Uppers for articles of footwear
Patent Information
- Authority / Receiving Office
- WO · WO
- Patent Type
- Applications
- Current Assignee / Owner
- LULULEMON ATHLETICA CANADA INC
- Filing Date
- 2026-01-30
- Publication Date
- 2026-08-06
Smart Images

Figure CA2026050144_06082026_PF_FP_ABST
Abstract
Description
[0001] UPPERS FOR ARTICLES OF FOOTWEAR
[0002] CROSS-REFERENCES
[0003] This application claims the benefit of U.S. Provisional Patent Application Serial No.
[0004] 63 / 751,457 entitled FLOCKED UPPER, filed January 30, 2025, which is hereby incorporated by reference herein in its entirety. However, such material is only incorporated to the extent that no conflict exists between the incorporated material and the statements and drawings set forth herein. In the event of any such conflict, including any conflict in terminology, the present disclosure is controlling.
[0005] FIELD
[0006] This disclosure relates to systems and methods for footwear. More specifically, the disclosed embodiments relate to uppers for articles of footwear.
[0007] INTRODUCTION
[0008] Uppers for articles of footwear both contain the foot within the article of footwear and insulate the foot from the environment. Uppers for articles of footwear constructed for athletic activities, such as running, dancing, cycling, and / or the like must both cushion the foot and facilitate the flow of air and water vapor through the upper. Accordingly, uppers that provide comfort in the form of ventilation and / or cushioning to the foot of a wearer while providing minimal material between the foot and the environment are needed.
[0009] SUMMARY
[0010] The present disclosure provides systems, apparatuses, and methods relating to uppers for articles of footwear, and to articles of footwear comprising the uppers.
[0011] In accordance with various embodiments, the uppers for articles of apparel described herein include a lining fabric having a plurality of plush areas. In accordance with various embodiments, each plush area of the plurality of plush areas comprises a plurality of exposed fibers affixed to and standing proud of a lining fabric base fabricstructure. In accordance with various embodiments, each plush area of the plurality of plush areas is separated from other of the plurality of plush areas by a ground area. In accordance with various embodiments, the ground area comprises or consists of the lining fabric base fabric structure, and is a portion of the lining fabric base fabric structure free of the exposed fibers standing proud of the lining fabric base fabric structure. In accordance with various embodiments, due to the presence of the exposed fibers standing proud of the lining fabric base fabric structure in each of the plurality of plush areas and the absence of the exposed fibers standing proud of the lining fabric base fabric structure in the ground area, a lining fabric average thickness in each plush area is greater than in the ground area.
[0012] In some examples, an article of footwear comprises: an upper and a sole structure affixed to the upper, wherein the upper comprises: a face fabric having a face fabric front side and a face fabric back side opposite the face fabric front side, wherein an outermost front surface of the upper includes an exposed face region defined by the face fabric front side, and the exposed face region forms an externally-facing outermost front surface of the upper; and a lining fabric having a lining fabric front side and a lining fabric back side opposite the lining fabric front side, wherein a portion of the lining fabric back side defines an outermost back surface of the upper and defines a foot-receiving cavity of the article of footwear; wherein the lining fabric includes a plurality of plush areas, a ground area, and a base fabric structure integrally connecting the plurality of plush areas and the ground area, wherein the plurality of plush areas and the ground area form a pattern on the lining fabric; wherein each plush area is separated from others of the plurality of plush areas by the ground area, and each plush area comprises a plurality of exposed fibers affixed to and standing proud of the lining fabric base fabric structure on at least one of the lining fabric front side and the lining fabric back side; wherein the ground area is free of the plurality of exposed fibers standing proud of the base fabric structure and is air permeable; wherein an average thickness of the lining fabric in each plush area is greater than an average thickness of the lining fabric in the ground area; and wherein the base fabric structure is a knitted or woven structure including a ground area yarn; wherein, in the upper, the lining fabric front side is positioned below and in contact with the face fabric back side, an exposed back region of the upper is defined by the lining fabric back side,the exposed back region defines at least an outermost back surface of the upper, and the exposed back region defines the foot-receiving cavity of an article of footwear; an exposed front region of the upper is defined by the face fabric front side, the exposed front region defines the outermost front surface of the upper; and the exposed back region and the exposed front region align in an exposed structure region of the upper, wherein the exposed structure region includes the pattern, and the pattern is configured to allow air to flow between the foot-receiving cavity and the outermost front surface of the upper.
[0013] Features, functions, and advantages may be achieved independently in various embodiments of the present disclosure, or may be combined in yet other embodiments, further details of which can be seen with reference to the following description and drawings.
[0014] BRIEF DESCRIPTION OF THE DRAWINGS
[0015] Fig. 1 is a schematic side view of an illustrative article of footwear including a upper for an article of footwear in accordance with aspects of the present disclosure.
[0016] Fig. 2 is a schematic top view of a upper suitable for inclusion in the article of footwear of Fig. 1, depicted in a flat (i.e., unlasted) configuration.
[0017] Fig. 3 is a first schematic sectional view of an example of the upper of Fig. 2, depicting the lining fabric, the face fabric, and associated plush areas.
[0018] Fig. 4 is a detail view of an illustrative plush area of the upper of Fig. 2.
[0019] Fig. 5 is a second schematic sectional view of an example of the upper of Fig. 2, depicting the lining and face fabric coupled to reinforcements, bonded layers, and additional textiles.
[0020] Fig. 6 is a top plan view of a first illustrative upper, depicted in a flat configuration. Fig. 7 is a bottom plan view of the first illustrative upper of Fig. 6.
[0021] Fig. 8 is a top plan view of a lining layer suitable for use in the first illustrative upper of Fig. 6.
[0022] Fig. 9 is a bottom plan view of the lining layer of Fig. 6.
[0023] Fig. 10 is a top plan view of a face layer suitable for use in the first illustrative upper of Fig. 6.Fig. 11 is a lateral side elevation view of the illustrative article of footwear of Fig.
[0024] 1.
[0025] Fig. 12 is a medial side elevation view of the illustrative article of footwear of Fig. 1. Fig. 13 is a top plan view of the illustrative article of footwear of Fig. 1.
[0026] Fig. 14 is an anterior elevation view of the illustrative article of footwear of Fig. 1. Fig. 15 is a posterior elevation view of the illustrative article of footwear of Fig. 1. Fig. 16 is a schematic sectional view of the illustrative article of footwear of Fig. 1. Fig. 17 is a schematic side view of an illustrative article of footwear including an upper in accordance with aspects of the present disclosure.
[0027] Fig. 18 is a schematic top view of an upper suitable for inclusion in the article of footwear of Fig. 17, depicted in a flat (i.e. , unlasted) configuration.
[0028] Fig. 19 is a schematic sectional view of the upper of Fig. 14.
[0029] Fig. 20 is a flow chart depicting steps of an illustrative method for manufacturing an article of footwear including an upper according to the present teachings.
[0030] DETAILED DESCRIPTION
[0031] Various aspects and examples of uppers for articles of footwear, as well as related methods, are described below and illustrated in the associated drawings. Unless otherwise specified, an upper in accordance with the present teachings, and / or its various components, may contain at least one of the structures, components, functionalities, and / or variations described, illustrated, and / or incorporated herein. Furthermore, unless specifically excluded, the process steps, structures, components, functionalities, and / or variations described, illustrated, and / or incorporated herein in connection with the present teachings may be included in other similar devices and methods, including being interchangeable between disclosed embodiments. The following description of various examples is merely illustrative in nature and is in no way intended to limit the disclosure, its application, or uses. Additionally, the advantages provided by the examples and embodiments described below are illustrative in nature and not all examples and embodiments provide the same advantages or the same degree of advantages.
[0032] This Detailed Description includes the following sections, which follow immediately below: (1) Definitions; (2) Overview; (3) Examples, Components, and Alternatives; (4)Advantages, Features, and Benefits; and (5) Conclusion. The Examples, Components, and Alternatives section is further divided into subsections, each of which is labeled accordingly.
[0033] Definitions
[0034] The following definitions apply herein, unless otherwise indicated.
[0035] “Comprising,” “including,” and “having” (and conjugations thereof) are used interchangeably to mean including but not necessarily limited to, and are open-ended terms not intended to exclude additional, unrecited elements or method steps.
[0036] Terms such as “first”, “second”, and “third” are used to distinguish or identify various members of a group, or the like, and are not intended to show serial or numerical limitation.
[0037] “AKA” means “also known as,” and may be used to indicate an alternative or corresponding term for a given element or elements.
[0038] “Elongate” or “elongated” refers to an object or aperture that has a length greater than its own width, although the width need not be uniform. For example, an elongate slot may be elliptical or stadium-shaped, and an elongate candlestick may have a height greater than its tapering diameter. As a negative example, a circular aperture would not be considered an elongate aperture.
[0039] The terms “medial,” “lateral,” “anterior,” “posterior,” “dorsal,” “plantar,” and the like are intended to refer to anatomical directions corresponding to a human foot. For example, “medial refers to a relative position disposed toward the center of the human body, while “lateral” refers to a relative position disposed away from the center of the human body. “Anterior” refers to a relative position closer to the toe of a wearer and “posterior” refers to a relative position closer to the heel of the wearer. “Dorsal” refers to a relative position closer to the top of a wearer’s foot and “plantar” refers to a relative position closer to the sole of a wearer’s foot. In the absence of a wearer, the same directional terms may be used as if the article of footwear is being worn in its expected configuration.
[0040] “Coupled” means connected, either permanently or releasably, whether directly or indirectly through intervening components.“Resilient” describes a material or structure configured to respond to normal operating loads (e.g., when compressed) by deforming elastically and returning to an original shape or position when unloaded.
[0041] “Rigid” describes a material or structure configured to be stiff, non-deformable, or substantially lacking in flexibility under normal operating conditions.
[0042] “Elastic” describes a material or structure configured to spontaneously resume its former shape after being stretched or expanded along at least one dimension by a factor of the at least one dimension. For example, “elastic” may describe a material or structure configured to spontaneously resume its former shape after being stretched or expanded by 200 percent.
[0043] Directional terms such as “up,” “down,” “vertical,” “horizontal,” and the like should be understood in the context of the particular object in question. For example, an object may be oriented around defined X, Y, and Z axes. In those examples, the X-Y plane will define horizontal, with up being defined as the positive Z direction and down being defined as the negative Z direction.
[0044] “Providing,” in the context of a method, may include receiving, obtaining, purchasing, manufacturing, generating, processing, preprocessing, and / or the like, such that the object or material provided is in a state and configuration for other steps to be carried out.
[0045] “Engineered fabric,” as used herein, refers to a fabric including two or more zones, each of which differs from the other zones based on at least one physical property of the fabric within the zone (e.g., a fabric weight, a level of stretch, a level of air permeability, a level of water resistance, a level of moisture regain, a level of durability, etc.) or based on types of materials present in the zone (e.g., different sizes and / or types of staple fibers, filaments, and / or yams), or based on both at least one physical property of the fabric within the zone and the types of materials present in the zone. In an engineered fabric, the positioning of each zone within the fabric is pre-determined. For example, an engineered fabric may be a knitted or woven fabric engineered (e.g., pre-determined, designed, configured, etc.) to have a specific use (e.g., as part of an upper for an article of footwear). In some examples, the two or more zones are configured to form different regions of an upper for an article of footwear (e.g., a toe region, a heel region, a medialregion, a lateral region, etc.) and provide properties and / or materials appropriate for the respective regions. In contrast, properties of a conventional fabric may simply vary across one or both sides of the fabric, without the zones of variation intended to correspond to a particular zone of a secondary article (such as an upper, garment, bag, and / or any other suitable soft good) in which the fabric will be used.
[0046] “Monofilament,” as used herein, may refer to yams comprising a single filament, in some examples, a single untwisted filament.
[0047] “Multifilament,” as used herein, may refer to yams comprising multiple filaments. In some examples, the multiple filaments may be bonded and / or twisted together.
[0048] In this disclosure, one or more publications, patents, and / or patent applications may be incorporated by reference. However, such material is only incorporated to the extent that no conflict exists between the incorporated material and the statements and drawings set forth herein. In the event of any such conflict, including any conflict in terminology, the present disclosure is controlling.
[0049] Overview
[0050] In general, an upper for an article of footwear in accordance with the present teachings includes a fabric having a plurality of plush areas separated by a ground area. Each plush area of the plurality of plush areas comprises a plurality of exposed fibers affixed to and standing proud of a base fabric structure, and the ground area comprises a portion of the base fabric structure which is free of the exposed fibers standing proud of the base fabric structure, meaning that the exposed fibers extend out from the base fabric structure, thereby increasing a thickness of the fabric. In one aspect, the exposed fibers comprise cut or uncut loops of fibers, filaments or yam, and extend out from the base fabric structure in a direction that is substantially perpendicular to the base fabric structure. The ground area separating an individual plush area from other plush areas of the plurality of plush areas may fully surround the individual plush area. In one aspect, the ground area may separate and fully surround each plush area of the plurality of plush areas, acting as an interconnecting “sea” separating and surrounding each plush area “island”. As the base fabric structure does not include the exposed fibers standing proud of the base fabric structure, the ground area is more air permeable than the plush areas.The lining fabric has a lining fabric front side and a lining fabric back side opposite the lining fabric front side. The ground area of the fabric may be configured to provide airflow and ventilation between the sides of the fabric. The plurality of plush areas may be on a front side of the fabric or may be on a back side of the fabric or may be on both the front side and the back side of the fabric. As the exposed fibers stand proud of the base fabric structure on the fabric front side, or on the fabric back side, or on both the fabric front side and the fabric back side, the average fabric thickness in a plush area is greater than the average fabric thickness in the ground area. In some aspects, the plurality of plush areas separated by the ground area may form a pattern, and the pattern may repeat across the fabric. In some aspects, a distribution of the plurality of plush areas throughout the fabric may be substantially irregular, with no repeating pattern. In the upper, the fabric may be a lining fabric defining at least a portion of an outermost back surface of the upper. In some examples, the pattern is configured to allow air to flow between the foot-receiving cavity and the outermost front surface of the upper.
[0051] In some aspects, the upper may further comprise a face fabric overlaying at least a portion of, or substantially all of, the lining fabric. Over much of the surface area of the upper, the face fabric may be substantially uncoated and / or free of plush areas, such that the majority of the face fabric is permeable to air, heat, and water vapor. The face fabric has a face fabric front side and a face fabric back side opposite the face fabric front side. An outermost front surface of the upper may include an exposed face region defined by the face fabric front side. An outermost front surface of the upper including the exposed face region is configured to form an externally-facing outermost front surface of the upper when the upper is in a finished article of footwear. The lining fabric front side is positioned below the face fabric back side and at least a portion of the lining fabric front side is in direct contact with the face fabric back side in an exposed back region of the upper defined by the lining fabric. The exposed back region defines at least an outermost back surface of the upper, and the outermost back surface of the upper including the exposed back region is configured to define a foot-receiving cavity when the upper is in a finished article of footwear.
[0052] When the fabric is a lining fabric, the plurality of plush areas and the ground area may be present in at least the exposed back region of the upper, meaning that, on thelining fabric back side, each plush area of the lining fabric is separated by the ground area. Each plush area on the lining fabric back side includes the plurality of exposed fibers affixed to and standing proud of the lining fabric base fabric structure, while the ground area is free of the exposed fibers standing proud of the lining fabric base fabric structure. The lack of the exposed fibers standing proud in the ground area allows air, heat, and water vapor to pass through the lining fabric. The plush areas including exposed fibers standing proud of the lining fabric base fabric structure on the lining fabric back side may be configured to act as a lining defining a foot-receiving cavity and may be configured to contact and cushion a foot of a wearer during wear of an article of footwear comprising the upper. In other words, the plush areas on the lining fabric back side define a footcontacting surface on the outermost back side of the upper. In contrast, the ground area of the lining fabric is configured to be permeable to air, heat, and water vapor, and to ventilate the foot of a wearer when the upper is worn. When the upper includes a face fabric, for at least a portion of the surface area of the upper, including a portion in which the lining fabric front side is in direct contact with the face fabric back side, both the face fabric and the lining fabric may be substantially free from thermoplastic or thermoset polymer coatings or films, as the presence of a polymer coating or film would reduce transmission ventilation of the upper. The face fabric may also comprise a plurality of face fabric plush areas separated by a face fabric ground area on the face fabric front side, the face fabric back side, or both the face fabric front side and the face fabric back side. Either or both of the face fabric and the lining fabric may comprise monofilament yams and / or multifilament yams, or may consist of monofilament yams and / or multifilament yams.
[0053] In one aspect, the lining fabric includes the plurality of plush areas separated by the ground area on at least the lining fabric front side, meaning that, on the lining fabric front side, each plush area of the lining fabric is separated by the ground area. Each plush area on the lining fabric front side includes the plurality of exposed fibers affixed to and standing proud of the lining fabric front fabric structure, while the ground area is free of the exposed fibers standing proud of the lining fabric front fabric structure. The lack of the exposed fibers standing proud in the ground area allows air, heat, and water vapor to pass through the lining fabric. The plush areas including exposed fibers standing proudof the lining fabric face fabric structure on the lining fabric back side may be configured to act as insulation within the upper and to insulate a foot of a wearer in the foot-receiving cavity during wear of an article of footwear comprising the upper, while the ground area of the lining fabric is configured to be permeable to air, heat, and water vapor, and to ventilate the foot of a wearer when the upper is worn. The plush areas on the lining fabric front side may be configured to increase durability of the upper by reducing friction between the lining fabric and the face fabric, and by increasing an overall thickness of the upper. When the upper includes a face fabric, for at least a portion of the surface area of the upper, including a portion in which the lining fabric front side is in direct contact with the face fabric back side, both the face fabric and the lining fabric may be substantially free from thermoplastic or thermoset polymer coatings or films, as the presence of a polymer coating or film would reduce transmission ventilation of the upper. The face fabric may also comprise a plurality of face fabric plush areas separated by a face fabric ground area on the face fabric front side, the face fabric back side, or both the face fabric front side and the face fabric back side. In some aspects, either or both of the face fabric and the lining fabric comprise or consist of monofilament yams or multifilament yams or both monofilament yams and multifilament yams.
[0054] In one aspect, the lining fabric defines at least a portion of a footbed of the upper, such the footbed of the upper is substantially continuous with the lining fabric. In some examples, at least one plush area of the plurality of plush areas of the lining fabric is configured to be disposed beneath the foot of a wearer when an article of footwear including the upper is worn. In these examples, the at least one plush area may be configured to cushion the sole of the foot of the wearer, while adjacent ground areas of the lining fabric may be configured to facilitate airflow to the sole of the foot of the wearer.
[0055] In one aspect, the lining fabric is configured to contact a foot of a wearer when the foot of the wearer is in the cavity of the upper. The lining fabric may include the plurality of plush areas separated by the ground area on the lining fabric front side or on the lining fabric back side. The plush areas may be configured to contact the foot of a wearer and to provide cushioning and / or comfort during wear. When the upper includes a lining fabric and a face fabric, the upper may include at least one exposed structure region. The at least one exposed structure region of the upper comprises the face fabric and the liningfabric. More specifically, the exposed back region of the upper defined by the lining fabric and the exposed front region of the upper defined by the face fabric align in the exposed structure region. In the exposed structure region, the face fabric and the lining fabric may be freely movable with respect to each other.
[0056] The at least one exposed structure region may consist of the face fabric and the lining fabric, meaning that at least a portion of the upper consists only of the face fabric and the lining fabric, without any additional components bonded to or extending over the front side of the face fabric or the back side of the lining fabric, and without any additional components between the back side of the face fabric and the front side of the lining fabric. In this aspect, the portion of the lining fabric in the exposed structure region may include the lining fabric plush areas and ground area on the front side of the lining fabric or on the back side of the lining fabric or on both the front side and the back side of the lining fabric. Accordingly, the at least one exposed structure region may consist of the following components: the face fabric, which is uncoated on either a front side or a back side of the face fabric but which may include a plurality of face fabric plush areas separated by a face fabric ground area on the face fabric front side and / or on the face fabric back side, and the lining fabric, which is uncoated on the lining fabric front side and the lining fabric back side, and which includes a plurality of lining fabric plush areas separated by a lining fabric ground area on the lining fabric front side or on the lining fabric back side. When, in the at least one exposed structure region, both the lining fabric and the face fabric are free of a continuous coating, the lack of a continuous coating prevents the upper from forming a heat and / or moisture barrier, trapping heat and water vapor within the footreceiving cavity of the upper. In this aspect, due to the presence of only the two fabric layers including their plush areas and ground areas in the at least one exposed structure region, the exposed structure region is a highly breathable region of the upper, as heat and water vapor readily pass through the lining fabric and through the face fabric to the external environment.
[0057] The uppers according to the present teachings are very light when compared with conventional uppers. The plush areas on the lining fabric back side may provide the cushion and comfort of a lining without the need to add additional fabric or coating layers. The plush areas on the lining fabric front side may provide insulation and / or durability tothe upper without the need to add additional fabric or coating layers. When present, the face fabric may provide a durable external surface to the upper, without affecting comfort due to the presence of the lining fabric. The uppers according to the present teachings may have increased durability, reduced weight, and improved breathability when compared with conventional uppers.
[0058] In one aspect, the face fabric and the lining fabric are coupled together at portions of peripheral edges of the face fabric and the lining fabric. In other words, the face fabric and the lining fabric are substantially free-floating except at portions of the peripheral edges of the face fabric and the lining fabric are coupled together. When the face fabric and the lining fabric are free-floating and freely movable with respect to each other in the exposed structure region, the face fabric and lining fabric may shift relative to each other when the article of footwear is worn, increasing comfort for the wearer while also providing stability and lock-down to the upper.
[0059] When the face fabric is present, at least a portion of a front side of the face fabric forms an outermost front surface of the upper, which is configured to function as the externally-facing surface of the upper when the upper is included in a finished article of footwear. Accordingly, when the upper is in aflat (i.e., unlasted, unstitched) configuration, the upper may include additional reinforcing layers, coating layers, and / or the like, which are configured to be hidden by seams, adhered to the strobel, adhered to a sole structure, or concealed by any other suitable method when the upper is in a finished configuration (e.g., stitched into a 3-D shape, lasted, coupled to a strobel, and / or the like). In other words, the outermost front surface of the upper includes exposed regions of the upper in the finished article of footwear, such as regions above the biteline. In some aspects, a majority of the externally-facing surface of the upper consists of one or more exposed structure region, with each of the one or more exposed structure region consisting of the face fabric and the lining fabric.
[0060] Similarly, at least a portion of a back side of the lining fabric forms an outermost back surface of the upper, which is configured to define the foot-receiving cavity in the finished article of footwear. Accordingly, when the upper is in a flat (i.e., unlasted, unstitched) configuration, the upper may include additional reinforcing layers, coating layers, and / or the like, which are configured to be hidden by seams, adhered to thestrobel, adhered to a sole structure, or concealed by any other suitable method when the upper is in a finished configuration. In other words, the outermost back surface of the upper includes exposed regions of the lining fabric in the finished article of footwear, not back surfaces of the upper which become hidden during the manufacturing process. In some aspects, a majority of a surface area of the foot-receiving cavity of the upper consists of one or more exposed structure region, each of the one or more exposed structure region consisting of the face fabric and the lining fabric. In one aspect, the lining fabric defines at least a portion of a footbed of the upper, such the footbed of the upper is substantially continuous with the lining fabric. In some examples, in the foot-receiving cavity, a majority of a surface area of the footbed may be defined by the lining fabric. In some examples, at least one plush area of the plurality of plush areas of the lining fabric is configured to be disposed beneath the foot of a wearer when an article of footwear including the upper is worn. In these examples, the at least one plush area may be configured to cushion the sole of the foot of the wearer, while adjacent ground areas of the lining fabric may be configured to facilitate airflow to the sole of the foot of the wearer.
[0061] A single-layer upper in accordance with the present teachings is also contemplated. The single-layer upper includes a lining fabric having a lining fabric front side and a lining fabric back side opposite the lining fabric front side. An exposed back area of the lining fabric back side defines at least an outermost back surface of the upper, and the outermost back surface of the upper including the exposed back area is configured to define a foot-receiving cavity when the upper is in a finished article of footwear. In the exposed back area, the lining fabric back side includes a plurality of plush areas separated by a ground area. The plush areas may be on the lining fabric front side or on the lining fabric back side or on the lining fabric front side and the lining fabric back side. The plurality of plush areas on the lining fabric back side may be configured to act as a lining defining a foot-receiving cavity and to directly contact a foot of a wearer to provide comfort to a foot of a wearer by providing cushioning and / or ventilation to the foot of the wearer. The plurality of plush areas on the lining fabric front side may be configured to act at insulation or to increase durability of the upper.Examples, Components, and Alternatives
[0062] The following sections describe selected aspects of illustrative uppers for articles of footwear as well as related systems and / or methods. The examples in these sections are intended for illustration and should not be interpreted as limiting the scope of the present disclosure. Each section may include one or more distinct embodiments or examples, and / or contextual or related information, function, and / or structure.
[0063] A. Illustrative Upper
[0064] As shown in Figs. 1 - 10, this section describes an illustrative upper 100. Upper 100 is an example of uppers, described above.
[0065] Fig. 1 schematically depicts a first article of footwear 10 including illustrative upper 100. Article of footwear 10 includes upper 100, which is coupled to a sole structure 20, such that upper 100 and sole structure 20 collectively define a foot-receiving cavity 102. Upper 100 and sole structure 20 may intersect at a biteline 22 disposed adjacent or at an outer perimeter 108 of upper 100, which defines an interface between the upper and the sole structure. Accordingly, certain portions of upper 100 may be described as being above the biteline and below the biteline when the upper is included in a finished article of footwear, such as article of footwear 10. Sole structure 20 may include any suitable structure(s) configured to support the foot of a wearer. In some examples, sole structure 20 includes any combination of outsole, a midsole, and / or an insole.
[0066] An inner perimeter 110 of upper 100 may form a collar 12 when the upper is included in a finished article of footwear. Similarly, inner perimeter 110 of upper 100 may include a closure mechanism 112. Closure mechanism 112 and collar 12 may each extend around a portion of inner perimeter 110. In some examples, closure mechanism 112 and collar 12 collectively define inner perimeter 110 when upper 100 is included in a finished article of footwear. In other words, closure mechanism 112 and collar 12 collectively define a foot-receiving opening 14 of the article of footwear. Article of footwear 10 may include any suitable closure mechanism 112, such as lacing structures, hook-and-loop fasteners, snaps, zippers, ties, and / or the like. In some examples, closure mechanism 112 comprises a lacing structure. Accordingly, in someexamples, upper 100 includes a plurality of lace receiving members, such as a plurality of eyelets configured to receive a lace. The lace may comprise a conventional lace, such as a flat lace, a round lace, and / or an elastic lace, or a no-tie lace, such as an elastic cord, a bungee, and / or the like.
[0067] Portions of upper 100 may be described in relation to their properties when included in a finished article of footwear. Accordingly, upper 100 may be described as having a heel region 104, which corresponds to portions of the upper disposed in a heel region of the shoe when the upper is included in a finished article of footwear. Similarly, upper 100 may be described as having a vamp region 105, which corresponds to portions of the upper disposed above a wearer’s midfoot. Similarly, upper 100 may be described as having a forefoot region (AKA toe region) 106, which corresponds to portions of the upper disposed in a forefoot region of the shoe when the upper is included in a finished article of footwear.
[0068] Upper 100 may be finished in any suitable manner to form article of footwear 10, such as by strobel lasting, slip lasting, string lasting, board lasting, and / or the like. Accordingly, in some examples, outer perimeter 108 of upper 100 is coupled to a strobel 116 to form foot-receiving cavity 102. In some examples, a first end 117 and a second end 118 of upper 100 are coupled together at a seam 120, forming foot-receiving cavity 102. Seam 120 may be disposed in any suitable region of the upper, such as in heel region 104, forefoot region 106, on a lateral side of upper 100, on a medial side of upper 100, in a vamp region 105 of upper 100, and / or the like. In some examples, article of footwear 10 includes reinforcements 160 applied to an externally-facing outermost surface 122 of upper 100. In the example of Fig. 1 , article of footwear 10 includes a toe cap 16 coupled to forefoot region 106 of upper 100. Additional and / or alternative examples of suitable reinforcements are discussed in more detail below.
[0069] In some examples, upper 100 includes a tongue 124 configured to cover a portion of foot-receiving opening 14. Accordingly, tongue 124 comprises any suitable flap of material configured to cover a portion of a dorsal region of the foot of a wearer when included in an article of footwear. Tongue 124 may be affixed to any suitable portion of upper 100, such as to outer perimeter 108 of upper 100, inner perimeter 110 of upper 100, both the outer perimeter and the inner perimeter of the upper, and / or the like.T urning now to Fig. 2, upper 100 is depicted in a flat configuration, prior to finishing and assembly of the article of footwear. Fig. 3 depicts a schematic sectional view of an exposed structure region 150 included in upper 100. Upper 100 includes a lining fabric 140 and, in some examples, a face fabric 130. Lining fabric 140 has a lining fabric front side 142 and a lining fabric back side 144 opposite the lining fabric front side. Lining fabric 140 defines an exposed back region 125 of the upper. Exposed back region 125 defines at least a portion of an outermost back surface 126 of the upper. The outermost back surface 126 of the upper is configured to define foot-receiving cavity 102 when the upper is included in a finished article of footwear, such as article of footwear 10.
[0070] Similarly, in some examples, face fabric 130 has a face fabric front side 132 and a face fabric back side 134 opposite the face fabric front side. An outermost front surface of the upper 121 includes an exposed face region 128 defined by the face fabric front side. The outermost front surface of the upper 121 including the exposed face region 128 is configured to form an externally-facing outermost front surface 122 of the upper when the upper is in a finished article of footwear, such as article of footwear 10. Lining fabric front side 142 is positioned below and in direct contact with face fabric back side 134 in exposed back region 125 of the upper defined by lining fabric 140.
[0071] In some examples, upper 100 consists of lining fabric 140, and an outermost front surface of the upper 121 is defined by lining fabric front side 142 when the upper is in a finished article of footwear, such as article of footwear 10.
[0072] In at least exposed back region 125, lining fabric 140 includes a plurality of plush areas 146 on the lining fabric back side 144. Each of the plurality of plush areas 146 on the lining fabric back side 144 comprises a plurality of exposed fibers 154 affixed to and standing proud of a lining fabric base fabric structure 151. The plurality of plush areas 146 includes an individual plush area 147 separated from other plush areas of the plurality by a ground area 148 comprising or consisting of lining fabric base fabric structure 151 , as is best depicted by Fig. 4. Accordingly, plurality of plush areas 146 is configured to act as a lining defining foot-receiving cavity 102 and to contact and cushion a foot of a wearer when the article of footwear is worn. Accordingly, plurality of plush areas 146 is configured to provide a soft, breathable surface on lining fabric 140. In some examples, back side126 of the upper on at least a medial side of the upper, on at least a lateral side of the upper, in at least a toe region of the upper, in at least a forefoot region of the upper, in at least a vamp region of the upper, and / or in any combination thereof.
[0073] Fig. 4 depicts an exemplary individual plush area 147 of the plurality of plush areas. As will be described in more detail below, an individual plush area 154 may consist of a single type of exposed fibers or may comprise multiple types of exposed fibers. The types of exposed fibers may vary within an individual plush area 147 or between separate plush areas based on one or more characteristics. Within an individual plush area 147, multiple types of exposed fibers may be randomly distributed, or may be segregated into separate subregions of the individual plush area 147. The one or more characteristics may vary based on fiber length, fiber color, fiber content, whether the exposed end of the fiber is cut or is a loop, an angle of the fiber relative to the fabric base structure, or any combination thereof. The exposed fibers may be cut or shaved fibers or may be looped fibers of filaments (e.g. terry loops). The exposed fibers may be positioned substantially perpendicular to the base fabric structure. Alternatively, the exposed fibers may be positioned at an oblique angle relative to the base fabric structure. The exposed fibers may be positioned substantially perpendicular to the base fabric structure at or adjacent to a point at which the fiber connects to the base fabric structure and may include a bend along a length of the fiber such that the exposed end of the fiber is at an oblique angle relative to its connection to the base fabric structure. The individual plush area 147 illustrated in Fig. 4 is an example of an individual plush area consisting of multiple types of exposed fibers segregated into separate subregions, including first plurality of exposed fibers 154a, second plurality of exposed fibers 154b, and third plurality of exposed fibers 154c. Each plurality of exposed fibers 154a, 154b, 154c includes a plurality of fibers, with each of the plurality of fibers affixed to and standing proud of lining fabric base fabric structure 151. First plurality 154a and second plurality of exposed fibers 154b both consist of cut or shaved fibers. The cut or shaved exposed fiber ends of first plurality 154a and second plurality 154b are both positioned at oblique angles relative to lining fabric base fabric structure 151. At the point of attachment of each fiber of first plurality 154a to base fabric structure 151 , the fibers are substantially perpendicular to the base fabric structure 151, and each fiber of first plurality 154a includes a bend along its length. The bend ispositioned at a point closer to the cut or shaved fiber end than a point of attachment of the fiber to the base fabric structure. Due to the bend, the cut end of the fiber is positioned at an oblique angle relative to the base fabric structure 151. In contrast, each of second plurality of exposed fibers 154b is positioned at an oblique angle to base fabric structure 151 along substantially its entire fiber length. Third plurality of exposed fibers 154c consists of uncut loops of fibers or filaments (e.g., terry loops). The fiber loops of third plurality of exposed fibers 154c are positioned substantially perpendicular to lining fabric base fabric structure 151. Each plush area 147 of the plurality of plush areas 146 may comprise one or more of first bunch of exposed fibers 154a, second bunch of exposed fibers 154b, and third bunch of exposed fibers 154c. In some examples, each plush area 147 consists essentially of a single type of exposed fibers. In some examples, each plush area 147 comprises a mixture of types of exposed fibers. Exposed fibers 154 may comprise any suitable fibers affixed to the lining fabric base fabric structure 151 in any suitable manner, as described in more detail below.
[0074] Ground area 148 is a portion of lining fabric base fabric structure 151 free of the exposed fibers standing proud of the lining fabric base fabric structure such that a lining fabric average thickness in each plush area is greater than in the ground area. In some examples, each plush area of the plurality of plush areas has an average thickness at least 10% greater, or at least 20% greater, or at least 30% greater than an average thickness of the ground area. In some examples, each plush area of the plurality of plush areas has an average thickness of at least 1mm, or at least 1.5mm, or at least 2mm, or at least 2.5mm, or at least 3mm. In some examples, ground area 148 has an average thickness of less than 1 ,5mm, or less than 1 mm, or less than 0.5mm.
[0075] In some examples, ground area 148 is configured to be air permeable. In some examples, the plurality of plush areas 146 separated by ground area 148 forms a pattern. In some examples, the pattern formed by plurality of plush areas 146 separated by ground area 148 repeats across the lining fabric of the upper. In some examples, the pattern is configured to allow air to flow between the foot-receiving cavity and the outermost front surface of the upper. In some examples, a majority of the plurality of exposed and affixed fibers of the plurality of plush areas on the lining fabric back side have a moisture regain of 4 percent or more, or ranging from about 4 percent to about 16 percent.Exposed back region 125 and exposed front region 121 align in an exposed structure region 150. In some examples, exposed structure region 150 consists of the face fabric 130 and the lining fabric 140 including plurality of plush areas 146 separated by ground area 148 on lining fabric back side 144. In some examples, as best seen in Fig. 6, as exposed structure region 150 consists of the face fabric 130 and the lining fabric 140, plurality of plush areas 146 is visible through exposed structure region 150 when viewed from the outermost front surface of the upper. Exposed structure region 150 is disposed in any suitable location within the upper, such as on a medial side of the upper, on a lateral side of the upper, in a vamp region of the upper, in a forefoot region of the upper, in a toe region of the upper, in a heel region of the upper, and / or in any combination thereof.
[0076] Exposed structure region 150 is breathable when compared with conventional uppers, as exposed structure region 150 consists of two layers of fabric and includes plurality of plush areas 146 separated by ground area 148. Accordingly, uppers 100 generally include exposed structure region 150 extending across continuous regions of the upper, providing comparatively large breathable areas. Exposed structure region 150 may include one or more features configured to increase breathability within the exposed structure region. In some examples, the lining fabric in exposed structure region 150 is air permeable. In some examples, the lining fabric in exposed structure region 150 has an air permeability of at least 200 liters per square meter per second, or of at least 300 liters per square meter per second, or at least 400 liters per square meter per second. In some examples, the face fabric in exposed structure region 150 is air permeable. In some examples, the face fabric in the exposed structure region has an air permeability of at least 200 liters per square meter per second, or of at least 300 liters per square meter per second, or at least 400 liters per square meter per second. In some examples, in the exposed structure region, the ground area separating each plush area from other plush areas of the plurality of plush areas has a minimum width of at least 1mm, or at least 1 ,5mm, or at least 2mm, or at least 2.5mm.
[0077] In some examples, exposed structure region 150 covers any suitable percent of outermost front surface 128, such as at least 20 percent, at least 30 percent, at least 40 percent, at least 50 percent, at least 60 percent, and / or the like. Exposed structure region150 may cover a majority of outermost front surface 128. In some examples, exposed structure region 150 has a minimum continuous surface area of 0.5 square centimeters, 1 square centimeter, 2 square centimeters, or more than 2 square centimeters, of more than 3 square centimeters, of more than 4 square centimeters, or of more than 6 square centimeters.
[0078] In one aspect, in a portion of the upper chosen from a portion of the lateral region of the upper, a portion of the medial region of the upper, a portion of a forefoot region of the upper, a portion of a toe region of the upper, and / or any combination thereof, the upper may consist of face fabric 130 and lining fabric 140 with plurality of plush areas 146 on lining fabric back side 144. In some examples, the portion of the upper consisting of the face fabric and the lining fabric with the plurality of plush areas 146 on the lining fabric back surface has a minimum continuous surface area of 0.5 square centimeters, or of 1 square centimeter, or of 2 square centimeters, or of more than 2 square centimeters, of more than 3 square centimeters, of more than 4 square centimeters, or of more than 6 square centimeters.
[0079] Face fabric 130 and lining fabric 140 may be affixed to each other, and to portions of article of footwear 10, such as sole structure 20, strobel 116, and / or the like, along an inner perimeter, along an outer perimeter of the upper, along seam 120 bringing two ends of the upper together, and / or any combination thereof. Face fabric 130 and lining fabric 140 may be affixed to each other and / or to sole structure 20 and / or strobel 116 using any suitable method, such as adhering, stitching, heat bonding, fusing, nailing, stapling, and / or the like. Face fabric 130 and lining fabric 140 may be affixed to each other and / or to sole structure 20 and / or strobel 116 using any suitable material, such as threads, adhesives, nails, brads, staples, cords, and / or the like. In some examples, face fabric 130 and lining fabric 140 are affixed directly to each other. In some examples, face fabric 130 and lining fabric 140 are affixed indirectly to each other, such as with an intermediate piece of material disposed between them at outer perimeter 108 and inner perimeter 110.
[0080] In some examples, face fabric 130 and lining fabric 140 are affixed directly or indirectly to each other only along inner perimeter 110 of the upper, outer perimeter 108 of the upper, along seam 120 bringing two ends of the upper together, or any combination thereof. In other words, in some examples, face fabric 130 and lining fabric 140 are free-floating between attachment points, such as those defined at outer perimeter 108, inner perimeter 110, seam 120 bringing two ends of the upper together, or any combination thereof.
[0081] In some examples, face fabric 130 and lining fabric 140 are not directly or indirectly affixed to each other in the exposed structure region of the upper. In other words, face fabric 130 and lining fabric 140 are disengaged from each other in exposed structure region 150. This disengagement between the face fabric and the lining fabric may facilitate comfort of the foot of a wearer. For example, it may facilitate airflow through the upper, as face fabric 130 and lining fabric 140 are free to move relative to each other and to the foot of a wearer.
[0082] In some examples, face fabric 130 and lining fabric 140 are directly or indirectly affixed to each other at one or more points in the outermost front surface of the upper. In some examples, face fabric 130 and lining fabric 140 are directly or indirectly affixed to each other across a total surface area of less than 30 percent, less than 20 percent, or less than 10 percent of exposed face region 128. Accordingly, in regions of upper 100 corresponding to exposed structure region 150, face fabric 130 and lining fabric 140 are disengaged from each other in exposed structure region 150, but affixed to each other at one or more points in the outermost front surface of the upper, such as those points corresponding to reinforcement regions of the upper.
[0083] In some examples, face fabric 130 and lining fabric 140 are directly or indirectly affixed to each other across a total surface area of greater than 50 percent, greater than 50 percent, or greater than 60 percent of exposed face region 128. In these examples, face fabric 130 and lining fabric 140 may be affixed to each other by adhering, stitching, heat bonding, fusing, and / or the like, to provide a more streamlined fit for upper 100. Specifically, a structure of upper 100 may remain consistent during movement, as face fabric 130 and lining fabric 140 are affixed to each other, and unable to move relative to each other. In some examples, the face fabric and the lining fabric are directly or indirectly affixed to each other on a medial side of the upper, on a lateral side of the upper, in a vamp region of the upper, in a forefoot region of the upper, in a toe region of the upper, in a heel region of the upper, or in any combination thereof.In some examples, face fabric 130 comprises one or more pluralities of face fabric plush areas. Face fabric 130 may be free of plush areas, or may comprise a plurality of face fabric plush areas on its front side, on its back side, or on its front side and on its backside. In some examples, face fabric 130 includes a plurality of face fabric plush areas 136 separated by a face fabric ground area 138, wherein each face fabric plush area of the plurality of face fabric plush areas 136 includes a plurality of exposed face fabric fibers affixed to and standing proud of a face fabric base fabric structure, each face fabric plush area is separated from other of the plurality of face fabric plush areas by a face fabric ground area 138 comprising or consisting of a face fabric base fabric structure 152, and the ground area 138 is a portion of the face fabric base fabric structure 152 free of the exposed fibers standing proud of the face fabric base fabric structure such that a face fabric average thickness in each plush area is greater than in the ground area. Face fabric plush areas 136 may comprise any suitable exposed fibers 154, such as bunches of exposed fibers 154a, 154b, 154c, and / or the like. Face fabric plush areas 136 are examples of plush areas 146, as described above.
[0084] In some examples, the plurality of face fabric plush areas 136 is on the face fabric front side 132 or is on the face fabric back side 134 or is on both the face fabric front side and the face fabric back side. In some examples, the plurality of face fabric plush areas 136 is configured to increase durability of the upper. In some examples, at least a portion of the plurality of face fabric plush areas 136 are aligned with at least a portion of the plurality of plush areas of the lining fabric 146. In some examples, a portion of the face fabric ground area is aligned with a portion of the ground area of the lining area 148. In some examples, these areas of alignment between the plurality of face fabric plush areas and the plush areas of the lining fabric are disposed within the exposed structure region 150. In some examples, at least a portion of the plurality of face fabric plush areas 136 are offset from at least a portion of the plurality of plush areas of the lining fabric 146, and a portion of the face fabric ground area 138 is offset from a portion of the ground area of the lining fabric 148.
[0085] In some examples, the lining fabric front side further includes a plurality of plush areas. Each of the plurality of plush areas 156 on the lining fabric front side 142 comprises a plurality of exposed fibers affixed to and standing proud of a lining fabric base fabricstructure 151. Plush areas 156 on the lining fabric front side may comprise any suitable exposed fibers 154, such as bunches of exposed fibers 154a, 154b, 154c, and / or the like. Plush areas 156 are examples of plush areas 146, described above. In some examples, the plurality of plush areas 156 includes an individual plush area 157 separated from other plush areas of the plurality by a ground area 158 comprising or consisting of lining fabric base fabric structure 151. The plurality of plush areas on the lining fabric front side is configured to act as insulation, insulating the foot of a wearer in the foot-receiving cavity. In some examples, the plurality of plush areas on the lining fabric front side is configured to increase durability of the upper. In some examples, the plurality of plush areas 156 on the lining fabric front side 142 is configured to both insulate the foot of a wearer in the foot-receiving cavity and to increase durability of the upper. In some examples wherein the upper includes a face fabric 130 having a face fabric front side 132 and a face fabric back side 134, the exposed fibers of each plush area 157 on the lining fabric front side 142 contact the face fabric back side 134, and the face fabric front side 132 is configured to define an outermost front surface of the upper in an article of footwear. In some examples, the portion of the lining fabric back side configured to define the outermost back surface of the upper 126 and the lining fabric front side 142 both include the plurality of plush areas 146, 156.
[0086] In some examples, the lining fabric defines at least a portion of a footbed 114 of an article of footwear 10 including upper 100. In some examples, the lining fabric back side 144 is configured to contact a foot of a wearer when the upper is in an article of footwear, and the lining fabric back side includes the plurality of plush areas 146. In some examples, the lining fabric back side is configured to contact a foot of a wearer when the upper is in an article of footwear, the lining fabric front side is opposite the lining fabric back side, and the lining fabric front side includes the plurality of plush areas.
[0087] In some examples, the tongue 124 comprises the lining fabric. In some examples, a density of the plurality of plush areas in the tongue is greater than an average density of the plurality of plush areas in the exposed structure region of the upper.
[0088] Face fabric 130 and lining fabric 140 may each comprise any suitable fabric, such as a knitted fabric, a crocheted fabric, a woven fabric, or a non-woven fabric, such as a felt or a synthetic leather. In general, both face fabric 130 and lining fabric 140 consist ofa single fabric layer. Face fabric 130 and lining fabric 140 may comprise any suitable material having any suitable composition, such as natural materials (e.g., natural rubber, wool, plant-based fibers such as cotton, linen, etc.), synthetic materials including regenerated natural polymers and / or synthetic polymers including thermoplastic and / or thermoset polymers, and / or the like.
[0089] Face fabric 130 may comprise a substantially uncoated fabric, such that face fabric 130 provides a comparatively greater degree of breathability than lining fabric 140. All of face fabric 130 present in the upper 100 may comprise an uncoated fabric, or the portions of face fabric 130 present in the at least one exposed structure region 150 may comprise an uncoated fabric. In some examples, face fabric 130 comprises an engineered fabric, such as an engineered knitted or woven fabric, including an engineered warp knitted fabric, described in more detail below. In some examples, the face fabric consists of a monofilament yarn, or consists of a multifilament yam, or consists of the monofilament yam and the multifilament yam. In some examples, the face fabric consists of the monofilament yam knitted, crocheted, woven or entangled with the multifilament yam. In some examples, wherein the face fabric consists of the monofilament yam knitted or woven with the multifilament yam. In some examples, the face fabric consists of the monofilament yam plaited and interlooped with the multifilament yam. The face fabric may have any suitable weight and / or gauge. In some examples, the face fabric has a fabric weight ranging from about 250 grams per square meter to about 550 grams per square meter, or from about 350 grams per square meter to about 450 grams per square meter. In some examples, the face fabric is a knit fabric, and a knit gauge of the knit fabric ranges from about 10 to about 30 or from about 15 to about 25 or is about 20.
[0090] As stated above, in at least exposed back region 125, lining fabric 140 includes a plurality of plush areas 146 separated by ground area 148 on lining fabric back side 144 or on lining fabric front side 142. A variety of methods known in the art can be used to make lining fabric 140 and / or face fabric 130, including knitting, crocheting, weaving, and entangling. When the plurality of plush areas 146 is present on the lining fabric back side 142, the plurality of exposed fibers affixed to and standing proud of the base fabric structure in each plush area 147 provides a soft, velvet-like surface suitable for directly contacting a foot of a wearer. When the plurality of plush areas 146 is present on thelining fabric front side 142, the plurality of exposed fibers affixed to and standing proud of the base fabric structure in each plush area may provide insulation and / or cushioning to a foot of a wearer, and may increase durability of the upper. When the plurality of plush areas 146 is present on the face fabric front side and / or back side, the plurality of exposed fibers affixed to and standing proud of the base fabric structure in each plush area may provide insulation and / or cushioning to a foot of a wearer, and may increase durability of the upper.
[0091] In some examples, the exposed and affixed fibers 154 of each plush area are configured to have a specific orientation and / or distribution, as is best depicted in Fig. 4. In some examples, a majority of the exposed and affixed fibers of each plush area are substantially perpendicular to the underlying fabric base fabric structure. Accordingly, in some examples, a majority of the exposed and affixed fibers of each plush area are substantially perpendicular to the lining fabric base fabric structure (e.g., in third bunch 154c). In some examples, a majority of the exposed and affixed fibers of each plush area are at an oblique angle relative to the underlying fabric base fabric structure (e.g., in first bunch 154a and second bunch 154b). Accordingly, in some examples, a majority of the exposed and affixed fibers of each plush area are at an oblique angle relative to the lining fabric base fabric structure. In some examples, a majority of the exposed and affixed fibers of the plurality of plush areas in a medial region of the upper or in a lateral region of the upper or in both the medial region of the upper and in the lateral region of the upper are angled toward a toe region of the upper or toward a heel region of the upper. In some examples, a majority of the exposed and affixed fibers of the plurality of plush areas in a heel region of the upper or in a toe region of the upper or in both a heel region of the upper and a toe region of the upper are substantially perpendicular to the lining fabric base fabric structure.
[0092] In one example, plurality of plush areas 146 includes a coating of relatively short fibers (e.g., flocking fibers) applied and affixed (e.g., adhesively or thermally bonded) to the lining fabric back side or front side, or to the face fabric back side or front side. In another example, the plurality of exposed fibers 154 affixed to and standing proud of the base fabric structure in each plush area comprises a plurality of fibers in the form of staple fibers, filaments or yarn(s) integrally knitted, crocheted woven, inlaid or entangled in thebase fabric structure. The plurality of fibers may comprise cut (sheared) or uncut terry loops of a yam, for example sheared terry loops of a second yam integrally knitted, crocheted woven, inlaid or entangled in the base fabric structure. The lining fabric 140 and / or the face fabric 130 may comprise a first plurality of staple fibers, filaments, or yam forming at least the base fabric structure in the ground area (e.g., a ground area yam) separating the plurality of plush areas.
[0093] For example, the base fabric structure may comprise a ground yam in the ground area, and an intarsia knitting process may be used to create the plush areas using a second yam (e.g., a plush area yam). In this aspect, the lining fabric and / or the face fabric may be an intarsia knit fabric. The plush area yam (and / or fibers and / or filaments) may form a plurality of terry loops in the plush area. The terry loops may be sheared to expose ends of the fibers or filaments of the plush area yam, resulting in exposed fibers or filaments affixed to and standing proud of the base fabric structure. When a knitting or weaving process such as intarsia knitting or jacquard weaving or knitting are used, the terry loops may be integrally knitted or woven with (e.g., interlooped with or interwoven with) or inlaid with (e.g., inlaid between courses of knit stitches or inlaid between weft yams) into portions of the base fabric structure (i.e., in each plush area), with the terry loops standing proud of the base fabric structure on at least one fabric side in each plush area. The length of the terry loops can be chosen to ensure only the second fibers, filaments and / or yarn(s) forming the terry loops is sheared, and not the first staple fibers, filaments or yam forming the base fabric structure and forming the ground area 148.
[0094] In some examples, the plurality of exposed fibers comprises or consists of staple fibers or filaments or a combination of staple fibers and filaments, and each of the plurality of plush areas comprises the lining fabric base fabric structure 151 with the plurality of exposed fibers 154 entangled in the lining fabric base fabric structure. In some examples, the plurality of exposed fibers 154 is needle entangled in the lining fabric base fabric structure 151. In some examples, the plurality of exposed fibers 154 is hydroentangled in the lining fabric base fabric structure 151. In some examples, the plurality of exposed fibers 154 comprises or consists of exposed fibers or filaments of a plush area yam, and each of the plurality of plush areas comprises the lining fabric base fabric structure with the plush area yam adhesively bonded to or thermally bonded to the lining fabric basefabric structure. In some examples, the plurality of exposed fibers comprises or consists of exposed fibers or filaments of a plush area yam, and each of the plurality of plush areas comprises the lining fabric base fabric structure with the plush area yam inlaid in the lining fabric base fabric structure. In some examples, the plush area yam is inlaid in a knitted lining fabric base structure. In some examples, plush area yam is inlaid in a woven lining fabric base structure. In some examples, the plurality of exposed fibers comprises or consists of exposed fibers or filaments of a plush area yam, and the lining fabric base fabric structure of each of the plurality of plush areas is a knitted lining fabric base fabric structure including the plush area yam interlooped with the ground area yam. In some examples, the exposed fibers or filaments include cut or uncut terry loops of the plush area yam. In some examples, the plurality of exposed fibers comprises or consists of exposed fibers or filaments of a plush area yam, and the lining fabric base fabric structure of each of the plurality of plush areas is a woven lining fabric base fabric structure including the plush area yam interwoven with the ground area yam. In some examples, the plush yam is a spun filament yam or is a multifilament yam. In some examples, the lining fabric base fabric structure further comprises an elasticated yam. In some examples, the lining fabric has a fabric weight ranging from about 50 grams per square meter to about 400 grams per square meter, or from about 150 grams per square meter to about 350 grams per square meter, or from about 200 grams per square meter to about 300 grams per square meter, or about 250 grams per square meter.
[0095] The fabric may include a first yam (e.g., a ground area yam) at least in the ground area and a second yam (e.g., a plush area yam) in the plurality of plush areas separated by the ground area, with the second yam forming the plurality of exposed and affixed fibers (e.g., staple fibers, filaments, and / or yarn(s). In other words, in some examples, the ground area of the lining fabric comprises a ground area yam in the lining fabric base fabric structure, and the plurality of plush areas of the lining fabric comprises the ground area yam and a plush area yam, wherein, in the plush areas, the ground area yam is in the lining fabric base fabric structure, and the plush area yam provides the plurality of exposed fibers and is affixed to the lining fabric base fabric structure. In these embodiments, the first yam may be a monofilament yam, and the second yam may be a multifilament yam. In some examples, each of the plurality of plush areas 147 comprisesa velvet or velveteen material. In some examples, the lining fabric is an engineered warp knit jacquard fabric. In some examples, the lining fabric is a voided velvet fabric. In some examples, the plurality of exposed and affixed fibers is applied to the lining fabric using any suitable method, such as masking and spraying, screen printing, or the application of adhesive, ink, or paint to the lining fabric in a pattern and the subsequent application of the plurality of exposed and affixed fibers to the adhesive, ink, or paint while the adhesive, ink, or paint is still wet. The plurality of plush areas may include a coating or adhesive affixing a plurality of flocking fibers to the lining fabric back side, with the affixed plurality of flocking fibers standing proud of the lining fabric base fabric structure.
[0096] In some examples, in substantially all of the ground area included in the exposed structure region, the lining fabric base fabric structure comprises or consists of the ground area yarn. In some examples, the lining fabric base fabric structure consists of the ground area yam. In some examples, the lining fabric base fabric structure comprises the ground area yam and the plush area yam, and, in the ground area, the plush area yam does not stand proud of the base fabric structure on the lining fabric front side or on the lining fabric back side. In some examples, wherein the ground area yam or the plush area yam or both the ground yam and the plush yam comprises or consists of at least one multifilament yam. In some examples, the ground area yam consists of the at least one multifilament yam. In some examples, the lining fabric base fabric structure is a knitted structure or is a woven structure. In some examples, the knitted structure or the woven structure consists of the at least one multifilament yam, or consists of the at least one multifilament yam and an elasticated yam.
[0097] Each of the plurality of plush areas 147 may have any suitable shape or size suitable for providing a soft contact surface for the foot of a wearer. For example, each plush area 147 may be substantially circular, square, oval, oblong, rectangular, amorphous, triangular, and / or the like. Lining fabric back side 144 may comprise plurality of plush areas 146 in any suitable location, such as within heel regions of the lining fabric, forefoot regions of the lining fabric, medial regions of the lining fabric, lateral regions of the lining fabric, and / or any combinations thereof.
[0098] Plurality of plush areas 146 may be distributed across the upper in any suitable distribution, such as a substantially regular distribution, a substantially irregulardistribution (i.e., not concentrated in any particular region), or may be concentrated in selected regions of the upper. Accordingly, in some examples, a density of the plurality of plush areas varies, providing a greater density in certain regions of the upper and a lower density in other regions of the upper. In some examples, the density of the plurality of plush areas varies across a portion of the lining fabric present in the exposed structure region.
[0099] In some examples, a density of the plurality of plush areas is greater in at least one of a lateral region of the upper, a medial region of the upper, in the heel region of the upper, and lower in a toe region of the upper and / or a forefoot region of the upper. In some examples, a density of the plurality of plush areas is lower in at least one of a lateral region of the upper, a medial region of the upper, and / or the heel region of the upper and greater in a toe region and / or a forefoot region of the upper. In some examples, within the exposed back region, the density of the plush areas is greatest in at least one of a lateral region of the upper, a medial region of the upper, and a heel region of the upper. In some examples, within the exposed back region, the density of the plurality of plush areas is greatest in a toe region of the upper or in a forefoot region of the upper.
[0100] In some examples, within the exposed back region, the density of the plurality of plush areas is lowest in a toe region of the upper or in a forefoot region of the upper. In some examples, within the exposed back region, the density of the plurality of plush areas is greater in at least one of a lateral region of the upper, a medial region of the upper, or in the heel region of the upper as compared to a toe region or forefoot region of the upper. In some examples, within the exposed back region, the density of the plurality of plush areas is lower in at least one of a lateral region of the upper, a medial region of the upper, or in the heel region of the upper as compared to a toe region or forefoot region of the upper. In some examples, a density of the plurality of plush areas in the heel region outside the exposed structure region is greater than an average density of the plurality of plush areas in the exposed structure region.
[0101] In some examples, variation in the density of the plurality of plush areas across the lining fabric results in variation in a level of stretch along a length of the upper or along a width of the upper or along both the length and the width of the upper. In some examples, any variation in the density of the plurality of plush areas across the exposed structureregion results in variation in a level of stretch in a medial region of the upper or in a lateral region of the upper or in both the medial region and the lateral region of the upper.
[0102] In some examples, a density of the plurality of plush areas is varied by including a plurality of plush areas having a same shape and size, which are disposed closer together and in greater number in high density regions and farther apart and in lesser number in low density regions. In some examples, a density of the plurality of plush areas is varied by including a plurality of plush areas having different shapes and / or sizes, which are disposed in a consistent numerical distribution throughout the patterned plush areas, but which are generally larger in size in high density regions and smaller in size in low density regions. In some examples, a density of the plurality of plush areas is varied by including a plurality of plush areas having different shapes and / or sizes, which are disposed closer together and in greater number in high density regions and farther apart and in lesser number in low density regions.
[0103] In some examples, a plurality of plush areas, such as plush areas 136, 146, 156 includes a first plurality of plush areas and a second plurality of plush areas having one or more properties different from the first plurality of plush areas. In some examples, a density of the first plurality of plush areas is greater than a density of the second plurality of plush areas in at least the exposed structure region of the upper. In some examples, a fabric thickness of the first plurality of plush areas is greater than the fabric thickness of the second plurality of plush areas. In some examples, an average fiber diameter of the plurality of exposed and affixed fibers of the first plush areas is greater than an average fiber diameter of the plurality of exposed and affixed fibers of the second plurality of plush areas. In some examples, the first plush areas are on the lining fabric front side, and the second plush areas are on the lining fabric back side. In some examples, the first plurality of plush areas comprises a first plush area filament yarn, the second plurality of plush areas comprises a second plush area filament yam, and an average denier per filament of the first plush area filament yarn is greater than an average denier per filament of the second plush area filament yam. In some examples, an average tensile strength of the plurality of exposed and affixed fibers of the first plurality of plush areas is greater than an average tensile strength of the plurality of exposed and affixed fibers of the second plurality of plush areas. In some examples, the first plurality of plush area comprises afirst plush area yarn, the second plurality of plush areas comprises a second plush area yam, and the first plush area yam has a greater tenacity than the second plush area yam. In some examples, an average moisture regain of the plurality of exposed and affixed fibers of the first plush areas is greater than an average moisture regain of the plurality of exposed and affixed fibers of the second plurality of plush areas. In some examples, an average angle of the plurality of exposed and affixed fibers of the first plurality of plush areas relative to the lining fabric base fabric structure is greater than an average angle of the plurality of exposed and affixed fibers of the second plurality of plush areas relative to the lining fabric base fabric structure. In some examples, a majority of the plurality of exposed and affixed fibers of the first plurality of plush areas is substantially perpendicular to the lining fabric base fabric structure, and a majority of the plurality of exposed and affixed fibers of the second plurality of plush areas is at an oblique angle to the lining fabric base fabric structure.
[0104] In some examples, the plurality of exposed and affixed fibers 154 are configured to conduct moisture. In some examples, the plurality of exposed and affixed fibers are configured to conduct moisture from the lining fabric to the face fabric, from the face fabric to the lining fabric, or vice versa. In some examples, the plurality of exposed and affixed fibers are configured to wick and retain moisture from the foot of a wearer, the external environment, or both the foot of a wearer and the external environment. In some examples, a majority of the plurality of exposed and affixed fibers of the plurality of plush areas on the lining fabric back side have a moisture regain of 4 percent or more, or ranging from about 4 percent to about 16 percent. In some examples, a majority of the plurality of exposed and affixed fibers of the plurality of plush areas on the lining fabric front side have a moisture regain of 3 percent or less, or ranging from about 0.1 percent to about 3 percent. In some examples, the lining fabric includes the plurality of plush areas on the lining fabric back side, and a majority of the plurality of exposed and affixed fibers of the plurality of plush areas on the lining fabric back side have a moisture regain of 4 percent or more, or ranging from about 4 percent to about 16 percent; and the lining fabric includes the plurality of plush areas on the lining fabric front side, and a majority of the plurality of exposed and affixed fibers of the plurality of plush areas on the lining fabric front side have a moisture regain of 3 percent or less, or ranging from about 0.1 percentto about 3 percent. In some examples, the lining fabric includes the plurality of plush areas on the lining fabric back side, and a majority of the plurality of exposed and affixed fibers of the plurality of plush areas on the lining fabric back side have a moisture regain of 3 percent or less, or ranging from about 0.1 percent to about 3 percent. In some examples, the lining fabric includes the plurality of plush areas on the lining fabric front side, and a majority of the plurality of exposed and affixed fibers of the plurality of plush areas on the lining fabric front side have a moisture regain of 4 percent or more, or ranging from about 4 percent to about 16 percent. In some examples, the lining fabric includes the plurality of plush areas on the lining fabric back side, and a majority of the plurality of exposed and affixed fibers of the plurality of plush areas on the lining fabric back side have a moisture regain of 3 percent or less, or ranging from about 0.1 percent to about 3 percent; and wherein the lining fabric includes the plurality of plush areas on the lining fabric front side, and a majority of the plurality of exposed and affixed fibers of the plurality of plush areas on the lining fabric front side have a moisture regain of 4 percent or more, or ranging from about 4 percent to about 16 percent. In some examples, the lining fabric is configured to transfer moisture from the lining back side to the lining fabric front side. In some examples, the upper is configured to transfer moisture from the foot-receiving cavity to the outermost surface of the upper.
[0105] In some examples, lining fabric back side 144 further comprises a solid (i.e., uninterrupted, continuous) plush area 149 providing a reinforced region of the lining fabric back side. In contrast to a plurality of plush areas 146, solid plush area 149 is free from discontinuities within the solid plush area, such as those formed by ground area 148. In some examples, the lining fabric back side comprises solid plush area 149 disposed in any suitable location, such as in at least a portion of a closure mechanism 112, such as a lacing structure, of the upper, at least a portion of a collar structure of the upper, at least a portion of a toe cap region of the upper, at least a portion of a heel region of the upper, and / or in any combination thereof.
[0106] In some examples, one or both of face fabric 130 and lining fabric 140 is an engineered fabric. Face fabric 130 and lining fabric 140 may comprise any suitable engineered fabric, such as an engineered knit fabric, an engineered woven fabric, or anengineered non-woven fabric. In some examples, the engineered fabric is engineered to have a greater fabric weight in a reinforced region 164 of the engineered fabric, and a lower fabric weight in a second region of the fabric. A greater fabric weight may be achieved by increasing a density of a knit or weaving pattern in the reinforced region, increasing a thickness of yams utilized in the reinforced region, adding a second yarn in the reinforced region, such as a second yam used to make terry loops in the reinforced region, and / or the like. The second yam may be a multifilament yam. In some examples, reinforced region 164 includes at least a portion of the inner perimeter 110 of the upper, at least a portion of the outer perimeter 108 of the upper, at least a portion of seam region 120 configured to bring two ends of the upper together, or any combination thereof. In some examples, reinforced region 164 of the engineered fabric includes at least a portion of a closure mechanism 112, such as a lacing structure, of the upper, a collar structure of the upper, a toe cap region of the upper, a heel region of the upper, and / or any combination thereof. In some examples, upper 100 comprises a reinforcing component 162 in reinforced region 164 of the engineered fabric.
[0107] In some examples, reinforced region 164 includes at least one plush area, or includes a reinforced region plurality of plush areas having a greater density than a density of the plurality of plush areas in the exposed structure region. In some examples, the at least one plush area or the reinforced region plurality of plush areas extends over at least 75 percent, or at least 85 percent, or at least 95 percent, or substantially all of a surface area of the reinforced region. In some examples, in the reinforced region, a perimeter of the at least one plush area or of the reinforced region plurality of plush areas substantially corresponds to a perimeter of the reinforcing component. In some examples, reinforced region 164 of the engineered fabric is outside of exposed structure region 150.
[0108] In some examples, in the exposed structure region, face fabric yarns, or lining fabric yarns, or both face fabric yams and lining fabric yams comprise spun staple fiber yams or multifilament yams or both spun staple fiber yams and multifilament yams. In some examples, in the exposed structure region, face fabric yams, or lining fabric yams, or both face fabric yams and lining fabric yams consist of multifilament yams or multifilament yams and monofilament yams. The face fabric may consist of a monofilament yam plaited with a multifilament yam, or may consist of a monofilamentyarn. The lining fabric may consist of a multifilament yam or of a monofilament yam (e.g., an elasticated yam) plaited with a multifilament yam (i.e. , plush yarn(s)) in the plurality of plush areas, and may consist of a multifilament yam or of a multifilament yam plaited with a monofilament yam (i.e., ground yarn(s)) in the ground area separating the each of the plurality of plush areas. One or more of the plush yarn(s) in the plurality of plush areas may create loops extending from the back surface of the lining fabric, creating islands of loops of the plush yarn(s) separated and / or surrounded by the ground area consisting of only the ground yarn(s). The loops of the one or more plush yarn(s) may be cut or shaved to expose the filaments of the multifilament yam, thereby forming the exposed fibers standing proud of the base fabric structure in each of the plurality plush areas. In some examples, in at least a portion of face fabric 130 in exposed structure region 150, a knit or woven structure of the face fabric comprises or consists of a face fabric monofilament yam or a face fabric multifilament yam or both a face fabric monofilament yam and a face fabric multifilament yam. In some examples, in substantially all of the face fabric in exposed structure region 150, the knit or woven structure of the face fabric comprises or consists of the face fabric monofilament yam or the face fabric multifilament yam or both the face fabric monofilament yam and the face fabric multifilament yam. In some examples, the portion of the exposed structure area of the face fabric comprising or consisting of the face fabric monofilament yam or the face fabric multifilament yam or both the face fabric monofilament yam and the face fabric multifilament yam has a minimum continuous surface area of 0.5 square centimeters, 1 square centimeter, 2 square centimeters, more than 2 square centimeters, more than 3 square centimeters, more than 4 square centimeters, or more than 6 square centimeters.
[0109] Similarly, in some examples, in at least a portion of the lining fabric in exposed structure region 150, a lining fabric base fabric structure 151 comprises or consists of a lining fabric multifilament yam or a lining fabric multifilament yam and a lining fabric monofilament yam (e.g., an elasticated monofilament yam). In some examples, in substantially all of the lining fabric in the exposed structure region, the lining fabric base fabric structure 151 comprises or consists of the lining fabric multifilament yam or the lining fabric multifilament yam and the lining fabric monofilament yam. In some examples, the portion of the lining fabric in exposed structure region comprising or consisting of thelining fabric multifilament yarn or the lining fabric multifilament yarn and the lining fabric monofilament yarn, has a minimum surface area of 1 square centimeter, 2 square centimeters, 3 square centimeters, 4 square centimeters, or 6 square centimeters.
[0110] Turning now to Fig. 5, Fig. 5 depicts a schematic sectional view of the upper of Fig. 2, including one or more reinforcements 160 and / or bonded layers 180 coupled to lining layer 140 and / or face layer 130. While in the example depicted in Fig. 5, lining layer 140 is depicted as having plurality of plush areas 146, upper 100 may further comprise any suitable combination of face fabric plush areas 136 and lining fabric front side plush areas 166, as best depicted in Fig. 3. In other words, reinforcements 160 and / or bonded layers 180 may be applied to any suitable lining layers 140 and face layers 130 having any suitable number and / or arrangement of plush areas arranged thereon.
[0111] In some examples, upper 100 further comprises a reinforcing component 162 in at least a region including a solid plush area 149. Accordingly, in some examples, upper 100 further comprises a reinforcing component 162 disposed in any suitable location, such as in at least a portion of a closure mechanism 112, such as a lacing structure, of the upper, at least a portion of a collar structure of the upper, at least a portion of a toe cap region of the upper, at least a portion of a heel region of the upper, and / or in any combination thereof. In some examples, the solid plush area 149 is disposed outside exposed structure region 150.
[0112] Figure 5 depicts a schematic sectional view of upper 100, including one or more optional additional components 170 coupled to face fabric 130 and / or lining fabric 140. Accordingly, in some examples, upper 100 further comprises an additional component 170 positioned between face fabric 130 and lining fabric 140. Similarly, in some examples, upper 100 further comprises an additional component 170 coupled to outermost front surface of the upper 121 and / or an additional component 170 coupled to innermost back surface of the upper 126. The additional component may comprise any suitable structure, such as a foam layer and / or a cable structure. In some examples, the additional component is directly or indirectly affixed to either and / or both of the face fabric or the lining fabric. Accordingly, in some examples, the additional component is directly or indirectly affixed to the face fabric, is directly or indirectly affixed to the lining fabric, or is directly or indirectly affixed to both the face fabric and the lining fabric. In someexamples, the additional component 170 is positioned between face fabric back side 134 and lining fabric front side 142. The additional component may be affixed to face fabric 130 and / or lining fabric 140 using any suitable method, such as adhering, stitching, heat bonding, fusing, nailing, stapling, and / or the like. The additional component may be affixed to face fabric 130 and / or lining fabric 140 using any suitable material, such as threads, adhesives, nails, brads, staples, cords, and / or the like.
[0113] The additional component may be affixed to upper 100 in any suitable location, such as in a forefoot region of the upper, a heel region of the upper, a medial side of the upper, a lateral side of the upper, a toe region of the upper, and / or the like. In some examples, the additional component is affixed to the face fabric or to the lining fabric only in regions not corresponding to exposed structure regions 150. Accordingly, in some examples, the additional component is affixed to the face fabric and / or to the lining fabric only along an inner perimeter of the upper, or only along an outer perimeter of the upper, or only in a heel region of the upper, or only along seam 120 bringing the two ends of the upper together, or only along an inner perimeter of the upper, along an outer perimeter of the upper, and along seam region 120 configured to bring two ends of the upper together. Similarly, in some examples, additional component 170 may be affixed to upper only in regions which are not visible when upper 100 is included in a finished article of footwear, such as regions below biteline 22. In some examples, additional component 170 is affixed to an outer perimeter of the upper, such that the additional component is visible above the biteline when upper 100 is included in a finished article of footwear.
[0114] In some examples, the plurality of plush areas of the lining fabric is effective to increase a bonding strength between the lining fabric and additional component 170 as compared to a lining fabric including the ground area without the plurality of plush areas. Accordingly, in some examples, the additional component 170 is affixed to plush areas of the lining fabric. In some examples, the additional component 170 is bonded to the lining fabric front side. In these examples, a bonded area between the lining fabric front side and the additional component includes at least one plush are on the lining fabric front side or on the lining fabric back side opposite a portion of the lining fabric front side in the bonded area. In some examples, the at least one plush area is effective to increase a bonding strength of the bond by at least 20% as compared to a bond strength of a similarbonded area between the lining fabric front side and the additional component without the at least one plush area. In some examples, the additional component is bonded to the face fabric back side. In these examples, a bonded area between the face fabric back side and the additional component includes at least one plush area on the face fabric back side or on the face fabric front side opposite a portion of the face fabric back side in the bonded area, and the at least one plush area is effective to increase a bonding strength of the bond by at least 20% as compared to a bond strength of a similar bonded area between the lining fabric front side and the additional component without the at least one plush area.
[0115] In some examples, the exposed structure region is free of any additional components positioned between the face fabric and the lining fabric. In some examples, the exposed structure region is free of any additional components affixed to the face fabric. In some examples, the exposed structure region is free of any additional components affixed to the lining fabric. In some examples, the exposed structure region is free of any additional components affixed to the face fabric and to the lining fabric.
[0116] In some examples, additional component 170 is a reinforcing layer 166 configured to provide additional structure to regions of upper 100 corresponding to seams and / or attachment points. For example, in some examples, upper 100 includes a reinforcing layer 166 disposed between face fabric 130 and lining fabric 140 in a heel region of the upper. In these examples, reinforcing layer 166 is configured to reinforce a seam 120 disposed in heel region 104 bringing two ends of the upper together. In some examples, upper 100 further comprises an additional textile 168 disposed in a heel region of the upper. Accordingly, in some examples, in a heel region of the upper, additional textile 168 defines the outermost back layer of the upper. In some examples, additional textile 168 is directly bonded to lining fabric back side 144. In some examples, in a heel region of the upper, the additional heel textile defines the outermost back layer of the upper. In some examples, the additional heel textile is directly bonded to the lining fabric back side.
[0117] Additional textile 168 may be coupled to lining fabric 140 using any suitable method, such as adhering, stitching, heat bonding, fusing, nailing, stapling, and / or the like. Additional textile 168 may be coupled to lining fabric 140 using any suitable material, such as threads, adhesives, nails, brads, staples, cords, and / or the like. In someexamples, face fabric front side 132 includes a plurality of raised surfaces 172 configured to increase the durability of the face fabric. In some examples, the plurality of raised surfaces 172 comprises screen printed elements, or polymeric skin bonded to the face fabric, or a plurality of exposed fibers affixed to face fabric base fabric structure 152.
[0118] In some examples, upper 100 further comprises a bonded layer 180 affixed to face fabric 130. In some examples, bonded layer 180 is an example of reinforcements 160. Bonded layer 180 may comprise any suitable material having any suitable composition, such as natural materials (e.g., natural rubber), synthetic materials, (e.g., polymers including thermoplastic elastomers, thermoset materials). Bonded layer 180 may comprise any suitable material having any suitable structure, such as films, coatings, fabrics, and / or the like. In some examples, bonded layer comprises a polymeric film, a polymeric coating, a third fabric, or any combination of a polymeric film, a polymeric coating and a third fabric. In some examples, the bonded layer is affixed directly to face fabric front side 132 or directly to face fabric back side 134. Bonded layer 180 may be affixed to face fabric 130 using any suitable method, such as fusing, adhering, heat bonding, and / or the like. In some examples, bonded layer 180 is affixed to face fabric 130 using a heat activated adhesive. In some examples, bonded layer 180 is fused directly to face fabric 130 such as by thermal welding, radio frequency welding, or ultrasonic welding. Bonded layer 180 may be disposed in any suitable location, such as on a medial side of the upper, on a lateral side of the upper, in a vamp region of the upper, in a forefoot region of the upper, in a toe region of the upper, in a heel region of the upper, or in any combination thereof. In some examples, bonded layer 180 is applied to regions of the upper which experience greater levels of wear, such as toe cap 16, closure mechanism 112, and / or the like. Bonded layer 180 may comprise any suitable number of layers of material, such as at least one layer, at least two layers, at least three layers, and / or the like. In some examples, bonded layer 180 comprises a thermoplastic layer disposed on and directly contacting face fabric 130 and a thermoset layer disposed on and directly contacting the thermoplastic layer. In some examples, regions of the upper which experience greater levels of wear, such as toe cap 16, closure mechanism 112, and / or the like include two layers of material applied to face fabric 130. In some examples, the bonded layer is not directly affixed to lining fabric front side 142 in exposed structureregion 150. In some examples, bonded layer 180 is positioned outside of exposed structure region 150.
[0119] In some examples, a durability of the upper is increased by fusing and / or melting fibers of the plurality of plush areas, thereby forming one or more fused plush areas 184 (see, e.g., Fig. 4). In some examples, the lining fabric or the face fabric or both the lining fabric and the face fabric includes a first plurality of plush areas comprising a first plurality of exposed and affixed first polymer fibers and a second plurality of plush areas comprising a second plurality of exposed and affixed second polymer fibers, wherein the first plurality of exposed and affixed first polymer fibers differ from the second plurality of exposed and affixed fibers based on at least one characteristic chosen from polymeric component, tensile strength, color, average diameter, average length, average moisture regain, and type of attachment of the plurality of fibers to a respective lining fabric or face fabric base fabric structure. In some examples, the lining fabric includes the first plurality of plush areas on the lining fabric front side and the second plurality of plush areas on the lining fabric back side. In some examples, the lining fabric includes the first plurality of plush areas on the lining fabric back side and the second plurality of plush areas on the lining fabric front side. In some examples, the lining fabric includes the first plurality of plush areas and the second plurality of plush areas on the lining fabric front side. In some examples, the lining fabric includes the first plurality of plush areas and the second plurality of plush areas on the lining fabric back side. In some examples, a first polymeric component of the first plurality of fibers has a lower hardness than a second polymeric component of the second plurality of fibers. In some examples, the first polymeric component of the first plurality of fibers has a lower tensile strength than the second polymeric component of the second plurality of fibers. In some examples, the first polymeric component of the first plurality of fibers has a lower moisture regain than the second polymeric component of the second plurality of fibers. In some examples, the first polymeric component of the first plurality of fibers has a lower melting temperature than the second polymeric component of the second plurality of fibers. In some examples, in at least one of the plurality of plush areas of the upper, the first plurality of exposed and affixed fibers of the at least one plush area comprise or consist of a plurality of low melt fibers having a lower melting temperature than materials of the base fabric structure, andthe plurality of low melt fibers are present in a fused plush area 184 in which the plurality of low melt fibers are fused to each other or are fused to other non-low melt fibers in the at least one plush area or are fused to the base fabric structure or any combination thereof. In some examples, the at least one fused plush area 184 is in the lining fabric, the plurality of low melt fibers are fused to each other, are fused to the lining fabric base fabric structure, and are fused to the face fabric, in a fused lining fabric and face fabric region. In some examples, the fused plush area 184 is within the exposed structure region. In some examples, the fused plush area 184 is outside the exposed structure region. In some examples, the fused plush area 184 defines an outermost surface of the upper. In some examples, the fused plush area 184 is on an inner layer of the upper. In some examples, the fused plush area 184 defines a surface configured to define a portion of the foot-receiving cavity of the upper. In some examples, the fused plush area 184 is in a heel region of the upper or is in a toe region of the upper. In some examples, the fused plush area 184 is in a lateral region of the upper or is in a toe region of the upper. In some examples, the fused plush area 184 is effective to reduce stretch of the fused plush area as compared to an unfused plush area of the same construction, and the fused plush area is configured to provide lock-down to a foot of a wearer when the upper is present in an article of footwear. In some examples, the fused plush area 184 is effective to increase durability of a surface of the upper as compared to an unfused plush area of the same construction. In some examples, the fused plush area 184 is effective to increase water resistance of a surface of the upper as compared to an unfused plush area of the same construction.
[0120] Turning now to Figs. 11 - 16, an example of article of footwear 10 including upper 100 is shown and described. As described above, article of footwear 10 is coupled to a sole structure 20, such that upper 100 and sole structure 20 collectively define a footreceiving cavity 102. Upper 100 and sole structure 20 may intersect at a biteline 22 disposed adjacent or at an outer perimeter 108 of upper 100, which defines an interface between the upper and the sole structure. Sole structure 20 may include any suitable structure(s) configured to support the foot of a wearer. In some examples, sole structure 20 includes any combination of outsole, a midsole, and / or an insole. In some examples, a first end 117 and a second end 118 of upper 100 are coupled together at aseam 120, forming foot-receiving cavity 102. Seam 120 may be disposed in any suitable region of the upper, such as in heel region 104, forefoot region 106, on a lateral side of upper 100, on a medial side of upper 100, in a vamp region of upper 100, and / or the like. In the example of Figs. 11 - 16, seam 120 is disposed in a heel region of the upper.
[0121] As described above, inner perimeter 110 of upper 100 may form a collar 12 when the upper is included in a finished article of footwear. Similarly, inner perimeter 110 of upper 100 may include a closure mechanism 112. Article of footwear 10 may include any suitable closure mechanism 112, such as lacing structures, hook-and-loop fasteners, snaps, zippers, ties, and / or the like. In some examples, closure mechanism 112 comprises a lacing structure. Accordingly, in some examples, upper 100 includes a plurality of lace receiving members, such as a plurality of eyelets configured to receive a lace. As described in more detail above, in some examples, article of footwear 10 includes reinforcements 160 applied to an externally-facing outermost surface 122 of upper 100, such as additional components 170 and bonded layers 180. In the example of Figs. 11 - 16, article of footwear 10 includes a toe cap 16 coupled to forefoot region 106 of upper 100. Toe cap 16 comprises a bonded layer 180.
[0122] Fig. 16 depicts a schematic sectional view of article of footwear 10. In the example of Fig. 16, outer perimeter 108 of upper 100 is coupled to a strobel 116 to form footreceiving cavity 102. Upper 100 may be coupled to strobel 116 in any suitable manner, such as stitching, adhering, nailing, stapling, and / or the like.
[0123] Turning now to Figs. 17 - 19, this section describes an illustrative upper 200 consisting of lining material 140 is shown and described.. Upper 200 is an example of uppers for articles of footwear as described above. Upper 200 is substantially identical to upper 100, except that upper 200 consists of lining material 140 and does not include face fabric 130.
[0124] Fig. 17 schematically depicts a second article of footwear 50 including illustrative upper 200. Article of footwear 50 includes upper 200, which is coupled to a sole structure 60, such that upper 200 and sole structure 60 collectively define a foot-receiving cavity 202. Upper 200 and sole structure 60 may intersect at a biteline 62 disposed adjacent or at an outer perimeter 208 of upper 200, which defines an interface between the upper and the sole structure. Accordingly, certain portions of upper 200 may bedescribed as being above the biteline and below the biteline when the upper is included in a finished article of footwear, such as article of footwear 50. Sole structure 60 may include any suitable structure(s) configured to support the foot of a wearer. In some examples, sole structure 60 includes any combination of outsole, a midsole, and / or an insole.
[0125] An inner perimeter 210 of upper 200 may form a collar 52 when the upper is included in a finished article of footwear. Similarly, inner perimeter 210 of upper 200 may include a closure mechanism 212. Closure mechanism 212 and collar 52 may each extend around a portion of inner perimeter 210. In some examples, closure mechanism 212 and collar 52 collectively define inner perimeter 210 when upper 200 is included in a finished article of footwear. In other words, closure mechanism 212 and collar 52 collectively define a foot-receiving opening 54 of the article of footwear. Article of footwear 50 may include any suitable closure mechanism 212, such as lacing structures, hook-and-loop fasteners, snaps, zippers, ties, and / or the like. In some examples, closure mechanism 212 comprises a lacing structure. Accordingly, in some examples, upper 200 includes a plurality of lace receiving members, such as a plurality of eyelets configured to receive a lace. The lace may comprise a conventional lace, such as a flat lace, a round lace, and / or an elastic lace, or a no-tie lace, such as an elastic cord, a bungee, and / or the like.
[0126] Portions of upper 200 may be described in relation to their properties when included in a finished article of footwear. Accordingly, upper 200 may be described as having a heel region 204, which corresponds to portions of the upper disposed in a heel region of the shoe when the upper is included in a finished article of footwear. Similarly, upper 200 may be described as having a vamp region 205, which corresponds to portions of the upper disposed above a wearer’s midfoot. Similarly, upper 200 may be described as having a forefoot region (AKA toe region) 206, which corresponds to portions of the upper disposed in a forefoot region of the shoe when the upper is included in a finished article of footwear.
[0127] Upper 200 may be finished in any suitable manner to form article of footwear 50, such as by strobel lasting, slip lasting, string lasting, board lasting, and / or the like. Accordingly, in some examples, outer perimeter 208 of upper 200 is coupled to astrobel 216 to form foot-receiving cavity 202. In some examples, a first end 217 and a second end 218 of upper 200 are coupled together at a seam 220, forming foot-receiving cavity 202. Seam 220 may be disposed in any suitable region of the upper, such as in heel region 204, forefoot region 206, on a lateral side of upper 200, on a medial side of upper 200, in a vamp region of upper 200, and / or the like. In some examples, article of footwear 50 includes reinforcements 260 applied to an externally-facing outermost surface 222 of upper 200. In the example of Fig. 15, article of footwear 50 includes a toe cap 56 coupled to forefoot region 206 of upper 200. Additional and / or alternative examples of suitable reinforcements are discussed in more detail below. In some examples, upper 200 includes a tongue configured to cover a portion of foot-receiving opening 54. The tongue is substantially identical to tongue 124, described above with respect to Figs. 1 - 11. In some examples, the tongue is affixed to the outer perimeter of the upper, to the inner perimeter of the upper, or to both the outer perimeter of the upper and the inner perimeter of the upper.
[0128] Turning now to Fig. 18, upper 200 is depicted in a flat configuration, prior to finishing and assembly of the article of footwear. Fig. 19 depicts a schematic sectional view of upper 200. Upper 200 includes a lining fabric 140. In some examples, upper 200 consists essentially of lining fabric 140. In other words, upper 200 does not include a face fabric contacting an outermost front surface of lining fabric 140. Instead, an outermost front surface of the upper is defined by lining fabric front side 142 when the upper is in a finished article of footwear, such as article of footwear 50. As described above, lining fabric 140 has a lining fabric front side 142 and a lining fabric back side 144 opposite the lining fabric front side. An exposed back region 225 of the upper defined by lining fabric 140 defines at least an outermost back surface 226 of the upper. The outermost back surface 226 of the upper is configured to define foot-receiving cavity 202 when the upper is included in a finished article of footwear, such as article of footwear 50.
[0129] As described above, in at least exposed back region 225, lining fabric 140 includes a plurality of plush areas 146. Each of the plurality of plush areas 146 on the lining fabric back side 144 comprises a plurality of exposed fibers affixed to and standing proud of a lining fabric base fabric structure 151. The plurality of plush areas 146 includes an individual plush area 147 separated from other plush areas of the plurality by a groundarea 148 comprising or consisting of lining fabric base fabric structure 251. Accordingly, plurality of plush areas 146 is configured to act as a lining defining foot-receiving cavity 202 and to directly contact and cushion a foot of a wearer when the article of footwear is worn. Accordingly, plurality of plush areas 146 separated by ground area 148 is configured to provide a soft, breathable surface on lining fabric 140. In some examples, back side 144 of the lining fabric including plurality of plush areas 146 forms outermost back surface 226 of the upper on at least a medial side of the upper, on at least a lateral side of the upper, in at least a toe region of the upper, in at least a forefoot region of the upper, in at least a vamp region of the upper, and / or in any combination thereof.
[0130] Lining fabric 240 comprises any suitable material having any suitable form. In general, lining fabric 240 consists of a single fabric layer. In some examples, suitable fabrics include woven fabrics, knitted fabrics, crocheted fabrics, non-woven fabrics, such as felts, and / or the like. Lining fabric 240 may comprise any suitable material having any suitable composition, such as natural materials (e.g., natural rubber, wool, plant-based fibers such as cotton, linen, etc.), synthetic materials, synthetic polymers including thermoplastic and / or thermoset polymers, and / or the like.
[0131] In some examples, the lining fabric front side further includes a plurality of plush areas. Each of the plurality of plush areas 156 on the lining fabric front side 142 comprises a plurality of exposed fibers affixed to and standing proud of a lining fabric base fabric structure 151. In some examples, the plurality of plush areas 156 includes an individual plush area 157 separated from other plush areas of the plurality by a ground area 158 comprising or consisting of lining fabric base fabric structure 151. In some examples, the plurality of plush areas on the lining fabric front side is configured to act as insulation, insulating the foot of a wearer in the foot-receiving cavity. In some examples, the plurality of plush areas on the lining fabric front side is configured to increase durability of the upper. In some examples, the plurality of plush areas 156 on the lining fabric front side 152 is configured to both insulate the foot of a wearer in the foot-receiving cavity and to increase durability of the upper. In some examples, the portion of the lining fabric back side configured to define the outermost back surface of the upper 126 and the lining fabric front side 142 both include the plurality of plush areas 146, 156. In some examples, the lining fabric defines at least a portion of a footbed of an article of footwear 50 includingupper 200. In some examples, the lining fabric back side 144 is configured to contact a foot of a wearer when the upper is in an article of footwear, and the lining fabric back side includes the plurality of plush areas 146. In some examples, the tongue 114 comprises the lining fabric.
[0132] In some examples, within the exposed back region, the density of the plush areas is greatest in at least one of a lateral region of the upper, a medial region of the upper, and a heel region of the upper. In some examples, within the exposed back region, the density of the plurality of plush areas is greatest in a toe region of the upper or in a forefoot region of the upper. In some examples, within the exposed back region, the density of the plurality of plush areas is lowest in a toe region of the upper or in a forefoot region of the upper. In some examples, within the exposed back region, the density of the plurality of plush areas is greater in at least one of a lateral region of the upper, a medial region of the upper, or in the heel region of the upper as compared to a toe region or forefoot region of the upper. In some examples, within the exposed back region, the density of the plurality of plush areas is lower in at least one of a lateral region of the upper, a medial region of the upper, or in the heel region of the upper as compared to a toe region or forefoot region of the upper.
[0133] In some examples, variation in the density of the plurality of plush areas across the lining fabric results in variation in a level of stretch along a length of the upper or along a width of the upper or along both the length and the width of the upper. In some examples, and variation in the density of the plurality of plush areas across the exposed structure region results in variation in a level of stretch in a medial region of the upper or in a lateral region of the upper or in both the medial region and the lateral region of the upper. In some examples, the heel region of the upper includes the lining fabric. In some examples, a density of the plurality of plush areas in the heel region outside the exposed structure region is greater than an average density of the plurality of plush areas in the exposed structure region. In some examples, a density of the plurality of plush areas in the tongue is greater than an average density of the plurality of plush areas in the exposed structure region of the upper. In some examples, lining fabric back side 144 further comprises a solid (i.e., uninterrupted, continuous) plush area 149 providing a reinforced region of the lining fabric back side. In contrast to plurality of plush areas 146 separated by groundarea 148, solid plush area 149 is free from discontinuities within the solid plush area, such as those formed by ground area 148. In some examples, the lining fabric back side comprises solid plush area 149 disposed in any suitable location, such as in at least a portion of a closure mechanism 212, such as a lacing structure, of the upper, at least a portion of a collar structure of the upper, at least a portion of a toe cap region of the upper, at least a portion of a heel region of the upper, and / or in any combination thereof. In some examples, upper 200 further comprises a reinforcing component 162 in at least a region of solid plush area 149. Accordingly, in some examples, upper 200 further comprises a reinforcing component 262 disposed in any suitable location, such as in at least a portion of a closure mechanism 212, such as a lacing structure, of the upper, at least a portion of a collar structure of the upper, at least a portion of a toe cap region of the upper, at least a portion of a heel region of the upper, and / or in any combination thereof. In some examples, as upper 200 includes a single lining fabric 140, plush area 149 and / or reinforcing component 162 reinforces portions of the upper which are coupled to the sole structure, increasing a thickness of the upper in junction regions.
[0134] In some examples, a density of the plurality of plush areas is varied by including a plurality of plush areas having a same shape and size, which are disposed closer together and in greater number in high density regions and farther apart and in lesser number in low density regions. In some examples, a density of the plurality of plush areas is varied by including a plurality of plush areas having different shapes and / or sizes, which are disposed in a consistent numerical distribution throughout the plurality of plush areas, but which are generally larger in size in high density regions and smaller in size in low density regions. In some examples, a density of the plurality of plush areas is varied by including a plurality of plush areas having different shapes and / or sizes, which are disposed closer together and in greater number in high density regions and farther apart and in lesser number in low density regions.
[0135] In some examples, lining fabric 140 is an engineered fabric. Lining fabric 140 may comprise any suitable engineered fabric, such as an engineered knit fabric, an engineered woven fabric, or an engineered non-woven fabric. In some examples, the engineered fabric is engineered to have a greater fabric weight in a reinforced region 164 of the engineered fabric, and a lower fabric weight in a second region of the fabric. Agreater fabric weight may be achieved by increasing a density of a knit or weaving pattern in the reinforced region, increasing a thickness of yams utilized in the reinforced region, including terry loops in the reinforced region, and / or the like. In some examples, reinforced region 164 includes at least a portion of the inner perimeter 210 of the upper, at least a portion of the outer perimeter 208 of the upper, at least a portion of seam region 220 configured to bring two ends of the upper together, or any combination thereof. In some examples, reinforced region 164 of the engineered fabric includes at least a portion of a closure mechanism 212, such as a lacing structure, of the upper, a collar structure of the upper, a toe cap region of the upper, a heel region of the upper, and / or any combination thereof. In some examples, upper 200 comprises a reinforcing component 162 in reinforced region 164 of the engineered fabric.
[0136] Figure 19 depicts a schematic sectional view of upper 200, including one or more optional additional components 170 coupled to lining fabric 140. Accordingly, in some examples, upper 200 further comprises an additional component 170 coupled to an outermost front surface of the upper and / or an additional component 170 coupled to an innermost back surface of the upper. The additional component may comprise any suitable structure, such as a foam layer and / or a cable structure. In some examples, the additional component is directly or indirectly affixed to the lining fabric. In some examples, additional component 170 is affixed to lining fabric 140 in reinforced regions 164 of the engineered fabric. The reinforcing component may be affixed to lining fabric 140 using any suitable method, such as adhering, stitching, heat bonding, fusing, nailing, stapling, and / or the like. The additional component may be affixed to lining fabric 140 using any suitable material, such as threads, adhesives, nails, brads, staples, cords, and / or the like.
[0137] The additional component may be affixed to upper 200 in any suitable location, such as in a forefoot region of the upper, a heel region of the upper, a medial side of the upper, a lateral side of the upper, a toe region of the upper, and / or the like. Accordingly, in some examples, the additional component is affixed to the lining fabric only along an inner perimeter of the upper, or only along an outer perimeter of the upper, or only in a heel region of the upper, or only along seam 220 bringing the two ends of the upper together, or only along an inner perimeter of the upper, along an outer perimeter of the upper, and along seam region 220 configured to bring two ends of the upper together.Similarly, in some examples, additional component 170 may be affixed to upper 200 only in regions which are not visible when upper 200 is included in a finished article of footwear, such as regions below biteline 62. In some examples, additional component 170 is affixed to an outer perimeter of the upper, such that the additional component is visible above the biteline when upper 200 is included in a finished article of footwear.
[0138] In some examples, upper 200 further comprises a bonded layer 180 affixed to lining fabric front side 142 or lining fabric back side 144. In some examples, bonded layer 180 is an example of reinforcements 160. Bonded layer 180 may comprise any suitable material having any suitable composition, such as natural materials (e.g., rubber), synthetic materials, (e.g., polymers, thermoplastic elastomers, thermoset materials). Bonded layer 180 may comprise any suitable material having any suitable structure, such as films, coatings, fabrics, and / or the like. In some examples, bonded layer 180 comprises a polymeric film, a polymeric coating, a third fabric, or any combination of a polymeric film, a polymeric coating and a third fabric. In some examples, the bonded layer is affixed directly to lining fabric front side 142 or lining fabric back side 144. Bonded layer 180 may be affixed to lining fabric 140 using any suitable method, such as fusing, adhering, heat bonding, and / or the like. In some examples, bonded layer 180 is affixed to lining fabric 140 using a heat activated adhesive. In some examples, bonded layer 180 is fused directly to lining fabric 140. Bonded layer 180 may be disposed in any suitable location, such as on a medial side of the upper, on a lateral side of the upper, in a vamp region of the upper, in a forefoot region of the upper, in a toe region of the upper, in a heel region of the upper, or in any combination thereof. In some examples, bonded layer 180 is applied to regions of the upper which experience greater levels of wear, such as toe cap 56, closure mechanism 212, and / or the like. Bonded layer 180 may comprise any suitable number of layers of material, such as at least one layer, at least two layers, at least three layers, and / or the like. In some examples, bonded layer 180 comprises a thermoplastic layer disposed on and directly contacting lining fabric 140 and a thermoset layer disposed on and directly contacting the thermoplastic layer. In some examples, regions of the article of footwear which experience greater levels of wear, such as toe cap 56, closure mechanism 212, and / or the like include two layers of material applied to lining fabric 140.B. Illustrative Method
[0139] This section describes steps of an illustrative method 300 for manufacturing articles of footwear; see Fig. 20. Aspects of articles of footwear 10, 50 and uppers 100, 200 may be utilized in the method steps described below. Where appropriate, reference may be made to components and systems that may be used in carrying out each step. These references are for illustration, and are not intended to limit the possible ways of carrying out any particular step of the method.
[0140] Fig. 20 is a flowchart illustrating steps performed in an illustrative method, and may not recite the complete process or all steps of the method. Although various steps of method 300 are described below and depicted in Fig. 20, the steps need not necessarily all be performed, and in some cases may be performed simultaneously or in a different order than the order shown.
[0141] Step 302 of method 300 includes optionally applying a bonded layer to a fabric layer configured to form a portion of an upper. In some examples, the fabric layer comprises a face fabric. In some examples, the fabric layer comprises a lining fabric. In some examples, applying a bonded layer to a fabric layer configured to form a portion of the upper includes affixing the bonded layer to the fabric layer using any suitable method, such as fusing, adhering, heat bonding, and / or the like. In some examples, fusing the bonded layer to the fabric layer includes thermal welding, radio frequency welding, or ultrasonic welding. The bonded layer may comprise any suitable material having any suitable structure, such as films, coatings, fabrics, and / or the like. In some examples, the bonded layer comprises a polymeric film, a polymeric coating, a fabric, or any combination of a polymeric film, a polymeric coating, and a fabric. The bonded layer may be disposed in any suitable location, such as on a medial side of the upper, on a lateral side of the upper, in a vamp region of the upper, in a forefoot region of the upper, in a toe region of the upper, in a heel region of the upper, or in any combination thereof. The bonded layer may comprise any suitable number of layers of material, such as at least one layer, at least two layers, at least three layers, and / or the like. In some examples, the bonded layer comprises a thermoplastic layer disposed on and directly contacting the fabric layer and a thermoset layer disposed on and directly contacting the thermoplastic layer.Step 304 of method 300 includes optionally affixing a face layer and a lining layer to each other to form the upper. In some examples, the upper is substantially identical to upper 100. In some examples, the upper consists of a single layer of fabric (e.g., a lining fabric), such as upper 200. In some examples, either and / or both of steps 302 and 304 may be referred to as affixing a lining fabric to a second component to form the upper.
[0142] Step 306 includes coupling one or more fabric layers to a sole structure. In some examples, step 306 includes coupling the upper to a sole structure. Uppers according to the present disclosure may be finished in any suitable manner to form an article of footwear, such as by strobel lasting, slip lasting, string lasting, board lasting, and / or the like. The fabric layers may be affixed to each other and / or to the sole structure using any suitable method, such as adhering, stitching, heat bonding, fusing, nailing, stapling, and / or the like. The fabric layers may be affixed to each other and / or to the sole structure using any suitable material, such as threads, adhesives, nails, brads, staples, cords, and / or the like. In some examples, the article of footwear is strobel lasted and the sole structure comprises a strobel. In some examples, steps 304 and 306 are performed substantially simultaneously, such that coupling the face layer and the lining layer to the strobel and / or sole structure couples the face layer and the lining layer to each other. In some examples, coupling the one or more fabric layers to the sole structure includes coupling a single lining layer to the sole structure. In some examples, an outer perimeter of the one or more fabric layers is coupled to the sole structure.
[0143] The following reference numerals may be utilized in the accompanying drawings: 10 first article of footwear
[0144] 12 collar
[0145] 14 foot-receiving opening
[0146] 16 toe cap
[0147] 20 sole structure
[0148] 22 biteline
[0149] 50 second article of footwear
[0150] 52 collar
[0151] 54 foot-receiving opening56 toe cap
[0152] 0 sole structure
[0153] 2 biteline
[0154] 100 upper
[0155] 102 foot-receiving cavity
[0156] 104 heel region
[0157] 105 vamp region
[0158] 106 forefoot region
[0159] 108 outer perimeter of upper
[0160] 110 inner perimeter of upper
[0161] 112 closure mechanism
[0162] 114 footbed
[0163] 116 strobel
[0164] 117 first end of upper
[0165] 118 second end of upper
[0166] 120 seam region
[0167] 121 outermost front surface of upper
[0168] 122 externally-facing outermost surface of upper 124 tongue
[0169] 125 exposed back region
[0170] 126 outermost back surface of upper
[0171] 128 exposed face region
[0172] 130 face fabric
[0173] 132 face fabric front side
[0174] 134 face fabric back side
[0175] 136 plurality of face fabric plush areas
[0176] 138 face fabric ground area
[0177] 140 lining fabric
[0178] 142 lining fabric front side
[0179] 144 lining fabric back side
[0180] 146 plurality of plush areas147 plush area
[0181] 148 ground area
[0182] 149 solid plush area
[0183] 150 exposed structure region
[0184] 151 lining fabric base fabric structure
[0185] 152 face fabric base fabric structure
[0186] 154, 154a, 154b, 154c exposed fibers
[0187] 156 plurality of plush areas on lining fabric front side 157 individual plush area
[0188] 158 lining fabric front side ground area
[0189] 160 reinforcements
[0190] 162 reinforcing component
[0191] 164 reinforced region
[0192] 166 reinforcing layer
[0193] 168 additional textile
[0194] 170 additional components
[0195] 172 raised surfaces
[0196] 180 bonded layer
[0197] 184 fused plush area
[0198] 200 upper
[0199] 202 foot-receiving cavity
[0200] 204 heel region
[0201] 205 vamp region
[0202] 206 forefoot region
[0203] 208 outer perimeter of upper
[0204] 210 inner perimeter of upper
[0205] 212 closure mechanism
[0206] 216 strobel
[0207] 217 first end of upper
[0208] 218 second end of upper
[0209] 220 seam222 externally-facing outermost surface of upper
[0210] 224 tongue
[0211] 225 exposed back region
[0212] 226 outermost back surface
[0213] 300 method
[0214] 302 step
[0215] 304 step
[0216] 306 step
[0217] C. Illustrative Combinations and Additional Examples
[0218] This section describes additional aspects and features of uppers for articles of footwear, presented without limitation as a series of clauses, some or all of which may be alphanumerically designated for clarity and efficiency. Each of these clauses can be combined with one or more other clauses, and / or with disclosure from elsewhere in this application, including the materials incorporated by reference in the Cross-References, in any suitable manner. Some of the clauses below may expressly refer to and further limit other clauses, providing without limitation examples of some of the combinations.
[0219] A0. An upper for an article of footwear, the upper comprising:
[0220] a lining fabric having a lining fabric front side and a lining fabric back side opposite the lining fabric front side, wherein a portion of the lining fabric back side is configured to define at least a portion of a foot-receiving cavity of an article of footwear;
[0221] wherein the lining fabric includes a plurality of plush areas, each plush area of the plurality of plush areas comprises a plurality of exposed fibers affixed to and standing proud of a lining fabric base fabric structure, each plush area is separated from other of the plurality of plush areas by a ground area comprising or consisting of the lining fabric base fabric structure, and the ground area is a portion of the lining fabric base fabric structure free of the exposed fibers standing proud of the lining fabric base fabric structure such that a lining fabric average thickness in each plush area is greater than in the ground area.
[0222] A1. The upper of clause A0, wherein the plurality of plush areas separated by the ground area forms a pattern.A1.1. The upper of clause A1 , wherein the pattern formed by the plurality of plush areas separated by the ground area repeats across the lining fabric of the upper.
[0223] A2. The upper of any of clauses AO through A1.1, wherein the lining fabric defines at least a portion of an outermost back surface of the upper, and the ground area of the lining fabric is configured to be air permeable.
[0224] A2.1. The upper of clause A2, wherein the portion of the lining fabric back side configured to define the outermost back surface of the upper includes the plurality of plush areas, the plurality of plush areas on the lining fabric back side is configured to contact and cushion a foot of a wearer in the foot-receiving cavity, and each plush area on the lining fabric back side includes the exposed fibers affixed to and standing proud of the lining fabric base fabric structure on the lining fabric back side.
[0225] A2.2 The upper of clause A2 or A2.1 , wherein the face fabric includes a plurality of face fabric plush areas separated by a face fabric ground area, wherein each face fabric plush area includes a plurality of exposed face fabric fibers affixed to and standing proud of a face fabric base fabric structure, each face fabric plush area is separated from other of the plurality of face fabric plush areas by a face fabric ground area comprising or consisting of a face fabric base fabric structure, and the ground area is a portion of the face fabric base fabric structure free of the exposed fibers standing proud of the face fabric base fabric structure such that a face fabric average thickness in each plush area is greater than in the ground area.
[0226] A2.2.1. The upper of clause A2.2, wherein the plurality of face fabric plush areas is on the face fabric front side or is on the face fabric back side or is on both the face fabric front side and the face fabric back side.
[0227] A2.2.1.1. The upper of clause A2.2.1 , wherein the plurality of face fabric plush areas is configured to increase durability of the upper.
[0228] A2.2.2. The upper of any of clauses A2.2 through A2.2.1 , wherein at least a portion of the plurality of face fabric plush areas are aligned with at least a portion of the plurality of plush areas of the lining fabric, and a portion of the face fabric ground area is aligned with a portion of the ground area of the lining fabric.
[0229] A2.2.3. The upper of any of clauses A2.2 through A2.2.1 , wherein at least a portion of the plurality of face fabric plush areas are offset from at least a portion of theplurality of plush areas of the lining fabric, and a portion of the face fabric ground area is offset from a portion of the ground area of the lining fabric.
[0230] A3. The upper of any one of clauses AO to A2.2.1 , wherein the lining fabric front side includes the plurality of plush areas, the plurality of plush areas on the lining fabric front side is configured to act as insulation and insulate a foot of a wearer in the footreceiving cavity or is configured to increase durability of the upper or is configured both to act as insulation and insulate a foot of a wearer in the foot-receiving cavity and to increase durability of the upper, and each plush area on the lining fabric front side includes the exposed fibers affixed to and standing proud of the lining fabric base fabric structure on the lining fabric front side.
[0231] A3.1. The upper of clause A3, wherein the upper further comprises a face fabric having a face fabric front side and a face fabric back side opposite the face fabric front side, the exposed fibers of each plush area on the lining fabric front side contact the lining fabric back side, and the face fabric front side is configured to define an outermost front surface of the upper in an article of footwear.
[0232] A3.2. The upper of clause A3 or A3.1 , wherein the face fabric includes a plurality of face fabric plush areas separated by a face fabric ground area, wherein each face fabric plush area includes a plurality of exposed face fabric fibers affixed to and standing proud of a face fabric base fabric structure, each face fabric plush area is separated from other of the plurality of face fabric plush areas by a face fabric ground area comprising or consisting of a face fabric base fabric structure, and the ground area is a portion of the face fabric base fabric structure free of the exposed fibers standing proud of the face fabric base fabric structure such that a face fabric average thickness in each plush area is greater than in the ground area.
[0233] A3.2.1. The upper A3.2, wherein the plurality of face fabric plush areas is on the face fabric front side or is on the face fabric back side or is on both the face fabric front side and the face fabric back side.
[0234] A3.2.1.1. The upper of clause A3.2.1 , wherein the plurality of face fabric plush areas is configured to increase durability of the upper.
[0235] A3.2.2. The upper of any of clauses A3.2 through A3.2.1.1 , wherein at least a portion of the plurality of face fabric plush areas are aligned with at least a portion ofthe plurality of plush areas of the lining fabric, and a portion of the face fabric ground area is aligned with a portion of the ground area of the lining fabric.
[0236] A3.2.3. The upper of any of clauses A3.2 through A3.2.1.1 , wherein at least a portion of the plurality of face fabric plush areas are offset from at least a portion of the plurality of plush areas of the lining fabric, and a portion of the face fabric ground area is offset from a portion of the ground area of the lining fabric.
[0237] A4. The upper of any one of clauses AO through A3.1 , wherein the portion of the lining fabric back side configured to define the outermost back surface of the upper and the lining fabric front side both include the plurality of plush areas, the plurality of plush areas on the lining fabric back side is configured to contact and cushion a foot of a wearer in the foot-receiving cavity, each plush area on the lining fabric back side includes the exposed fibers affixed to and standing proud of the lining fabric base fabric structure on the lining fabric back side, the plurality of plush areas on the lining fabric front side is configured to act as insulation and insulate a foot of a wearer in the foot-receiving cavity or is configured to increase durability of the upper or is configured both to act as insulation and insulate a foot of a wearer in the foot-receiving cavity and to increase durability of the upper, and each plush area on the lining fabric front side includes the exposed fibers affixed to and standing proud of the lining fabric base fabric structure on the lining fabric front side.
[0238] A5. The upper of any one of clauses AO through A4, wherein the lining fabric defines at least a portion of a footbed of the upper.
[0239] A5.1. The upper of clause A5, wherein the lining fabric back side is configured to contact a foot of a wearer when the upper is in an article of footwear, and the lining fabric back side includes the plurality of plush areas.
[0240] A5.2. The upper of clause A5 or A5.1, wherein the lining fabric back side is configured to contact a foot of a wearer when the upper is in an article of footwear, the lining fabric front side is opposite the lining fabric back side, and the lining fabric front side includes the plurality of plush areas.
[0241] A6. The upper of any one of clauses AO through A5.2, wherein the plurality of plush areas is effective to increase a bonding strength between the lining fabric and asecond component as compared to a lining fabric including the ground area without the plurality of plush areas.
[0242] A7. The upper of any one of clauses AO through A5, wherein the upper further comprises a face fabric having a face fabric front side and a face fabric back side opposite the face fabric front side.
[0243] A7.1. The upper of clause A7, wherein the exposed fibers on the lining fabric front side contact the face fabric back side.
[0244] A7.2. The upper of A7 or A7.1 , wherein the face fabric front side is configured to define an outermost front surface of the upper in an article of footwear.
[0245] A7.2.1. The upper of clause A7.2, wherein the face fabric front side includes a plurality of raised surfaces configured to increase the durability of the face fabric.
[0246] A7.2.1.1. The upper of clause A7.2.1, wherein the plurality of raised surfaces comprises screen printed elements, or polymeric skin bonded to the face fabric, or a plurality of exposed fibers affixed to a face fabric base fabric structure.
[0247] A7.2.2. The upper of clause A7.2 or A7.2.1 , wherein an outermost front surface of the upper includes an exposed face region defined by the face fabric front side, and the outermost front surface of the upper including the exposed face region is configured to form an externally-facing outermost front surface of the upper when the upper is present in a finished article of footwear;
[0248] wherein the lining fabric front side is positioned below and in contact with the face fabric back side in an exposed back region of the upper defined by the lining fabric, the exposed back region and the exposed front region align in an exposed structure region, and
[0249] wherein the exposed structure region includes the ground area and the plurality of plush areas on the lining fabric front side or on the lining fabric back side or on both the lining fabric front side and the lining fabric back side.
[0250] A7.2.2.1. The upper of clause A7.2.2, wherein the pattern is visible in the exposed structure region when viewed through the externally-facing outermost front surface of the upper when the upper is present in a finished article of footwear.A7.3. The upper of clause A7.2.2 or A7.2.1.1, wherein the face fabric and the lining fabric are directly or indirectly affixed to each other at one or more points on the outermost front surface of the upper.
[0251] A.8. The upper of any one of clauses A7 to A7.3, wherein the face fabric and the lining fabric are directly or indirectly affixed to each other across a total surface area of less than 30 percent, or less than 20 percent, or less than 10 percent of the exposed face region.
[0252] A8.2. The upper of clause A8, wherein the face fabric and the lining fabric are directly or indirectly affixed to each other across a total surface area of greater than 40 percent or greater than 50 percent, or greater than 60 percent of the exposed face region.
[0253] A8.3. The upper of clause A8 or A8.2, wherein the face fabric and the lining fabric are directly or indirectly affixed to each other on a medial side of the upper, on a lateral side of the upper, in a vamp region of the upper, in a forefoot region of the upper, in a toe region of the upper, in a heel region of the upper, or in any combination thereof.
[0254] A9. The upper of any of clauses A0-A8.3, wherein the face fabric and the lining fabric are affixed directly or indirectly to each other only along an inner perimeter of the upper, or along an outer perimeter of the upper, or along a seam bringing two ends of the upper together, or any combination thereof.
[0255] A9.1. The upper of clause A9, wherein the inner perimeter of the upper includes a lacing structure.
[0256] A9.2. The upper of clause A9 or A9.1 , wherein the face fabric or the lining fabric or both the face fabric and the lining fabric are configured to be attached to a strobel along the outer perimeter of the upper.
[0257] A9.3. The upper of any of clauses A9 through A9.2, wherein the seam bringing the two ends of the upper together is in a heel region of the upper, or is on a lateral side of the upper, or is on a medial side of the upper, or is in a vamp region of the upper, or is in a toe region of the upper.
[0258] A10. The upper of any of clauses A7.2.2 through A9.3, wherein the face fabric and the lining fabric are not directly or indirectly affixed to each other in the exposed structure region of the upper.A11. The upper of any of clauses A7.2.2 through A10, wherein the exposed structure region is on a medial side of the upper, is on a lateral side of the upper, is in a vamp region of the upper, is in a forefoot region of the upper, is in a toe region of the upper, or is in any combination thereof.
[0259] A12. The upper of any of clauses A7.2.2 through A11, wherein the exposed structure region of the upper covers at least 20 percent, or at least 30 percent, or at least 40 percent, or at least 50 percent, or at least 60 percent of the outermost front surface of the upper.
[0260] A13. The upper of any of clauses A7.2.2 through A12, wherein, in the exposed structure region, the ground area separating each plush area from other plush areas of the plurality of plush areas has a minimum width of at least 1 mm, or at least 1 ,5mm, or at least 2mm, or at least 2.5mm.
[0261] A14. The upper of any of clauses A7 through A13, wherein the upper further comprises an additional component positioned between the face fabric back side and the lining fabric front side.
[0262] A14.1. The upper of clause A14, wherein the additional component comprises a foam layer or a cable structure.
[0263] A14.1.1. The upper of clause A14.1, wherein the foam layer or cable structure is directly or indirectly affixed to the face fabric back side, is directly or indirectly affixed to the lining fabric front side, or is directly or indirectly affixed to both the face fabric back side and the lining fabric front side.
[0264] A14.2. The upper of any of clauses A14 through A14.1.1, wherein the additional component is affixed to the face fabric or to the lining fabric only along an inner perimeter of the upper, or only along an outer perimeter of the upper, or only in a heel region of the upper, or only along a seam bringing two ends of the upper together, or only along an inner perimeter of the upper, along an outer perimeter of the upper, and along a seam region configured to bring two ends of the upper together.
[0265] A14.3. The upper of any of clauses A14 through A14.2, wherein the additional component is a reinforcing layer.
[0266] A14.4. The upper of any of clauses A14 through A14.3, wherein the additional component is bonded to the lining fabric front side, a bonded area between the liningfabric front side and the additional component includes at least one plush area on the lining fabric front side or on the lining fabric back side opposite a portion of the lining fabric front side in the bonded area, and the at least one plush area is effective to increase a bonding strength of the bond by at least 20% as compared to a bond strength of a similar bonded area between the lining fabric front side and the additional component without the at least one plush area.
[0267] A14.5. The upper of any of clauses A14 through A14.4, wherein the additional component is bonded to the face fabric back side, a bonded area between the face fabric back side and the additional component includes at least one plush area on the face fabric back side or on the face fabric front side opposite a portion of the face fabric back side in the bonded area, and the at least one plush area is effective to increase a bonding strength of the bond by at least 20% as compared to a bond strength of a similar bonded area between the lining fabric front side and the additional component without the at least one plush area.
[0268] A15. The upper of any of clauses A7 through A14.3, wherein the exposed structure region is free of any additional components positioned between the face fabric and the lining fabric.
[0269] A15.1. The upper of any of clauses A7 through A15, wherein the exposed structure region is free of any additional components affixed to the face fabric.
[0270] A15.2. The upper of any of clauses A7 through A15.1, wherein the exposed structure region is free of any additional components affixed to the lining fabric.
[0271] A15.3. The upper of any of clauses A7 through A15.2, wherein the exposed structure region is free of any additional components affixed to the face fabric and to the lining fabric.
[0272] A16. The upper of any of clauses A7 through A15.3, wherein the face fabric includes a bonded layer comprising a polymeric film, a polymeric coating, a third fabric or any combination of a polymeric film, a polymeric coating and a third fabric, and the bonded layer is affixed directly to the face fabric front side or directly to the face fabric back side.
[0273] A16.1.The upper of clause A16, wherein the bonded layer is not directly affixed to the lining fabric front side in the exposed structure region.A16.2. The upper of clause A16 or A16.1 , wherein the bonded layer is on a medial side of the upper, is on a lateral side of the upper, is in a vamp region of the upper, is in a forefoot region of the upper, is in a toe region of the upper, is in a heel region of the upper, or is in any combination thereof.
[0274] A16.3. The upper of any of clauses A16 through A16.2, wherein the bonded layer is positioned outside of the exposed structure region.
[0275] A17. The upper of any of clauses A7 through A17.3, wherein the face fabric is an engineered fabric, or wherein the lining fabric is an engineered fabric, or wherein the face fabric is an engineered fabric and the lining fabric is an engineered fabric.
[0276] A17.1. The upper of clause A17, wherein the engineered fabric is an engineered knit fabric or an engineered woven fabric.
[0277] A18. The upper of clause A17 or A17.1 , wherein the engineered fabric includes a reinforced region, and the reinforced region has a greater fabric weight than in the exposed structure region of the of the upper.
[0278] A18.1. The upper of clause A18, wherein the reinforced region of the engineered fabric includes at least a portion of the inner perimeter of the upper, or at least a portion of an outer perimeter of the upper, or at least a portion of a seam region configured to bring two ends of the upper together, or any combination thereof.
[0279] A18.2. The upper of clause A18 or A18.2, wherein the reinforced region of the engineered fabric includes at least a portion of a lacing structure of the upper, or a collar structure of the upper, or a toe cap region of the upper, or a heel region of the upper, or any combination thereof.
[0280] A18.3. The upper of any of clauses A18 through A18.2, wherein the upper comprises a reinforcing component in the reinforced region of the engineered fabric.
[0281] A18.4. The upper of any of clauses A18 through A18.3, wherein the reinforced region of the engineered fabric is outside of the exposed structure region.
[0282] A18.5. The upper of any of clauses A18 through A18.4, wherein the reinforced region includes the lining fabric back side or the lining front side in at least a portion of a lacing structure of the upper, or in at least a portion of a collar structure of the upper, or in at least a portion of a toe cap region of the upper, or in at least a heel region of the upper, or in any combination thereof.A18.6. The upper of any of clauses A18 through A18.5, wherein the reinforced region includes at least one plush area, or includes a reinforced region plurality of plush areas having a greater density than a density of the plurality of plush areas in the exposed structure region.
[0283] A18.7. The upper of clause A18.6, wherein the at least one plush area or the reinforced region plurality of plush areas extends over at least 75 percent, or at least 85 percent, or at least 95 percent, or substantially all of a surface area of the reinforced region.
[0284] A18.7.1. The upper of clause A18.7, wherein, in the reinforced region, a perimeter of the at least one plush area or of the reinforced region plurality of plush areas substantially corresponds to a perimeter of the reinforcing component.
[0285] A18.7.2. The upper of clause A18.7 or A18.7.1, wherein the reinforced region is outside the exposed structure region.
[0286] A19. The upper of any of clauses AO through A18.7.2, wherein a density of the plurality of plush areas varies across the lining fabric.
[0287] A19.1. The upper of clause A19, wherein the density of the plurality of plush areas of the lining fabric is greater in at least one region chosen from a lateral region of the upper, a medial region of the upper, and the heel region of the upper as compared to a toe region or a heel region of the upper.
[0288] A19.2. The upper of clause A19, wherein the density of the plurality of plush areas of the lining fabric is lower in at least one region chosen from a lateral region of the upper, a medial region of the upper, and the heel region of the upper as compared to a toe region or a heel region of the upper.
[0289] A19.3. The upper of any of clauses A7.2.2 through A19.2, wherein the density of the plurality of plush areas varies across a portion of the lining fabric present in the exposed structure region.
[0290] A19.3.1. The upper of clause A19.3, wherein, within the exposed back region, the density of the plush areas is greatest in at least one region chosen from a lateral region of the upper, a medial region of the upper, and the heel region of the upper.
[0291] A19.3.2. The upper of clause A19.3 or A19.3.2, wherein, within the exposed back region, the density of the plurality of plush areas is lowest in at least one regionchosen from a lateral region of the upper, a medial region of the upper, and the heel region of the upper.
[0292] A19.3.3. The upper of any of clauses A19.3 through A19.3.2, wherein, within the exposed back region, the density of the plurality of plush areas is greatest in a toe region of the upper or in a forefoot region of the upper.
[0293] A19.3.4. The upper of any of clauses A19.3 through A19.3.3, wherein, within the exposed back region, the density of the plurality of plush areas is lowest in a toe region of the upper or in a forefoot region of the upper.
[0294] A19.3.5. The upper of any of clauses A19.3 through A19.3.4, wherein, within the exposed back region, the density of the plurality of plush areas is greater in at least one of a lateral region of the upper, a medial region of the upper, or in the heel region of the upper as compared to a toe region or forefoot region of the upper.
[0295] A19.3.6. The upper of any of clauses A19.3 through A19.3.5, wherein, within the exposed back region, the density of the plurality of plush areas is lower in at least one of a lateral region of the upper, a medial region of the upper, or in the heel region of the upper as compared to a toe region or forefoot region of the upper.
[0296] A19.3.7. The upper of any of clauses A19 through A19.3.6, wherein the density of the plurality of plush areas varies across the lining fabric, and variation in the density of the plurality of plush areas results in variation in a level of stretch along a length of the upper or along a width of the upper or along both the length and the width of the upper.
[0297] A19.3.8. The upper of any of clauses A19 through A19.3.7, wherein the density of the plurality of plush areas varies across the exposed structure region, and variation in the density of the plurality of plush areas results in variation in a level of stretch in a medial region of the upper or in a lateral region of the upper or in both the medial region and the lateral region of the upper.
[0298] A20. The upper of any of clauses AO through A19.3.8, wherein the heel region of the upper includes the lining fabric.
[0299] A20.1. The upper of clause A20, wherein a density of the plurality of plush areas in the heel region outside the exposed structure region is greater than an average density of the plurality of plush areas in the exposed structure region.A21. The upper of any of clauses AO through A20.1 , wherein the upper further comprises a tongue, optionally wherein the tongue is affixed to the outer perimeter of the upper, or to the inner perimeter of the upper, or to both the outer perimeter of the upper and the inner perimeter of the upper.
[0300] A21.1.The upper of clause A21 , wherein the tongue comprises the lining fabric, and a density of the plurality of plush areas in the tongue is greater than an average density of the plurality of plush areas in the exposed structure region of the upper.
[0301] A22. The upper of any one of clauses AO to A21.1, wherein a majority of the exposed and affixed fibers of each plush area are substantially perpendicular to the lining fabric base fabric structure.
[0302] A23. The upper of any one of clauses AO to A21.1, wherein a majority of the exposed and affixed fibers of each plush area are at an oblique angle relative to the lining fabric base fabric structure.
[0303] A24. The upper of any one of clauses AO to A21.1, wherein a majority of the exposed and affixed fibers of the plurality of plush areas in a medial region of the upper or in a lateral region of the upper or in both the medial region of the upper and in the lateral region of the upper are angled toward a toe region of the upper or toward a heel region of the upper.
[0304] A25. The upper of any one of clauses AO to A24, wherein a majority of the exposed and affixed fibers of the plurality of plush areas in a heel region of the upper or in a toe region of the upper or in both a heel region of the upper and a toe region of the upper are substantially perpendicular to the lining fabric base fabric structure.
[0305] A26. The upper of any of clauses AO through A25, wherein the plurality of plush areas includes a first plurality of plush areas and a second plurality of plush areas.
[0306] A26.1.The upper of clause A26, wherein a density of the first plurality of plush areas is greater than a density of the second plurality of plush areas in at least the exposed structure region of the upper.
[0307] A26.2. The upper of clause A26 or A26.1 , wherein a fabric thickness of the first plurality of plush areas is greater than the fabric thickness of the second plurality of plush areas.A26.3.The upper of any of clauses A26 to A26.2, wherein an average fiber diameter of the plurality of exposed and affixed fibers of the first plush areas is greater than an average fiber diameter of the plurality of exposed and affixed fibers of the second plurality of plush areas.
[0308] A26.3.1. The upper of clause A26.3, wherein the first plush areas are on the lining fabric front side, and the second plush areas are on the lining fabric back side.
[0309] A26.3.2. The upper of clause A26.3.1 , wherein the first plurality of plush area comprises a first plush area filament yam, the second plurality of plush areas comprises a second plush area filament yam, and an average denier per filament of the first plush area filament yam is greater than an average denier per filament of the second plush area filament yam.
[0310] A26.4. The upper of any of clauses A26 to A26.3, wherein an average tensile strength of the plurality of exposed and affixed fibers of the first plurality of plush areas is greater than an average tensile strength of the plurality of exposed and affixed fibers of the second plurality of plush areas.
[0311] A26.4.1. The upper of clause A26.4, wherein the first plush areas are on the lining fabric front side, and the second plush areas are on the lining fabric back side.
[0312] A26.4.2. The upper of clause A26.4.1 , wherein the first plurality of plush area comprises a first plush area yam, the second plurality of plush areas comprises a second plush area yam, and the first plush area yam has a greater tenacity than the second plush area yam.
[0313] A26.5.The upper of any of clauses A26 to A26.4, wherein an average moisture regain of the plurality of exposed and affixed fibers of the first plush areas is greater than an average moisture regain of the plurality of exposed and affixed fibers of the second plurality of plush areas.
[0314] A26.6. The upper of any of clauses A26 to A26.5, wherein an average angle of the plurality of exposed and affixed fibers of the first plurality of plush areas relative to the lining fabric base fabric structure is greater than an average angle of the plurality of exposed and affixed fibers of the second plurality of plush areas relative to the lining fabric base fabric structure.A26.6.1. The upper of clause A26.6.1, wherein a majority of the plurality of exposed and affixed fibers of the first plurality of plush areas is substantially perpendicular to the lining fabric base fabric structure, and a majority of the plurality of exposed and affixed fibers of the second plurality of plush areas is at an oblique angle to the lining fabric base fabric structure.
[0315] A27. The upper of any of clauses AO through A26.6.1, wherein the lining fabric includes the plurality of plush areas on the lining fabric back side, and a majority of the plurality of exposed and affixed fibers of the plurality of plush areas on the lining fabric back side have a moisture regain of 4 percent or more, or ranging from about 4 percent to about 16 percent.
[0316] A28. The upper of any of clauses AO through A27, wherein the lining fabric includes the plurality of plush areas on the lining fabric front side, and a majority of the plurality of exposed and affixed fibers of the plurality of plush areas on the lining fabric front side have a moisture regain of 3 percent or less, or ranging from about 0.1 percent to about 3 percent.
[0317] A29. The upper of any of clauses A0 through A26.6.1, wherein the lining fabric includes the plurality of plush areas on the lining fabric back side, and a majority of the plurality of exposed and affixed fibers of the plurality of plush areas on the lining fabric back side have a moisture regain of 4 percent or more, or ranging from about 4 percent to about 16 percent; and the lining fabric includes the plurality of plush areas on the lining fabric front side, and a majority of the plurality of exposed and affixed fibers of the plurality of plush areas on the lining fabric front side have a moisture regain of 3 percent or less, or ranging from about 0.1 percent to about 3 percent.
[0318] A30. The upper of any of clauses A0 through A26.61 , wherein the lining fabric includes the plurality of plush areas on the lining fabric back side, and a majority of the plurality of exposed and affixed fibers of the plurality of plush areas on the lining fabric back side have a moisture regain of 3 percent or less, or ranging from about 0.1 percent to about 3 percent.
[0319] A31. The upper of any of clauses A0 through A27, wherein the lining fabric includes the plurality of plush areas on the lining fabric front side, and a majority of the plurality of exposed and affixed fibers of the plurality of plush areas on the lining fabricfront side have a moisture regain of 4 percent or more, or ranging from about 4 percent to about 16 percent.
[0320] A32. The upper of any of clauses AO through A26.61 , wherein the lining fabric includes the plurality of plush areas on the lining fabric back side, and a majority of the plurality of exposed and affixed fibers of the plurality of plush areas on the lining fabric back side have a moisture regain of 3 percent or less, or ranging from about 0.1 percent to about 3 percent; and wherein the lining fabric includes the plurality of plush areas on the lining fabric front side, and a majority of the plurality of exposed and affixed fibers of the plurality of plush areas on the lining fabric front side have a moisture regain of 4 percent or more, or ranging from about 4 percent to about 16 percent.
[0321] A32.1.The upper of clause A32, wherein the lining fabric is configured to transfer moisture from the lining back side to the lining fabric front side.
[0322] A32.2.The upper of clause A32 or A32.1, wherein the upper is configured to transfer moisture from the foot-receiving cavity to the outermost surface of the upper.
[0323] A33. The upper of any of clauses A26 to A32.2, wherein the lining fabric or the face fabric or both the lining fabric and the face fabric includes a first plurality of plush areas comprising a first plurality of exposed and affixed first polymer fibers and a second plurality of plush areas comprising a second plurality of exposed and affixed second polymer fibers, wherein the first plurality of exposed and affixed first polymer fibers differ from the second plurality of exposed and affixed fibers based on at least one characteristic chosen from polymeric component, tensile strength, color, average diameter, average length, average moisture regain, and type of attachment of the plurality of fibers to a respective lining fabric or face fabric base fabric structure.
[0324] A33.1 The upper of clause A33, wherein the lining fabric includes the first plurality of plush areas on the lining fabric front side and the second plurality of plush areas on the lining fabric back side.
[0325] A33.2. The upper of clause A33, wherein the lining fabric includes the first plurality of plush areas on the lining fabric back side and the second plurality of plush areas on the lining fabric front side.
[0326] A33.3. The upper of clause A33, wherein the lining fabric includes the first plurality of plush areas and the second plurality of plush areas on the lining fabric front side.A33.4. The upper of clause A33, wherein the lining fabric includes the first plurality of plush areas and the second plurality of plush areas on the lining fabric back side.
[0327] A33.5.The upper of any of clauses A33 through A33.4, wherein a first polymeric component of the first plurality of fibers has a lower hardness than a second polymeric component of the second plurality of fibers.
[0328] A33.6.The upper of any of clauses A33 through A33.5, wherein the first polymeric component of the first plurality of fibers has a lower tensile strength than the second polymeric component of the second plurality of fibers.
[0329] A33.7.The upper of any of clauses A33 through A33.6, wherein the first polymeric component of the first plurality of fibers has a lower moisture regain than the second polymeric component of the second plurality of fibers.
[0330] A33.8.The upper of any of clauses A33 through A33.7, wherein the first polymeric component of the first plurality of fibers has a lower melting temperature than the second polymeric component of the second plurality of fibers.
[0331] A33.8.1. The upper of clause A33.8, wherein, in at least one of the plurality of plush areas of the upper, the first plurality of exposed and affixed fibers of the at least one plush area comprise or consist of a plurality of low melt fibers having a lower melting temperature than materials of the base fabric structure, and the plurality of low melt fibers are present in a fused plush area in which the plurality of low melt fibers are fused to each other or are fused to other non-low melt fibers in the at least one plush area or are fused to the base fabric structure or any combination thereof.
[0332] A33.8.1.1. The upper of clause A33.8.1 , wherein, in the fused plush area, the at least one fused plush area is in the lining fabric, the plurality of low melt fibers are fused to each other, are fused to the lining fabric base fabric structure, and are fused to the face fabric, in a fused lining fabric and face fabric region.
[0333] A33.8.1.2. The upper of clause A33.8.1 or A33.8.1.1, wherein the fused plush area is within the exposed structure region.
[0334] A33.8.1.3. The upper of any one of clauses A33.8.1 through A33.8.1.2, wherein the fused plush area is outside the exposed structure region.
[0335] A33.8.1.4. The upper of any one of clauses A33.8.1 through A33.8.1.3, wherein the fused plush area defines an outermost surface of the upper.A33.8.1.5. The upper of any one of clauses A33.8.1 through A33.8.1.4, wherein the fused plush area is on an inner layer of the upper.
[0336] A33.8.1.6. The upper of any one of clauses A33.8.1 through A33.8.1.5, wherein the fused plush area defines a surface configured to define a portion of the foot-receiving cavity of the upper.
[0337] A33.8.1.7. The upper of any one of clauses A33.8.1 through A33.8.1.6, wherein the fused plush area is in a heel region of the upper or is in a toe region of the upper.
[0338] A33.8.1.8. The upper of any one of clauses A33.8.1 through A33.8.1.7, wherein the fused plush area is in a lateral region of the upper or is in a toe region of the upper.
[0339] A33.8.1.9. The upper of any one of clauses A33.8.1 through A33.8.1.8, wherein the fused plush area is effective to reduce stretch of the fused plush area as compared to an unfused plush area of the same construction, and the fused plush area is configured to provide lock-down to a foot of a wearer when the upper is present in an article of footwear.
[0340] A33.8.1.10. The upper of any one of clauses A33.8.1 through A33.8.1.9, wherein the fused plush area is effective to increase durability of a surface of the upper as compared to an unfused plush area of the same construction.
[0341] A33.8.1.11. The upper of any one of clauses A33.8.1 through A33.8.1.10, wherein the fused plush area is effective to increase water resistance of a surface of the upper as compared to an unfused plush area of the same construction.
[0342] A34. The upper of any of clauses A7 through A33.8.1.6, wherein the plurality of plush areas is visible through the exposed structure region when viewed from the outermost front surface of the upper.
[0343] A34.1. The upper of clause A34, wherein the plurality of plush areas separated by the ground area form a pattern, and the pattern is visible through the exposed structure region when viewed from the outermost front surface of the upper.
[0344] A35. The upper of any of clauses A7 through A34.1, wherein, in the exposed structure region, the upper consists of the face fabric and the lining fabric and the lining fabric includes the plurality of plush area separated by the ground area.A35.1.The upper of clause A35, wherein, in the exposed structure region, the upper consists of the face fabric and the lining fabric and the lining fabric back surface includes the plurality of plush area separated by the ground area.
[0345] A35.2.The upper of clause 35, wherein, in the exposed structure region, the upper consists of the face fabric and the lining fabric and the lining fabric face surface includes the plurality of plush area separated by the ground area.
[0346] A35.3. The upper of clause 35, wherein, in the exposed structure region, the upper consists of the face fabric and the lining fabric and both the lining fabric back surface and the lining fabric face surface include the plurality of plush area separated by the ground area.
[0347] A36. The upper of any of clauses A7 through A35.3, wherein the exposed structure region has a minimum continuous surface area of 0.5 square centimeters, or of 1 square centimeter, or of 2 square centimeters, or of more than 2 square centimeters, or of more than 4 square centimeters, or of more than 6 square centimeters.
[0348] A37. The upper of any of clauses A0 through A36, wherein, in a portion of the upper chosen from a portion of a lateral region of the upper, a portion of a medial region of the upper, a portion of a forefoot region of the upper, a portion of a toe region of the upper, and any combination thereof, the upper consists of the face fabric or consists of the lining fabric or consists of the face fabric and the lining fabric.
[0349] A37.1.The upper of clause A37, wherein the portion of the upper consisting of the face fabric or consisting of the lining fabric or consisting of the face fabric and the lining fabric has a minimum continuous surface area of 0.5 square centimeters, or of 1 square centimeter, or of 2 square centimeters, or of more than 2 square centimeters, or of more than 3 square centimeters, or more than 4 square centimeters, or more than 6 square centimeters.
[0350] A38. The upper of any of clauses A0 through A37.1, wherein each plush area of the plurality of plush areas has an average thickness at least 10% greater, or at least 20% greater, or at least 30% greater than an average thickness of the ground area.
[0351] A39. The upper of any of clauses A0 through A38, wherein each plush area of the plurality of plush areas has an average thickness of at least 1 mm, or at least 1 ,5mm, or at least 2mm, or at least 2.5mm, or at least 3mm.A40. The upper of any of clauses AO through A39, wherein the ground area has an average thickness of less than 1.5mm, or less than 1mm, or less than 0.5mm.
[0352] A41. The upper of any of clauses A0 through A40, wherein the lining fabric back side defines the outermost back layer of the upper on a medial side of the upper, or on a lateral side of the upper, or in a toe region of the upper, or in a forefoot region of the upper, or in a vamp region of the upper, or in any combination thereof.
[0353] A42. The upper of any of clauses A0 through A41 , wherein, in a heel region of the upper, an additional heel textile defines the outermost back layer of the upper.
[0354] A42.1.The upper of clause A42, wherein the additional heel textile is directly bonded to the lining fabric back side.
[0355] A43. The upper of any of clauses A7 through A42.1, wherein the face fabric in the exposed structure region is air permeable.
[0356] A43.1.The upper of clause A43, wherein the face fabric in the exposed structure region has an air permeability of at least 200 liters per square meter per second, or of at least 300 liters per square meter per second, or at least 400 liters per square meter per second.
[0357] A44. The upper of any one of clauses A7 through A44.1 , wherein the face fabric consists of a single knitted, crocheted, woven or non-woven face fabric.
[0358] A44.1.The upper of A44, wherein the face fabric consists of a single knitted face fabric having a uniform knit structure.
[0359] A44.2. The upper A44 or A44.1 , wherein the face fabric comprises a monofilament yam.
[0360] A44.3.The upper of any one of clauses A44 through A44.2, wherein substantially all of the face fabric in the exposed structure region consists of a monofilament yam, or consists or a multifilament yam, or consists of a monofilament yam and a multifilament yam.
[0361] A44.3.1. The upper of clause A44.3, wherein the face fabric consists of the monofilament yam, or consists of the multifilament yam, or consists of the monofilament yam and the multifilament yam.
[0362] A44.3.1.1. The upper of clause A44.3.1 , wherein the face fabric consists of the monofilament yam knitted, crocheted, woven or entangled with the multifilament yam.A44.3.1.2. The upper of clause A44.3.1 or A44.3.1.1, wherein the face fabric consists of the monofilament yarn knitted or woven with the multifilament yam.
[0363] A44.3.1.2. The upper of any of clause A44.3.1 through A44.3.1.2, wherein the face fabric consists of the monofilament yam plaited and interlooped with the multifilament yam.
[0364] A44.4.The upper of any one of clauses A43 through A44.3.1.1, wherein the face fabric has a fabric weight ranging from about 250 grams per square meter to about 550 grams per square meter, or from about 350 grams per square meter to about 450 grams per square meter.
[0365] A44.5. The upper of any one of clauses A43 through A44.4, wherein the face fabric is a knit fabric, and a knit gauge of the knit fabric ranges from about 10 to about 30 or from about 15 to about 25 or is about 20.
[0366] A44.6.The upper of any of clauses A43 through A44.5, wherein the portion of the face fabric present in the exposed structure region has a minimum continuous surface area of 0.5 square centimeters, or of 1 square centimeter, or of 2 square centimeters, or of more than 2 square centimeters, or of more than 3 square centimeters, or more than 4 square centimeters, or more than 6 square centimeters.
[0367] A45. The upper of any of clauses A7 through A44.6, wherein the lining fabric in the exposed structure region has an air permeability of at least 200 liters per square meter per second, or of at least 300 liters per square meter per second, or at least 400 liters per square meter per second.
[0368] A46. The upper of any of clauses A7 through A45, wherein the lining fabric consists of a single knitted, crocheted, woven or non-woven face fabric.
[0369] A46.1.The upper of clause A46, wherein the lining fabric consists of a single knitted, crocheted, woven or non-woven face fabric, and the plurality of plush areas are integrally knitted, crocheted, woven, or entangled with the ground area.
[0370] A47. The upper of any one of clauses A0 through A46.1 , wherein the lining fabric consists of the plurality of plush areas and the ground area.
[0371] A48. The upper of any one of clauses A0 through A47, wherein the ground area of the lining fabric comprises a ground area yam in the lining fabric base fabric structure, and the plurality of plush areas of the lining fabric comprises the ground area yam and aplush area yarn, wherein, in the plush areas, the ground area yam is in the lining fabric base fabric structure, and the plush area yam provides the plurality of exposed fibers and is affixed to the lining fabric base fabric structure.
[0372] A48.1.The upper of clause A48, wherein, in substantially all of the ground area included in the exposed structure region, the lining fabric base fabric structure comprises or consists of the ground area yam.
[0373] A48.2.The upper of clause A48 or A48.1, wherein the lining fabric base fabric structure consists of the ground area yam.
[0374] A48.3.The upper of clause A48, wherein the lining fabric base fabric structure comprises the ground area yam and the plush area yam, and, in the ground area, the plush area yam does not stand proud of the base fabric structure on the lining fabric front side or on the lining fabric back side.
[0375] A48.4.The upper of any one of clauses A48 through A48.3, wherein the ground area yam or the plush area yam or both the ground yam and the plush yam comprises or consists of at least one multifilament yam.
[0376] A48.4.1The upper of clause A48.4, wherein the ground area yam consists of the at least one multifilament yam.
[0377] A48.5.The upper of any one of clauses A48 to A48.4.1, wherein the lining fabric base fabric structure is a knitted structure or is a woven structure.
[0378] A48.5.1. The upper of clause A48.5, wherein the knitted structure or the woven structure consists of the at least one multifilament yam, or consists of the at least one multifilament yam and an elasticated yam.
[0379] A49. The upper of any one of clauses AO to A48.4.1, wherein the plurality of exposed fibers comprises or consists of staple fibers or filaments or a combination of staple fibers and filaments, and each of the plurality of plush areas comprises the lining fabric base fabric structure with the plurality of exposed fibers bonded to the lining fabric base fabric structure on the lining fabric front side, on the lining fabric back side, or on both the lining fabric front side and the lining fabric back side.
[0380] A49.1.The upper of clause A49, wherein the plurality of exposed fibers is adhesively bonded to the lining fabric base fabric structure.A49.2. The upper of clause A49, wherein the plurality of exposed fibers is thermally bonded to the lining fabric base fabric structure.
[0381] A50. The upper of any one of clauses AO to A49.4.1, wherein the plurality of exposed fibers comprises or consists of staple fibers or filaments or a combination of staple fibers and filaments, and each of the plurality of plush areas comprises the lining fabric base fabric structure with the plurality of exposed fibers entangled in the lining fabric base fabric structure.
[0382] A50.1.The upper of clause A50, wherein the plurality of exposed fibers is needle entangled in the lining fabric base fabric structure.
[0383] A50.2.The upper of clause A50, wherein the plurality of exposed fibers is hydroentangled in the lining fabric base fabric structure.
[0384] A51. The upper of any one of clauses AO to A50.2.1, wherein the plurality of exposed fibers comprises or consists of exposed fibers or filaments of a plush area yarn, and each of the plurality of plush areas comprises the lining fabric base fabric structure with the plush area yam adhesively bonded to or thermally bonded to the lining fabric base fabric structure.
[0385] A52. The upper of any one of clauses AO to A50.2.1, wherein the plurality of exposed fibers comprises or consists of exposed fibers or filaments of a plush area yarn, and each of the plurality of plush areas comprises the lining fabric base fabric structure with the plush area yarn inlaid in the lining fabric base fabric structure.
[0386] A52.1.The upper of clause A52, wherein the plush area yarn is inlaid in a knitted lining fabric base structure.
[0387] A52.2.The upper of clause A52, wherein the plush area yarn is inlaid in a woven lining fabric base structure.
[0388] A53. The upper of any one of clauses AO to A50.2.1, wherein the plurality of exposed fibers comprises or consists of exposed fibers or filaments of a plush area yarn, and the lining fabric base fabric structure of each of the plurality of plush areas is a knitted lining fabric base fabric structure including the plush area yam interlooped with the ground area yam.
[0389] A53.1.The upper of clause A53, wherein the exposed fibers or filaments include cut or uncut terry loops of the plush area yam.A54. The upper of any one of clauses AO to A53.2.1, wherein the plurality of exposed fibers comprises or consists of exposed fibers or filaments of a plush area yarn, and the lining fabric base fabric structure of each of the plurality of plush areas is a woven lining fabric base fabric structure including the plush area yam interwoven with the ground area yarn.
[0390] A54.1. The upper of clause A54, wherein exposed fibers or filaments include cut or uncut terry loops of the plush area yam.
[0391] A55. The upper of any one of clauses AO through A54.1 , wherein the plush yam is a spun filament yam or is a multifilament yam.
[0392] A56. The upper of any one of clauses AO through A55, wherein the lining fabric base fabric structure further comprises an elasticated yam.
[0393] A57. The upper of any one of clauses AO through A56, wherein the lining fabric has a fabric weight ranging from about 50 grams per square meter to about 400 grams per square meter, or from about 150 grams per square meter to about 350 grams per square meter, or from about 200 grams per square meter to about 300 grams per square meter, or about 250 grams per square meter.
[0394] A58. The upper of any of clauses A0 through A57, wherein the portion of the lining fabric present in the exposed structure region has a minimum continuous surface area of 0.5 square centimeters, or of 1 square centimeter, or of 2 square centimeters, or of more than 2 square centimeters, or of more than 3 square centimeters, or more than 4 square centimeters, or more than 6 square centimeters.
[0395] A59. The upper of any one of clauses A0 through A58, wherein an area of the lining fabric covered by the plurality of plush areas has a minimum surface area of 1 square centimeter, or of 2 square centimeters, or of 3 square centimeters, or of 4 square centimeters, or of 6 square centimeters.
[0396] B0. An upper for an article of footwear, the upper comprising:
[0397] a face fabric having a face fabric front side and a face fabric back side opposite the face fabric front side, wherein an outermost front surface of the upper includes an exposed face region defined by the face fabric front side, the outermost front surface of the upper includes the exposed face region, and the exposed face region is configured to form an externally-facing outermost front surface of the upper; anda lining fabric comprising a lining fabric having a lining fabric front side and a lining fabric back side opposite the lining fabric front side, the lining fabric consists of a single knit or woven fabric layer and includes a plurality of plush areas separated by a ground area, each of the plurality of plush areas includes a plurality of exposed fibers affixed to and standing proud of a lining fabric base fabric structure, the ground area includes the lining fabric base fabric structure and, in the ground area, the lining fabric base fabric structure is free of any exposed fibers standing proud of the lining fabric base fabric structure;
[0398] wherein the upper includes the lining fabric front side positioned below and in contact with the face fabric back side, an exposed back region of the upper is defined by the lining fabric back side and defines at least an outermost back surface of the upper, and is configured to define a foot-receiving cavity of an article of footwear; an exposed front region of the upper is defined by the face fabric front side and is configured to define an outermost front surface of an upper of the article of footwear; and the exposed back region and the exposed front region align in an exposed structure region of the upper.
[0399] B1. The upper for an article of footwear according to clause BO, wherein the upper is the upper according to any one of A1 to A59.
[0400] CO. An upper for an article of footwear comprising:
[0401] a face fabric having a face fabric front side and a face fabric back side opposite the face fabric front side, wherein the face fabric is a knitted or woven fabric comprising a monofilament yarn, an outermost front surface of the upper includes an exposed face region defined by the face fabric front side, the outermost front surface of the upper includes the exposed face region, and the exposed face region forms an externally-facing outermost front surface of the upper; and
[0402] a lining fabric having a lining fabric front side and a lining fabric back side opposite the lining fabric front side, a portion of the lining fabric back side defines an outermost back surface of the upper and defines a foot-receiving cavity of an article of footwear; wherein the lining fabric includes a plurality of plush areas, a ground area, and a base fabric structure integrally connecting the plurality of plush areas and the ground area, with the plurality of plush areas and the ground area forming a pattern on lining fabric;each plush area is separated from others of the plurality by the ground area, and each plush area comprises a plurality of exposed fibers affixed to and standing proud of the lining fabric base fabric structure on at least one of the lining fabric front side and the lining fabric back side;
[0403] the ground area is free of the plurality of exposed fibers standing proud of the base fabric structure and is air permeable;
[0404] an average thickness of the lining fabric in each plush area is greater than an average thickness of the lining fabric in the ground area;
[0405] the base fabric structure is a knitted or woven structure including a ground area yam;
[0406] wherein, in the upper, the lining fabric front side is positioned below and in contact with the face fabric back side, an exposed back region of the upper is defined by the lining fabric back side, the exposed back region defines at least an outermost back surface of the upper, and the exposed back region defines a foot-receiving cavity of an article of footwear; an exposed front region of the upper is defined by the face fabric front side, the exposed front region defines an outermost front surface of the upper of the article of footwear; and the exposed back region and the exposed front region align in an exposed structure region of the upper, the exposed structure region includes the pattern, and the pattern is configured to allow air to flow between the foot-receiving cavity and the outermost front surface of the upper.
[0407] C1. The upper for an article of footwear according to clause CO, wherein the upper is the upper according to any one of A1 to A59.
[0408] DO. An article of footwear comprising an upper according to any of clauses AO through B1.
[0409] E0. A method of manufacturing an upper for an article of footwear, comprising affixing a lining fabric to a second component to form the upper, wherein the upper is an upper according to any of clauses AO through C1.
[0410] F0. A method of manufacturing an article of footwear, the method comprising affixing an upper to a sole structure, wherein the upper is an upper according to any one of clauses AO through B1.GO. A product comprising any feature described herein, either individually or in combination with any other such feature, in any configuration.
[0411] HO. A process for manufacturing an upper, the process comprising any process step described herein, in any order, using any modality.
[0412] Advantages, Features, and Benefits
[0413] The different embodiments and examples of the uppers described herein provide several advantages over known solutions for providing lightweight, breathable uppers. For example, illustrative embodiments and examples described herein allow heat and moisture to dissipate through the upper, cooling the foot of a wearer.
[0414] Additionally, and among other benefits, illustrative embodiments and examples described herein are lightweight, including upper regions consisting of only two fabric layers.
[0415] Additionally, and among other benefits, illustrative embodiments and examples described herein provide a soft surface directly contacting the foot of a wearer or provide an insulating layer or provide a durable outer layer or any combination thereof without decreasing a breathability of the article of footwear.
[0416] No known system or device can perform these functions. However, not all embodiments and examples described herein provide the same advantages or the same degree of advantage.
[0417] Conclusion
[0418] The disclosure set forth above may encompass multiple distinct examples with independent utility. Although each of these examples has been disclosed in its preferred form(s), the specific embodiments thereof as disclosed and illustrated herein are not to be considered in a limiting sense, because numerous variations are possible. The subject matter of the example(s) includes all novel and nonobvious combinations and subcombinations of the various elements, features, functions, and / or properties disclosed herein.
[0419] Certain combinations and subcombinations regarded as novel and nonobvious are particularly pointed out throughout this disclosure. Other combinations andsubcombinations of features, functions, elements, and / or properties may be claimed, with or without variation in scope, in applications claiming priority from this or a related application.
[0420] Explicit reference is hereby made to all examples, embodiments, inventions, labels, terms, descriptions, and illustrative measurements shown in the drawings and / or in any included appendices, whether or not described further herein. To the extent that section headings are used within this disclosure, such headings are for organizational purposes only.
Claims
CLAIMS:
1. An article of footwear comprisingan upper and a sole structure affixed to the upper, wherein the upper comprises:a face fabric having a face fabric front side and a face fabric back side opposite the face fabric front side, wherein an outermost front surface of the upper includes an exposed face region defined by the face fabric front side, and the exposed face region forms an externally-facing outermost front surface of the upper; anda lining fabric having a lining fabric front side and a lining fabric back side opposite the lining fabric front side, wherein a portion of the lining fabric back side defines an outermost back surface of the upper and defines a foot-receiving cavity of the article of footwear;wherein the lining fabric includes a plurality of plush areas, a ground area, and a base fabric structure integrally connecting the plurality of plush areas and the ground area, wherein the plurality of plush areas and the ground area form a pattern on the lining fabric;wherein each plush area is separated from others of the plurality of plush areas by the ground area, and each plush area comprises a plurality of exposed fibers affixed to and standing proud of the lining fabric base fabric structure on at least one of the lining fabric front side and the lining fabric back side;wherein the ground area is free of the plurality of exposed fibers standing proud of the base fabric structure and is air permeable;wherein an average thickness of the lining fabric in each plush area is greater than an average thickness of the lining fabric in the ground area; andwherein the base fabric structure is a knitted or woven structure including a ground area yarn;wherein, in the upper, the lining fabric front side is positioned below and in contact with the face fabric back side, an exposed back region of the upper is defined by the lining fabric back side, the exposed back region defines at least an outermost back surface of the upper, and the exposed back region defines the foot-receiving cavity of an article of footwear; an exposed front region of the upper is defined by the face fabric front side, theexposed front region defines the outermost front surface of the upper; and the exposed back region and the exposed front region align in an exposed structure region of the upper, wherein the exposed structure region includes the pattern, and the pattern is configured to allow air to flow between the foot-receiving cavity and the outermost front surface of the upper.
2. The article of footwear of claim 1, wherein the face fabric and the lining fabric are affixed directly or indirectly to each other only along an inner perimeter of the upper, along an outer perimeter of the upper, along a seam bringing two ends of the upper together, or any combination thereof.
3. The article of footwear of claim 2, wherein the seam bringing the two ends of the upper together is in a heel region of the upper, or is on a lateral side of the upper, or is on a medial side of the upper, or is in a vamp region of the upper, or is in a toe region of the upper.
4. The article of footwear of claim 1, wherein the face fabric and the lining fabric are not directly or indirectly affixed to each other in the exposed structure region of the upper.
5. The article of footwear of claim 1, wherein the exposed structure region is on a medial side of the upper, is on a lateral side of the upper, is in a vamp region of the upper, is in a forefoot region of the upper, is in a toe region of the upper, or is in any combination thereof.
6. The article of footwear of claim 1 , wherein the exposed structure region of the upper covers at least 20 percent of the outermost front surface of the upper.
7. The article of footwear of claim 1 , wherein the exposed structure region of the upper has a continuous surface area of at least 3 square centimeters, the plurality of plush areas in the exposed structure region has a total surface area of at least 2 squarecentimeters, and the ground area separating each plush area of the plurality of plush areas has a width of at least 2 millimeters.
8. The article of footwear of claim 1 , wherein each plush area of the plurality of plush areas of the lining fabric has an average thickness at least 20% greater than an average thickness of the ground area.
9. The article of footwear of claim 1 , wherein the upper further comprises an additional component positioned between the face fabric and the lining fabric in the exposed structure region.
10. The article of footwear of claim 9, wherein the additional component is affixed to the face fabric or to the lining fabric along an inner perimeter of the upper, or along an outer perimeter of the upper, or in a heel region of the upper, or along a seam bringing two ends of the upper together, or any combination thereof.
11. The article of footwear of claim 1, wherein the upper further comprises a bonded layer chosen from a polymeric film, a polymeric coating, a third fabric, or any combination thereof; the bonded layer is affixed to the face fabric front side or the lining fabric back side; and the exposed structure region is free of the bonded layer.
12. The article of footwear of claim 1, wherein the exposed structure region consists of the face fabric and the lining fabric.
13. The article of footwear of claim 1, wherein the face fabric is a knitted, crocheted, or woven fabric.
14. The article of footwear of claim 14, wherein the face fabric comprises a monofilament yarn.
15. The article of footwear of claim 1, wherein the lining fabric is a knitted, crocheted or woven fabric.
16. The article of footwear of claim 15, wherein the lining fabric comprises the ground area yam and a plush area yam, and at least one of the ground area yam and the plush area yam is a spun fiber yam or is a multifilament yam.
17. The article of footwear of claim 16, wherein each plush area of the plurality of plush areas includes terry loops of the plush area yam inlaid, knitted, or woven in the lining fabric base fabric structure, and the terry loops stand proud of the lining fabric base fabric structure.
18. The article of footwear of claim 1, wherein the plurality of exposed and affixed fibers comprise fibers or filaments adhesively or thermally bonded to the lining fabric back side or to the lining fabric front side or to both the lining fabric back side and the lining fabric front side.
19. The article of footwear of claim 1 , wherein, in the exposed structure region, the lining fabric front side includes the plurality of plush areas, the plurality of plush areas on the lining fabric front side contact the face fabric back side, and the plurality of plush areas on the lining fabric front side are configured to act as insulation and insulate a foot of a wearer in the foot-receiving cavity.
20. The article of footwear of claim 1 , wherein, in the exposed structure region, the lining fabric back side includes the plurality of plush areas, and the plurality of plush areas on the lining fabric back side are configured to contact and cushion a foot of a wearer in the foot-receiving cavity.