Upper with engineered support structure for article of footwear

Abstract

Examples of an upper with an engineered support structure for an article of footwear are described. In one embodiment, an upper for an article of footwear has an engineered support structure. The upper includes a first layer, a second layer, and an engineering support structure. An engineered support structure includes a matrix pattern of bond dots disposed between a first layer and a second layer. An engineered support structure has at least one first zone having a first support level defined by a first bond density or a first bond size in a matrix pattern of bonds, and at least one second zone having a second support level defined by a second bond density or a second bond size in the matrix pattern of bonds, the at least one second zone has a second support level defined by a second bond point density or a second bond point size in the matrix pattern of bond points. The first support level is different than the second support level.

Description

Technical Field

[0001] This embodiment relates to footwear products, and more particularly to an upper for a footwear product having an engineered support structure. Background Art

[0002] Conventional footwear products typically include two main elements: an upper and a sole assembly. The upper is secured to the sole assembly and forms a cavity within the footwear product for comfortably and securely receiving a foot. The sole assembly is secured to the lower surface of the upper so as to be positioned between the upper and the ground.

[0003] A variety of materials are commonly used to manufacture the upper. The materials can be selected based on various properties, including, for example, tensile strength, abrasion resistance, flexibility, breathability, compressibility, and moisture absorbency, each material imparting different characteristics to the upper.

[0004] There is a need in the art for a footwear product having an upper with an engineered support structure that provides an improved fit and feel for the wearer. Summary of the Invention

[0005] In one aspect, the present disclosure provides an upper for a footwear product having an engineered support structure. The upper includes a first layer, a second layer, and an engineered support structure. The engineered support structure includes a matrix pattern of bond points disposed between the first layer and the second layer. The engineered support structure has at least one first zone and at least one second zone, the at least one first zone having a first support level defined by a first bond point density or a first bond point size in the matrix pattern of bond points, the at least one second zone having a second support level defined by a second bond point density or a second bond point size in the matrix pattern of bond points. The first support level is different from the second support level.

[0006] In another aspect, the present disclosure provides a method of forming an upper having an engineered support structure. The method includes providing a first layer of the upper, the first layer having an inner surface and an opposite outer surface. The method further includes providing a second layer of the upper, the second layer having a first surface and an opposite second surface. The method further includes depositing a plurality of bond points onto either the inner surface of the first layer or the first surface of the second layer according to a matrix pattern of bond points to form the engineered support structure. The engineered support structure has at least one first zone and at least one second zone, the at least one first zone having a first support level defined by a first bond point density or a first bond point size in the matrix pattern of bond points, the at least one second zone having a second support level defined by a second bond point density or a second bond point size in the matrix pattern of bond points. The first support level is different from the second support level.

[0007] In another aspect, the present disclosure provides an engineered support structure for a shoe upper. The engineered support structure includes a plurality of adhesive dots deposited onto a face of a layer of the shoe upper according to an adhesive dot matrix pattern. The adhesive dot matrix pattern provides at least one first zone and at least one second zone for the engineered support structure, the at least one first zone having a first support level defined by a first adhesive dot density or a first adhesive dot size in the adhesive dot matrix pattern, and the at least one second zone having a second support level defined by a second adhesive dot density or a second adhesive dot size in the adhesive dot matrix pattern. The first support level is different from the second support level.

[0008] Other systems, methods, features, and advantages of the present disclosure will be or will become apparent to one of ordinary skill in the art upon examination of the following drawings and detailed description. All such additional systems, methods, features, and advantages are intended to be included within this specification and this summary, are within the scope of the present disclosure, and are protected by the appended claims. BRIEF DESCRIPTION OF THE DRAWINGS

[0009] The present disclosure may be better understood with reference to the following drawings and description. Throughout the drawings, reference numerals may be reused to indicate corresponding relationships between the elements being referenced. The drawings are provided to illustrate exemplary embodiments described herein and are not intended to limit the scope of the present disclosure. The dimensions and relative positions of the elements in the drawings are not necessarily drawn to scale. For example, the shapes and dimensions of various elements and angles are not drawn to scale, and some of these elements are arbitrarily enlarged and positioned to improve the readability of the drawings.

[0010] Figure 1 is an isometric view of an exemplary embodiment of a footwear article including a shoe upper having an engineered support structure;

[0011] Figure 2 is a schematic plan view of an exemplary embodiment of a shoe upper having an engineered support structure;

[0012] Figure 3 is an exploded view of an exemplary embodiment of a shoe upper having an engineered support structure;

[0013] Figure 4 is a representative view of an exemplary embodiment of an adhesive dot matrix pattern for a shoe upper;

[0014] Figure 5 is a representative view of an exemplary embodiment of a process of applying an adhesive dot matrix pattern to a portion of a shoe upper;

[0015] Figure 6 is a representative cross-sectional view of an exemplary embodiment of an outer layer and an inner layer joined by an adhesive dot matrix pattern;

[0016] Figure 7A is a schematic view of an exemplary embodiment of an adhesive dot matrix arrangement that permits four-way stretch;

[0017] Figure 7B is a schematic view of an exemplary embodiment of an adhesive dot matrix arrangement that permits two-way stretch;

[0018] Figure 8 is a schematic view of an exemplary embodiment of a shoe upper having various regions of four-way stretch or two-way stretch;

[0019] Figure 9 is a representative view of an alternative embodiment of an adhesive dot matrix pattern for a shoe upper; and

[0020] Figure 10 is a representative view of another alternative embodiment of an adhesive dot matrix pattern for a shoe upper. DETAILED DESCRIPTION

[0021] Described herein are footwear articles having a shoe upper with an engineered support structure. The techniques of the present embodiments provide a shoe upper for a footwear article that distributes pressure in a manner comfortable to a wearer while also effectively supporting the movement of the wearer's foot. In some aspects, the shoe upper of the present embodiments includes an engineered support structure having different support zones throughout the region of the shoe upper to permit support of the wearer's foot.

[0022] For consistency and convenience, directional adjectives are employed throughout the detailed description corresponding to the illustrated embodiments. For purposes of the present disclosure, when referring to a footwear article, the following directional terms refer to the footwear article when positioned in an upright position, with the sole facing the ground, i.e., the orientation when the footwear article is worn by a wearer standing on a substantially horizontal surface. The terms "medial", "lateral", "front", "rear", etc. are intended to refer to the anatomical directions corresponding to the person on which the article is configured to be placed or worn. For example, "medial" refers to a relative position disposed toward the center of the body, while "lateral" refers to a relative position disposed away from the center of the body. With respect to footwear, the term "front" refers to a relative position closer to the toes of the wearer, and "rear" refers to a relative position closer to the heel of the wearer. In the absence of a wearer, the same directional terms may be used as if the footwear article were worn in its intended configuration.

[0023] As used throughout this detailed description and in the claims, the term "longitudinal" refers to the direction extending along the length of the article. In some cases, the longitudinal direction may extend from the toe region to the heel region of the article. Additionally, as used throughout this detailed description and in the claims, the term "lateral" refers to the direction extending across the width of the article. In other words, the lateral direction may extend between the inner and outer sides of the article.

[0024] Terms such as "upper", "lower", "vertical", "horizontal", etc. should be understood in the context of the particular article being discussed. For example, the article may be oriented about defined X, Y, and Z axes, where the X axis corresponds to the longitudinal direction and the Y axis corresponds to the lateral direction. In those examples, the X-Y plane will define the horizontal, where "upper" is defined as the positive Z direction and "lower" is defined as the negative Z direction. Additionally, as used throughout this detailed description and in the claims, the term "vertical" refers to a direction generally perpendicular to the X-Y plane and / or the lateral and longitudinal directions. For example, in the case where the article is lying flat on the ground, the vertical direction may extend upward from the ground. It should be understood that each of these directional adjectives may apply to various components of the article, such as the upper and / or sole assembly.

[0025] The accompanying drawings illustrate an exemplary embodiment of a footwear article 100. For clarity, the following detailed description discusses the exemplary embodiment in the form of a casual shoe, but it should be noted that the techniques described herein may be applied to any form of footwear article, including but not limited to: athletic shoes, running shoes, training shoes, yoga shoes, soccer shoes, football shoes, basketball shoes, baseball shoes, rugby shoes, other types of athletic shoes, casual shoes, hiking boots, and other types of footwear. As Figures 1 to 10 shown, the footwear article 100 (also referred to simply as the article 100) is intended to be used with the right foot; however, it should be understood that the following discussion may equally apply to a mirror image of the footwear article 100 intended to be used with the left foot.

[0026] Reference Figures 1 to 10 , for reference purposes, the article 100 may include a toe region 10, a midfoot region 20, and a heel region 30. The toe region 10 may generally be associated with the toes and the joints connecting the metatarsals to the phalanges. The midfoot region 20 may generally be associated with the arch of the foot. Similarly, the heel region 30 may generally be associated with the heel including the calcaneus. Additionally, the article 100 may include an inner side 40 and an outer side 50. In particular, the inner side 40 and the outer side 50 may be opposite sides of the article 100. Additionally, both the inner side 40 and the outer side 50 may extend through the toe region 10, the midfoot region 20, and the heel region 30.

[0027] It should be understood that the forefoot region 10, the midfoot region 20, and the heel region 30 of the shoe are for descriptive purposes only and are not intended to demarcate precise regions of the article 100, but rather to describe relative positions. Similarly, the medial side 40 and the lateral side 50 are intended to generally denote the two sides of the article and not to precisely divide the article 100 into two halves. Additionally, the forefoot region 10, the midfoot region 20, and the heel region 30, as well as the medial side 40 and the lateral side 50, can also be applied to the various components of the article, such as the sole assembly and / or the upper.

[0028] The article 100 can include an upper 110 and a sole assembly 120. In some embodiments, the sole assembly 120 can be configured to provide traction friction to the article 100. In addition to providing traction friction, the sole assembly 120 can attenuate ground reaction forces when compressed between the foot and the ground during walking, running, or other locomotive activities. The configuration of the sole assembly 120 can vary significantly in different embodiments to include various conventional or unconventional structures. In some cases, the configuration of the sole assembly 120 can be constructed according to one or more types of ground on which the sole assembly 120 can be used. Examples of ground include, but are not limited to: dirt, concrete, paved surfaces, natural turf, synthetic turf, and other surfaces.

[0029] The sole assembly 120 is fixed to the upper 110 and extends between the foot and the ground when the article 100 is worn. In different embodiments, the sole assembly 120 can include different components. For example, the sole assembly 120 can include an outsole, a midsole, and / or an insole. In some cases, one or more of these components can be optional. Additionally, in some cases, the sole assembly 120 itself can be optional.

[0030] The upper 110 can generally be configured to receive and cover the foot. To this end, the upper 110 can include an opening 112 that provides access to the interior of the upper 110 and / or the article 100. In an exemplary embodiment, the upper 110 can be configured as a slip-on upper that does not include laces or fastening members for securing the article 100 to the wearer's foot. In other embodiments, the upper 110 can include provisions for tightening or otherwise securing the upper 110 and the article 100 to the wearer's foot. In some embodiments, for example, the upper 110 can be provided with lace receiving members that can include a plurality of eyelets configured to receive laces. Although not shown in the present embodiment, some embodiments of the article 100 can include laces or other fastening members that can be used to adjust the size of the opening 112 and thus the fit of the upper 110 around the wearer's foot.

[0031] In this embodiment, the upper 110 of the article 100 includes a front upper region 114 that is configured to cover the instep on top of the wearer's foot. As Figure 1 shown, the front upper region 114 extends from the toe end 116 of the upper 110 at the front of the article 100 to the front throat edge 118 at the opening 112. Some embodiments of the upper 110 may include a tongue to enhance the comfort and fit of the upper 110 and / or the article 100. For example, an embodiment of the upper 110 may have a tongue that longitudinally extends from the opening 112 in a direction toward the front shoe region 10 through the front upper region 114 of the upper 110. In these embodiments, the tongue is configured to cover the instep of the wearer's foot of the article 100.

[0032] Now referring Figure 2 , a planar or flat configuration of the upper 110 is shown. In this embodiment, the upper 110 includes an outer perimeter 200 that extends around the perimeter of the upper 110 in the flat configuration. As Figure 2 shown, the outer perimeter 200 of the upper 110 includes a front edge 202 that extends from the front of the upper 110 in two directions (e.g., toward the inner side 40 and the outer side 50) from the toe end 116. The outer perimeter 200 includes an outer side edge 204 on the outer side 50 and continues to a heel edge 206 that will form the heel of the upper 110 when the upper 110 is formed into the footwear article 100 (as Figure 1 shown). The outer perimeter 200 also includes an inner side edge 208 on the inner side 40 on the side of the upper 110 opposite the outer side edge 204 on the outer side 50.

[0033] In this embodiment, the upper 110 has an asymmetric arrangement where the heel portion 210 of the upper 110 extends from the outer side edge 204 on the outer side 50. In one embodiment, the heel portion 210 of the upper 110 includes a first rear edge 212 that extends from the heel edge 206 and is configured to engage or mate with a second rear edge 214 that extends from the inner side edge 208. That is, the first rear edge 212 and the second rear edge 214 are configured to be brought together and joined by stitching, adhesive, or other attachment mechanisms to close the rear of the upper 110 and form an opening 112 in the upper 110 (as Figure 1 shown). With this arrangement, when the rear of the upper 110 is closed to form the opening 112, the inner perimeter of the opening 112 is defined by an inner inner edge 216 on the inner side 40, the front throat edge 118, and an outer inner edge 218 on the outer side 50.

[0034] Now referring Figure 3, showing an exploded view of the upper 110. In some embodiments, the upper 110 of the article 100 may include multiple layers, including an outer layer 300 and an inner layer 302. The outer layer 300 forms at least a part of the exterior of the article 100, and the inner layer 302 forms at least a part of the interior of the article 100 and is configured to face the wearer's foot when the article 100 is being worn. Each layer of the upper 110 may be made of a separate fabric or textile. In an exemplary embodiment, the fabric or textile forming the outer layer 300 and / or the inner layer 302 may have two-way stretchability, four-way stretchability, moisture-absorbing properties, quick-drying properties, and combinations thereof. In one embodiment, the outer layer 300 and the inner layer 302 may be made of knitted textiles. In some cases, the fabric or textile of the outer layer 300 may be different from that of the inner layer 302. For example, the outer layer 300 may be made of a knitted textile having a greater amount or percentage of stretchable fibers or yarns (e.g., elastomeric fibers or similar fibers / yarns) than the inner layer 302. In other cases, the fabric or textile of the outer layer 300 may be the same as that of the inner layer 302. In other cases, the outer layer 300 and the inner layer 302 may be made of any type or kind of fabric or textile, including combinations of textiles and / or fabrics.

[0035] In an exemplary embodiment, the outer layer 300 of the upper 110 includes an outer surface 304 on the exterior of the upper 110 and an opposite inner surface 306 that faces inwardly toward the wearer's foot. When the inner layer 302 and the outer layer 300 are joined together to form the upper 110, the inner surface 306 of the outer layer 300 faces the first surface 308 of the inner layer 302. The inner layer 302 further includes a second surface 310 that is opposite to the first surface 308 and faces the wearer's foot when the article 100 including the upper 110 is being worn. In some embodiments, the second surface 310 of the inner layer 302 is within the interior of the upper 110.

[0036] According to the technology of this embodiment, the upper (including the upper 110) may be provided with an engineered support structure that allows the upper to have zones of different support (i.e., tensile resistance) in different regions of the upper and the article (e.g., the article 100) including the upper. In some embodiments, the engineered support structure may be formed by selectively applying droplets or dots of adhesive in different patterns between the layers of the upper to create zones of different support. When the layers forming the upper are joined, the pattern of the adhesive allows the upper to stretch to different degrees or amounts, depending on the separation distance between the droplets or dots of adhesive forming each zone. With this arrangement, an upper having an engineered support structure can be formed that provides zones of different support for the foot of the wearer of the footwear article.

[0037] As Figure 3As shown, the bonding point matrix pattern 312 joins or bonds the outer layer 300 and the inner layer 302 together to form the shoe upper 110. As will be described in more detail below, the bonding point matrix pattern 312 includes a plurality of bonding points arranged at different densities (e.g., by varying the separation distance and / or the bonding point size), which provide different support zones for the shoe upper 110. In this embodiment, the outer layer 300 of the shoe upper 110 can be joined to the inner layer 302 by aligning the first face 308 of the inner layer 302 with the inner face 306 of the outer layer 300 and placing the opposing faces (e.g., 308, 306) together to join the outer layer 300 and the inner layer 302, thereby forming the shoe upper 110.

[0038] In one embodiment, the engineered support structure can include two or more layers of bonding point matrix patterns, including, for example, the bonding point matrix pattern 312. Each of the two or more layers can be applied over or above or under or below another layer to produce a multi-layer bonding point matrix pattern. In some cases, the bonding point matrix pattern in each layer of the multi-layer bonding point matrix pattern can be the same or different from the pattern below and / or above it. The multiple layers of the multi-layer bonding point matrix pattern can be partially or fully overlapped to produce zones with different properties in different zones or regions of the shoe upper 110 and / or the article 100.

[0039] Now referring Figure 4 to, an exemplary embodiment of the bonding point matrix pattern 312 of the engineered support structure for forming the shoe upper 110 is shown. In this embodiment, the bonding point matrix pattern 312 includes four horizontal bonding point densities (e.g., associated with different separation distances and / or bonding point sizes) arranged in different regions of the shoe upper 110 to provide zones with different support levels. As Figure 4 shown, the bonding point matrix pattern 312 includes a first bonding point density 400, which is associated with the lowest bonding point density having the greatest separation distance and / or the smallest bonding point size to provide the lowest level of support. That is, the first bonding point density 400 joins the opposing layers (e.g., Figure 3 the outer layer 300 and the inner layer 302 shown in) such that the regions of the shoe upper 110 having the first bonding point density 400 provide the least tensile resistance.

[0040] In this embodiment, the first bonding point density 400 can be used in at least the central portion of the forefoot region 10 of the shoe upper 110, in the region corresponding to the toe box of the article 100. The first bonding point density 400 can also be used in the regions along the front throat edge 118 and the heel portion 210 of the shoe upper 110. With this arrangement, these regions of the shoe upper 110 can be configured to allow the maximum amount of stretching (i.e., provide the least tensile resistance).

[0041] The bonding point matrix pattern 312 further includes a second bonding point density 402 associated with a low bonding point density, the separation distance of the second bonding point density 402 being less than the separation distance of the first bonding point density 400 (and / or the bonding point size of the second bonding point density 402 being greater than the bonding point size of the first bonding point density 400), thereby providing a support level greater than the support level provided by the first bonding point density 400. That is, the second bonding point density 402 bonds the opposing layers (e.g., Figure 3 the outer layer 300 and the inner layer 302 shown in), such that the amount or degree of tensile resistance provided by the region of the upper 110 having the second bonding point density 402 is greater than the amount or degree of tensile resistance provided by the first bonding point density 400.

[0042] In this embodiment, the second bonding point density 402 may be used in at least one region around the central portion of the toe region 10 of the upper 110, the at least one region surrounding the region having the first bonding point density 400 corresponding to the toe box of the article 100. As Figure 4 shown, the second bonding point density 402 extends through at least a portion of the toe cap region 114 of the upper 110, including regions adjacent to the inner side edge 208 on the inner side 40, the outer side edge 204 on the outer side 50, and the front edge 202 at the front of the upper 110.

[0043] The bonding point matrix pattern 312 further includes a third bonding point density 404 associated with a medium bonding point density, the separation distance of the third bonding point density 404 being less than the separation distances of the second bonding point density 402 and the first bonding point density 400 (and / or the bonding point size of the third bonding point density 404 being greater than the bonding point sizes of the second bonding point density 402 and the first bonding point density 400), thereby providing a support level greater than the support levels provided by the second bonding point density 402 and the first bonding point density 400. That is, the third bonding point density 404 bonds the opposing layers (e.g., Figure 3 the outer layer 300 and the inner layer 302 shown in), such that the amount or degree of tensile resistance provided by the region of the upper 110 having the third bonding point density 404 is greater than the amounts or degrees of tensile resistance provided by the second bonding point density 402 and the first bonding point density 400.

[0044] In this embodiment, the third bond point density 404 can be used in at least a portion of the front panel area 114 of the shoe upper on the inboard side 40 and the outboard side 50. The third bond point density 404 can also be used at least in the area extending along the outboard-to-inboard edge 218 of the opening 112 and in the area above the heel portion 210 having the first bond point density 400. With this arrangement, the third bond point density 404 along the outboard-to-inboard edge 218 can limit stretching around the opening 112 (i.e., a greater amount of stretch resistance) to keep the foot of the wearer of the article 100 fixed within the shoe upper 110.

[0045] In this embodiment, the bond point matrix pattern 312 further includes a fourth bond point density 406 associated with a high bond point density, the separation distance of the fourth bond point density 406 being less than the separation distances of the third bond point density 404, the second bond point density 402, and the first bond point density 400 (and / or the bond point size of the fourth bond point density 406 being greater than the bond point sizes of the third bond point density 404, the second bond point density 402, and the first bond point density 400), thereby providing a higher level of support than that provided by the third bond point density 404, the second bond point density 402, and the first bond point density 400. That is, the fourth bond point density 406 bonds the opposing layers (e.g., Figure 3 the outer layer 300 and the inner layer 302 as shown), such that the amount or degree of stretch resistance provided by the area of the shoe upper 110 having the fourth bond point density 406 is greater than the amount or degree of stretch resistance provided by the third bond point density 404, the second bond point density 402, and the first bond point density 400.

[0046] In this embodiment, the fourth bond point density 406 can be used in at least one area extending along most of the outer perimeter 200 of the shoe upper 110, including along the front edge 202 extending from the front of the shoe upper 110, and further extending along the outer side edge 204 on the outboard side 50 in two directions (e.g., toward the inboard side 40 and the outboard side 50) to the heel portion 210 and along the inner side edge 208 on the inboard side 40 to the second rear edge 214. The fourth bond point density 406 can also be used in at least one area extending transversely across the top of the front panel area 114 of the shoe upper from the inboard side 40 to the outboard side 50. With this arrangement, the fourth bond point density 406 in this area can form a band structure on top of the foot of the wearer, which restricts the lateral (i.e., left-right) stretching of the shoe upper 110 when the article 100 is worn. In addition, the fourth bond point density 406 can be used in the area extending from the heel portion 210 to the first rear edge 212. With this arrangement, the bond point matrix pattern 312 forms an engineered support structure between the outer layer 300 and the inner layer 302 of the shoe upper 110 for providing improved fit and feel for the article 100.

[0047] In one embodiment, adjacent bonding points of the first bonding point density 400 are separated by a first separation distance D1. For example, as Figure 4 shown, the first bonding point 410 and the second bonding point 412 in the region having the first bonding point density 400 are spaced apart from each other by the first separation distance D1. Adjacent bonding points of the second bonding point density 402 are separated by a second separation distance D2, which is less than the first separation distance D1. For example, as Figure 4 shown, the third bonding point 414 and the fourth bonding point 416 in the region having the second bonding point density 402 are spaced apart from each other by the second separation distance D2. Adjacent bonding points of the third bonding point density 404 are separated by a third separation distance D3, which is less than the first separation distance D1 and the second separation distance D2. For example, as Figure 4 shown, the fifth bonding point 418 and the sixth bonding point 420 in the region having the third bonding point density 404 are spaced apart from each other by the third separation distance D3.

[0048] In an exemplary embodiment, the separation distance between adjacent bonding points in each region decreases outward from the central portion of the upper 110 in the shoe front region 10 that surrounds the region corresponding to the toe cap towards the outer perimeter 200 at the toe end 116, such that the first separation distance D1 is greater than the second separation distance D2 and the third separation distance D3, and the second separation distance D2 is greater than the third separation distance D3. In one embodiment, the first separation distance D1 is approximately 6 millimeters (mm), the second separation distance D2 is approximately 4 mm, and the third separation distance D3 is approximately 3 mm. In other embodiments, the specific separation distances may vary. The same variation in the separation distance between adjacent bonding points can also be applied in different directions. For example, by changing the separation distance between adjacent bonding points in the direction along the regions having different zones, the same effect can be achieved (e.g., in each region, adjacent bonding points have the same separation distance in the zone having the first bonding point density 400, and in the zone having the second bonding point density 402, the adjacent bonding points are further separated from the adjacent bonding points having the same separation distance in the adjacent region).

[0049] Furthermore, in some embodiments, a region having a fourth bonding point density 406 may surround at least a portion of the outer perimeter 200 of the upper 110 and enclose the regions having the first bonding point density 400, the second bonding point density 402, and the third bonding point density 404. In an exemplary embodiment, the separation distance between the bonding points in the region having the fourth bonding point density 406 may be less than each of the first separation distance D1, the second separation distance D2, and the third separation distance D3. For example, in Figure 4In the illustrated embodiment, the separation distance between the bonding points in the zone having the fourth bonding point density 508 can be about 1 mm or less.

[0050] With this arrangement, the regions of the upper 110 having a bonding point density with a greater separation distance between the bonding points provide a lower amount or degree of tensile resistance (e.g., allowing more stretching), and the regions of the chest support garment 100 having a bonding point density with a smaller separation distance between the bonding points provide a higher amount or degree of tensile resistance (e.g., allowing less stretching). That is, as Figure 4 shown, compared to the regions of the upper 110 having a second bonding point density 402 associated with a second separation distance D2 and a third bonding point density 404 associated with a third separation distance D3, the region of the upper 110 having a first bonding point density 400 associated with a first separation distance D1 provides less support and allows greater stretching. The region of the upper 110 having a second bonding point density 402 associated with a second separation distance D2 provides more support and allows less stretching than the region of the upper 110 having the first bonding point density 400, but provides less support and allows more stretching than the region of the upper 110 having a third bonding point density 404 associated with a third separation distance D3. With this arrangement, the regions of the upper 110 can be provided with an engineered support structure having different support levels determined by a specific bonding point matrix pattern applied between the layers (e.g., outer layer 300 and inner layer 302) of the upper 110.

[0051] Furthermore, by providing an engineered support structure between the layers (e.g., outer layer 300 and inner layer 302) forming the upper 110, a graduated stretch can be provided in a single material. That is, the stretchability of the outer layer 300 and / or the inner layer 302 can be selectively adjusted to achieve greater or less stretching in specific regions of the upper 110 without using different materials or textiles to form those regions of the upper 110. For example, in some embodiments, one of the outer layer 300 or the inner layer 302 can be made of a knitted material having a greater degree or amount of stretch. Applying the techniques of this embodiment for forming an engineered support structure, selected regions of the knitted material can have a greater amount of tensile resistance (e.g., exhibit less stretching) than the knitted material itself without the engineered support structure. In this way, the techniques of this embodiment allow additional tensile resistance to be provided to a fabric or textile.

[0052] Now referring to Figure 5, shows a process 500 for forming an engineered support structure on a shoe upper 110. In some embodiments, the process 500 can be implemented using an adhesive deposition printer that allows individual droplets or dots of adhesive to be directly deposited onto the surface of a fabric, such as the shoe upper 110, in a predetermined pattern. In this embodiment, the process 500 is implemented by an adhesive deposition printer 502 that includes a nozzle 504 that deposits droplets or dots 506 of adhesive at specific locations on a first face 308 of an inner layer 302.

[0053] The printer 502 can be pre-programmed to apply a predetermined pattern of adhesive dots to the shoe upper 110 to form an adhesive dot matrix pattern 312, as well as other adhesive dot matrix patterns, including but not limited to the adhesive dot matrix pattern 900 (as Figure 9 shown) and the adhesive dot matrix pattern 1000 (as Figure 10 shown). In an exemplary embodiment, each droplet or dot 506 of adhesive can have a predetermined volume. For example, the droplet or dot 506 of adhesive can have a volume of approximately 0.5 cubic millimeters. In other embodiments, the volume of each droplet or dot can vary. Additionally, in some embodiments, the size or volume of each droplet or dot 506 of adhesive can vary as described below to change or modify the support level of the area of the shoe upper where the adhesive dots are applied.

[0054] Figure 5 shows distributing adhesive dots in different regions of the shoe upper 110 by printing or deposition. However, those skilled in the art will understand that without departing from the scope of protection, the placement of the adhesive dots can be random, and the support level provided in each area will be defined by the size and / or density of the adhesive dots in that area. In one embodiment, multiple layers of adhesive dots can be printed or deposited one on top of the other.

[0055] As Figure 5 shown, the printer 502 deposits a plurality of adhesive dots 508 in a specific pattern on the first face 308 of the inner layer 302 in an area corresponding to one or more zones of the adhesive dot matrix pattern 312. Each of the plurality of adhesive dots 508 is spaced apart by a separation distance that can vary in different regions of the shoe upper 110 to provide an engineered support structure with zones having different support levels (i.e., different levels of tensile resistance). The process 500 can continue by using the printer 502 to cover all, substantially all, or most of the first face 308 of the inner layer 302 with adhesive dots having varying separation distances to form an engineered support structure with different support zones.

[0056] In one embodiment, the printer 502 may deposit a plurality of bonding points 508 in a specific first pattern on the first surface 308 of the inner layer 302 in a region corresponding to one or more zones of the bonding point matrix pattern (e.g., the bonding point matrix pattern 312). Then, the printer 502 may deposit a specific second pattern of a plurality of bonding points on top of the first pattern in another bonding point matrix pattern such that at least some of the bonding points in the second pattern at least partially overlap the bonding points of the first pattern (i.e., at least one bonding point in the second pattern is deposited on top of a bonding point of the first pattern below it) to form a multi-layer bonding point pattern.

[0057] In these embodiments, the first pattern applied in the first layer of the multi-layer bonding point matrix pattern may be the same as or different from the second pattern applied in the second layer of the multi-layer bonding point matrix pattern. The printer 502 may be pre-programmed to include a plurality of different bonding point matrix patterns of single-layer or multi-layer configurations. The multiple layers of the multi-layer bonding point matrix pattern may be aligned (one on top of the other) or offset from each other. In one implementation, a certain amount of time may be allowed for the first pattern of bonding points forming the first layer deposited on the first surface 308 of the inner layer 302 to cure before applying the second layer of bonding points in the second pattern.

[0058] In one implementation of the process 500, once the process 500 has been completed (e.g., the printer 502 has deposited a plurality of bonding points 508 or multiple layers of the multi-layer bonding point matrix pattern according to a predetermined dot matrix pattern), the material layers of the shoe upper 110 may be joined together by aligning and placing the opposing faces of the corresponding layers together to form the shoe upper 110. It should be understood that in one or more implementations of the process 500, the bonding point matrix pattern may be applied to different faces of the respective layers. For example, as shown here, the first surface 308 of the inner layer 302 may be joined to the inner surface 306 of the outer layer 300 such that the bonding point matrix pattern 312 is deposited between the outer layer 300 and the inner layer 302 to form the shoe upper 110 (as Figure 3 shown).

[0059] In other implementations, each droplet or point 506 of the bonding point matrix pattern may be deposited on either side or face of either of the two layers to be joined together by the bonding point matrix pattern. That is, for example, in Figure 3In the illustrated embodiment of the shoe upper 110, where the bond point matrix pattern 312 is located between the outer layer 300 and the inner layer 302, a process 500 can be used to apply the bond point matrix pattern 312 to the first face 308 of the inner layer 302 or the inner face 306 of the outer layer 300. Additionally, in the case of a multi-layer bond point matrix pattern, each layer of the bond point matrix pattern can be applied to either side or face of any one of the material layers forming the shoe upper (e.g., the shoe upper 110). It should be understood that the same principle applies to the various embodiments and implementations of the shoe uppers described herein, such that in the case where the bond point matrix pattern is disposed between two layers, the bond point matrix pattern can be applied to either or both of the two opposing faces.

[0060] Bond points (e.g., a plurality of bond points 508) arranged in a dot matrix pattern join two layers (e.g., the outer layer 300 and the inner layer 302) at positions corresponding to a pattern of droplets or dots of adhesive to form an engineered support structure between the outer layer 300 and the inner layer 302 of the shoe upper 110. At the locations where the adhesive is present, the outer layer 300 and the inner layer 302 are joined to each other, and relative movement of the layers at that location is restricted, thereby restricting stretching. By varying the separation distance between the discrete droplets or dots of adhesive that join the two layers, the amount or degree of tensile resistance can vary correspondingly. That is, in regions where the separation distance between the droplets or dots of adhesive is smaller (i.e., the droplets or dots of adhesive are spaced closer together), the tensile resistance in these regions will be greater (i.e., less stretching is allowed) to provide a greater amount of support. Conversely, in regions where the separation distance between the droplets or dots of adhesive is larger (i.e., the droplets or dots of adhesive are spaced farther apart), the tensile resistance in these regions will be smaller (i.e., more stretching is allowed) to provide a lesser amount of support.

[0061] Additionally, in some embodiments, the amount or degree of tensile resistance can also be varied by changing the size or volume of the bond points that form the bond point matrix pattern. For example, by using bond points of a first size that are larger than a second size, the larger-sized bond points join more material of the opposing layers together, thereby allowing less stretching in those regions where the bond point size is larger than in regions where the bond point size is smaller. In still other embodiments, the engineered support structure can utilize variations in the separation distance and bond point size to vary the support level (e.g., tensile resistance) in different regions of the shoe upper 110.

[0062] In one embodiment, each droplet or dot 506 of the bond point matrix pattern can have a circular or annular shape, e.g., as Figure 5As shown. In other embodiments, the shape or configuration of each droplet or dot of the adhesive point matrix pattern can be different, including but not limited to oval, line, dotted line, and other regular or irregular shapes. In some cases, the adhesive point matrix pattern may include droplets or dots having the same shape or configuration. In other cases, the adhesive point matrix pattern may include droplets or dots having different shapes and configurations throughout the pattern.

[0063] In some embodiments, the adhesive points of the adhesive point matrix pattern (e.g., adhesive point matrix pattern 312) forming the engineered support structure of the upper 110 can penetrate or permeate into the fabric or textile of the opposing layers (e.g., outer layer 300 and inner layer 302) forming the upper 110 to join or bond the opposing faces together. Now referring to Figure 6 , it is shown that the outer layer 300 and the inner layer 302 of the upper 110 are joined or bonded together by a plurality of adhesive points 600 arranged according to an adhesive point matrix pattern 312 having a first adhesive point density 400, a second adhesive point density 402, and a third adhesive point density 404, as described above. In an exemplary embodiment, the outer layer 300 includes an outer face 304 forming the outer surface of the upper 110, and when the article 100 is worn, the second face 310 of the inner layer 302 faces the wearer's foot within the upper 110.

[0064] As Figure 6 shown, a plurality of adhesive points 600 are joined or attached to the opposing faces of the outer layer 300 and the inner layer 302. In this embodiment, the plurality of adhesive points 600 are directly joined between the first face 308 of the inner layer 302 and the inner face 306 of the outer layer 300. That is, the plurality of adhesive points 600 are arranged in a thin layer between the opposing faces of the outer layer 300 and the inner layer 302. With this arrangement, the plurality of adhesive points 600 form an engineered support structure between the outer layer 300 and the inner layer 302 of the upper 110.

[0065] In this embodiment, the separation distance (e.g., first separation distance D1) between the plurality of adhesive points 600 having the first adhesive point density 400 is greater than the separation distance (e.g., second separation distance D2) between the plurality of adhesive points 600 having the second adhesive point density 402, and the separation distance (e.g., second separation distance D2) between the plurality of adhesive points 600 having the second adhesive point density 402 is greater than the separation distance (e.g., third separation distance D3) between the plurality of adhesive points 600 having the third adhesive point density 404.

[0066] In some embodiments, the arrangement of each bonding point in the bonding point matrix pattern (e.g., bonding point matrix pattern 312) can vary to provide four-way stretch or two-way stretch to a region of the upper 110. In an exemplary embodiment, four-way stretch or two-way stretch can be provided by varying the separation distance of the bonding points in one orientation within each region or zone of the bonding point density to allow for four-way stretch or two-way stretch. Figure 7A and Figure 7B Exemplary embodiments of bonding point arrangements that allow for four-way stretch and two-way stretch are shown. First, referring to Figure 7A , a schematic view of an exemplary embodiment of a bonding point matrix arrangement 700 that allows for four-way stretch is shown.

[0067] In this embodiment, the bonding point matrix arrangement 700 allows for four-way stretch such that the upper 110 can be stretched in a first longitudinal direction 702 and an opposite second longitudinal direction 704, as well as in a first transverse direction 706 and an opposite second transverse direction 708. For example, in one embodiment, the first longitudinal direction 702 and the second longitudinal direction 704 can be aligned or oriented along the longitudinal length of the upper 110 and the article 100 (e.g., from the toe end 116 to the heel end at the opposite end of the upper 110 and the article 100). Similarly, the first transverse direction 706 and the second transverse direction 708 can be aligned or oriented along the transverse width of the upper 110 and the article 100 (e.g., between the inner side 40 and the outer side 50). As Figure 7A shown, four-way stretch of the bonding point matrix arrangement 700 is provided by arranging the bonding points such that the longitudinal separation distance (D LONG ) is equal to the transverse separation distance (D LAT ).

[0068] That is, on each region of the upper 110 that requires four-way stretch, each bonding point among the plurality of bonding points in the zone forming the bonding point matrix pattern (e.g., bonding point matrix pattern 312) can have an equal separation distance (D LONG = D LAT ) from each adjacent or neighboring bonding point in both the longitudinal direction (702, 704) and the transverse direction (706, 708). Thus, the bonding point matrix arrangement 700 allows for four-way stretch such that the upper 110 can be stretched longitudinally and transversely.

[0069] Now referring to Figure 7B, a schematic diagram of an exemplary embodiment of a bonding point matrix arrangement 710 that allows biaxial stretching is shown. In this embodiment, the bonding point matrix arrangement 710 allows biaxial stretching, so that the upper 110 can stretch in a first lateral direction 706 and an opposite second lateral direction 708, but substantially constrains or prevents stretching in a first longitudinal direction 702 and an opposite second longitudinal direction 704. Figure 7B As shown, by arranging the bonding points so that the lateral separation distance (D LAT ) is greater than the longitudinal separation distance (D LONG ) (e.g., D LAT > D LONG ), to provide two-way stretching of the bonding point matrix arrangement 710.

[0070] Similarly, the bonding point matrix arrangement 710 can be configured to allow biaxial stretching, such that the upper 110 can stretch in the first longitudinal direction 702 and the opposite second longitudinal direction 704, but substantially restrain or prevent stretching in the first lateral direction 706 and the opposite second lateral direction 708 by arranging the bonding points in the bonding point matrix arrangement 710 such that the longitudinal separation distance (D LONG ) is greater than the horizontal separation distance (D LAT ) (e.g., D LONG > D LAT ), to achieve it.

[0071] That is, at each area of ​​the upper 110 that requires biaxial stretch, each of the plurality of bonding points forming a region of a bonding point matrix pattern (e.g., bonding point matrix pattern 312) may be stretched in the lateral direction (706, 708) (e.g., Figure 7B ) or longitudinal direction (702, 704) with each adjacent or neighboring bonding point having an unequal separation distance (D LAT > D LONG , or D LONG > D LAT ). By arranging the bonding points of the bonding point matrix pattern closer together in one direction, the fabric layers bonded together at locations closer to the arranged bonding points are restricted or prevented from stretching relative to each other in that direction. Thus, the bonding point matrix arrangement 710 allows for bidirectional stretching, such that the upper 110 can only stretch longitudinally or transversely.

[0072] Although the four-way stretch of the bonding point matrix arrangement 700 and the two-way stretch of the bonding point matrix arrangement 710 have been described relative to the longitudinal and transverse directions of the upper 110 and / or the article 100, it should be understood that similar arrangements may be provided to allow or restrict stretching relative to the upper 110 and / or the article 100 in other specific directions, e.g., diagonal or offset angles that are substantially misaligned with the longitudinal or transverse directions.

[0073] Figure 8 An exemplary embodiment of an upper having various regions with four-way or two-way stretch is shown. In this embodiment, the upper 110 is provided with different regions or zones having four-way and two-way stretch. For example, as Figure 8 shown, by arranging the bonding points of the bonding point matrix pattern 312 according to the bonding point matrix arrangement 710, a first region 800 may be provided with two-way stretch. By arranging the bonding points of the bonding point matrix pattern 312 according to the bonding point matrix arrangement 700, a second region 802 and a third region 804 may each be provided with four-way stretch. Additionally, in this embodiment, a fourth region 806 of the upper 110 may be provided with limited stretch or no stretch.

[0074] In this embodiment, the first region 800 is associated with the toe box in the toe region 10 of the upper 110. Providing two-way stretch in the first region 800 allows the toe box of the upper 110 to stretch laterally between the inner side 40 and the outer side 50, but the stretch in the longitudinal direction between the heel and the toe is restricted. In this embodiment, the second region 802 is associated with the inner side 40 in the midfoot region 20 and a portion of the toe region 10. Providing four-way stretch in the second region 802 allows the inner side 40 of the upper 110 to accommodate the movement of the wearer's foot during activity, such that the upper 110 can undergo both lateral and longitudinal stretch. In this embodiment, the third region 804 is associated with the region of the upper 110 that extends above the top of the wearer's foot. Providing four-way stretch in the third region 802 allows the portion of the upper 110 that covers the top of the wearer's foot to accommodate the movement of the wearer's foot during activity, such that the upper 110 can undergo both lateral and longitudinal stretch.

[0075] Furthermore, as Figure 8 shown, the fourth region 806 is associated with the outer side 50 that extends from the heel region 30 into the midfoot region 20 and wraps around the front of the upper 110 in the toe region 10. The fourth region 806 also includes a portion that extends laterally above the top of the foot between the first region 800 and the third region 804 in the toe region 10. By providing the fourth region 806 with limited stretch or no stretch, additional support can be provided to the upper 110 during activity.

[0076] In some embodiments, different engineered support structures can be provided by using different matrix patterns of adhesion points applied between layers of the upper, thereby providing zones of the upper with different levels of support. Figure 9 and Figure 10 Some alternative embodiments of matrix patterns of adhesion points that provide zones of different support levels to regions of the upper are shown.

[0077] Now referring Figure 9 , an alternative embodiment of a matrix pattern 900 of adhesion points for forming an engineered support structure of an upper 110 is shown. In this embodiment, the matrix pattern 900 of adhesion points includes three levels of adhesion point density (e.g., associated with different separation distances and / or adhesion point sizes) arranged in different regions of the upper 110 to provide zones with different support levels. As Figure 9 shown, the matrix pattern 900 of adhesion points includes a first adhesion point density 902, which is associated with the lowest adhesion point density having the greatest separation distance and / or the smallest adhesion point size to provide the lowest level of support. That is, the first adhesion point density 902 bonds opposing layers (e.g., Figure 3 the outer layer 300 and the inner layer 302 shown in such that the regions of the upper 110 having the first adhesion point density 902 provide the least amount of tensile resistance.

[0078] In this embodiment, the first adhesion point density 902 can be used in at least a central portion of the forefoot region 10 of the upper 110, in a region corresponding to the toe box of the article 100. The first adhesion point density 902 can also be used in regions along the front throat edge 118 and the heel portion 210 of the upper 110. With this arrangement, these regions of the upper 110 can be configured to allow the greatest amount of stretch (i.e., provide the least amount of tensile resistance).

[0079] The matrix pattern 900 of adhesion points further includes a second adhesion point density 904 associated with a lower adhesion point density, the separation distance of the second adhesion point density 904 being less than the separation distance of the first adhesion point density 902 (and / or the adhesion point size of the second adhesion point density 904 being greater than the adhesion point size of the first adhesion point density 902), thereby providing a support level greater than that provided by the first adhesion point density 902. That is, the second adhesion point density 904 bonds opposing layers (e.g., Figure 3 the outer layer 300 and the inner layer 302 shown in such that the regions of the upper 110 having the second adhesion point density 904 provide an amount or degree of tensile resistance greater than the amount or degree of tensile resistance provided by the first adhesion point density 902.

[0080] In this embodiment, the second bond point density 904 can be used in at least one region around the central portion of the shoe front region 10 of the shoe upper 110, the at least one region surrounding the region having the first bond point density 902 corresponding to the toe box of the article 100. As Figure 9 shown, the second bond point density 904 extends through at least a portion of the shoe front panel region 114 of the shoe upper 110, including extending to regions along the inner side edge 208 on the inner side 40 and the outer side edge 204 on the outer side 50.

[0081] The bond point matrix pattern 900 further includes a third bond point density 906 associated with a medium bond point density, the separation distance of the third bond point density 906 being less than the separation distances of the second bond point density 904 and the first bond point density 902 (and / or the bond point size of the third bond point density 906 being greater than the bond point sizes of the second bond point density 904 and the first bond point density 902), thereby providing a higher level of support than that provided by the second bond point density 904 and the first bond point density 902. That is, the third bond point density 906 bonds the opposing layers (e.g., Figure 3 the outer layer 300 and the inner layer 302 shown therein), such that the amount or degree of tensile resistance provided by the region of the shoe upper 110 having the third bond point density 906 is greater than the amount or degree of tensile resistance provided by the second bond point density 904 and the first bond point density 902.

[0082] In this embodiment, the third bond point density 906 can be used in at least the central portion of the shoe front panel region 114 and extends along the outer perimeter 200 around the front of the shoe upper 110, closer to the toe end 116 than the second bond point density 904 and the first bond point density 902. The third bond point density 906 can also be used at least in the region extending along the outer-to-inner edge 218 of the opening 112 and in the region above the heel portion 210 having the first bond point density 902. With this arrangement, the third bond point density 906 along the outer-to-inner edge 218 can limit the stretching around the opening 112 (i.e., a greater amount of tensile resistance) to keep the foot of the wearer of the article 100 fixed within the shoe upper 110.

[0083] Now referring to Figure 10 , another alternative embodiment of the bond point matrix pattern 1000 for forming the engineered support structure of the shoe upper 110 is shown. In this embodiment, the bond point matrix pattern 1000 includes four levels of bond point density (e.g., associated with different separation distances and / or bond point sizes) arranged in different regions of the shoe upper 110 to provide zones with different levels of support. As Figure 10As shown, the bonding point matrix pattern 1000 includes a first bonding point density 1002 that is associated with a minimum bonding point density having a maximum separation distance and / or a minimum bonding point size to provide a minimum level of support. That is, the first bonding point density 1002 bonds the opposing layers (e.g., Figure 3 the outer layer 300 and the inner layer 302 shown in

[0084] such that the area of the upper 110 having the first bonding point density 1002 provides the least tensile resistance. In this embodiment, the first bonding point density 1002 can be used in at least a central portion of the toe region 10 of the upper 110, which is located in the area corresponding to the toe box of the article 100. With this arrangement, this area of the upper 110 can be configured to allow the maximum amount of stretch (i.e., provide the least tensile resistance). Figure 3 The bonding point matrix pattern 1000 also includes a second bonding point density 1004 that is associated with a low bonding point density, and the separation distance of the second bonding point density 1004 is less than the separation distance of the first bonding point density 1002 (and / or the bonding point size of the second bonding point density 1004 is greater than the bonding point size of the first bonding point density 1002), thereby providing a higher level of support than that provided by the first bonding point density 1002. That is, the second bonding point density 1004 bonds the opposing layers (e.g.,

[0085] the outer layer 300 and the inner layer 302 shown in Figure 10 such that the area of the upper 110 having the second bonding point density 1004 provides a greater amount or degree of tensile resistance than that provided by the first bonding point density 1002.

[0086] The bonding point matrix pattern 1000 also includes a third bonding point density 1006 associated with a medium bonding point density, the separation distance of the third bonding point density 1006 being less than the separation distances of the second bonding point density 1004 and the first bonding point density 1002 (and / or the bonding point size of the third bonding point density 1006 being greater than the bonding point sizes of the second bonding point density 1004 and the first bonding point density 1002), thereby providing a support level greater than that provided by the second bonding point density 1004 and the first bonding point density 1002. That is, the third bonding point density 1006 bonds the opposing layers (e.g., Figure 3 the outer layer 300 and the inner layer 302 shown in

[0087] such that the amount or degree of tensile resistance provided by the region of the upper 110 having the third bonding point density 1006 is greater than the amount or degree of tensile resistance provided by the second bonding point density 1004 and the first bonding point density 1002.

[0088] In this embodiment, the third bonding point density 1006 may be used at least across a portion of the front panel region 114 of the upper that extends between the medial side 40 and the lateral side 50. The third bonding point density 1006 may also be used at least in a region that extends along the outer-to-inner edge 218 of the opening 112 and above the heel portion 210 having the second bonding point density 1004. With this arrangement, the third bonding point density 1006 along the outer-to-inner edge 218 can limit the stretching around the opening 112 (i.e., a greater amount of tensile resistance) to keep the foot of the wearer of the article 100 fixed within the upper 110. Figure 3 the outer layer 300 and the inner layer 302 shown in

[0089] In this embodiment, the fourth bond point density 1008 can be used in at least one region that extends along a majority of the outer perimeter 200 of the upper 110, including along the front edge extending from the front portion of the upper 110 and further along the outer side edge 204 on the outer side 50 in two directions (e.g., towards the inner side 40 and the outer side 50) to the heel portion 210 and along the inner side edge 208 on the inner side 40 to the second rear edge 214. The fourth bond point density 1008 can also be used in at least one region that extends around the front throat edge 118 at the opening 112. Additionally, the fourth bond point density 1008 can be used in the region extending from the heel portion 210 to the first rear edge 212. With this arrangement, the bond point matrix pattern 1000 forms an engineered support structure between the outer layer 300 and the inner layer 302 of the upper 110 for providing an improved fit and feel for the article 100.

[0090] This embodiment has been described herein with reference to the upper 110 of the article 100, which has two layers and has an engineered support structure formed by a bond point matrix pattern disposed between the two layers. In other embodiments, an upper having a different number of layers can be provided, and the different number of layers can be joined or bonded using one or more bond point matrix patterns according to the techniques described herein. For example, the bond point matrix pattern or a multi-layer bond point matrix pattern can be applied between one or more pairs of adjacent layers of a multi-layer upper formed of any number of layers using the techniques described herein.

[0091] Furthermore, in some embodiments, the techniques described herein for applying a bond point matrix pattern between the layers of an upper can be further used as a method for customizing the internal fit between the inner lining and the upper of a footwear article for a wearer's foot. For example, the bond point matrix pattern can be applied to the inner surface of the material forming the upper (i.e., facing inwards towards the internal cavity of the footwear article) and / or to the outer surface of the lining material within the internal cavity of the footwear article (i.e., facing outwards away from the interior).

[0092] In such an embodiment, the bond points of the bond point matrix pattern can be made of an adhesive material that is not activated during the footwear manufacturing process so as to remain unbonded to the adjacent layer in which the bond point matrix pattern is located. After the footwear article has been constructed, a custom foot form (i.e., customized for the wearer's foot) can be inserted into the interior cavity of the footwear article, and the footwear article with the custom foot form inside can be further heated and pressed in a separate process. This second heating and pressing process will activate the adhesive material of the bond point matrix pattern to bond the adjacent layers together, e.g., to bond the material forming the upper and the lining material only in the areas where they contact each other. This customization process creates a form-fitting inner lining for the footwear article and can also provide an engineered support structure for areas of the upper and the footwear article where the wearer's foot may have a greater circumference than a footwear article of a general or conventional shape.

[0093] In some embodiments, an additional lining layer can be provided between the bond point matrix pattern and the opposing layer so as to define a recess or void between the layers. In these embodiments, the additional lining layer can be smaller than each of the opposing layers. For example, by adding an additional lining layer between the opposing layers, the bond point matrix pattern will bond the opposing layers at the area surrounding the lining layer, but the lining layer will prevent a portion of one of the opposing layers from bonding to the other.

[0094] For example, referring again to Figure 3 , an additional lining layer formed of a textile material can be disposed between layer 300 and the bond point matrix pattern 312, and / or between the inner layer 310 and the bond point matrix pattern 312. At the location corresponding to this additional lining layer, the bond point matrix pattern 312 will bond or join layer 300 to the additional lining layer, while the inner layer 310 remains unattached to layer 300 or the additional lining layer at this location. Thus, a recess or void can be formed between one face of the additional lining layer and the first face 308 of the inner layer 302. Similarly, if the additional lining layer is located between the bond point matrix pattern 312 and the inner layer 302, at the location corresponding to this additional lining layer, the bond point matrix pattern 312 will bond or join the inner layer 302 to the additional lining layer, while layer 300 remains unattached to the inner layer 310 or the additional lining layer at this location. Thus, a recess or void can be formed between one face of the additional lining layer and the inner face 306 of layer 300.

[0095] The cavities or voids between the layers of the shoe upper can also be formed in another way. In some embodiments, one or more regions of the bonding point matrix pattern may be substantially free of bonding points so as to define regions where the opposing layers are not joined or attached to each other through the bonding point matrix pattern. For example, by leaving regions of the bonding point matrix pattern substantially free of bonding points, the layers of the shoe upper can remain unattached in those regions to form cavities or voids between the layers forming the shoe upper.

[0096] For example, referring again to Figure 3 , at least one region of the bonding point matrix pattern 312 may be substantially free of bonding points. Thus, when the layer 300 of the shoe upper 110 is joined to the inner layer 302 through the bonding point matrix pattern 312, at least one region of the bonding point matrix pattern 312 that is substantially free of bonding points will form a void or cavity between the layer 300 and the inner layer 302. That is, while the bonding point matrix pattern 312 joins or bonds the first face 308 of the inner layer 302 to the inner face 306 of the outer layer 300 at the regions where the bonding point matrix pattern 312 includes bonding points, at least one region that is substantially free of bonding points will keep the first face 308 of the inner layer 302 unattached to the inner face 306 of the outer layer 300.

[0097] By providing one or more regions of the bonding point matrix pattern that are substantially free of bonding points, voids or cavities can be formed between the layers of the shoe upper at different parts of the shoe upper. For example, the cavities can be formed in this way along one or both of the inner and outer sides of the shoe upper (e.g., the inner side 40 and / or the outer side 50 of the shoe upper 110). The cavities can also be formed at other positions on the shoe upper, including but not limited to parts of the front region 10 and / or the heel region 30 of the shoe. In some cases, the cavities formed in the heel region 30 in this way can have a rigid support member inserted into the cavities to provide additional rigidity to the shoe upper and thus support for the wearer's heel.

[0098] In some embodiments, the cavities or voids formed between the layers forming the shoe upper in this way can include spacer fabric and / or spacer yarn within the cavities or voids. In this way, the spacer fabric or spacer yarn can provide a substantially three-dimensional structure to the regions of the shoe upper. With such an arrangement, the cavities or voids including the spacer fabric or spacer yarn disposed within the cavities or voids between the layers of the shoe upper can provide cushioning or padding to the regions of the shoe upper. For example, the regions of the shoe upper that surround the wearer's ankle or heel can be provided with spacer fabric or spacer yarn within the cavities or voids in the shoe upper to provide additional cushioning or padding for the wearer's ankle or heel when wearing a footwear product including the shoe upper. It should be understood that the spacer fabric or spacer yarn can be disposed within the cavities or voids located in other regions of the shoe upper.

[0099] In addition, in some embodiments, as described above, spacer yarns disposed within voids or cavities between layers of the upper can be fixed or fused together using a matrix pattern of bonding points to form regions having different amounts or degrees of tensile resistance. For example, the fused regions of the spacer yarns can be varied by varying or changing the density of the bonding points or the size of the bonding points in the matrix pattern of bonding points in the regions where the fused regions are desired to be produced.

[0100] Although various embodiments of the present disclosure have been described, the description is intended to be exemplary and not restrictive, and it will be apparent to those of ordinary skill in the art that more embodiments and implementations within the scope of the present disclosure are possible. Accordingly, the present disclosure is not limited except as by the appended claims and their equivalents. Moreover, various modifications and changes can be made within the scope of the appended claims.

Claims

1. An upper for a footwear product having an engineered support structure, comprising: a first layer; a second layer; an engineered support structure including a matrix pattern of bond points disposed between the first layer and the second layer, wherein the engineered support structure includes at least one first zone and at least one second zone, the at least one first zone having a first support level defined by a first bond point density or a first bond point size in the bond point matrix pattern, the at least one second zone having a second support level defined by a second bond point density or a second bond point size in the bond point matrix pattern, the first support level being different from the second support level.

2. The upper according to claim 1, wherein, the first layer forms at least a part of the exterior of the upper; and wherein the second layer forms at least a part of the interior of the upper.

3. The upper according to claim 1, wherein, the first support level is greater than the second support level.

4. The upper according to claim 1, further comprising: at least one area having four-way stretch; and at least one area having two-way stretch.

5. The upper according to claim 4, wherein, the at least one area having four-way stretch includes a bond point matrix arrangement of a part of the bond point matrix pattern, wherein the bond points are separated from adjacent bond points by a separation distance, the separation distance being equal in the transverse direction and the longitudinal direction.

6. The upper according to claim 4, wherein, the at least one area having two-way stretch includes a bond point matrix arrangement of a part of the bond point matrix pattern, wherein the separation distance between the bond points and adjacent bond points is different in the transverse direction from that in the longitudinal direction.

7. The upper according to claim 1, wherein, the engineered support structure includes at least one third zone having a third support level defined by a third bond point density or a third bond point size in the bond point matrix pattern.

8. The upper according to claim 7, wherein, the third support level is greater than both the first support level and the second support level.

9. The upper according to claim 1, wherein, the upper is configured to engage with a sole assembly to form a footwear product.

10. A method of forming an upper having an engineered support structure, comprising: providing a first layer of the upper, the first layer of the upper having an inner surface and an opposite outer surface; providing a second layer of the upper, the second layer of the upper having a first surface and an opposite second surface; and depositing a plurality of bond points onto one of the inner surface of the first layer or the first surface of the second layer according to a bond point matrix pattern to form the engineered support structure; Wherein, the engineered support structure includes at least one first zone and at least one second zone, the at least one first zone having a first support level defined by a first bond point density or a first bond point size in the bond point matrix pattern, the at least one second zone having a second support level defined by a second bond point density or a second bond point size in the bond point matrix pattern, and the first support level being different from the second support level.

11. The method according to claim 10, wherein, the first layer forms at least a part of the exterior of the shoe upper, and wherein the second layer forms at least a part of the interior of the shoe upper, and the method further includes: bonding an inner layer to an outer layer, wherein the bond point matrix pattern bonds the inner layer and the outer layer together.

12. The method according to claim 10, wherein, the first support level is greater than the second support level.

13. The method according to claim 10, further includes: providing at least one region of the shoe upper with four-way stretch; and providing at least one region of the shoe upper with two-way stretch.

14. The method according to claim 13, wherein, providing the at least one region with four-way stretch includes depositing the plurality of bond points in a bond point matrix arrangement, wherein the bond points are separated from adjacent bond points by a separation distance, and the separation distance is equal in the transverse direction and the longitudinal direction.

15. The method according to claim 13, wherein, providing the at least one region with two-way stretch includes depositing the plurality of bond points in a bond point matrix arrangement, wherein the separation distance of the bond points from adjacent bond points in the transverse direction is different from the separation distance in the longitudinal direction.

16. The method according to claim 10, wherein, the engineered support structure further includes at least one third zone having a third support level defined by a third bond point density or a third bond point size in the bond point matrix pattern.

17. The method according to claim 16, wherein, the third support level is greater than both the first support level and the second support level.

18. The method according to claim 10, further includes: attaching the shoe upper to a sole assembly to form a footwear article.

19. An engineered support structure for a shoe upper, comprising: a plurality of bond points deposited onto a face of a layer of the shoe upper according to a bond point matrix pattern; wherein, the bond point matrix pattern provides the engineered support structure with at least one first zone and at least one second zone, the at least one first zone having a first support level defined by a first bond point density or a first bond point size in the bond point matrix pattern, the at least one second zone having a second support level defined by a second bond point density or a second bond point size in the bond point matrix pattern, and the first support level being different from the second support level.

20. The engineered support structure according to claim 19, wherein, the shoe upper includes at least a first layer and a second layer; and Wherein, the engineering support structure is disposed between the first layer and the second layer and joins opposite surfaces of the first layer and the second layer.

21. The engineering support structure according to claim 20, wherein, at least one region of the adhesive dot matrix pattern is substantially free of adhesive dots; and wherein the first layer and the second layer are held non - attached to each other at positions corresponding to the at least one region that is substantially free of adhesive dots so as to form a void between the first layer and the second layer at those positions.

22. The engineering support structure according to claim 20, further comprising an additional layer disposed between the first layer and the second layer, wherein, the adhesive dot matrix pattern joins the additional lining layer to one of the first layer or the second layer and forms a void between the additional lining layer and one of the second layer or the first layer.

23. The shoe upper according to claim 1, further comprising an additional lining layer disposed between the first layer and the second layer, wherein, the adhesive dot matrix pattern joins the additional lining layer to one of the first layer or the second layer and forms a void between the additional lining layer and one of the second layer or the first layer.

24. The shoe upper according to claim 1, wherein, the adhesive dot matrix pattern includes at least one region that is substantially free of adhesive dots; and wherein the first layer and the second layer are held non - attached to each other at positions corresponding to the at least one region that is substantially free of adhesive dots so as to form a void between the first layer and the second layer at those positions.

25. The method according to claim 10, further comprising forming a void between the first layer and the second layer of the shoe upper in at least one region of the shoe upper.

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