Thermoforming footwear method

Abstract

An article of footwear and method of manufacturing an article of footwear comprises an upper, a sole structure adjacent the upper and a thermoplastic material sheet attached to the upper to fixedly secure one or more components to the upper or fixedly secure the upper to a sole structure where the thermoplastic material sheet provides the primary or only means for securing the components to the upper and the upper to the sole structure.

What is claimed is: 
     
         1 . An article of footwear comprising:
 an upper;   a sole structure adjacent said upper; and   a thermoplastic material sheet attached to said upper and said sole structure to fixedly attach said upper to said sole structure, wherein said thermoplastic material sheet provides the primary or only means for securing the upper to the sole structure.   
     
     
         2 . The article of footwear of  claim 1 , further comprising a reinforcing mesh material juxtaposed with said thermoplastic material sheet and positioned over a seam between said upper and said sole structure. 
     
     
         3 . The article of footwear of  claim 1 , wherein said sole structure includes at least one of a midsole and an outsole. 
     
     
         4 . The article of footwear of  claim 1 , wherein said sole structure includes a bottom surface and said thermoplastic material sheet extends onto at least a portion of said bottom surface of said sole structure. 
     
     
         5 . The article of footwear of  claim 1 , wherein said thermoplastic material sheet comprises polyurethane. 
     
     
         6 . The article of footwear of  claim 1 , wherein said thermoplastic material sheet comprises at least one opening. 
     
     
         7 . The article of footwear of  claim 1 , wherein said thermoplastic material sheet comprises different thicknesses in different areas of the upper. 
     
     
         8 . A method of manufacturing footwear comprising:
 providing an upper and a sole structure;   heating a thermoplastic material sheet; and   applying said thermoplastic material sheet over said upper and at least a portion of said sole structure to fixedly attach said upper to said sole structure.   
     
     
         9 . The method of  claim 8 , wherein said thermoplastic material sheet comprises polyurethane. 
     
     
         10 . The method of  claim 8 , further comprising inverting the upper and the sole structure prior to applying said thermoplastic material sheet over said upper and at least a portion of said sole structure. 
     
     
         11 . The method of  claim 8 , further comprising removably attaching at least one cover plate onto the upper and the sole structure to cover at least a portion of the upper and the sole structure to enable at least a portion of the thermoplastic material sheet to be cut away. 
     
     
         12 . The method of  claim 8 , wherein said step of applying comprises forming a partial vacuum with said upper to draw said thermoplastic sheet to said upper. 
     
     
         13 . A method of making at least a footwear upper comprising:
 removably attaching a base material layer to a last;   placing at least one component on said base material layer;   heating a thermoplastic material sheet;   applying said heated thermoplastic material sheet to said base material layer and over said at least one component, while said base material layer is attached to the last to fixedly attach said at least one component to said base material layer and form at least a portion of a footwear upper; and   removing said footwear upper portion from the last.   
     
     
         14 . The method of  claim 13 , wherein said at least one component includes an eyestay, a pre-formed collar, a tongue or a heel support. 
     
     
         15 . The method of  claim 13 , further comprising the step of placing a sole structure on the last adjacent to said base material layer, and wherein the step of applying said heated thermoplastic sheet includes extending said thermoplastic material sheet onto at least a portion of said sole structure to fixedly secure the sole structure to said upper portion. 
     
     
         16 . The method of  claim 13 , further comprising imprinting at least one texture on said thermoplastic material sheet. 
     
     
         17 . The method of  claim 13 , wherein the step of applying said heated thermoplastic material sheet includes pressing said material sheet over said base material layer and said at least one component to fixedly attach said at least one component and said base material together and conform said base material layer to a shape of the last. 
     
     
         18 . The method of  claim 13 , wherein said thermoplastic material sheet includes polyurethane. 
     
     
         19 . The method of  claim 13 , further comprising inverting the last. 
     
     
         20 . The method of  claim 13 , further comprising placing a plurality of footwear components on the base material layer and attaching the footwear components to the base material layer by applying said heated thermoplastic material sheet over said base material layer and said footwear components substantially without adhesive or sewing. 
     
     
         21 . The method of  claim 13 , further comprising drawing a partial vacuum through an opening in said last using a vacuum generator to draw said heated thermoplastic material sheet onto said base material layer and over said at least one component. 
     
     
         22 . A method of manufacturing footwear comprising:
 providing an upper and a sole structure;   heating a tape made of a thermoplastic material; and   pressing said tape over at least a portion of said upper and at least a portion of said sole structure to fixedly attach said upper to said sole structure.   
     
     
         23 . An article of footwear comprising a collar with a flap that overlaps an edge of an upper and an internal rib that accurately indexes the collar to the last.