Footwear upper with molded geometry

Abstract

An article of footwear includes a sole structure and an upper secured to the sole structure. The upper includes a heel section, lateral side section, medial side section, instep and toe cage that define an interior cavity operable to receive a foot of a wearer. At least a portion of the upper includes a laminate, where the laminate includes an inner layer facing the cavity, an outer layer forming an exterior of the shoe, and an intermediate layer disposed between inner and outer layers, the intermediate layer comprising a reinforcing layer having a rigidity that is greater than the rigidity of the inner and outer layers. The reinforcing layer extends from the lateral side section to the medial side section.

What is claimed: 
     
         1 . An article of footwear comprising:
 a sole structure; and   an upper secured to the sole structure;   wherein:
 the upper includes a heel section, a lateral side section, a medial side section, an instep and a toe cage that define an interior cavity operable to receive a foot of a wearer; and 
 at least a portion of the upper comprises a laminate comprising an inner layer facing the cavity, an outer layer forming an exterior of the shoe, and an intermediate layer disposed between inner and outer layers, the intermediate layer comprising a reinforcing layer having a rigidity that is greater than the rigidity of the inner and outer layers, the reinforcing layer extending from the lateral side section to the medial side section. 
   
     
     
         2 . The article of footwear of  claim 1 , wherein the reinforcing layer comprises a structural support member having a hardness value that is greater than the hardness value of the inner and outer layers. 
     
     
         3 . The article of footwear of  claim 2 , wherein the inner and outer layers comprise fabric materials, and the structural support member comprises a plastic material. 
     
     
         4 . The article of footwear of  claim 3 , wherein the structural support member comprises a thermoplastic polyurethane material or an ethylene vinyl acetate material. 
     
     
         5 . The article of footwear of  claim 3 , further comprising a plurality of intermediate layers disposed between the inner layer and the outer layer, at least one of the intermediate layers comprising a foam layer. 
     
     
         6 . The article of footwear of  claim 5 , wherein the laminate includes a first foam layer disposed between the structural support member and the inner layer and a second foam layer disposed between the structural support member and the outer layer. 
     
     
         7 . The article of footwear of  claim 3 , wherein the structural support member comprises an internal heel counter located at the heel section of the upper. 
     
     
         8 . The article of footwear of  claim 7 , wherein the internal heel counter has a generally U-shaped configuration. 
     
     
         9 . The article of footwear of  claim 1 , wherein the upper comprises a first portion coupled with a second portion. 
     
     
         10 . The article of footwear of  claim 9 , wherein the first portion comprises a planum portion that directly covers and/or engages a majority of a bottom side of the wearer's foot wherein the planum portion comprises the laminate, and the second portion comprises a dorsum portion that directly covers and/or engages a majority of an upper side of the wearer's foot. 
     
     
         11 . An upper for an article of footwear, the upper comprising:
 a heel section, a lateral side section, a medial side section, an instep and a toe cage that define an interior cavity operable to receive a foot of a wearer;   wherein at least a portion of the upper comprises a laminate comprising an inner layer facing the cavity, an outer layer forming an exterior of the upper, and an intermediate layer disposed between the inner and outer layers, the intermediate layer comprising a reinforcing layer having a rigidity that is greater than the rigidity of the inner and outer layers.   
     
     
         12 . A method of forming an upper for an article of footwear, the method comprising:
 combining a plurality of portions including a first portion with a second portion, the plurality of portions defining a heel section, a lateral side section, a medial side section, an instep and a toe cage that define an interior cavity of the upper operable to receive a foot of a wearer, wherein the first portion is formed by a laminate, the laminate being formed by:
 combining a plurality of layers together, including an inner layer that faces the cavity with an outer layer forming an exterior of the upper and an intermediate layer disposed between the inner and outer layers, the intermediate layer comprising a reinforcing layer having a rigidity that is greater than the rigidity of the inner and outer layers. 
   
     
     
         13 . The method of  claim 12 , wherein the reinforcing layer comprises a structural support member having a hardness value that is greater than the hardness value of the inner and outer layers. 
     
     
         14 . The method of  claim 12 , wherein the layers are combined to form the laminate by:
 combining the layers in a mold and compressing the layers together while being heated to a temperature sufficient to soften at least one layer so as to adhere the layers together.   
     
     
         15 . The method of  claim 14 , wherein the layers are compressed together while being heated to a temperature about 130° C. to about 200° C. 
     
     
         16 . The method of  claim 14 , wherein the mold includes mold parts that compress the layers together in a shape to define a contoured curve portion of the upper. 
     
     
         17 . The method of  claim 16 , wherein the layers are compressed within the mold to form a curved heel cup portion of the heel section of the upper, such that the reinforcing member is formed between the inner and outer layers as an internal heel counter of the upper having a generally U-shaped configuration. 
     
     
         18 . The method of  claim 12 , wherein the plurality of layers includes further intermediate layers disposed between the inner layer and the outer layer, at least one of the further intermediate layers comprising a foam layer. 
     
     
         19 . The method of  claim 18 , wherein the further intermediate layers include a first foam layer disposed between the inner layer and the reinforcing layer and a second foam layer disposed between the reinforcing layer and the outer layer. 
     
     
         20 . The method of  claim 12 , wherein the first portion comprises a planum portion that directly covers and/or engages a majority of a bottom side of the wearer's foot, and the second portion comprises a dorsum portion that directly covers and/or engages a majority of an upper side of the wearer's foot.