Thermoforming upper process with reinforcement

Abstract

An article of footwear is provided and includes an upper having a medial side and a lateral side simultaneously formed from a single sheet of material in a thermoforming mold. The medial side and lateral side are joined to each other such that a joint between the medial side and the lateral side extends continuously from a heel portion of the upper to a toe portion of the upper.

1 . An article of footwear comprising:
 an upper including a medial side and a lateral side simultaneously formed from a single sheet of material in a thermoforming mold and joined to each other such that a joint between said medial side and said lateral side extends continuously from a heel portion of said upper to a toe portion of said upper.   
     
     
         2 . The article of footwear according to  claim 1 , further comprising a tongue connected to said upper and formed simultaneously with said medial and lateral sides from said single sheet of material. 
     
     
         3 . The article of footwear according to  claim 1 , further comprising an outsole disposed on a bottom portion of said upper. 
     
     
         4 . The article of footwear according to  claim 3 , wherein said outsole is over-injected directly onto said upper. 
     
     
         5 . The article of footwear according to  claim 3 , wherein said outsole includes a tread pattern or a plurality of integrally formed cleats. 
     
     
         6 . The article of footwear according to  claim 3 , further comprising a counter integrally formed with said outsole. 
     
     
         7 . The article of footwear according to  claim 1 , further comprising a toe cover disposed over a portion of said joint. 
     
     
         8 . The article of footwear according to  claim 1 , wherein said sheet of material includes at least one localized thick spot operable to form an area of increased strength on said upper. 
     
     
         9 . The article of footwear according to  claim 1 , wherein said area of increased strength is at least one of a heel counter and a toe counter. 
     
     
         10 . The article of footwear according to  claim 1 , further comprising at least one reinforcement member molded into at least one of said medial side and said lateral side. 
     
     
         11 . The article of footwear according to  claim 1 , wherein said joint between said medial and lateral sides is formed by at least one of stitching, high-frequency welding, and adhesive bonding. 
     
     
         12 . An upper for an article of footwear, the upper comprising:
 a medial portion including a first heel portion, a first bottom portion, and a first toe portion formed from a sheet of material in a thermoforming mold; and   a lateral portion including a second heel portion, a second bottom portion, and a second toe portion formed from said sheet of material in said thermoforming mold, said lateral portion joined to said medial portion to attach said first heel portion to said second heel portion, said first bottom portion to said second bottom portion, and said first toe portion to said second toe portion.   
     
     
         13 . The upper according to  claim 12 , wherein said medial portion is attached to said lateral portion along a continuous joint extending from a joint between said first and second heel portions, along a joint between said first and second bottom portions, and to a joint between said first and second toe portions. 
     
     
         14 . The upper according to  claim 13 , wherein said continuous joint is formed by at least one of stitching, high-frequency welding, and adhesive bonding. 
     
     
         15 . The upper according tot  claim 14 , further comprising a tongue formed simultaneously from said sheet of material. 
     
     
         16 . The upper according to  claim 12 , further comprising an outsole over-injected directly onto said first bottom portion and said second bottom portion. 
     
     
         17 . The upper according to  claim 16 , wherein said outsole includes a tread pattern or a plurality of integrally formed cleats. 
     
     
         18 . The upper according to  claim 16 , further comprising a counter integrally formed with said outsole. 
     
     
         19 . The upper according to  claim 12 , further comprising integrally formed counter halves respectively formed with said medial portion and said lateral portion. 
     
     
         20 . The upper according to  claim 12 , further comprising at least one reinforcement member molded into at least one of said medial portion and said lateral portion. 
     
     
         21 . A method of manufacturing an upper for an article of footwear, the method comprising:
 providing a sheet of material;   forming said sheet into a medial portion of the upper in a thermoforming mold;   forming said sheet into a lateral portion of the upper in a thermoforming mold;   separating said medial portion from said sheet;   separating said lateral portion from said sheet; and   attaching said medial portion to said lateral portion along a joint extending from a heel portion to a toe portion of said attached medial and lateral portions.   
     
     
         22 . The method of  claim 21 , wherein said forming steps are performed in the same mold. 
     
     
         23 . The method of  claim 21 , wherein said separating includes laser cutting said medial portion and said lateral portion from said sheet. 
     
     
         24 . The method of  claim 21 , wherein said joining includes at least one of stitching, high-frequency welding, and adhesively bonding. 
     
     
         25 . The method of  claim 21 , wherein said joining includes forming a continuous joint between said medial portion and said lateral portion extending from said heel portion to said toe portion. 
     
     
         26 . The method of  claim 21 , further comprising forming an outsole over a bottom portion of said joined medial and lateral portions. 
     
     
         27 . The method of  claim 26 , wherein said forming said outsole includes over-injecting said outsole onto said joined medial and lateral portions. 
     
     
         28 . The method of  claim 21 , further comprising forming a reinforced heel counter on said medial and lateral portions. 
     
     
         29 . The method of  claim 28 , wherein first and second portions of said reinforced heel counter are formed simultaneously with said medial and lateral portions. 
     
     
         30 . The method of  claim 21 , further comprising positioning a sock liner within said joined medial and lateral portions.