Method For Assembling A Tongue For An Article Of Footwear

Abstract

An article of footwear includes a tongue. The tongue includes a top layer and a bottom layer. The top layer is attached to a portion of an upper. The bottom layer is attached to the top layer at a distance that is staggered from where the top layer is attached to the upper. An intermediate layer of cushioning material is optionally provided between the top layer and the bottom layer. Alternatively, the top layer of the tongue is formed integrally from the material of a portion of the upper. The bottom layer is attached to the top layer with the optional intermediate layer of cushioning material disposed in between. The staggered attachment of the top and bottom layers of the tongue provides a smooth surface in contact with a foot of a wearer on the inside of the article of footwear and presents a stitchless visible tongue to the wearer on the outside of the article of footwear.

1 . An article of footwear, comprising:
 an upper;   a tongue, the tongue including a top layer and a bottom layer;   an attachment region associated with a portion of the upper and the top layer of the tongue; and   wherein the bottom layer is attached to the top layer of the tongue with a staggered attachment that is displaced from the attachment region by a distance.   
     
     
         2 . The article of footwear according to  claim 1 , wherein the attachment region comprises the top layer of the tongue being integrally formed with the portion of the upper. 
     
     
         3 . The article of footwear according to  claim 2 , wherein the portion of the upper comprises substantially all of the upper. 
     
     
         4 . The article of footwear according to  claim 1 , wherein the attachment region comprises the top layer of the tongue attached to the portion of the upper. 
     
     
         5 . The article of footwear according to  claim 4 , wherein the portion of the upper comprises a vamp. 
     
     
         6 . The article of footwear according to  claim 4 , wherein the top layer of the tongue is attached to the portion of the upper using stitching. 
     
     
         7 . The article of footwear according to  claim 1 , wherein an overlay element is disposed on the attachment region. 
     
     
         8 . The article of footwear according to  claim 1 , wherein the tongue further comprises an intermediate layer disposed between the top layer and the bottom layer. 
     
     
         9 . A method for assembling a tongue for an article of footwear, comprising:
 providing at least a portion of an upper, the portion of the upper including a first portion configured to be associated with a forefoot region of the article of footwear and a second portion disposed opposite the first portion;   providing a portion of a tongue, the portion of the tongue including a top layer having a front edge and a rear edge;   attaching the second portion of the upper and the front edge of the top layer of the tongue at an attachment region; and   attaching a bottom layer to the top layer of the tongue, the bottom layer having a staggered attachment that is displaced from the attachment region by a distance.   
     
     
         10 . The method according to  claim 9 , further comprising attaching the bottom layer to the top layer along the rear edge of the top layer. 
     
     
         11 . The method according to  claim 10 , wherein the step of attaching the bottom layer to the top layer further comprises:
 stitching the bottom layer to the top layer at a first distance from the front edge; and   stitching the bottom layer to the top layer at a second distance from the rear edge.   
     
     
         12 . The method according to  claim 11 , wherein the first distance is larger than the second distance. 
     
     
         13 . The method according to  claim 9 , wherein the front edge of the top layer of the tongue is attached to the second portion of the upper using stitching. 
     
     
         14 . The method according to  claim 9 , further comprising:
 providing at least one overlay element;   aligning the at least one overlay element over the attachment region; and   applying heat to the at least one overlay element to attach the overlay element to the portion of the upper and the top layer at the attachment region.   
     
     
         15 . The method according to  claim 9 , further comprising disposing an intermediate layer between the bottom layer and the top layer. 
     
     
         16 . A method for assembling a tongue for an article of footwear, comprising:
 providing an upper, the upper including a first portion configured to be associated with a majority of an exterior of the article of footwear and a second portion configured to be associated with a top layer of a tongue, the first portion and the second portion being integrally formed at an attachment region;   providing a bottom layer of the tongue, the bottom layer being initially separate from the upper; and   attaching the bottom layer to the top layer of the tongue, the bottom layer having a staggered attachment that is displaced from the attachment region by a distance.   
     
     
         17 . The method according to  claim 16 , further comprising attaching the bottom layer to the top layer along a rear edge of the top layer. 
     
     
         18 . The method according to  claim 17 , wherein the step of attaching the bottom layer to the top layer further comprises:
 stitching the bottom layer to the top layer at a first distance from the attachment region; and   stitching the bottom layer to the top layer at a second distance from the rear edge.   
     
     
         19 . The method according to  claim 18 , wherein the first distance is larger than the second distance. 
     
     
         20 . The method according to  claim 16 , further comprising disposing an intermediate layer between the top layer and the bottom layer.