divide it into three parts: (a) the posterior third (including the lateral hind heel portion 702 and the medial hind heel portion 710), (b) the middle third (including the lateral midfoot portion 704 and the medial midfoot portion 708), and (c) the anterior third (including the forefoot portion 706). In at least some examples of the invention, the sixth layer 700 will consist substantially of this filamentary structure, or even entirely of this filamentary structure (optionally shaped as a continuous path and / or a monolithic construction). For this example of the sixth layer 700 Figure 3J The visible blank spaces in the middle constitute the open spaces between the filamentary path segments (for example, where one can have a complete view of the sixth layer 700).

[0076] While the path segments of the sixth layer 700 can be extruded in any desired order without departing from the invention, in some embodiments of the invention, the outer periphery (e.g., 700P) can be extruded first, and then the remainder of the sixth layer 700 can be extruded, for example, in a "grating" manner, to fill the area within the periphery 700P. In the illustrated example, the entire path of the extruded sixth layer 700 lays out a sixth filament over a large portion of the entire surface area of ​​the sixth layer 700 as a sixth plurality of non-intersecting, spaced path segments extending in a generally front-to-back direction of the sixth layer 700. Figure 3JAs shown, in the lateral hind heel portion 702, forefoot portion 706, medial midfoot portion 708, and medial hind heel portion 710, the sixth plurality of non-intersecting path segments of the sixth layer 700 extend in a gently curving manner in the direction forward from the hind heel portions 702 / 710. However, in the lateral midfoot portion 704, at least some of the sixth plurality of non-intersecting spaced path segments extend in a serpentine configuration including at least two peaks (708P) and at least two valleys (708V). The path segments in these different regions 702, 704, 706, 708, and 710 may have the aforementioned features for... Figures 2A to 2F Any of the features and / or options of the path segment shown.

[0077] like Figure 3J As further shown, the sixth path of the filament defines a first inner edge at the outer instep opening edge 704s, a first outer edge 704t at the outer midfoot region 704, a second inner edge at the inner instep opening edge 708s, and a second outer edge 708t at the inner midfoot region 708. The instep opening 712 of the sixth layer 700 is defined between the first inner edge at 704s and the second inner edge at 708s. The sixth path of the filament in the example layer 700 includes: (a) a first plurality of non-intersecting spaced path segments located between a first inner edge and a first outer edge 704t at 704s, wherein the plurality of first plurality of non-intersecting spaced path segments located between the first inner edge and the first outer edge 704t at 704s extend in a serpentine configuration and have at least two peaks 708P and at least two valleys 708V; and (b) a second plurality of non-intersecting spaced path segments located between a second inner edge and a second outer edge 708t at 708s, wherein the second plurality of non-intersecting spaced path segments of the sixth path are linear and / or curved without defining a plurality of peaks and valleys. Figure 3J The sixth layer 700 may include at least 4 path segments, at least 6 path segments, at least 8 path segments, at least 10 path segments, or even at least 12 path segments, which extend generally in parallel and / or have the serpentine configuration described above.

[0078] In layer 6, 700, a path segment within a zone does not need to have a constant interval with directly adjacent path segments in other zones of layer 6, 700. For example, as Figure 3J As shown, compared to the multiple non-intersecting spaced path segments in the midfoot region 704 / 708, the multiple non-intersecting spaced path segments in the forefoot region 706 of the sixth layer 700 are more closely spaced, and / or compared to the multiple non-intersecting spaced path segments in the heel region 702 / 710 of the sixth layer 700, the multiple non-intersecting spaced path segments in the forefoot region 706 and / or the midfoot region 704 / 708 are more closely spaced.

[0079] from Figure 3J and Figure 3A , Figure 3B , Figure 3D , Figure 3F and Figure 3H The comparison clearly shows that the path segments of layer 6 (700) will intersect roughly with the path segments of layer 1 (300), layer 2 (350), layer 3 (400), layer 4 (500), and layer 5 (600) over most of their paths. The intersecting path segments form the typical diamond shape, which can be seen in... Figure 3K This is seen in the combined first to sixth layers 740 shown. The path segments of the sixth layer 700 can intersect with the path segments of the first layer 300, the second layer 350, the third layer 400, the fourth layer 500, and / or the fifth layer 600 at any desired angle, for example, from 5° to 175°, and in some examples, from 15° to 165°, from 25° to 155°, from 35° to 145°, from 45° to 135°, from 55° to 125°, from 60° to 120°, from 65° to 90°, etc. In at least some examples of the present invention: (a) the sixth path of the sixth layer 700 will overlap with one or more of the first path of the first layer 300, the second path of the second layer 350, the third path of the third layer 400, the fourth path of the fourth layer 500, and / or the fifth path of the fifth layer 600 for less than 50% (and in some examples, less than 40%, less than 30%, less than 20%, or even less than 10%) of the total length of the sixth path; and / or (b) the sixth path of the sixth layer 700 will overlap with one or more of the first path of the first layer 300, the second path of the second layer 350, the third path of the third layer 400, the fourth path of the fourth layer 500, and / or the fifth path of the fifth layer 600 for less than 50% (and in some examples, less than 40%, less than 30%, less than 20%, or even less than 10%) of the total length of the respective first path, second path, third path, fourth path, and / or fifth path.

[0080] Therefore, when the sixth layer 700 is extruded, the filaments of the sixth layer 700 will directly contact the filaments of the first layer 300, the second layer 350, the third layer 400, the fourth layer 500, and / or the fifth layer 600 (at the intersecting contact area 202). When the sixth layer 700 is extruded, the heat (and / or another heat source) from the sixth layer 700 causes the sixth filament path segment to melt together with any or any combination of the first, second, third, fourth, and / or fifth filament path segments at location 202 where the sixth filament path segment contacts any or any combination of the first, second, third, fourth, and / or fifth filament path segments (e.g., the filament material of the sixth layer 700 can polymerize and seamlessly bond with the filament materials of the first layer 300, second layer 350, third layer 400, fourth layer 500, and / or fifth layer 600). In this way, the sixth layer 700 of the upper or upper blank 1000 can be fixedly bonded to the first layer 300, second layer 350, third layer 400, fourth layer 500 and / or fifth layer 600 of the upper or upper blank 1000 in a non-adhesive manner at contact location 202 to form the combined first to sixth layers 740. The upper component or intermediate including the combined first to sixth layers 740 constitutes an integral structure, wherein the first layer 300, second layer 350, third layer 400, fourth layer 500, fifth layer 600 and sixth layer 700 are fixed together only by non-adhesive melting. The upper component or intermediate body, including the first to sixth layers 740, can be substantially composed of the first layer 300, the second layer 350, the third layer 400, the fourth layer 500, the fifth layer 600 and the sixth layer 700, or even composed of the first layer 300, the second layer 350, the third layer 400, the fourth layer 500, the fifth layer 600 and the sixth layer 700.

[0081] After the sixth layer 700 is extruded (e.g., on the first layer 300, the second layer 350, the third layer 400, the fourth layer 500, the fifth layer 600 and / or the substrate 106), the seventh layer 800 of the entire upper or upper blank 1000 can then be applied to the combined first to sixth layers 740. Figure 3L This example shows a single path segment of layer 7, 800, and... Figure 3M The illustration schematically shows the production of the seventh layer 800 on top of the previously prepared combined first to sixth layers 740 to produce the combined first to seventh layers 840 of the upper or upper blank 1000. More specifically, Figure 3LA seventh layer 800 is shown, which is formed from a seventh filament (e.g., having any of the aforementioned filament features and characteristics) and is formed by, for example, extruding the seventh material into a plurality of path segments (e.g., having any of the aforementioned path and / or path segment characteristics) via a solid deposition molding process. Optionally, the seventh layer 800 can be extruded as a seventh continuous path. In the illustrated example, the seventh path of the seventh filament (optionally as a continuous path) forms the following portions of the seventh layer 800: (a) a seventh lateral heel portion 802 (e.g., extending along and / or adjacent to the lateral side 802s of the ankle / foot opening 814 of the seventh layer 800); (b) a seventh lateral midfoot portion 804 (e.g., extending along and / or adjacent to the lateral side 804s (or inner edge) of the instep opening 812 of the seventh layer 800); (c) the seventh forefoot portion 806 (e.g., which bridges from the outer side to the inner side of the seventh layer 800 in front of the midfoot portion); (d) the seventh medial midfoot portion 808 (e.g., extending along and / or adjacent to the inner side 808s (or inner edge) of the instep opening 812 of the seventh layer 800); and (e) the seventh medial heel portion 810 (e.g., extending along and / or adjacent to the inner side 810s of the ankle / foot opening 814 of the seventh layer 800). Figure 3L The vertical dashed lines shown typically define the seventh layer 800 and divide it into three parts: (a) the posterior third (including the lateral hind heel portion 802 and the medial hind heel portion 810), (b) the middle third (including the lateral midfoot portion 804 and the medial midfoot portion 808), and (c) the anterior third (including the forefoot portion 806). In at least some examples of the invention, the seventh layer 800 will consist substantially of this filamentary structure, or even entirely of this filamentary structure (optionally shaped as a continuous path and / or a monolithic construction). For this example of the seventh layer 800... Figure 3L The visible blank spaces in the middle form open spaces between the filamentary path segments (for example, where one can see the seventh layer 800 completely).

[0082] While the path segments of the seventh layer 800 can be extruded in any desired order without departing from the invention, in some embodiments of the invention, the outer periphery (e.g., 800P) can be extruded first, and then the remainder of the seventh layer 800 can be extruded, for example, in a "grating" manner, to fill the area within the periphery 800P. In the illustrated example, the entire path of the extruded seventh layer 800 lays out the seventh filament over a large portion of the entire surface area of ​​the seventh layer 800 as a seventh plurality of non-intersecting, spaced path segments, which extend in a generally front-to-back direction of the seventh layer 800. Figure 3LAs shown, in the lateral hind heel portion 802, forefoot portion 806, medial midfoot portion 808, and medial hind heel portion 810, a seventh plurality of non-intersecting path segments extend in a gently curving manner in the direction forward from the hind heel portions 802 / 810. However, in the lateral midfoot portion 804, at least some of the seventh plurality of non-intersecting spaced path segments extend in a serpentine configuration including at least two peaks (808P) and at least two valleys (808V). The path segments in these different regions 802, 804, 806, 808, and 810 may have the aforementioned features for... Figures 2A to 2F Any of the features and / or options of the path segment shown.

[0083] like Figure 3L As further shown, the seventh path of the filament defines a first inner edge at the outer instep opening edge 804s, a first outer edge 804t at the outer midfoot region 804, a second inner edge at the inner instep opening edge 808s, and a second outer edge 808t at the inner midfoot region 808. The instep opening 812 of the seventh layer 800 is defined between the first inner edge at 804s and the second inner edge at 808s. The seventh path of the filament in the example layer 800 includes: (a) a first plurality of non-intersecting spaced path segments located between a first inner edge and a first outer edge 804t at 804s, wherein the plurality of first plurality of non-intersecting spaced path segments located between the first inner edge and the first outer edge 804t at 804s extend in a serpentine configuration and have at least two peaks 808P and at least two valleys 808V, and (b) a second plurality of non-intersecting spaced path segments located between a second inner edge and a second outer edge 808t at 808s, wherein the second plurality of non-intersecting spaced path segments of the seventh path are linear and / or curved without defining a plurality of peaks and valleys. Figure 3L The seventh layer 800 may include at least 4 path segments, at least 6 path segments, at least 8 path segments, at least 10 path segments, or even at least 12 path segments, which extend generally in parallel and / or have the serpentine configuration described above.

[0084] from Figure 3J and Figure 3L The comparison clearly shows that the path segments of layer 6 (700) and layer 7 (800) extend in a generally parallel manner over most of their entire paths. Therefore, the path segment of layer 7 (800) can be as follows: Figure 2C and Figure 2EThe manner shown typically involves extruding and / or being extruded in parallel to overlap with the path segment of layer 700 over a large portion of the entire path length. If necessary: ​​(a) at least 25% of the entire path length of layer 800 (and in some examples, at least 40%, at least 50%, at least 60%, at least 75%, at least 85%, or even at least 90%) will be extruded. Figure 2C and Figure 2E The manner shown overlaps with the path segment of layer 6 700, and / or (b) at least 25% (and in some examples, at least 40%, at least 50%, at least 60%, at least 75%, at least 85%, or even at least 90%) of the total path length of layer 6 700 will be... Figure 2C and Figure 2E The arrangement shown overlaps with the path segment of the seventh layer 800. Therefore, when the seventh layer 800 is extruded, the filaments of the seventh layer 800 will directly contact the filaments of the sixth layer 700 (at the overlapping contact area 202). During extrusion, heat from the seventh layer 800 (and / or another heat source) causes the seventh filament path segment and the sixth filament path segment to melt together at their contact point 202 (e.g., the filament material of the seventh layer 800 can polymerize and seamlessly bond with the filament material of the sixth layer 700). In this way, the sixth layer 700 of the upper or upper blank 1000 can be securely bonded to the seventh layer 800 of the upper or upper blank 1000 at the contact point 202 without adhesive.

[0085] from Figure 3L and Figure 3A , Figure 3B , Figure 3D , Figure 3F and Figure 3H The comparison clearly shows that the path segments of layer 7 (800) will intersect roughly with the path segments of layer 1 (300), layer 2 (350), layer 3 (400), layer 4 (500), and layer 5 (600) over most of their paths. The intersecting path segments form the typical diamond shape, which can be seen in... Figure 3MThis is seen in the combined first to seventh layers 840 shown. The path segments of the seventh layer 800 can intersect with the path segments of the first layer 300, the second layer 350, the third layer 400, the fourth layer 500, and / or the fifth layer 600 at any desired angle, for example, from 5° to 175°, and in some examples, from 15° to 165°, from 25° to 155°, from 35° to 145°, from 45° to 135°, from 55° to 125°, from 60° to 120°, from 65° to 90°, etc. In at least some examples of the present invention: (a) the seventh path of the seventh layer 800 will overlap with one or more of the first path of the first layer 300, the second path of the second layer 350, the third path of the third layer 400, the fourth path of the fourth layer 500, and / or the fifth path of the fifth layer 600 for less than 50% (and in some examples, less than 40%, less than 30%, less than 20%, or even less than 10%) of the total length of the seventh path; and / or (b) the seventh path of the seventh layer 800 will overlap with one or more of the first path of the first layer 300, the second path of the second layer 350, the third path of the third layer 400, the fourth path of the fourth layer 500, and / or the fifth path of the fifth layer 600 for less than 50% (and in some examples, less than 40%, less than 30%, less than 20%, or even less than 10%) of the total length of the respective first path, second path, third path, fourth path, and / or fifth path.

[0086] Therefore, when the seventh layer 800 is extruded, the filaments of the seventh layer 800 will directly contact one or more of the filaments of the first layer 300, the second layer 350, the third layer 400, the fourth layer 500, and / or the fifth layer 600 (at the intersecting contact area 202). When the seventh layer 800 is extruded, heat (and / or another heat source) from the seventh layer 800 causes the seventh filament path segment to melt together with any one or any combination of the first filament path segment, the second filament path segment, the third filament path segment, the fourth filament path segment, and / or the fifth filament path segment at the location 202 where the seventh filament path segment contacts any one or any combination of the first filament path segment, the second filament path segment, the third filament path segment, the fourth filament path segment, and / or the fifth filament path segment (e.g., the filament material of the seventh layer 800 can polymerize and seamlessly bond with the filament materials of the first layer 300, the second layer 350, the third layer 400, the fourth layer 500, and / or the fifth layer 600).

[0087] In these ways, the seventh layer 800 of the upper or upper blank 1000 can be fixedly bonded to the first layer 300, second layer 350, third layer 400, fourth layer 500, fifth layer 600 and / or sixth layer 700 of the upper or upper blank 1000 at the contact location 202 without adhesive, to form the combined first to seventh layers 840. The upper component or intermediate including the combined first to seventh layers 840 constitutes an integral structure, wherein the first layer 300, second layer 350, third layer 400, fourth layer 500, fifth layer 600, sixth layer 700 and seventh layer 800 are fixed together only by non-adhesive melting. The upper component or intermediate body, including the first to seventh layers 840, can be substantially composed of the first layer 300, the second layer 350, the third layer 400, the fourth layer 500, the fifth layer 600, the sixth layer 700, and the seventh layer 800, or even composed of the first layer 300, the second layer 350, the third layer 400, the fourth layer 500, the fifth layer 600, the sixth layer 700, and the seventh layer 800.

[0088] In layer 7, 800, a path segment within a zone does not need to have a constant interval with directly adjacent path segments in other zones of layer 7, 800. For example, as Figure 3L As shown, compared to the multiple non-intersecting spaced path segments in the midfoot region 804 / 808, the multiple non-intersecting spaced path segments in the forefoot region 806 of the seventh layer 800 are more closely spaced, and / or compared to the multiple non-intersecting spaced path segments in the heel region 802 / 810 of the seventh layer 800, the multiple non-intersecting spaced path segments in the forefoot region 806 and / or the midfoot region 804 / 808 are more closely spaced.

[0089] After the seventh layer 800 is extruded (e.g., on the first layer 300, the second layer 350, the third layer 400, the fourth layer 500, the fifth layer 600, the sixth layer 700 and / or the substrate 106), the eighth layer 900 of the entire upper or upper blank 1000 can then be applied to the combined first to seventh layers 840. Figure 3N This example shows a single path segment of layer 8, 900, and... Figure 3O The illustration schematically shows the production of the eighth layer 900 on top of the previously prepared combined first to seventh layers 840 to produce the combined first to eighth layers 1000 of the upper or upper blank 1000. More specifically, Figure 3NAn eighth layer 900 is shown, which is formed from an eighth filament (e.g., having any of the aforementioned filament features and characteristics) and is formed by, for example, extruding the eighth material into a plurality of path segments (e.g., having any of the aforementioned path and / or path segment characteristics) via a solid deposition molding process. Optionally, the eighth layer 900 can be extruded as an eighth continuous path. In the illustrated example, the eighth path of the eighth filament (optionally as a continuous path) forms the following portions of the eighth layer 900: (a) an eighth lateral heel portion 902 (e.g., extending along and / or adjacent to the lateral side 902s of the ankle / foot opening 914 of the eighth layer 900); (b) an eighth lateral midfoot portion 904 (e.g., extending along and / or adjacent to the lateral side 904s (or inner edge) of the instep opening 912 of the eighth layer 900); (c) the eighth forefoot portion 906 (e.g., which bridges from the outer side to the inner side of the eighth layer 900 in front of the midfoot portion); (d) the eighth medial midfoot portion 908 (e.g., extending along and / or adjacent to the inner side 908s (or inner edge) of the instep opening 912 of the eighth layer 900); and (e) the eighth medial heel portion 910 (e.g., extending along and / or adjacent to the inner side 910s of the ankle / foot opening 914 of the eighth layer 900). Figure 3N The vertical dashed lines shown typically define the eighth layer 900 and divide it into three parts: (a) the posterior third (including the lateral hind heel portion 902 and the medial hind heel portion 910), (b) the middle third (including the lateral midfoot portion 904 and the medial midfoot portion 908), and (c) the anterior third (including the forefoot portion 906). In at least some examples of the invention, the eighth layer 900 will consist substantially of this filamentary structure, or even entirely of this filamentary structure (optionally shaped as a continuous path and / or a monolithic construction). For this example of the eighth layer 900 Figure 3N The visible blank spaces in the middle form open spaces between the filamentary path segments (for example, where one can see the eighth layer 900 completely).

[0090] While the path segments of the eighth layer 900 can be extruded in any desired order without departing from the invention, in some embodiments of the invention, the outer periphery (e.g., 900P) can be extruded first, and then the remainder of the eighth layer 900 can be extruded, for example, in a "grating" manner, to fill the area within the periphery 900P. In the illustrated example, the entire path of the extruded eighth layer 900 lays out the eighth filament over a large portion of the entire surface area of ​​the eighth layer 900 as a plurality of non-intersecting, spaced path segments extending in a generally front-to-back direction of the eighth layer 900. Figure 3NAs shown, in the lateral hind heel portion 902, forefoot portion 906, medial midfoot portion 908, and medial hind heel portion 910, a plurality of eighth non-intersecting path segments extend in a gently curving manner in the direction forward from the hind heel portions 902 / 910. However, in the lateral midfoot portion 904, at least some of the eighth plurality of non-intersecting spaced path segments extend in a serpentine configuration including at least two peaks (908P) and at least two valleys (908V). The path segments in these different regions 902, 904, 906, 908, and 910 may have the aforementioned features for... Figures 2A to 2F Any of the features and / or options of the path segment shown.

[0091] like Figure 3N As further shown, the eighth path of the filament defines a first inner edge at the outer instep opening edge 904s, a first outer edge 904t at the outer midfoot region 904, a second inner edge at the inner instep opening edge 908s, and a second outer edge 908t at the inner midfoot region 908. The instep opening 912 of the eighth layer 900 is defined between the first inner edge at 904s and the second inner edge at 908s. The eighth path of the filament in the example layer 900 includes: (a) a first plurality of non-intersecting spaced path segments located between a first inner edge and a first outer edge 904t at 904s, wherein the plurality of first plurality of non-intersecting spaced path segments located between the first inner edge and the first outer edge 904t at 904s extend in a serpentine configuration and have at least two peaks 908P and at least two valleys 908V; and (b) a second plurality of non-intersecting spaced path segments located between a second inner edge and a second outer edge 908t at 908s, wherein the second plurality of non-intersecting spaced path segments of the eighth continuous path are linear and / or curved without defining a plurality of peaks and valleys. Figure 3N The eighth layer 900 may include at least 4 path segments, at least 6 path segments, at least 8 path segments, at least 10 path segments, or even at least 12 path segments, which extend generally in parallel and / or have the serpentine configuration described above.

[0092] from Figure 3J , Figure 3L and Figure 3N The comparison clearly shows that the path segments of layer 6 (700), layer 7 (800), and layer 8 (900) extend in a generally parallel manner over most of their entire paths. Therefore, the path segment of layer 8 (900) can be arranged as follows: Figure 2C and Figure 2EThe manner shown typically involves extruding and / or being extruded in parallel to overlap with path segments of layer 6 700 and / or layer 7 800 for a significant portion of their total path length. If necessary: ​​(a) at least 25% of the total path length of layer 8 900 (and in some examples, at least 40%, at least 50%, at least 60%, at least 75%, at least 85%, or even at least 90%) will be extruded. Figure 2C and Figure 2E The manner shown overlaps with path segments of at least one of Layer 6 700 and / or Layer 7 800, and / or (b) at least 25% (and in some examples, at least 40%, at least 50%, at least 60%, at least 75%, at least 85%, or even at least 90%) of the total path length of Layer 6 700 and / or Layer 7 800 will be... Figure 2C and Figure 2E The arrangement shown overlaps with the path segment of the eighth layer 900. Therefore, when the eighth layer 900 is extruded, the filaments of the eighth layer 900 will directly contact the filaments of the sixth layer 700 and / or the seventh layer 800 (at the overlapping contact area 202). During extrusion, heat (and / or another heat source) from the eighth layer 900 causes the eighth filament path segment to fuse with any one or two of the sixth and / or seventh filament path segments at location 202 where the eighth filament path segment contacts any one or two of the sixth and / or seventh filament path segments (e.g., the filament material of the eighth layer 900 can polymerize and seamlessly bond with the filament material of the sixth layer 700 and / or the seventh layer 800). In this way, the sixth layer 700 and / or the seventh layer 800 of the upper or upper blank 1000 can be fixedly bonded to the eighth layer 900 of the upper or upper blank 1000 at the contact position 202 without adhesive.

[0093] from Figure 3N and Figure 3A , Figure 3B , Figure 3D , Figure 3F and Figure 3H The comparison clearly shows that the path segments of layer 8 (900) will intersect roughly with the path segments of layer 1 (300), layer 2 (350), layer 3 (400), layer 4 (500), and layer 5 (600) over most of their paths. The intersecting path segments form the typical diamond shape, which can be seen in... Figure 3O and Figure 3PThe first through eighth layers 1000, as shown in the diagram, are combined. Path segments of the eighth layer 900 can intersect with path segments of the first layer 300, the second layer 350, the third layer 400, the fourth layer 500, and / or the fifth layer 600 at any desired angle, for example, from 5° to 175°, and in some examples, from 15° to 165°, from 25° to 155°, from 35° to 145°, from 45° to 135°, from 55° to 125°, from 60° to 120°, from 65° to 90°, etc. In at least some examples of the present invention: (a) the eighth path of the eighth layer 900 will overlap with one or more of the first path of the first layer 300, the second path of the second layer 350, the third path of the third layer 400, the fourth path of the fourth layer 500, and / or the fifth path of the fifth layer 600 for less than 50% (and in some examples, less than 40%, less than 30%, less than 20%, or even less than 10%) of the total length of the eighth path; and / or (b) the eighth path of the eighth layer 900 will overlap with one or more of the first path of the first layer 300, the second path of the second layer 350, the third path of the third layer 400, the fourth path of the fourth layer 500, and / or the fifth path of the fifth layer 600 for less than 50% (and in some examples, less than 40%, less than 30%, less than 20%, or even less than 10%) of the total length of the respective first path, second path, third path, fourth path, and / or fifth path.

[0094] Therefore, when the eighth layer 900 is extruded, the filaments of the eighth layer 900 will directly contact one or more of the filaments of the first layer 300, the second layer 350, the third layer 400, the fourth layer 500, and / or the fifth layer 600 (at the intersecting contact area 202). When the eighth layer 900 is extruded, heat (and / or another heat source) from the eighth layer 900 causes the eighth filament path segment to melt together with any one or any combination of the first filament path segment, the second filament path segment, the third filament path segment, the fourth filament path segment, and / or the fifth filament path segment at the location 202 where the eighth filament path segment contacts any one or any combination of the first filament path segment, the second filament path segment, the third filament path segment, the fourth filament path segment, and / or the fifth filament path segment (e.g., the filament material of the eighth layer 900 can polymerize and seamlessly bond with the filament materials of the first layer 300, the second layer 350, the third layer 400, the fourth layer 500, and / or the fifth layer 600).

[0095] In these ways, the eighth layer 900 of the upper or upper blank 1000 can be fixedly bonded to the first layer 300, second layer 350, third layer 400, fourth layer 500, fifth layer 600, sixth layer 700 and / or seventh layer 800 of the upper or upper blank 1000 without adhesive at contact location 202, to form the combined first to eighth layers 1000. The upper component or intermediate comprising the combined first to eighth layers 1000 constitutes an integral structure, wherein the first layer 300, second layer 350, third layer 400, fourth layer 500, fifth layer 600, sixth layer 700, seventh layer 800 and eighth layer 900 are fixed together only by non-adhesive melting. The upper component or upper blank 1000 can be basically composed of a first layer 300, a second layer 350, a third layer 400, a fourth layer 500, a fifth layer 600, a sixth layer 700, a seventh layer 800 and an eighth layer 900, or even composed of a first layer 300, a second layer 350, a third layer 400, a fourth layer 500, a fifth layer 600, a sixth layer 700, a seventh layer 800 and an eighth layer 900.

[0096] In layer 8, 900, a path segment within a zone does not need to have a constant interval with directly adjacent path segments in other zones of layer 8, 900. For example, as Figure 3N As shown, compared to the multiple non-intersecting spaced path segments in the midfoot region 904 / 908, the multiple non-intersecting spaced path segments in the forefoot region 906 of the eighth layer 900 are more closely spaced, and / or compared to the multiple non-intersecting spaced path segments in the heel region 902 / 910 of the eighth layer 900, the multiple non-intersecting spaced path segments in the forefoot region 906 and / or the midfoot region 904 / 908 are more closely spaced.

[0097] After all the necessary layers of the upper or upper blank 1000 are formed, the extruded and melted layers form a molten upper component (e.g., upper blank 1000). The molten upper component 1000 can then be removed from the base substrate 106 to which it has been extruded, optionally trimmed (e.g., around its peripheral edges if desired) or otherwise treated (e.g., coated, painted, etc.), optionally joined to another upper component, and / or incorporated into the footwear structure, as will be explained in more detail below. As described above, layers of filaments are extruded onto the surfaces 106s of the substrate 106, which can be smooth or textured if desired. The surfaces of the upper blank 1000 (e.g., individual filaments) that contact the surfaces 106s of the substrate 106 can then exhibit the smooth (or textured) characteristics of the surfaces 106s of the substrate 106, which the surfaces of the upper blank 1000 contact and form on the surfaces 106s of the substrate 106. Therefore, in some examples of the present invention, one surface of the upper blank 1000 (e.g., the inner surface or the bottom surface) may be smooth or textured to correspond to the texture on the surface 106s of the substrate 106, while the opposite surface of the upper blank 1000 (e.g., the outer surface or the top surface) may have a texture corresponding to multiple overlapping layers of filaments.

[0098] Figures 3Q to 3W Provided in Figure 3P The enlarged view of the upper blank 1000 in areas A to G shown is to show more details of the structure of these examples. Figure 3Q and Figure 3R Enlarged views of the upper blank 1000 at the outer heel portion 1002 and the inner heel portion 1010 (areas A and B, respectively) are provided; Figure 3S and Figure 3T Enlarged views of the upper blank 1000 at the lateral midfoot portion 1004 and the medial midfoot portion 1008 (areas C and D, respectively) are provided; and Figure 3U , Figure 3V and Figure 3W Enlarged views of the upper blank 1000 at the lateral forefoot portion, medial forefoot portion, and extreme forefoot portion (areas E, F, and G, respectively) are provided.

[0099] like Figure 3QAs shown, at this location on the upper blank 1000, the filaments of the first layer 300 and the second layer 350 (the filaments of the first layer 300 and the second layer 350 may be generally parallel and / or overlap for most of their length) generally extend in a direction (e.g., in the medial-lateral direction) between the ankle opening 1014 and the bottom peripheral edge of the upper blank 1000. The filaments of the third layer 400, the fourth layer 500, and the fifth layer 600 are generally curved (and generally parallel and / or overlap) and extend in the front-back direction. Similarly, the filaments of the sixth layer 700, the seventh layer 800, and the eighth layer 900 are generally curved (and generally parallel and / or overlap) and extend in the front-back direction. The filaments of the first layer 300 and the second layer 350 intersect with the filaments of the third layer 400, the fourth layer 500, and the fifth layer 600 and form a generally parallelogram or rhomboid shape (e.g., where the angle is between 60° and 120°). Similarly, the filaments of the first layer 300 and the second layer 350 intersect with the filaments of the sixth layer 700, the seventh layer 800, and the eighth layer 900, forming a typical parallelogram or rhombus shape (e.g., where the angles are between 60° and 120°). The filaments of the third layer 400, the fourth layer 500, and the fifth layer 600 intersect with the filaments of the sixth layer 700, the seventh layer 800, and the eighth layer 900, forming a typical parallelogram or rhombus shape (e.g., where two angles are between 5° and 60° and two angles are between 120° and 175°). When formed into a parallelogram and / or rhombus shape, the major axis of the parallelogram / rhombus shape formed by the filaments of layers 400 / 500 / 600 and layers 700 / 800 / 900 can typically extend in the front-to-back direction of the upper blank 1000 (e.g., as shown in the image). Figure 3Q (The diamond-shaped DIA is highlighted in the image).

[0100] like Figure 3RAs shown, at this location on the upper blank 1000, the filaments of the first layer 300 and the second layer 350 (the filaments of the first layer 300 and the second layer 350 may be generally parallel and / or overlap for most of their length) generally extend in a direction (e.g., in the medial-lateral direction) between the ankle opening 1014 and the bottom peripheral edge of the upper blank 1000. The filaments of the third layer 400, the fourth layer 500, and the fifth layer 600 are generally curved (and generally parallel and / or overlap) and extend in the front-back direction. Similarly, the filaments of the sixth layer 700, the seventh layer 800, and the eighth layer 900 are generally curved (and generally parallel and / or overlap) and extend in the front-back direction. The filaments of the first layer 300 and the second layer 350 intersect with the filaments of the third layer 400, the fourth layer 500, and the fifth layer 600 and form a generally parallelogram or rhomboid pattern (e.g., where the angle is between 60° and 120°). Similarly, the filaments of the first layer 300 and the second layer 350 intersect with the filaments of the sixth layer 700, the seventh layer 800, and the eighth layer 900, forming a typical parallelogram or rhombus shape (e.g., where the angles are between 60° and 120°). The filaments of the third layer 400, the fourth layer 500, and the fifth layer 600 intersect with the filaments of the sixth layer 700, the seventh layer 800, and the eighth layer 900, forming a typical parallelogram or rhombus shape (e.g., where two angles are between 5° and 60° and two angles are between 120° and 175°). When formed into a parallelogram and / or rhombus shape, the major axis of the parallelogram / rhombus shape formed by the filaments of layers 400 / 500 / 600 and layers 700 / 800 / 900 can typically extend in the front-to-back direction of the upper blank 1000 (e.g., as shown in the image). Figure 3R (The diamond-shaped DIA is highlighted in the image).

[0101] like Figure 3S As shown, the filaments of the first layer 300 and the second layer 350 at this location on the upper blank 1000 (the filaments of the first layer 300 and the second layer 350 may be generally parallel and / or overlap for most of their length) generally extend in the direction between the instep opening 1012 and the peripheral edge of the bottom of the upper blank 1000 (e.g., in the medial-lateral direction). The filaments of the third layer 400, the fourth layer 500, and the fifth layer 600 are generally curved (and generally parallel and / or overlap) and extend in the front-back direction. The filaments of the sixth layer 700, the seventh layer 800, and the eighth layer 900 in this area of ​​the upper blank 1000 form the aforementioned serpentine pattern (and are generally parallel and / or overlap), and generally extend in the front-back direction. The intersecting filaments of each layer may have the above-described combination. Figure 3Q and Figure 3RAny of the aforementioned angular characteristics. In this particular area of ​​the upper blank 1000, intersecting filaments define some more “square” or rectangular openings through the upper blank 1000.

[0102] like Figure 3T As shown, the filaments of the first layer 300 and the second layer 350 at this location on the upper blank 1000 (the filaments of the first layer 300 and the second layer 350 may be generally parallel and / or overlap for most of their length) generally extend in the direction between the instep opening 1012 and the peripheral edge of the bottom of the upper blank 1000 (e.g., in the medial-lateral direction). The filaments of the third layer 400, the fourth layer 500, and the fifth layer 600 in this area of ​​the upper blank 1000 form the aforementioned serpentine pattern (and are generally parallel and / or overlap), and generally extend in the front-back direction. The filaments of the sixth layer 700, the seventh layer 800, and the eighth layer 900 are generally curved (and are generally parallel and / or overlap) and extend in the front-back direction. The intersecting filaments of each layer may have the above-described combination. Figure 3Q and Figure 3R Any of the aforementioned angular characteristics. In this particular area of ​​the upper blank 1000, intersecting filaments define some more “square” or rectangular openings through the upper blank 1000.

[0103] like Figure 3UAs shown, at this location on the upper blank 1000, the filaments of the first layer 300 and the second layer 350 (the filaments of the first layer 300 and the second layer 350 may be generally parallel and / or overlap for most of their length) typically extend in an inside-outside direction (e.g., from inside to outside) across the upper blank 1000. The filaments of the third layer 400, the fourth layer 500, and the fifth layer 600 typically curve (and are generally parallel and / or overlap) and extend in a front-back direction. Similarly, the filaments of the sixth layer 700, the seventh layer 800, and the eighth layer 900 typically curve (and are generally parallel and / or overlap) and extend in a front-back direction. The filaments of the first layer 300 and the second layer 350 intersect with the filaments of the third layer 400, the fourth layer 500, and the fifth layer 600 and form a generally parallelogram or rhomboid shape (e.g., where the angle is between 60° and 120°). Similarly, the filaments of the first layer 300 and the second layer 350 intersect with the filaments of the sixth layer 700, the seventh layer 800, and the eighth layer 900, forming a typical parallelogram or rhombus shape (e.g., where the angles are between 60° and 120°). The filaments of the third layer 400, the fourth layer 500, and the fifth layer 600 intersect with the filaments of the sixth layer 700, the seventh layer 800, and the eighth layer 900, forming a typical parallelogram or rhombus shape (e.g., where two angles are between 5° and 60° and two angles are between 120° and 175°). When formed into a parallelogram and / or rhombus shape, the major axis of the parallelogram / rhombus shape formed by the filaments of layers 400 / 500 / 600 and layers 700 / 800 / 900 can typically extend in the front-to-back direction of the upper blank 1000 (e.g., as shown in the image). Figure 3U (The diamond-shaped DIA is highlighted in the image).

[0104] like Figure 3VAs shown, at this location on the upper blank 1000, the filaments of the first layer 300 and the second layer 350 (the filaments of the first layer 300 and the second layer 350 may be generally parallel and / or overlap for most of their length) typically extend in an inside-outside direction (e.g., from inside to outside) across the upper blank 1000. The filaments of the third layer 400, the fourth layer 500, and the fifth layer 600 typically bend (and are generally parallel and / or overlap) and extend in a front-back direction. Similarly, the filaments of the sixth layer 700, the seventh layer 800, and the eighth layer 900 typically bend (and are generally parallel and / or overlap) and extend in a front-back direction. The filaments of the first layer 300 and the second layer 350 intersect with the filaments of the third layer 400, the fourth layer 500, and the fifth layer 600 and form a generally parallelogram or rhomboid shape (e.g., where the angle is between 60° and 120°). Similarly, the filaments of the first layer 300 and the second layer 350 intersect with the filaments of the sixth layer 700, the seventh layer 800, and the eighth layer 900, forming a typical parallelogram or rhombus shape (e.g., where the angles are between 60° and 120°). The filaments of the third layer 400, the fourth layer 500, and the fifth layer 600 intersect with the filaments of the sixth layer 700, the seventh layer 800, and the eighth layer 900, forming a typical parallelogram or rhombus pattern (e.g., where two angles are between 5° and 60° and two angles are between 120° and 175°). When formed into a parallelogram and / or rhombus shape, the major axis of the parallelogram / rhombus shape formed by the filaments of layers 400 / 500 / 600 and layers 700 / 800 / 900 can typically extend in the front-to-back direction of the upper blank 1000 (e.g., as shown in the image). Figure 3V (The diamond-shaped DIA is highlighted in the image).

[0105] like Figure 3WAs shown, at this location on the upper blank 1000, the filaments of the first layer 300 and the second layer 350 (the filaments of the first layer 300 and the second layer 350 may be generally parallel and / or overlap for most of their length) typically extend in an inside-outside direction (e.g., from inside to outside) across the upper blank 1000. The filaments of the third layer 400, the fourth layer 500, and the fifth layer 600 typically bend (and are generally parallel and / or overlap) and extend in a front-back direction. Similarly, the filaments of the sixth layer 700, the seventh layer 800, and the eighth layer 900 typically bend (and are generally parallel and / or overlap) and extend in a front-back direction. The filaments of the first layer 300 and the second layer 350 intersect with the filaments of the third layer 400, the fourth layer 500, and the fifth layer 600 and form a generally parallelogram or rhomboid shape (e.g., where the angle is between 60° and 120°). Similarly, the filaments of the first layer 300 and the second layer 350 intersect with the filaments of the sixth layer 700, the seventh layer 800, and the eighth layer 900, forming a typical parallelogram or rhombus shape (e.g., where the angles are between 60° and 120°). The filaments of the third layer 400, the fourth layer 500, and the fifth layer 600 intersect with the filaments of the sixth layer 700, the seventh layer 800, and the eighth layer 900, forming a typical parallelogram or rhombus shape (e.g., where two angles are between 5° and 60° and two angles are between 120° and 175°). When formed into a parallelogram and / or rhombus shape, the major axis of the parallelogram / rhombus shape formed by the filaments of layers 400 / 500 / 600 and layers 700 / 800 / 900 can typically extend in the front-to-back direction of the upper blank 1000 (e.g., as shown in the image). Figure 3W (The diamond-shaped DIA is highlighted in the image).

[0106] from Figures 3Q to 3V and Figure 3W The comparison clearly shows that the spacing between directly adjacent filaments in a given layer is generally smaller in the forefoot area of ​​this example upper blank 1000 compared to the spacing between directly adjacent filaments in the same layer at the heel and / or midfoot portion of the upper blank 1000. Moreover, as these figures show, the diamond-shaped openings formed by the intersections of the filaments of (a) the third layer 400, the fourth layer 500, and the fifth layer 600 and (b) the sixth layer 700, the seventh layer 800, and the eighth layer 900 towards the forefoot area of ​​the upper blank 1000 are smaller than the corresponding diamond-shaped openings provided at the heel and / or midfoot portion of the upper blank 1000. Compared to at least some other areas, these features provide improved support, durability, lockdown, and less stretching in the forefoot area of ​​the upper blank 1000. Figures 3Q to 3WAs can be further clearly seen in the magnified view, a large portion of the space within the periphery of the upper or upper blank constitutes open spaces between the intersecting filaments in the layers of the upper or upper blank 1000. In at least some embodiments of the invention, the upper or upper blank 1000 may constitute at least 15% open space between the filaments in each layer, and in some embodiments, at least 25%, at least 30%, at least 40%, or even at least 50% open space may exist between the filaments in the upper or upper blank 1000.

[0107] Without departing from the invention, numerous variations are possible in the structure of the upper or upper blank 1000 and / or in the individual upper layers of the filaments. As some examples, the upper or upper blank 1000 may include more or fewer upper layers than the eight layers described above (e.g., from 2 to 24 layers, and in some examples, from 3 to 20 layers, from 4 to 16 layers, from 5 to 12 layers, etc.). As additional or alternative examples, the layering order of the aforementioned filament layers may be changed in some embodiments of the invention. Additionally or alternatively, although... Figure 3D , Figure 3F and Figure 3H The serpentine configuration formed at the inner mid-leg portion of the third layer 400, the fourth layer 500, and the fifth layer 600 are shown respectively. Figure 3J , Figure 3L and Figure 3N The diagram shows a serpentine configuration formed on the outer midfoot portion of the sixth layer 700, seventh layer 800, and eighth layer 900, respectively. However, the upper or upper blank according to some examples of the invention may include more or fewer of this same type of "serpentine" configuration, for example, in one or more of the forefoot area, heel area, etc. More or fewer layers of the upper blank 1000 may also include this type of "serpentine" configuration. The bending and serpentine configuration of the filament layers provide enhanced flexibility.

[0108] The filament materials provided in each layer of a single upper or upper blank 1000 may be the same or different without departing from the present invention. As some more specific examples, the upper or upper blank and / or its individual layers may have one or more of the following characteristics: (a) the filament material in all layers of the upper or upper blank may be the same material; (b) the filament material in one layer of the upper or upper blank may be different from the filament material in one or more other layers of the upper or upper blank; (c) the filament material in each layer of the upper or upper blank may be different; (d) the filaments in all layers of the upper or upper blank may be the same color; (e) the color of the filaments in one layer of the upper or upper blank may be different from the color of the filaments in one or more other layers of the upper or upper blank; (f) the color of the filaments in each layer of the upper or upper blank may be different; (g) the filaments in one or more layers of the upper or upper blank may be made of a transparent or translucent material; (h) the filaments in one or more layers of the upper or upper blank (and optionally in each layer of the upper or upper blank) may be made of a transparent or translucent material. The filaments are made of thermoplastic materials (e.g., thermoplastic polyurethane materials); (i) the filaments in one or more layers of the upper or upper preform (and optionally in each layer of the upper or upper preform) may be made of a material that is substantially non-absorbent; (j) the filaments in one or more layers of the upper or upper preform (and optionally in each layer of the upper or upper preform) may be made of a hydrophobic material; (k) the filaments in one or more layers of the upper or upper preform (and optionally in each layer of the upper or upper preform) may be made of a material that can be melted into other layers, for example, in a binderless manner (e.g., via solid deposition modeling); (l) the filament material in all layers of the upper or upper preform may have the same diameter, width, and / or thickness (or other dimensions); and / or (m) the filament material in one layer of the upper or upper preform may differ in diameter, width, and / or thickness (or other dimensions) from the filament material in one or more other layers of the upper or upper preform. In some embodiments of the invention, the upper or upper blank (e.g., two or more layers thereof cooperatively) can produce, for example, Figure 1 and Figures 3A to 3P The Mohr effect is shown in the figure.

[0109] As described above, in at least some embodiments of the invention, one or more of the various upper layers (e.g., layers 300, 350, 400, 500, 600, 700, 800, and / or 900) can be formed as a continuous path of extruded filaments. For example, in some embodiments of the invention, the entire upper layer (e.g., as...) Figure 3A (First floor 300) Figure 3B (Second layer 350) Figure 3D (Third floor 400) Figure 3F(Fourth floor 500) Figure 3H (Fifth floor 600) Figure 3J (Sixth floor 700) Figure 3L (7th floor 800) and Figure 3N (Eighth layer 900) as shown in one or more of them) can be achieved by starting extrusion at one location in a single upper layer and continuously extruding the material (including all necessary turns through the extruder nozzle 104 / head) until the entire layer is completely extruded (e.g., to form Figure 3A , Figure 3B , Figure 3D , Figure 3F , Figure 3H , Figure 3J , Figure 3L and Figure 3N It is formed by one or more of the forms shown in the invention. However, this type of continuous extrusion path (having a start and an end point when extruding the entire layer) is not necessary. Instead, in at least some examples of the invention, a single upper layer (e.g., similar to the form shown in the invention) is formed. Figure 3A , Figure 3B , Figure 3D , Figure 3F , Figure 3H , Figure 3J , Figure 3L and Figure 3N Those shown can be formed in a discontinuous manner (e.g., each individual layer has two or more pairs of extrusion start / stop actions). The extrusion nozzle 104 / head can be moved between the extrusion start point and the end point (when extrusion stops) to another desired location of the upper layer, so that the extrusion path segment of the layer can start / end at any desired location.

[0110] also, Figures 3A to 3PThe illustration shows that each individual layer 300, 350, 400, 500, 600, 700, 800, 900 in the upper or upper blank 1000 includes a single path segment extending through each of the lateral heel portion, lateral midfoot portion, forefoot portion, medial midfoot portion, and medial heel portion. This is not required. Rather, if desired, according to some examples of the invention, an individual upper layer (e.g., one or more of 300, 350, 400, 500, 600, 700, 800, and / or 900) does not need to extend to and / or extend through all of the stated areas. As some more specific examples, if necessary: ​​(a) one or more layers of the upper may exist only in the forefoot region of the entire upper; (b) one or more layers may exist only in the lateral midfoot region and / or medial midfoot region of the entire upper; (c) one or more layers may exist in one or both of the forefoot region and the lateral midfoot region and / or the medial midfoot region of the entire upper; (d) one or more layers may be omitted in one or both of the lateral heel region and / or the medial heel region; (e) only a small number of filaments may be present in some portions or regions of a single layer, etc. Selectively including filaments in all areas smaller than the upper layers allows one to selectively control the properties of that area of ​​the entire upper or upper blank (e.g., control of breathability, stretchability, permeability, lockdown, etc.). When one or more layers are omitted in a single area or region, it is not necessary to continuously extrude the filament layer included in that single area or region throughout the entire upper production process. For example, if desired, a single area or region of the upper or upper blank may include a first layer 300, a second layer 350, a fourth layer 500, a sixth layer 700, and a seventh layer 800 (or any number and / or combination of layers as needed, including layers with paths different from the specific example shown in the figure).

[0111] Figures 3A to 3PThe illustration further illustrates an example of upper layers laid out as filaments in a specific order: layer 300, then layer 350, then layer 400, then layer 500, then layer 600, then layer 700, then layer 800, and then layer 900. The order in which the layers are placed can affect the characteristics and / or properties of the entire upper or upper blank 1000. For example, if layers with larger filament spacing are laid closer to the interior of the upper, and layers with smaller filament spacing are laid closer to the exterior of the upper, this can enhance the overall upper's ability to absorb water (or other materials) and / or resist the introduction of water (or other materials) into the interior and / or inner lining, compared to an upper with the same layers formed in a different order but closer to the exterior. Changing the order of the layers can also affect the zoning or overall performance of the upper (e.g., affecting lockdown, directional stretch, breathability, permeability, etc.). By changing the order of the layers, the intersections of different layers can be altered and / or changed in position, and therefore the fusion of one layer with other layers can be altered and / or changed to different positions and / or orientations. These changes can affect the overall characteristics, performance, and / or feel of the upper (e.g., lockdown, directional stretch, breathability, permeability, etc.).

[0112] As described above, if necessary, the above-described upper blank 1000 or upper component, which is composed of one or more extruded filament layers, can be joined with one or more other upper components. Figures 4A to 4C An example is illustrated in which filaments 1102, 1104, 1106, 1108 of one or more layers of an extruded filament-based upper component 1100 are bonded to another upper component 1110 by an adhesive or bonding agent 1112. The extruded filament-based upper component 1100 can be made of one or more layers of extruded filaments, for example, comprising one or more of the aforementioned layers 300, 350, 400, 500, 600, 700, 800, and / or 900. The upper component 1110 can be any desired type of upper component, including those conventionally known and used in the footwear industry, such as fabrics, textiles, elastic materials, knitted components, woven components, leather (natural or synthetic), thermoplastic materials, thermoplastic polyurethane, other polymeric materials, etc. The extruded filament-based upper component 1100: (A) can be located on the outer side of another upper component 1110 facing outwards from the footwear and away from the wearer's foot. Figure 4A (b) may be located on the inside of another upper component 1110 facing inwards and closer to (and optionally adjacent to or in contact with) the wearer's foot. Figure 4B (c) may be on the inside and outside of another upper part 1110. Figure 4CAdditional upper components 1110 may provide additional support elements (e.g., heel stabilizers, toe boxes, structural supports, shape supports, lacing-fit supports along the instep opening 1012, structures for joining sole components, etc.) in desired areas; soft foot contact surfaces (e.g., around the ankle opening 1014, as a "tongue" component spanning the instep opening 1012, etc.); supports for joining other footwear components, etc. The combined upper components 1100 / 1110 can be integrated into the overall footwear structure, as will be described in more detail below.

[0113] However, Figures 5A to 5C The illustration shows a method of bonding an extruded filament-based upper component 1100 to another upper component 1120 without adhesives by directly melting (or fusing) filaments in the upper component 1100 to the material of another upper component 1120. This assembled upper component 1100 / 1120 may include: (a) a first upper component 1100 comprising at least a first layer formed to include a first material as a first filament 1102 (…). Figures 5A to 5C (a) Four filaments 1102, 1104, 1106, and 1108 are shown, optionally including a first plurality of non-intersecting, spaced-apart path segments of the filaments, wherein the first extruded filament has a width dimension of less than 3 mm (and in some examples, less than 2 mm, less than 1.5 mm, less than 1 mm, or even less than 0.75 mm); and (b) a second upper component 1120, which includes a fabric element formed at least partially of a fusible material (e.g., any of the types described above for upper component 1110, such as fabric, textile, elastic material, thermoplastic material, etc.). The upper component 1100 based on the extruded filaments may be made of one or more layers of extruded filaments, such as including one of more layers similar to layers 300, 350, 400, 500, 600, 700, 800, and / or 900 described above. In these structures, the fusible material of the second upper component 1120 is fused to the filaments 1102, 1104, 1106, and / or 1108 of the first upper component 1100. If necessary or required, heat and / or pressure may be applied to the assembled upper components 1100 / 1120 to fuse the filaments comprising the upper component 1100 to the fabric element upper component 1120. Polymerizing and seamlessly bonding the material of one or more filaments 1102 to 1108 with the fusible material of the fabric element 1120 can result in melting between components 1100 and 1120.

[0114] Figures 5A to 5CAn example is illustrated in which filaments 1102, 1104, 1106, 1108 of one or more layers of extruded filament upper component 1100 are joined to an upper component 1120 comprising a fusible material as part of a fabric element. Extruded filament upper component 1100: (A) may be located on the outer side of another upper component 1120 facing outwards from the footwear and away from the wearer's foot. Figure 5A (b) may be located on the inside of another upper component 1120 facing inwards and closer to (and optionally adjacent to or in contact with) the wearer's foot. Figure 5B (c) may be on the inside and outside of another upper component 1120. Figure 5C Additional upper components 1120 may provide additional support elements (e.g., heel stabilizers, toe boxes, structural supports, shape supports, lacing-in supports along the instep opening 1012, structures for joining sole components, etc.) in desired areas; soft foot contact surfaces (e.g., around the ankle opening 1014, as a "tongue" component spanning the instep opening 1012, etc.); structures for joining other footwear components, etc. The combined upper components 1100 / 1120 can be integrated into the overall footwear structure, as will be described in more detail below.

[0115] Figures 5D to 5F Examples are provided of how the fusible material can be incorporated into the fabric element 1120. As an example, such as... Figure 5D As shown, fabric element 1120 can be formed as a woven, knitted, or non-woven structure, wherein at least one strand (e.g., yarn) of fabric element 1120 is formed of a fusible material adapted to be melted with one or more of the filaments of upper component 1100. Figure 5D In this arrangement, one color of yarn 1122 is made of a conventional fabric material (e.g., made of polyester, cotton, elastomer, etc.), and another color of yarn 1124 is made of a fusible material of the type used in filaments, such as thermoplastic polyurethane or other thermoplastic materials. In this arrangement, yarn 1124 can be directly melted onto filaments 1102, 1104, 1106, and 1108 of the filament-based upper component 1100.

[0116] As another option, such as Figure 5EAs shown, the fabric element 1120 can be formed as a woven, knitted, or non-woven structure, which includes at least one yarn in the fabric element structure 1120, the yarn being formed by: (a) strands 1132 made of conventional fabric materials (e.g., made of polyester, cotton, elastomer materials, etc.) and (b) strands 1134 made of a fusible material of the type of fusible material used in filaments, such as thermoplastic polyurethane or other thermoplastic materials. In this arrangement, the fusible yarn strands 1134 can be directly melted onto the filaments 1102, 1104, 1106, 1108 of the filament-based upper component 1100.

[0117] As another option, Figure 5F A cross-sectional view is provided of yarns or plies that can be used to manufacture fabric element 1120 into, for example, woven, knitted, or non-woven structures. The plies or yarns are formed as coaxial elements over at least a portion of their axial length, comprising: (a) an inner core 1142 made of coated (e.g., co-extruded or otherwise formed) conventional fabric material (e.g., made of polyester, cotton, elastomeric materials, etc.) and (b) an outer cover 1144 made of a fusible material of the type described above for fusible materials in filaments, such as thermoplastic polyurethane or other thermoplastic materials. In this arrangement, the fusible outer cover 1144 can be directly melted onto the filaments 1102, 1104, 1106, 1108 of the filament-based upper component 1100.

[0118] Figures 6A to 6E An example of this approach is illustrated, wherein a conventional fabric element (or other footwear component) 1110 and / or includes a fusible material (e.g., the combination described above). Figures 5D to 5F The fabric element 1120 of the aforementioned type can be combined with the multilayer fusible upper component 1100 (e.g., the above combination). Figures 3A to 3W The type of bonding is described above. First, the shoe upper blank intermediate 1200 can be made into one or more layers comprising extruded filaments formed as described above (e.g., by solid deposition molding technology, as a continuous path, having multiple non-intersecting path segments, etc.). Figure 6A An intermediate body 1200 for the shoe upper blank is shown, which is formed as the first four layers 300, 350, 400, and 500 comprising filaments as described above. For example, it can be formed in the same manner as described above. Any number of filament layers with any desired filament paths and arrangements can be provided as the intermediate body 1200 for the shoe upper blank (including one or more filament-based layers and / or any single layer and / or a combination of the layers described above).

[0119] Once the desired upper preform intermediate 1200, comprising one or more filament layers, has been prepared on the extruder substrate 106 (e.g., by extrusion, solid deposition molding, etc.), a release liner 1202 can be applied, for example, to cover a portion of the top surface of the upper preform intermediate 1200 (e.g., the release liner 1202 can cover a portion of the first layer extending inward from the outer edge of the first layer, such as a portion around one or both sides of the instep opening, a portion around one or both sides of the ankle opening, a portion around the bottom edge of the upper where it will connect to the sole structure, etc.). The release liner 1202 can be made of paper, plastic, or any type of material, as long as the release liner 1202 is not permanently attached to the filament material to be included in the upper component in subsequent steps.

[0120] When the release liner 1202 is in place, one or more additional filament layers can be extruded to form one or more additional layers of the upper component. For example, as... Figure 6B As shown, the fifth layer 600, sixth layer 700, seventh layer 800, and / or eighth layer 900 described above can be extruded onto the release liner 1202 and the upper intermediate 1200 (which may include the first layer 300, second layer 350, third layer 400, and / or fourth layer 500 described above). In the illustrated example, one or more additional materials are extruded to form one or more additional extruded filament layers, optionally including additional multiple non-intersecting spaced path segments in a single layer. The additional extruded filaments may have any of the dimensions and / or other filament characteristics described above. The additional layer extrusion step in this example may include: (a) applying a first portion of the additional filament layer to the release liner 1202 such that the release liner 1202 extends between the first portion of the previously extruded filament layer (in the upper intermediate 1200) and the first portion of the additional filament layer; and (b) melting a second portion of the additional filament layer to the second portion of the previously extruded filament layer (in the upper intermediate 1200) at the location where the most recently extruded filament layer contacts the previously extruded filament layer. In this way, the additional filament layer applied after positioning the release liner 1202 will bond (in an adhesive-free manner) to the previously extruded filament layer in an area away from the release liner 1202 to provide an integral upper component (e.g., a complete upper component similar to the upper blank 1000 described above).

[0121] Once all the necessary additional filament layers have been extruded and bonded to the previously extruded filament layers of the upper intermediate 1200, there will be an assembled upper component 1210 and release liner 1202, for example, as Figure 6CAs shown. At this time, one or more of the filament layers of the upper component 1210 are located below the bottom surface of the release liner 1202, and one or more of the filament layers of the upper component 1210 are located above the top surface of the release liner 1202. At this time, the upper component 1210 and the release liner 1202 can be removed from the extruder substrate 106, and the release liner 1202 can be removed from its position between the first portion of the lower filament layer (e.g., layers 300, 350, 400, 500) of the upper component 1210 and the first portion of the upper filament layer (e.g., layers 600, 700, 800, 900) of the upper component 1210. Due to the prior presence of the release liner 1202, the first portion of the lower filament layer (e.g., layers 300, 350, 400, 500) of the upper component 1210 will remain unattached to the first portion of the upper filament layer (e.g., layers 600, 700, 800, 900) of the upper component 1210 at the location where the release liner 1202 is present (although all layers 300 to 900 can be attached together at their "second portion," where the release liner 1202 is not present). In other words, the presence and removal of the release liner 1202 create a "pocket" between the layers of the upper component 1210.

[0122] At this time, as Figure 6D As shown, another upper component (e.g., fabric components 1110, 1120 similar to those described above) can be placed into a "pocket" formed between the layers of upper component 1210, wherein release pad 1202 is removed. Upper component 1110 can be bonded to upper component 1210 via adhesive, as described above. Figure 4C Description. Alternatively, when the upper component 1120 includes a fusible material (e.g., the combination above), Figures 5D to 5F When the fabric element of the aforementioned type is used, the upper component 1120 can be bonded to the upper component 1210 in an adhesive-free manner, for example, by melting the fusible material of the upper component 1120 with the extruded filament layer of the upper component 1210. This action can place and fix the upper component 1120 between the individual layers of the upper component 1210, for example, as... Figure 5C The cross-section is shown. If desired, the melting step may include, for example (e.g., using...) Figure 6E Heat and / or pressure are applied to the assembled upper component 1120 / 1210 (as shown in the diagram). If necessary, the upper component 1120 (and / or 1210) may be trimmed, combined with other upper components, and / or otherwise treated, for example, in the preparation for integration into the footwear structure. Although Figures 6A to 6EUpper components 1110 / 1120 are shown between the intermediate layers of the filament-based upper component 1210, but this is not necessary. Instead, without departing from the invention, upper components 1110 / 1120 can be placed between any desired filament layers of the upper component 1210 (e.g., between layers closer to the inner part of the upper and / or between layers closer to the outer part of the upper).

[0123] Without departing from the invention, upper components 1110, 1120 can form any desired portion or proportion of the footwear upper structure. As some more specific examples, upper components 1110, 1120 may provide or overlap less than 50% of the total surface area of ​​upper component 1210, and in some examples, may provide or overlap less than 40%, less than 30%, less than 20%, or even less than 10% of the total surface area of ​​upper component 1210 (as used herein, "total surface area" means the entire area defined within the outermost periphery of upper component 1210, including the open spaces defined between the individual filaments of upper component 1210). Second (e.g., fabric) upper components 1110, 1120 can form any desired portion of the entire upper structure, including one or more of the following: the instep / tongue portion of the upper, the forefoot portion of the upper, the lacing joint portion of the upper, the foot receiving opening of the upper, the collar of the upper, the heel joint portion of the upper, etc.

[0124] Figures 7A to 7C An example footwear article 2000 is illustrated, which includes an upper 2002, at least a portion of which is formed as a multi-layered filament type upper blank 1000 as described above. As shown in these figures, the upper 2002 includes, for example, the above-described combination. Figures 6A to 6E The type of combined upper components 1110, 1120 / 1210 are described. Upper components 1110, 1120 can be combined with filament-based upper components (e.g., similar to upper blank 1000) in any desired manner, including the combinations described above. Figures 4A to 6E (Described in various ways). As shown in these figures, the upper components 1110, 1120 of this example are one or more fabric elements that extend along the lacing engagement area and instep area of ​​the upper 2002 (e.g., forming a “tongue”-like element and / or the forefoot portion of the upper 2002), extend around the foot insertion opening 2006 (e.g., to provide a collar that enhances comfort around the ankle), and extend downward around the heel portion of the upper 2002 (e.g., to provide comfort at the heel).

[0125] The illustrated example fabric upper components 1110, 1120 and filament-based upper component 1210 all include openings and / or other structures for engaging the laces 2008. Alternatively, if desired, only one of the fabric upper components 1110, 1120 and filament-based upper component 1210 may include a lacing engagement opening or structure. As another option or alternative, if desired, the fabric upper components 1110, 1120 may include a lacing engagement opening or structure in one or more areas of the upper 2002, and the filament-based upper component 1210 may include a lacing engagement opening or structure in one or more other areas of the upper 2002. If desired, when the filament-based upper component 1210 engages the laces 2008, the laces 2008 may extend through the openings provided in the filament-based upper component 1210 between the individual filaments of the multi-layered upper structure.

[0126] The upper component 2002 can be joined to the sole structure 2004 in any desired manner, including in conventional ways known and used in the footwear industry (e.g., adhesives, mechanical connectors, stitching seams, etc.). Any desired type of sole structure 2004 can be provided, including sole structures with one or more components known and used in the footwear industry. In some examples of the invention, the sole structure 2004 will include a lightweight foam or fluid-filled bladder structure (optionally made of hydrophobic, waterproof, and / or non-absorbent materials). The sole structure 2004 may also include track spikes, anti-slip studs, and / or other traction-enhancing elements.

[0127] Footwear uppers according to examples of the present invention, comprising upper components of the type described above based on extruded filaments (including upper blank 1000, upper component 1210, and / or upper 2002), can provide many desirable properties, particularly for athletic footwear construction. Considering the numerous openings between the individual filaments in each layer, the thin structure of the filaments, and the relatively reduced volume of the heavier material present, upper blank 1000, upper component 1210, and / or upper 2002 can be manufactured to be very lightweight and / or breathable. As another potential advantage, as mentioned above, the filaments can be made of hydrophobic and / or substantially non-absorbent materials. Therefore, if the upper 2002 is exposed to wet conditions during use, the filaments can shed / repel water, thereby maintaining lightweight properties. Even when used in wet conditions, such an upper structure can further enhance the ability to maintain lightweight conditions, including that any fabric-based upper components in the upper 2002 (e.g., components 1110, 1120) are also (at least partially) made of hydrophobic materials and / or substantially non-absorbent materials (e.g., thermoplastic polyurethane materials and / or other thermoplastic materials and / or other hydrophobic and / or waterproof materials, which may, for example, be made of... Figures 5D to 5FOne or more of the methods described in the text are provided as fusible components, and / or if the sole structure 2004 (at least partially) is formed of a hydrophobic material and / or a substantially non-absorbent material (e.g., thermoplastic polyurethane material and / or other thermoplastic materials and / or other hydrophobic and / or waterproof materials), the ability to maintain lightweight conditions can be further enhanced. When the upper component 1210 is at least partially formed as a multi-layered filament construction, many different colors and color combinations can be used to provide a wide range of aesthetic and design opportunities, including producing, for example, Figure 1 and Figures 3A to 3P The Mohr effect is shown in the figure.

[0128] Furthermore, the extruded filament type structure and production method allow for seamless transitions between upper structural features that provide different functions and / or characteristics (e.g., seamless transitions between areas providing more support and lockdown and areas providing improved flexibility, seamless variations in breathability in different areas, etc., by changing the size, spacing, material, etc. of the filaments). In addition, the relatively uniform overall upper thickness with a multi-layered filament construction can provide varying tensile and / or breathability characteristics in different areas of the upper, which has a seamless, one-piece, integral construction. As another potential advantage / feature, the upper preform 1000 / upper component 1210 can be formed by a multi-layer extrusion process without inducing tensile stress on the individual filaments of the upper construction.

[0129] In the specific examples above, the filament-based upper component forms an upper component (e.g., an upper blank) that substantially covers or surrounds the wearer's foot (from the heel area to the midfoot area and then to the forefoot area). Other options are possible, in which the filament-based upper component (e.g., having any required number of extruded layers, including from 1 to 20 layers, and in some examples from 2 to 16 layers, from 3 to 12 layers, from 4 to 10 layers, or even 8 layers) forms one or more discrete portions of the entire upper. Figure 8A and Figure 8B The illustration shows a footwear article 3000 having an upper 3002 that engages with a sole structure 3004. As shown in the figures, the upper 3002 in this example includes one or more fabric-based upper components 3002a and one or more filament-based upper components 3002b (which may include one or more layers of filaments of the type described above). The filament-based upper component 3002b in this example forms an outer-side upper panel. Figure 8A ) and a separate inward-facing upper panel ( Figure 8B These extruded filament-based upper components 3002b can be joined to another upper component 3002a in any desired manner, including the aforementioned joining methods. Figures 4A to 6EAny of the methods described (including via adhesive and / or in an adhesive-free manner).

[0130] like Figure 8A and Figure 8B As further shown, both the fabric upper component 3002a and the filament-based upper component 3002b include openings and / or other structures for engaging the laces 3008. Alternatively, if desired, only one of the fabric upper component 3002a and the filament-based upper component 3002b may include a lacing engagement opening or structure. As another option or alternative, if desired, the fabric upper component 3002a may include a lacing engagement opening or structure in one or more areas of the upper 3002, and the filament-based upper component 3002b may include a lacing engagement opening or structure in one or more other areas of the upper 3002. If desired, when the filament-based upper component 3002b engages the laces 3008, the laces 3008 may extend through the openings provided in the filament-based upper component 3002b between the individual filaments of the multi-layered upper structure.

[0131] Without departing from the present invention, the upper component 3002a may have any desired structure and / or may be made of any desired material, including conventional structures and / or materials and / or combinations thereof known and used in the footwear industry. Figures 5A to 7C The described structure includes hydrophobic, waterproof, and / or non-absorbent materials. The sole structure 3004 can be any desired type of sole structure, including sole structures with one or more components known and used in the footwear industry. In some examples of the invention, the sole structure 3004 will include a lightweight foam or fluid-filled bladder structure (optionally made of hydrophobic, waterproof, and / or non-absorbent materials). The sole structure 3004 may also include track spikes, anti-slip studs, and / or other traction-enhancing elements.

[0132] Enhanced breathability and / or lightweight properties can be achieved even if only a portion of the upper 3002 is formed from the extruded filament-based upper component 3002b. The extruded filament-based upper component 3002b can be placed wherever enhanced breathability is required or needed. Regarding weight reduction, in Figures 8A to 8BIn the example structure, compared to a similar upper made entirely of component 3002a (i.e., component 3002a extending through the medial and lateral midfoot areas), using two filament-based upper components 3002b reduces the total weight of the upper 3002 by approximately 24 grams. In some embodiments of the invention, the filament-based upper components 3002b can form 15% to 100% of the entire upper surface area, and in some embodiments, they can form 25% to 100%, 35% to 100%, 50% to 100%, 60% to 100%, or even 75% to 100% of the entire upper surface area.

[0133] If needed, such as Figure 9 Typically, as shown, when one or more of the upper layers (e.g., one or more of layers 300, 350, 400, 500, 600, 700, 800, and / or 900) are formed by filament extrusion / solid deposition molding (e.g., forming an upper preform 1000), the footwear insert (or insole) 1020 can be formed together with one or more of the filament layers by extrusion / solid deposition molding technology (optionally, as part of a continuous path having one or more of the filament layers). Figure 9 As shown, for example, along one or more edges of the upper component 1000 (e.g., at the outer lower peripheral edge, inner lower peripheral edge, forefoot edge, one or more heel edges, etc.), the straw part 1020 can be integrally formed with the upper component 1000. The straw part 1020 can be formed as filaments, for example having any of the aforementioned properties, features, and / or options for filaments (e.g., having a mesh or matrix structure, in multiple layers, having intersecting / overlapping filament path segments, etc.). Once the entire upper / straw assembly 1040 is formed, the straw part 1020 can be folded along its integral edge with the upper component 1000 and attached at its free peripheral edge 1020P to the bottom peripheral edge 1000P of the upper component 1000 (e.g., by adhesive, by melting, etc.). The straw part 1020 can be formed as two or more parts, for example at two or more separate locations along the upper perimeter 1000P.

[0134] III. Conclusion

[0135] The invention has been disclosed above with reference to various embodiments and / or options in the accompanying drawings. However, the purpose of this disclosure is to provide examples of various features and concepts related to the invention, and not to limit the scope of the invention. Those skilled in the art will recognize that various changes and modifications can be made to the features of the invention described above without departing from the scope of the invention as defined by the appended claims.

[0136] For the avoidance of doubt, this application includes at least the subject matter described in the following numbered clauses:

[0137] Clause 1. An upper for footwear articles, said upper comprising:

[0138] A first upper component includes a first layer comprising a first material as a first filament, the first filament comprising a first plurality of non-intersecting, spaced-apart path segments, wherein the first filament has a width dimension of less than 1 mm; and

[0139] The second upper component includes a fabric element formed at least partially of a fusible material; and

[0140] The fusible material of the second upper component is melted into the first material of the first upper component.

[0141] Clause 2. The upper according to Clause 1, wherein the first upper component further comprises a second layer, the second layer comprising a second material as a second filament, the second filament comprising a second plurality of non-intersecting spaced path segments, wherein the second filament has a width dimension of less than 1 mm, and wherein the second layer is fused to the first layer at the location where the second layer contacts the first layer.

[0142] Clause 3. The upper according to Clause 2, wherein the second plurality of non-intersecting spaced path segments comprises at least five second non-intersecting path segments, wherein each of the at least five second non-intersecting path segments is spaced less than 5 mm from each directly adjacent second non-intersecting path segment in a length dimension of at least 25 mm.

[0143] Clause 4. The upper according to Clause 2, wherein the second plurality of non-intersecting spaced path segments comprises at least five second non-intersecting path segments, wherein each of the at least five second non-intersecting path segments is spaced less than 5 mm from each directly adjacent second non-intersecting path segment in a length dimension of at least 50 mm.

[0144] Clause 5. The upper according to any one of Clauses 2 to 4, wherein the second upper component has a first main surface and a second main surface opposite to the first main surface, wherein the fusible material at the first main surface of the second upper component is fused to the first material, and wherein the fusible material at the second main surface of the second upper component is fused to the second material.

[0145] Clause 6. The upper according to any one of Clauses 2 to 5, wherein the plurality of non-intersecting spaced path segments of the second filament extend over a path segment length of at least 25 mm parallel to and partially overlapping the plurality of non-intersecting spaced path segments of the first filament.

[0146] Clause 7. The upper according to any one of Clauses 2 to 5, wherein the plurality of non-intersecting spaced path segments of the second filament extend over a path segment length of at least 50 mm parallel to and partially overlapping the plurality of non-intersecting spaced path segments of the first filament.

[0147] Clause 8. The upper according to Clause 6 or 7, wherein 15% to 60% of the width of one or more filaments in the second plurality of non-intersecting spaced path segments of the second filament overlaps with one or more corresponding filaments in the first plurality of non-intersecting spaced path segments of the first filament in the length of the path segment.

[0148] Clause 9. The upper according to Clause 6 or 7, wherein 25% to 50% of the width of one or more filaments in the second plurality of non-intersecting spaced path segments of the second filament overlaps with one or more corresponding filaments in the first plurality of non-intersecting spaced path segments of the first filament in the length of the path segment.

[0149] Clause 10. The upper according to any one of Clauses 2 to 5, wherein a plurality of non-intersecting spaced path segments of the second plurality of non-intersecting spaced path segments of the second filament intersect with a plurality of non-intersecting spaced path segments of the first plurality of non-intersecting spaced path segments of the first filament and form an angle.

[0150] Clause 11. The upper as described in Clause 10, wherein the angle is in the range of 65° to 90°.

[0151] Clause 12. The upper according to Clause 10 or 11, wherein the plurality of non-intersecting spaced path segments in the second plurality of non-intersecting spaced path segments of the second filament and the plurality of non-intersecting spaced path segments in the first plurality of non-intersecting spaced path segments of the first filament cooperate to form one or more diamond shapes.

[0152] Clause 13. The upper as described in Clause 12, wherein the diamond shape is located at least in the forefoot region of the upper.

[0153] Clause 14. The upper as described in Clause 12 or 13, wherein the long axis of the plurality of said rhomboid shapes extends in a generally front-to-back direction of the upper.

[0154] Clause 15. The upper according to any one of Clauses 2 to 14, wherein the first filament has a first thickness in a first region of the upper, wherein the second filament has a second thickness in a second region of the upper, and wherein the first thickness is different from the second thickness.

[0155] Clause 16. The upper according to any one of Clauses 2 to 15, wherein the first filament has a first diameter in a first region of the upper, wherein the second filament has a second diameter in a second region of the upper, and wherein the first diameter is different from the second diameter.

[0156] Clause 17. The upper as described in Clause 2, wherein portions of the first and second layers are oriented relative to each other to form an intersecting mesh of the first filament extending in a first direction and the second filament extending in a second direction.

[0157] Clause 18. The upper according to any one of Clauses 2 to 17, wherein the first upper component further comprises a third layer, the third layer comprising a third material as a third filament, the third filament comprising a third plurality of non-intersecting spaced path segments, wherein the third filament has a width dimension of less than 1 mm, and wherein the third layer is fused to any one or both of the first layer and the second layer at locations where the third layer contacts any one or both of the first layer and the second layer respectively.

[0158] Clause 19. The upper according to Clause 18, wherein the first upper component further comprises a fourth layer, the fourth layer comprising a fourth material as a fourth filament, the fourth filament comprising a fourth plurality of non-intersecting spaced path segments, wherein the fourth filament has a width dimension of less than 1 mm, and wherein the fourth layer is fused to any one or any combination of the first layer, the second layer, and the third layer at locations where the fourth layer respectively contacts any one or any combination of the first layer, the second layer, and the third layer.

[0159] Clause 20. The upper according to Clause 19, wherein the first upper component further comprises a fifth layer, the fifth layer comprising a fifth material as a fifth filament, the fifth filament comprising a fifth plurality of non-intersecting spaced path segments, wherein the fifth filament has a width dimension of less than 1 mm, and wherein the fifth layer is fused to any one or any combination of the first layer, the second layer, the third layer, and the fourth layer at locations where the fifth layer respectively contacts any one or any combination of the first layer, the second layer, the third layer, and the fourth layer.

[0160] Clause 21. The upper according to Clause 20, wherein the first upper component further comprises a sixth layer, the sixth layer comprising a sixth material as a sixth filament, the sixth filament comprising a sixth plurality of non-intersecting spaced path segments, wherein the sixth filament has a width dimension of less than 1 mm, and wherein the sixth layer is fused to any one or any combination of the first layer, the second layer, the third layer, the fourth layer, and the fifth layer at locations where the sixth layer respectively contacts any one or any combination of the first layer, the second layer, the third layer, the fourth layer, and the fifth layer.

[0161] Clause 22. The upper according to Clause 21, wherein the first upper component further comprises a seventh layer, the seventh layer comprising a seventh material as a seventh filament, the seventh filament comprising a seventh plurality of non-intersecting spaced path segments, wherein the seventh filament has a width dimension of less than 1 mm, and wherein the seventh layer is fused to any one or any combination of the first layer, the second layer, the third layer, the fourth layer, the fifth layer, and the sixth layer at locations where the seventh layer respectively contacts any one or any combination of the first layer, the second layer, the third layer, the fourth layer, the fifth layer, and the sixth layer.

[0162] Clause 23. The upper according to Clause 22, wherein the first upper component further comprises an eighth layer, the eighth layer comprising an eighth material as an eighth filament, the eighth filament comprising an eighth plurality of non-intersecting spaced path segments, wherein the eighth filament has a width dimension of less than 1 mm, and wherein the eighth layer is fused to any one or any combination of the first layer, the second layer, the third layer, the fourth layer, the fifth layer, the sixth layer, and the seventh layer at locations where the eighth layer respectively contacts any one or any combination of the first layer, the second layer, the third layer, the fourth layer, the fifth layer, the sixth layer, and the seventh layer.

[0163] Clause 24. The upper according to any one of Clauses 1 to 23, wherein the first filament of the first layer defines a periphery, and wherein filament segments of the first filament extend between portions of the periphery.

[0164] Clause 25. The upper according to any one of Clauses 1 to 24, wherein the first plurality of non-intersecting spaced path segments extend in a serpentine configuration comprising at least two peaks and at least two valleys.

[0165] Clause 26. The upper according to any one of Clauses 1 to 24, wherein the first plurality of non-intersecting, spaced-apart path segments extend in a generally front-to-back direction of the upper and include a serpentine configuration having at least two peaks and at least two valleys.

[0166] Clause 27. The upper as described in Clause 25 or 26, wherein the serpentine configuration is formed at least on the inner midfoot portion of the upper component.

[0167] Clause 28. The upper as described in Clause 25 or 26, wherein the serpentine configuration is formed at least at the outer midfoot portion of the upper component.

[0168] Clause 29. The upper according to any one of Clauses 1 to 28, wherein the first filament has a first thickness in a first region of the upper, wherein the first filament has a second thickness in a second region of the upper, and wherein the first thickness is different from the second thickness.

[0169] Clause 30. The upper according to any one of Clauses 1 to 28, wherein the first filament has a first diameter in a first region of the upper, wherein the first filament has a second diameter in a second region of the upper, and wherein the first diameter is different from the second diameter.

[0170] Clause 31. The upper according to any one of Clauses 1 to 30, wherein the first layer forms the periphery of the upper.

[0171] Clause 32. The upper according to any one of Clauses 1 to 31, wherein the filaments in each layer of the first upper component are made of the same material.

[0172] Clause 33. The upper according to any one of Clauses 1 to 32, wherein the filaments in each layer of the first upper component comprise thermoplastic polyurethane material or other thermoplastic material.

[0173] Clause 34. The upper according to any one of Clauses 1 to 33, wherein the filaments in each layer of the first upper component comprise a material that is substantially non-absorbent.

[0174] Clause 35. The upper according to any one of Clauses 1 to 34, wherein the filaments in each layer of the first upper component comprise a hydrophobic material.

[0175] Clause 36. The upper according to any one of Clauses 1 to 35, wherein at least a portion of the first upper component exhibits a moiré effect.

[0176] Clause 37. The upper according to any one of Clauses 1 to 36, wherein the second upper component has a first main surface and a second main surface opposite to the first main surface, and wherein the first upper component is engaged with at least the first main surface of the second upper component.

[0177] Clause 38. The upper according to any one of Clauses 1 to 37, wherein the first plurality of non-intersecting spaced path segments comprises at least five first non-intersecting path segments, wherein each of the at least five first non-intersecting path segments is spaced less than 5 mm from each directly adjacent first non-intersecting path segment in a length dimension of at least 25 mm.

[0178] Clause 39. The upper according to any one of Clauses 1 to 37, wherein the first plurality of non-intersecting spaced path segments comprises at least five first non-intersecting path segments, wherein each of the at least five first non-intersecting path segments is spaced less than 5 mm from each directly adjacent first non-intersecting path segment in a length dimension of at least 50 mm.

[0179] Clause 40. The upper according to any one of Clauses 1 to 39, wherein the second upper component forms the instep portion or the forefoot portion of the upper.

[0180] Clause 41. The upper according to any one of Clauses 1 to 40, wherein the second upper component defines a foot-receiving opening or collar of the upper.

[0181] Clause 42. The upper according to any one of Clauses 1 to 41, wherein the second upper component forms the heel joint portion of the upper.

[0182] Clause 43. The upper according to any one of Clauses 40 to 42, wherein the first upper component is engaged with the outer surface of the second upper component.

[0183] Clause 44. The upper according to any one of Clauses 1 to 43, wherein the second upper component overlaps with the total surface area of ​​the first upper component by less than 30%.

[0184] Clause 45. The upper according to any one of Clauses 1 to 44, wherein the fabric element of the second upper component comprises at least one yarn formed of the fusible material.

[0185] Clause 46. The upper according to any one of Clauses 1 to 44, wherein the fabric element of the second upper component comprises a first yarn formed of the fusible material, the first yarn being entangled with a second yarn formed of the nonfusible material.

[0186] Clause 47. The upper according to any one of Clauses 1 to 44, wherein the fabric element of the second upper component comprises a first yarn formed of an infusible material, the infusible material being at least partially coated with the fusible material.

[0187] Clause 48. The upper as described in Clause 46 or 47, wherein the non-fusible material comprises polyester material.

[0188] Clause 49. The upper according to any one of Clauses 1 to 48, wherein the fusible material comprises thermoplastic polyurethane or other thermoplastic materials.

[0189] Article 50. A footwear article comprising:

[0190] The upper according to any of clauses 1 to 49; and

[0191] The sole structure that is joined to the upper.

[0192] Clause 51. A method for forming an upper for footwear articles, the method comprising:

[0193] Extruding a first material to form a first layer comprising a first extruded filament, the first extruded filament comprising a first plurality of non-intersecting spaced path segments, wherein the first extruded filament has a width dimension of less than 1 mm, and wherein the first layer forms at least a portion of a first upper component; and

[0194] A second upper component is melted onto a first upper component, wherein the second upper component comprises a fabric element formed at least partially of a fusible material, wherein the fusible material of the second upper component is melted onto the first material of the first upper component.

[0195] Clause 52. The method described in Clause 51 further includes:

[0196] The second material is extruded to form a second layer comprising a second extruded filament comprising a second plurality of non-intersecting spaced path segments, wherein the second extruded filament has a width dimension of less than 1 mm, wherein the step of extruding the second material includes melting the second layer into the first layer at a location where the second layer contacts the first layer, and wherein the second layer forms part of the first upper component.

[0197] Clause 53. The method according to Clause 52, wherein a plurality of non-intersecting spaced path segments of the second plurality of non-intersecting spaced path segments of the second filament are extruded to extend over a path segment length of at least 25 mm parallel to and partially overlapping a plurality of non-intersecting spaced path segments of the first filament.

[0198] Clause 54. The method according to Clause 52, wherein a plurality of non-intersecting spaced path segments of the second plurality of non-intersecting spaced path segments of the second filament are extruded to extend over a path segment length of at least 50 mm parallel to and partially overlapping a plurality of non-intersecting spaced path segments of the first filament.

[0199] Clause 55. The method according to Clause 53 or 54, wherein 15% to 60% of the width of one or more filaments of the plurality of non-intersecting spaced path segments in the second plurality of non-intersecting spaced path segments of the second filament is extruded to overlap with one or more corresponding filaments of the plurality of non-intersecting spaced path segments in the first plurality of non-intersecting spaced path segments of the first filament in the length of the path segment.

[0200] Clause 56. The method according to Clause 53 or 54, wherein 25% to 50% of the width of one or more filaments of the plurality of non-intersecting spaced path segments in the second plurality of non-intersecting spaced path segments of the second filament is extruded to overlap with one or more corresponding filaments of the plurality of non-intersecting spaced path segments in the first plurality of non-intersecting spaced path segments of the first filament in the length of the path segment.

[0201] Clause 57. The method according to Clause 52, wherein a plurality of non-intersecting spaced path segments of the second plurality of non-intersecting spaced path segments of the second filament are extruded to intersect with and form an angle with a plurality of non-intersecting spaced path segments of the first plurality of non-intersecting spaced path segments of the first filament.

[0202] Clause 58. The method described in Clause 57, wherein the angle is in the range of 65° to 90°.

[0203] Clause 59. The method according to Clause 57 or 58, wherein the plurality of non-intersecting spaced path segments in the second plurality of non-intersecting spaced path segments of the second filament and the plurality of non-intersecting spaced path segments in the first plurality of non-intersecting spaced path segments of the first filament are extruded to form a rhomboid shape.

[0204] Clause 60. The method according to Clause 59, wherein at least a portion of the diamond shape is located at least in the forefoot region of the upper.

[0205] Clause 61. The method according to Clause 59 or 60, wherein the long axis of at least a portion of the rhombus shape extends in a generally front-to-back direction on the upper.

[0206] Clause 62. The method according to any one of Clauses 52 to 61, wherein the first filament is extruded to have a first thickness in a first region of the upper, wherein the second filament is extruded to have a second thickness in a second region of the upper, and wherein the first thickness is different from the second thickness.

[0207] Clause 63. The method according to any one of Clauses 52 to 62, wherein the first filament is extruded to have a first diameter in a first region of the shoe upper, wherein the second filament is extruded to have a second diameter in a second region of the shoe upper, and wherein the first diameter is different from the second diameter.

[0208] Clause 64. The method according to Clause 52, wherein portions of the first and second layers are extruded to be oriented relative to each other to form an intersecting mesh of the first filament extending in a first direction and the second filament extending in a second direction.

[0209] Clause 65. The method according to any one of Clauses 52 to 64 further includes:

[0210] A third material is extruded to form a third layer comprising a third extruded filament comprising a third plurality of non-intersecting spaced path segments, wherein the third extruded filament has a width dimension of less than 1 mm, wherein the step of extruding the third material includes melting the third layer into any one or two of the first layer and the second layer at locations where the third layer respectively contacts any one or two of the first layer and the second layer, and wherein the third layer forms part of the first shoe upper component.

[0211] Clause 66. The method described pursuant to Clause 65 further includes:

[0212] Extruding a fourth material to form a fourth layer comprising a fourth extruded filament comprising a fourth plurality of non-intersecting spaced path segments, wherein the fourth extruded filament has a width dimension of less than 1 mm, wherein the step of extruding the fourth material comprises melting the fourth layer into any one or any combination of the first layer, the second layer and the third layer at locations where the fourth layer respectively contacts any one or any combination of the first layer, the second layer and the third layer, and wherein the fourth layer forms part of the first upper component.

[0213] Clause 67. The method described pursuant to Clause 66 further includes:

[0214] A fifth material is extruded to form a fifth layer comprising a fifth extruded filament comprising a fifth plurality of non-intersecting spaced path segments, wherein the fifth extruded filament has a width dimension of less than 1 mm, wherein the step of extruding the fifth material comprises melting the fifth layer into any one or any combination of the first layer, the second layer, the third layer, and the fourth layer at locations where the fifth layer respectively contacts any one or any combination of the first layer, the second layer, the third layer, and the fourth layer, and wherein the fifth layer forms part of the first upper component.

[0215] Clause 68. The method described pursuant to Clause 67 further includes:

[0216] A sixth material is extruded to form a sixth layer comprising a sixth extruded filament comprising a sixth plurality of non-intersecting spaced path segments, wherein the sixth extruded filament has a width dimension of less than 1 mm, wherein the step of extruding the sixth material includes melting the sixth layer into any one or any combination of the first layer, the second layer, the third layer, the fourth layer, and the fifth layer at locations where the sixth layer respectively contacts any one or any combination of the first layer, the second layer, the third layer, the fourth layer, and the fifth layer, and wherein the sixth layer forms part of the first upper component.

[0217] Clause 69. The method described pursuant to Clause 68 further includes:

[0218] A seventh material is extruded to form a seventh layer comprising a seventh extruded filament comprising a seventh plurality of non-intersecting spaced path segments, wherein the seventh extruded filament has a width dimension of less than 1 mm, wherein the step of extruding the seventh material includes melting the seventh layer into any one or any combination of the first layer, the second layer, the third layer, the fourth layer, the fifth layer, and the sixth layer at locations where the seventh layer respectively contacts any one or any combination of the first layer, the second layer, the third layer, the fourth layer, the fifth layer, and the sixth layer, and wherein the seventh layer forms part of the first upper component.

[0219] Clause 70. The method described pursuant to Clause 69 further includes:

[0220] An eighth material is extruded to form an eighth layer comprising an eighth extruded filament comprising a plurality of non-intersecting spaced path segments, wherein the eighth extruded filament has a width dimension of less than 1 mm, wherein the step of extruding the eighth material includes melting the eighth layer into any one or any combination of the first layer, the second layer, the third layer, the fourth layer, the fifth layer, the sixth layer, and the seventh layer at locations where the eighth layer respectively contacts any one or any combination of the first layer, the second layer, the third layer, the fourth layer, the fifth layer, the sixth layer, and the seventh layer, and wherein the eighth layer forms part of the first upper component.

[0221] Clause 71. The method according to any one of Clauses 51 to 70, wherein the step of melting the second upper component to the first upper component includes melting the inner surface of the first upper component to the outer surface of the second upper component.

[0222] Clause 72. A method for forming an upper for footwear articles, the method comprising:

[0223] The first material is extruded to form a first layer comprising a first extruded filament, the first extruded filament comprising a first plurality of non-intersecting spaced path segments, wherein the first extruded filament has a width dimension of less than 1 mm, and wherein the first layer forms part of a first upper component.

[0224] Cover a portion of the first layer with a release liner;

[0225] The second material is extruded to form a second layer comprising a second extruded filament, the second extruded filament comprising a second plurality of non-intersecting spaced path segments, wherein the second extruded filament has a width dimension of less than 1 mm, wherein the step of extruding the second material comprises: (a) applying a first portion of the second layer to the release liner such that the release liner extends between the first portion of the first layer and the first portion of the second layer, and (b) melting a second portion of the second layer to the second portion of the first layer at a location where the second layer contacts the first layer, and wherein the second layer forms part of the first upper component;

[0226] Remove the release liner from between the first portion of the first layer and the first portion of the second layer;

[0227] A portion of the second upper component is placed between the first portion of the first layer and the first portion of the second layer, wherein the portion of the second upper component comprises at least partially a fabric element formed of a fusible material; and

[0228] The second upper component is melted into the first upper component, wherein the fusible material of the second upper component is melted into the first material of the first upper component and the second material of the first upper component.

[0229] Clause 73. The method according to Clause 72, wherein the second upper component includes a first main surface and a second main surface opposite to the first main surface, wherein, in the placement step, the portion of the second upper component is placed between the first portion of the first layer and the first portion of the second layer such that: (a) the first main surface directly contacts the first layer and does not directly contact the second layer, and (b) the second main surface directly contacts the second layer and does not directly contact the first layer.

[0230] Clause 74. The method described pursuant to Clause 72 or 73 further includes:

[0231] Melting the first material into the fusible material of the second shoe upper component; and

[0232] The second material is melted into the fusible material of the second shoe upper component.

[0233] Clause 75. The method according to any one of Clauses 72 to 74, wherein the step of extruding the first material comprises extruding the first material onto a pre-existing layer comprising filamentary material.

[0234] Clause 76. The method according to any one of Clauses 72 to 75, wherein before melting the second upper component to the first upper component, the method further comprises:

[0235] Extruding a third material to form a third layer comprising a third extruded filament to at least partially overlap the first layer and the second layer, wherein the third extruded filament has a width dimension of less than 1 mm, wherein the step of extruding the third material comprises: (a) applying a first portion of the third layer to the release liner such that the release liner extends between the first portion of the first layer and the first portion of the third layer, and (b) melting a second portion of the third layer into any one or both portions of the first layer and the second layer at locations where the third layer contacts either or both of the first layer and the second layer, and wherein the third layer forms part of the first upper component.

[0236] Clause 77. The method according to any one of Clauses 51 to 76, wherein the first upper component is fully formed before the second upper component is melted into the first upper component.

[0237] Clause 78. The method according to any one of Clauses 51 to 77, wherein the first filament of the first layer is extruded to define a periphery and produce filament segments of the first filament extending between portions of the periphery.

[0238] Clause 79. The method according to any one of Clauses 51 to 78, wherein the first plurality of non-intersecting spaced path segments are squeezed out to extend in a serpentine configuration comprising at least two peaks and at least two valleys.

[0239] Clause 80. The method according to any one of Clauses 51 to 78, wherein the first plurality of non-intersecting spaced path segments are extruded to extend in a generally front-to-back direction on the upper and include a serpentine configuration having at least two peaks and at least two valleys.

[0240] Clause 81. The method according to Clause 79 or 80, wherein the first plurality of non-intersecting spaced path segments are extruded to form the serpentine configuration at least on the inner midfoot portion of the upper component.

[0241] Clause 82. The method according to Clause 79 or 80, wherein the first plurality of non-intersecting spaced path segments are extruded to form the serpentine configuration at least on the outer midfoot portion of the upper component.

[0242] Clause 83. The method according to any one of Clauses 51 to 82, wherein the first filament is extruded to have a first thickness in a first region of the upper, wherein the first filament is extruded to have a second thickness in a second region of the upper, and wherein the first thickness is different from the second thickness.

[0243] Clause 84. The method according to any one of Clauses 51 to 82, wherein the first filament is extruded to have a first diameter in a first region of the upper, wherein the first filament is extruded to have a second diameter in a second region of the upper, and wherein the first diameter is different from the second diameter.

[0244] Clause 85. The method according to any one of Clauses 51 to 84, wherein the first filament is extruded to form the periphery of the shoe upper.

[0245] Clause 86. The method according to any one of Clauses 51 to 85, wherein the extruded filaments in each layer of the first upper component are made of the same material.

[0246] Clause 87. The method according to any one of Clauses 51 to 86, wherein the extruded filaments in each layer of the first upper component comprise thermoplastic polyurethane material or other thermoplastic material.

[0247] Clause 88. The method according to any one of Clauses 51 to 87, wherein the extruded filaments in each layer of the first upper component comprise a material that is substantially non-absorbent.

[0248] Clause 89. The method according to any one of Clauses 51 to 88, wherein the extruded filaments in each layer of the first upper component comprise a hydrophobic material.

[0249] Clause 90. The method according to any one of Clauses 51 to 89, wherein at least a portion of the first upper component exhibits a moiré effect.

[0250] Clause 91. The method according to any one of Clauses 51 to 90, wherein the second upper component forms the instep portion or the forefoot portion of the upper.

[0251] Clause 92. The method according to any one of Clauses 51 to 91, wherein the second upper component defines a foot-receiving opening or collar of the upper.

[0252] Clause 93. The method according to any one of Clauses 51 to 92, wherein the second upper component forms the heel joint portion of the upper.

[0253] Clause 94. The method according to any one of Clauses 51 to 93, wherein the second upper component overlaps with the total surface area of ​​the first upper component by less than 30%.

[0254] Clause 95. The method according to any one of Clauses 51 to 94, wherein the fabric element of the second upper component comprises at least one yarn formed of the fusible material.

[0255] Clause 96. The method according to any one of Clauses 51 to 94, wherein the fabric element of the second upper component comprises a first yarn formed of the fusible material, the first yarn being entangled with a second yarn formed of the nonfusible material.

[0256] Clause 97. The method according to any one of Clauses 51 to 94, wherein the fabric element of the second upper component comprises a first yarn formed of an infusible material, the infusible material being at least partially coated with the fusible material.

[0257] Clause 98. The method according to Clause 96 or 97, wherein the infusible material comprises polyester material.

[0258] Clause 99. The method according to any one of Clauses 51 to 98, wherein the fusible material comprises thermoplastic polyurethane material or other thermoplastic material.

[0259] Clause 100. A method for forming an upper for footwear articles, the method comprising:

[0260] A first material is extruded to form a first layer comprising a first extruded filament, the first extruded filament comprising a first plurality of non-intersecting spaced path segments, wherein the first extruded filament has a width dimension of less than 1 mm, and wherein the first layer forms at least a portion of a first upper component;

[0261] Cover a portion of the first layer with a release liner;

[0262] Extruding a second material to form a second layer comprising a second extruded filament, the second extruded filament comprising a second plurality of non-intersecting spaced path segments, wherein the second extruded filament has a width dimension of less than 1 mm, wherein the step of extruding the second material includes: (a) applying a first portion of the second layer to the release liner such that the release liner extends between the first portion of the first layer and the first portion of the second layer, and (b) melting a second portion of the second layer to the second portion of the first layer at a location where the second layer contacts the first layer, wherein the second layer forms part of the first upper component; and

[0263] Remove the release liner between the first portion of the first layer and the first portion of the second layer.

[0264] Clause 101. The method according to Clause 100, wherein the step of extruding the first material includes extruding the first material onto a pre-existing layer comprising filament material.

[0265] Clause 102. The method according to Clause 100 or 101, wherein the first filament of the first layer is extruded to define a periphery and produce filament segments of the first filament extending between portions of the periphery.

[0266] Clause 103. The method according to any one of Clauses 100 to 102, wherein the first plurality of non-intersecting spaced path segments are squeezed out to extend in a serpentine configuration comprising at least two peaks and at least two valleys.

[0267] Clause 104. The method according to any one of Clauses 100 to 102, wherein the first plurality of non-intersecting spaced path segments are extruded to extend in a generally front-to-back direction on the upper and include a serpentine configuration having at least two peaks and at least two valleys.

[0268] Clause 105. The method according to Clause 103 or 104, wherein the first plurality of non-intersecting spaced path segments are extruded to form the serpentine configuration at least on the inner midfoot portion of the upper component.

[0269] Clause 106. The method according to Clause 103 or 104, wherein the first plurality of non-intersecting spaced path segments are extruded to form the serpentine configuration at least on the outer midfoot portion of the upper component.

[0270] Clause 107. The method according to any one of Clauses 100 to 106, wherein the first filament is extruded to have a first thickness in a first region of the upper, wherein the first filament is extruded to have a second thickness in a second region of the upper, and wherein the first thickness is different from the second thickness.

[0271] Clause 108. The method according to any one of Clauses 100 to 106, wherein the first filament is extruded to have a first diameter in a first region of the shoe upper, wherein the first filament is extruded to have a second diameter in a second region of the shoe upper, and wherein the first diameter is different from the second diameter.

[0272] Clause 109. The method according to any one of Clauses 100 to 108, wherein the first filament is extruded to form the periphery of the shoe upper.

[0273] Clause 110. The method according to any one of Clauses 100 to 109, wherein the first extruded filament and the second extruded filament are made of the same material.

[0274] Clause 111. The method according to any one of Clauses 100 to 109, wherein the first extruded filament and the second extruded filament are made of different materials.

[0275] Clause 112. The method according to any one of Clauses 100 to 111, wherein the first extruded filament and the second extruded filament each comprise a thermoplastic polyurethane material or other thermoplastic material.

[0276] Clause 113. The method according to any one of Clauses 100 to 112, wherein the first extruded filament and the second extruded filament each comprise a material that is substantially non-absorbent.

[0277] Clause 114. The method according to any one of Clauses 100 to 113, wherein the first extruded filament and the second extruded filament each comprise a hydrophobic material.

[0278] Clause 115. The method according to any one of Clauses 100 to 114, wherein at least a portion of the first upper component exhibits a moiré effect.

[0279] Clause 116. The method according to any one of Clauses 100 to 115, wherein the portion of the first layer covered by the release liner step extends inward from the outer periphery of the first layer.

[0280] Clause 117. A method of manufacturing footwear, the method comprising:

[0281] Forming an upper according to any one of clauses 51 to 116; and

[0282] The upper is joined to the sole structure.

[0283] Clause 118. An upper formed by any one of Clauses 51 to 116.

Claims

1. An upper for footwear articles, the upper comprising: The first shoe upper component includes: - A first layer, the first layer being formed from a first material into a first continuous path of a first extruded filament, the first extruded filament comprising a first plurality of non-intersecting, spaced path segments extending in a generally medial-lateral direction of the upper, wherein the first extruded filament has a width dimension of less than 3 mm, and wherein the first continuous path of the first extruded filament extends continuously to form: (i) a lateral heel portion of the first layer, (ii) a lateral midfoot portion of the first layer, (iii) a forefoot portion of the first layer, (iv) a medial midfoot portion of the first layer, and (v) a medial heel portion of the first layer; and - A second filament layer, the second filament layer being formed from a second material into a second continuous path of a second extruded filament, the second extruded filament comprising a second plurality of non-intersecting, spaced-apart path segments extending in a generally front-to-back direction of the upper, wherein the second continuous path of the second extruded filament extends continuously to form: (i) a lateral heel portion of the second filament layer, (ii) a lateral midfoot portion of the second filament layer, (iii) a forefoot portion of the second filament layer, (iv) a medial midfoot portion of the second filament layer, and (v) a medial heel portion of the second filament layer; and The second upper component includes a fabric element formed at least partially of a fusible material; The fusible material of the second upper component is melted into the first material of the first upper component.

2. The upper according to claim 1, wherein the second filament layer is fused to the first layer at the location where the second filament layer contacts the first layer.

3. The upper according to claim 2, wherein the second plurality of non-intersecting spaced path segments comprises at least five second non-intersecting path segments, wherein each of the at least five second non-intersecting path segments is spaced less than 5 mm from each directly adjacent second non-intersecting path segment in a length dimension of at least 25 mm.

4. The upper of claim 2, wherein the second upper component has a first main surface and a second main surface opposite to the first main surface, wherein the fusible material at the first main surface of the second upper component is fused to the first material, and wherein the fusible material at the second main surface of the second upper component is fused to the second material.

5. The upper of claim 2, wherein a portion of the second plurality of non-intersecting spaced path segments of the second extruded filament extends over a path segment length of at least 25 mm parallel to and partially overlapping a portion of the first plurality of non-intersecting spaced path segments of the first extruded filament.

6. The upper of claim 5, wherein 15% to 60% of the width of one or more filaments in the portion of the second plurality of non-intersecting spaced-apart path segments of the second extruded filament overlaps with one or more corresponding filaments in the portion of the first plurality of non-intersecting spaced-apart path segments of the first extruded filament over the length of the path segment.

7. The upper according to claim 2, wherein a plurality of non-intersecting spaced path segments of the second plurality of non-intersecting spaced path segments of the second extruded filament intersect with a plurality of non-intersecting spaced path segments of the first plurality of non-intersecting spaced path segments of the first extruded filament and form an angle.

8. The upper of claim 7, wherein the plurality of non-intersecting spaced path segments in the second plurality of non-intersecting spaced path segments of the second extruded filament and the plurality of non-intersecting spaced path segments in the first plurality of non-intersecting spaced path segments of the first extruded filament cooperate to form one or more rhomboid shapes, and wherein the long axis of the plurality of rhomboid shapes extends in a generally front-to-back direction of the upper.

9. The upper of claim 2, wherein the first upper component further comprises a third layer, the third layer comprising a third material as a third filament, the third filament comprising a third plurality of non-intersecting spaced path segments, wherein the third filament has a width dimension of less than 3 mm, and wherein the third layer is fused to any one or two of the first layer and the second filament layer at locations where the third layer respectively contacts any one or two of the first layer and the second filament layer.

10. The upper of claim 9, wherein the first upper component further comprises a fourth layer, the fourth layer comprising a fourth material as a fourth filament, the fourth filament comprising a fourth plurality of non-intersecting spaced path segments, wherein the fourth filament has a width dimension of less than 3 mm, and wherein the fourth layer is fused to any one or any combination of the first layer, the second filament layer, and the third layer at locations where the fourth layer respectively contacts any one or any combination of the first layer, the second filament layer, and the third layer.

11. The upper according to claim 10, wherein the first upper component further comprises: (a) A fifth layer comprising a fifth material as a fifth filament, the fifth filament comprising a fifth plurality of non-intersecting spaced path segments, wherein the fifth filament has a width dimension of less than 3 mm, and wherein the fifth layer is fused to any one or any combination of the first layer, the second filament layer, the third layer and the fourth layer at locations where the fifth layer respectively contacts any one or any combination of the first layer, the second filament layer, the third layer and the fourth layer; (b) A sixth layer comprising a sixth material as a sixth filament, the sixth filament comprising a sixth plurality of non-intersecting spaced path segments, wherein the sixth filament has a width dimension of less than 3 mm, and wherein the sixth layer is fused to any one or any combination of the first layer, the second filament layer, the third layer, the fourth layer, and the fifth layer at locations where the sixth layer respectively contacts any one or any combination of the first layer, the second filament layer, the third layer, the fourth layer, and the fifth layer; (c) A seventh layer comprising a seventh material as a seventh filament, the seventh filament comprising a seventh plurality of non-intersecting spaced path segments, wherein the seventh filament has a width dimension of less than 3 mm, and wherein the seventh layer is fused to any one or any combination of the first layer, the second filament layer, the third layer, the fourth layer, the fifth layer, and the sixth layer at locations where the seventh layer respectively contacts any one or any combination of the first layer, the second filament layer, the third layer, the fourth layer, the fifth layer, and the sixth layer; and (d) An eighth layer comprising an eighth material as an eighth filament comprising an eighth plurality of non-intersecting spaced path segments, wherein the eighth filament has a width dimension of less than 3 mm, and wherein the eighth layer is fused to any one or any combination of the first layer, the second filament layer, the third layer, the fourth layer, the fifth layer, the sixth layer, and the seventh layer at locations where the eighth layer respectively contacts any one or any combination of the first layer, the second filament layer, the third layer, the fourth layer, the fifth layer, the sixth layer, and the seventh layer.

12. The upper of claim 1, wherein the first plurality of non-intersecting spaced path segments extend in a serpentine configuration comprising at least two peaks and at least two valleys.

13. The upper of claim 2, wherein each of the first extruded filament and the second extruded filament of the first upper component comprises a substantially non-absorbent material, and / or wherein each of the first extruded filament and the second extruded filament of the first upper component comprises a hydrophobic material.

14. The upper of claim 1, wherein at least a portion of the first upper component exhibits a moiré effect.

15. The upper of claim 1, wherein the second upper component has a first main surface and a second main surface opposite to the first main surface, and wherein the first upper component is engaged with at least the first main surface of the second upper component.

16. The upper of claim 1, wherein the first plurality of non-intersecting spaced path segments comprises at least five first non-intersecting path segments, and wherein each of the at least five first non-intersecting path segments is spaced less than 5 mm from each directly adjacent first non-intersecting path segment in a length dimension of at least 25 mm.

17. The upper according to claim 1, wherein: (a) The second upper component forms the instep portion or the front portion of the upper; (b) The second upper component defines a foot-receiving opening or collar for the upper; (c) The second upper component forms the heel joint portion of the upper; (d) The outer surfaces of the first upper component and the second upper component are joined; and / or (e) The second upper component overlaps with the total surface area of ​​the first upper component by less than 30%.

18. The upper according to claim 1, wherein: (a) The fabric element of the second upper component comprises at least one yarn formed of the fusible material; (b) The fabric element of the second upper component comprises a first yarn formed of the fusible material, the first yarn being entangled with a second yarn formed of a non-fusible material; or (c) The fabric element of the second upper component includes a first yarn formed of an infusible material, the infusible material being at least partially coated with the fusible material.

19. The upper of claim 1, wherein the first extruded filament has a width dimension of less than 2 mm, wherein a serpentine configuration is formed at least at the inner midfoot portion of the first upper component and the outer midfoot portion of the first upper component, and wherein the first plurality of non-intersecting spaced-apart path segments extend in a generally front-to-back direction of the upper.

20. An upper for footwear products, comprising: The first shoe upper component includes a first layer and a second layer. The first layer is formed of a first material as a first continuous path of a first extruded filament, the first layer comprising a first plurality of non-intersecting spaced path segments extending in a generally medial-lateral direction of the upper, and wherein the first continuous path of the first extruded filament extends continuously to form: (i) a lateral heel portion of the first layer, (ii) a lateral midfoot portion of the first layer, (iii) a forefoot portion of the first layer, (iv) a medial midfoot portion of the first layer, and (v) a medial heel portion of the first layer. The second layer is formed of a second material as a second continuous path of a second extruded filament, the second layer comprising a second plurality of non-intersecting spaced path segments extending in a generally front-to-back direction of the upper, and wherein the second continuous path of the second extruded filament extends continuously to form: (i) a lateral heel portion of the second layer, (ii) a lateral midfoot portion of the second layer, (iii) a forefoot portion of the second layer, (iv) a medial midfoot portion of the second layer, and (v) a medial heel portion of the second layer. A portion of the second plurality of non-intersecting spaced path segments of the second extruded filament extends on the path segment parallel to and partially overlapping a portion of the first plurality of non-intersecting spaced path segments of the first extruded filament. as well as The second upper component includes a fabric element formed at least partially of a fusible material; The fusible material of the second upper component is melted into the first material of the first upper component.

21. A method for forming an upper for footwear articles, the method comprising: A first material is extruded to form a first layer comprising a first continuous path of a first extruded filament, the first extruded filament comprising a first plurality of non-intersecting spaced path segments, wherein the first extruded filament has a width dimension of less than 3 mm, and wherein the first continuous path of the first extruded filament extends continuously to form: (i) an outer heel portion of the first layer, (ii) an outer midfoot portion of the first layer, (iii) a forefoot portion of the first layer, (iv) an inner midfoot portion of the first layer, and (v) an inner heel portion of the first layer; A second material is extruded to form a second layer comprising a second continuous path of a second extruded filament, the second extruded filament comprising a second plurality of non-intersecting spaced path segments, wherein the second extruded filament has a width dimension of less than 3 mm, wherein the second continuous path of the second extruded filament extends continuously to form: (i) a lateral heel portion of the second layer, (ii) a lateral midfoot portion of the second layer, (iii) a forefoot portion of the second layer, (iv) a medial midfoot portion of the second layer, and (v) a medial heel portion of the second layer, and wherein the first layer and the second layer form at least a portion of a first upper component; and A second upper component is melted onto a first upper component, wherein the second upper component comprises a fabric element formed at least partially of a fusible material, wherein the fusible material of the second upper component is melted onto the first material of the first upper component.

22. The method of claim 21, wherein the step of extruding the second material includes melting the second layer into the first layer at a location where the second layer contacts the first layer, and wherein the second layer forms part of the first upper component.

23. The method of claim 22, wherein a portion of the second plurality of non-intersecting spaced path segments of the second extruded filament is extruded to extend over a path segment length of at least 25 mm parallel to and partially overlapping a portion of the first plurality of non-intersecting spaced path segments of the first extruded filament.

24. The method of claim 22, wherein a portion of the second plurality of non-intersecting spaced path segments of the second extruded filament is extruded to extend over a path segment length of at least 50 mm parallel to and partially overlapping a portion of the first plurality of non-intersecting spaced path segments of the first extruded filament.

25. The method of claim 24, wherein 15% to 60% of the width of one or more filaments in the portion of the second plurality of non-intersecting spaced-apart path segments of the second extruded filament is extruded to overlap with one or more corresponding filaments in the portion of the first plurality of non-intersecting spaced-apart path segments of the first extruded filament over the length of the path segment.

26. The method of claim 22, wherein a plurality of non-intersecting spaced path segments of the second plurality of non-intersecting spaced path segments of the second extruded filament are extruded to intersect with and form an angle with a plurality of non-intersecting spaced path segments of the first plurality of non-intersecting spaced path segments of the first extruded filament.

27. The method of claim 26, wherein the angle is in the range of 65° to 90°.

28. The method of claim 27, wherein the plurality of non-intersecting spaced path segments in the second plurality of non-intersecting spaced path segments of the second extruded filament and the plurality of non-intersecting spaced path segments in the first plurality of non-intersecting spaced path segments of the first extruded filament are extruded to form a rhomboid shape.

29. The method of claim 28, wherein at least a portion of the rhomboid shape is located at least in the forefoot region of the upper.

30. The method of claim 29, wherein the long axis of at least a portion of the rhomboid shape extends in a generally front-to-back direction on the upper.

31. The method of claim 30, wherein the first extruded filament is extruded to have a first thickness in a first region of the shoe upper, wherein the second extruded filament is extruded to have a second thickness in a second region of the shoe upper, and wherein the first thickness is different from the second thickness.

32. The method of claim 31, wherein the first extruded filament is extruded to have a first diameter in a first region of the shoe upper, wherein the second extruded filament is extruded to have a second diameter in a second region of the shoe upper, and wherein the first diameter is different from the second diameter.

33. The method of claim 22, wherein portions of the first layer and the second layer are extruded to be oriented relative to each other to form an intersecting mesh of the first extruded filament extending in a first direction and the second extruded filament extending in a second direction.

34. The method of claim 22, further comprising: A third material is extruded to form a third layer comprising a third extruded filament comprising a third plurality of non-intersecting spaced path segments, wherein the third extruded filament has a width dimension of less than 3 mm, wherein the step of extruding the third material includes melting the third layer into any one or two of the first layer and the second layer at locations where the third layer respectively contacts any one or two of the first layer and the second layer, and wherein the third layer forms part of the first shoe upper component.

35. The method of claim 34, further comprising: A fourth material is extruded to form a fourth layer comprising a fourth extruded filament comprising a fourth plurality of non-intersecting spaced path segments, wherein the fourth extruded filament has a width dimension of less than 3 mm, wherein the step of extruding the fourth material comprises melting the fourth layer into any one or any combination of the first layer, the second layer and the third layer at locations where the fourth layer respectively contacts any one or any combination of the first layer, the second layer and the third layer, and wherein the fourth layer forms part of the first upper component.

36. The method of claim 35, further comprising: A fifth material is extruded to form a fifth layer comprising a fifth extruded filament comprising a fifth plurality of non-intersecting spaced path segments, wherein the fifth extruded filament has a width dimension of less than 3 mm, wherein the step of extruding the fifth material includes melting the fifth layer into any one or any combination of the first layer, the second layer, the third layer, and the fourth layer at locations where the fifth layer respectively contacts any one or any combination of the first layer, the second layer, the third layer, and the fourth layer, and wherein the fifth layer forms part of the first upper component.

37. The method of claim 36, further comprising: A sixth material is extruded to form a sixth layer comprising a sixth extruded filament comprising a sixth plurality of non-intersecting spaced path segments, wherein the sixth extruded filament has a width dimension of less than 3 mm, wherein the step of extruding the sixth material includes melting the sixth layer into any one or any combination of the first layer, the second layer, the third layer, the fourth layer, and the fifth layer at locations where the sixth layer respectively contacts any one or any combination of the first layer, the second layer, the third layer, the fourth layer, and the fifth layer, and wherein the sixth layer forms part of the first upper component.

38. The method of claim 37, further comprising: A seventh material is extruded to form a seventh layer comprising a seventh extruded filament comprising a seventh plurality of non-intersecting spaced path segments, wherein the seventh extruded filament has a width dimension of less than 3 mm, wherein the step of extruding the seventh material includes melting the seventh layer into any one or any combination of the first layer, the second layer, the third layer, the fourth layer, the fifth layer, and the sixth layer at locations where the seventh layer respectively contacts any one or any combination of the first layer, the second layer, the third layer, the fourth layer, the fifth layer, and the sixth layer, and wherein the seventh layer forms part of the first upper component.

39. The method of claim 38, further comprising: An eighth material is extruded to form an eighth layer comprising an eighth extruded filament comprising a plurality of non-intersecting spaced path segments, wherein the eighth extruded filament has a width dimension of less than 3 mm, wherein the step of extruding the eighth material comprises melting the eighth layer into any one or any combination of the first layer, the second layer, the third layer, the fourth layer, the fifth layer, the sixth layer, and the seventh layer at locations where the eighth layer respectively contacts any one or any combination of the first layer, the second layer, the third layer, the fourth layer, the fifth layer, the sixth layer, and the seventh layer, and wherein the eighth layer forms part of the first upper component.

40. The method of claim 21, wherein the step of melting the second upper component to the first upper component includes melting the inner surface of the first upper component to the outer surface of the second upper component.

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