Shoe with an upper made of a flat composite and method of making the shoe

Abstract

An upper is made of a flat composite which includes a substantially flat plastic layer molded directly over a fabric layer. The plastic layer has at least one ventilation hole, an inner peripheral end defining an opening, an outer peripheral end extending around the inner peripheral end, and two opposite marginal ends each extending from the inner peripheral end to the outer peripheral end. The flat composite is looped and formed into the upper when the marginal ends are connected to each other. The plastic layer further has at least one molded ventilation hole. The fabric layer has an integral extension flap that extends beyond the outer peripheral end.

We claim:  
     
         1 . A shoe comprising 
 an upper made of a flat composite which includes a substantially flat molded plastic layer and a fabric layer bonded to one side of said molded plastic layer, said plastic layer having an inner peripheral end defining an opening, an outer peripheral end extending around said inner peripheral end, and two opposite marginal ends each extending from said inner peripheral end to said outer peripheral end, both of said inner and outer peripheral ends being terminated at said marginal ends, said flat composite being looped and formed into said upper when said marginal ends are connected to each other, said fabric layer further having an extension flap that extends beyond said outer peripheral end and that is formed as one piece with said fabric layer.    
     
     
         2 . The shoe as claimed in  claim 1 , wherein said plastic layer is molded directly over said fabric layer.  
     
     
         3 . The shoe as claimed in  claim 1 , wherein said plastic layer further has at least one molded ventilation hole, said fabric layer covering said ventilation hole.  
     
     
         4 . The shoe as claimed in  claim 1 , wherein said marginal ends are interconnected by sewing.  
     
     
         5 . The shoe as claimed in  claim 1 , wherein said upper is composed of an upper portion and a lower portion, said lower portion having a toe region, two shank regions extending rearwardly from said toe region, and a heel region connected to said shank regions, said upper portion being connected to a top end of said lower portion, said marginal ends are interconnected in said heel region.  
     
     
         6 . The shoe as claimed in  claim 1 , wherein said plastic layer includes a material selected from a group consisting of thermoplastic polyurethane, thermoplastic rubber and polyvinylchloride.  
     
     
         7 . The shoe as claimed in  claim 1 , wherein said flat composite further includes a reinforcing stitch line which extends along said outer peripheral end of said plastic layer to secure said fabric layer to said plastic layer.  
     
     
         8 . The shoe as claimed in  claim 1 , wherein said plastic layer includes a plurality of said ventilation holes in the form of mesh openings, said fabric layer covering said mesh openings.  
     
     
         9 . The shoe as claimed in  claim 1 , further comprising a breathable waterproof layer disposed inside said upper and attached to said flat composite.  
     
     
         10 . A shoe comprising 
 an upper made of a flat composite which includes a substantially flat molded plastic layer and a fabric layer adhered to one side of said molded plastic layer, said plastic layer having an inner peripheral end defining an opening, an outer peripheral end extending around said inner peripheral end, and two opposite marginal ends each interconnecting said inner and outer peripheral ends, said marginal ends being connected to each other so that said flat composite is looped and formed into said upper, said plastic layer further having at least one molded ventilation hole, said fabric layer covering said ventilation hole, wherein no cementing material is provided between said plastic layer and said fabric layer at least in a region where said ventilation hole is formed.    
     
     
         11 . The shoe of  claim 10 , wherein no cementing material is provided in all regions between said plastic and said fabric layers.  
     
     
         12 . A method of making a shoe comprising: 
 molding a substantially flat plastic layer directly over a fabric layer to form a flat composite, said plastic layer being formed with at least one ventilation hole, two opposite marginal ends, and inner and outer peripheral ends interconnecting said marginal ends, said inner peripheral end defining an opening, said outer peripheral end extending around said inner peripheral end,    providing said fabric layer with an extension flap that extends beyond said outer peripheral end and between said two marginal ends and that is formed as one piece with said fabric layer; and    interconnecting said marginal ends so that said flat composite is looped and formed into at least a portion of an upper.    
     
     
         13 . The method of  claim 12 , wherein said portion of said upper includes a toe region, two shank regions extending rearwardly from said toe region, and a heel region connected to said shank regions, said marginal ends being interconnected in said heel region.  
     
     
         14 . The method of  claim 13 , wherein said upper is composed of upper and lower portions, said lower portion having said toe, shank and heel regions, and a top end connected to said upper portion, said lower portion being made of said flat composite.  
     
     
         15 . The method of  claim 12 , further comprising trimming said fabric layer relative to said inner and outer peripheral ends and said marginal ends, said extension flap being provided during the trimming of said fabric layer.  
     
     
         16 . The method of  claim 12 , further comprising sewing said fabric layer to said plastic layer along said outer peripheral end.