Compression molded footwear and methods of manufacture

Abstract

An article of footwear having an upper, which includes a first foam layer having a first surface and a second surface remote from the first surface, a second foam layer having a first surface and a second surface remote from the first surface, and a middle layer having a first surface and a second surface remote from the first surface. The first surface of the middle layer is affixed to the second surface of the first foam layer, and the second surface of the middle layer is affixed to the first surface of the second foam layer. The upper defines at least a portion of a foot receiving cavity for the article of footwear.

1 . An article of footwear, comprising an upper including: 
 a first foam layer having a first surface and a second surface remote from said first surface thereof;    a second foam layer having a first surface and a second surface remote from said first surface thereof; and    a middle layer having a first surface and a second surface remote from said first surface thereof;    wherein said first surface of said middle layer is affixed to said second surface of said first foam layer and said second surface of said middle layer is affixed to said first surface of said second foam layer, and said upper defines at least a portion of a foot receiving cavity for the article of footwear.    
   
   
       2 . The upper of  claim 1 , wherein at least one of said first and second foam layers comprises an open-cell foam.  
   
   
       3 . The upper of  claim 1 , wherein at least one of said first and second foam layers comprises a thermoformable foam.  
   
   
       4 . The upper of  claim 3 , wherein at least one of said first and second foam layers comprises a thermoset foam.  
   
   
       5 . The upper of  claim 3 , wherein at least one of said first and second foam layers comprises a thermoplastic foam.  
   
   
       6 . The upper of  claim 5 , wherein said thermoplastic foam is an EVA foam.  
   
   
       7 . The upper of  claim 1 , wherein said first foam layer further includes a feature affixed to said first surface thereof.  
   
   
       8 . The upper of  claim 7 , wherein said feature is a protective feature and is located in a toe region of said upper.  
   
   
       9 . The upper of  claim 7 , wherein said feature is a supportive feature and is located in an ankle region of said upper.  
   
   
       10 . The upper of  claim 9 , wherein said feature is integrally formed with said first foam layer.  
   
   
       11 . The upper of  claim 8 , wherein said feature comprises a coating applied to at least a portion of said first surface of said first foam layer.  
   
   
       12 . The upper of  claim 11 , wherein said coating comprises a latex paint.  
   
   
       13 . The upper of  claim 11 , wherein said coating comprises a lacquer.  
   
   
       14 . The upper of  claim 1 , wherein: 
 said first foam layer, said second foam layer, and said middle layer form a unitary piece of layered material having a first seam and a second seam;    said unitary piece of layered material defines a first substantially seamless portion on a medial side of said upper between said first seam and said second seam; and    wherein said upper defines a second substantially seamless portion on a lateral side of said upper between said first seam and said second seam.    
   
   
       15 . The upper of  claim 14 , wherein said first seam is positioned at a heal section of said upper, and wherein said second seam is positioned at a toe section of said upper.  
   
   
       16 . An article of footwear comprising: 
 a sole; and    a unitary upper affixed to said sole and formed of a layered material having: 
 a first foam layer;  
 a second foam layer; and  
 a middle layer interposed between said first and second foam layers, said upper defining at least a portion of a foot-receiving cavity of said article of footwear.  
   
   
   
       17 . The article of  claim 16 , wherein said middle layer is adhesively affixed between said first and second foam layers.  
   
   
       18 . The article of  claim 16 , wherein said middle layer is a mesh textile material.  
   
   
       19 . The article of  claim 16 , wherein said first and second foam layers each comprise a thermoformable foam.  
   
   
       20 . The article of  claim 19 , wherein said thermoformable foam is a thermoplastic foam.  
   
   
       21 . The article of  claim 20 , wherein said thermoplastic foam is an EVA foam.  
   
   
       22 . The article of  claim 21 , wherein said EVA foam comprises an open-cell foam.  
   
   
       23 . The article of  claim 19 , wherein said thermoformable foam comprises a polyester foam.  
   
   
       24 . The article of  claim 19 , wherein said thermoformable foam comprises a polyether foam.  
   
   
       25 . The article of  claim 19 , wherein said thermoformable foam comprises a latex foam.  
   
   
       26 . A method for making an article of footwear, comprising: 
 providing a first foam layer, a second foam layer and a middle layer and integrally forming said first foam layer, said second foam layer and said middle layer by interposing said middle layer between said first foam layer and said second foam layer to form a blank defining a profile having first and second mating portions; and    forming an upper defining a portion of a foot receiving cavity from said blank by aligning said first and second mating portions.    
   
   
       27 . The method of  claim 26 , wherein integrally forming said first foam layer, second foam layer and middle layer includes compression molding said first and second foam layers and said middle layer together.  
   
   
       28 . The method of  claim 27 , wherein said compression molding includes the use of a mold, said mold being used to form a sole for said article of footwear concurrently with said integrally forming said first foam layer, second foam layer and middle layer.  
   
   
       29 . The method of  claim 27 , wherein integrally forming said first foam layer, second foam layer and middle layer further includes adhesively affixing said middle layer between said first foam layer and said second foam layer.  
   
   
       30 . The method of  claim 26 , wherein said integrally forming said first foam layer, second foam layer and middle layer includes cold molding of the first and second foam layers and the middle layer.  
   
   
       31 . The method of  claim 30 , wherein said cold molding includes using rollers.  
   
   
       32 . The method of  claim 31 , wherein said cold molding includes using plates, said plates being substantially flat.  
   
   
       33 . The method of  claim 26 , further including trimming said layered material to form a blank.  
   
   
       34 . The method of  claim 26 , further including applying a coating to said first surface of said first foam layer after said step of compression molding.  
   
   
       35 . The method of  claim 26  further including forming a first seam from said first mating portion, and forming a second seam from said second mating portion.  
   
   
       36 . The method of  claim 26  further including: 
 affixing an insole to said upper at an outside edge thereof so as to define a foot receiving cavity therebetween;    inserting a last into said foot receiving cavity;    heating said upper so as to form said upper to a shape of said last;    allowing said upper to cool; and    removing said last from said foot receiving cavity.    
   
   
       37 . An article of footwear having a unitary upper formed from a layered material, and a sole, said upper forming at least a portion of a foot receiving cavity of said article of footwear, and said sole being affixed to said upper, said article of footwear being formed by the process of: 
 providing a first foam layer, a second foam layer and a middle layer and integrally forming said first foam layer, said second foam layer and said middle layer by interposing said middle layer between said first foam layer and said second foam layer to form a blank defining a profile having first and second mating portions; and    forming said upper from said blank by forming first and second seams from said first and second mating portions; and    affixing said sole to said upper.    
   
   
       38 . The article of  claim 37 , wherein integrally forming said first foam layer, second foam layer and middle layer includes compression molding of the first and second foam layers and the middle layer.  
   
   
       39 . The article of  claim 38 , wherein said middle layer is formed of a textile material defining a plurality of open portions such that said process step of compression molding forces said first foam layer and said second foam layer into mutual contact within said open portions so as provide tensile strength to said layered material.  
   
   
       40 . The article of  claim 39 , wherein said process step of integrally forming said first foam layer, second foam layer and middle layer includes adhesively affixing said middle layer between said first foam layer and said second foam layer.  
   
   
       41 . The article of  claim 40 , wherein said process step of adhesively affixing includes applying a heat-activated adhesive to a surface of said middle layer and applying heat thereto.  
   
   
       42 . An article of footwear comprising: 
 a sole; and    a unitary upper affixed to said sole so as to define a foot receiving cavity therein, said unitary upper being formed of a layered material consisting essentially of: 
 a first layer of a thermoformable foam and having a first surface and a second surface remote from said first surface thereof; and  
 a second layer having a first surface and a second surface remote from said first surface thereof;  
 wherein said second surface of said first layer is affixed to said first surface of said second layer, said upper defining at least a portion of a foot-receiving cavity.  
   
   
   
       43 . The article of  claim 42 , wherein said second layer is a textile material.  
   
   
       44 . The article of  claim 43 , wherein said first surface of said first layer is disposed toward said foot receiving cavity such that said second surface of said second layer is spaced apart from said foot receiving cavity.  
   
   
       45 . The article of  claim 42  wherein said first layer further includes a feature affixed to said first surface thereof.  
   
   
       46 . The upper of  claim 45 , wherein said feature is integrally formed with said first foam layer.  
   
   
       47 . An article of footwear comprising: 
 an upper; and    a bottom affixed to said upper;    wherein said upper and said bottom are formed from a unitary piece of layered material including: 
 a first layer of thermoformable foam having a first surface and a second surface remote from said first surface thereof; and  
 a second layer having a first surface and a second surface remote from said first surface thereof;  
 said second surface of said first layer being affixed to said first surface of said second layer.  
   
   
   
       48 . The article of  claim 47 , wherein said second layer includes a first region and a second region, said first region comprising a first material and said second region comprising a second material.  
   
   
       49 . The article of  claim 48 , wherein said first material is a rubber and said second material is a textile.