Upper with Zonal Contouring and Fabrication of Same

Abstract

A composite panel portion of an upper may include a contouring element located between a backing and an outer panel. The outer panel conforms to the contouring element and the backing so as to form a raised contour.

1 . A portion of an upper, comprising:
 a backing;   a contouring element; and   a porous outer panel, wherein
 the backing and the outer panel each has an interior side configured to face toward an interior space of an article of footwear, and an exterior side configured to face away from the interior space, when the upper is incorporated into the article of footwear, 
 the contouring element is located between the exterior side of the backing and the interior side of the outer panel, and 
 the backing, the contouring element and the outer panel form a bonded composite panel in which the outer panel conforms to the contouring element and the backing so as to form a raised contour. 
   
     
     
         2 . The upper portion of  claim 1 , wherein the outer panel has a thickness less than a thickness of the contouring element, and wherein regions of the outer panel interior side not contacting the contouring element are bonded to regions of the backing exterior side not contacting the contouring element. 
     
     
         3 . The upper portion of  claim 1 , wherein regions of the outer panel overlaying the contouring element are under tension and deform the contouring element. 
     
     
         4 . The upper portion of  claim 1 , wherein the outer panel comprises a mesh. 
     
     
         5 . The upper portion of  claim 4 , wherein the backing includes at least one opening defining a ventilation window, and wherein a portion of the mesh spans the ventilation window and is bonded to regions of the backing exterior side at an edge of the ventilation window. 
     
     
         6 . The upper portion of  claim 4 , wherein
 the backing includes openings defining a plurality of ventilation windows,   each of the ventilation windows is spanned by a corresponding portion of the mesh, and   each of the window spanning mesh portions is bonded to regions of the backing exterior side at edges of the corresponding ventilation window.   
     
     
         7 . The upper portion of  claim 4 , further comprising a second contouring element located between the exterior side of backing and the interior side of the mesh, wherein
 the second contouring element is surrounded by adjacent regions of the backing exterior side not contacting the second contouring element, and   the adjacent backing regions surrounding the second contouring element are bonded to the interior side of the mesh.   
     
     
         8 . The upper portion of  claim 1 , wherein the contouring element is surrounded by adjacent regions of the backing exterior side not contacting the contouring element, and wherein the surrounding adjacent regions are bonded to the interior side of the outer panel. 
     
     
         9 . The upper portion of  claim 1 , wherein the contouring element has a thickness greater than the combined thicknesses of the outer panel and of the backing. 
     
     
         10 . The upper of  claim 9 , wherein the backing includes at least one ventilation window, and wherein a portion of the flexible porous fabric spans the ventilation window and is bonded to regions of the backing exterior side at an edge of the ventilation window. 
     
     
         11 . The upper portion of  claim 9 , wherein the contouring element is surrounded by adjacent regions of the backing exterior side not contacting the contouring element, and wherein the surrounding adjacent regions are bonded to the interior side of the outer panel. 
     
     
         12 . The upper portion of  claim 11 , wherein the outer panel comprises a mesh. 
     
     
         13 . The upper portion of  claim 12 , wherein regions of the outer panel overlaying the contouring element are under tension and deform the contouring element. 
     
     
         14 . A portion of an upper for an article of footwear, comprising:
 a backing;   a contouring element; and   a porous outer panel, wherein
 the backing and the outer panel each has an interior side configured to face toward an interior space of an article of footwear, and an exterior side configured to face away from the interior space, when the upper is incorporated into the article of footwear, 
 the contouring element is located between the exterior side of the backing and the interior side of the outer panel, and 
 the outer panel is bonded to portions of the backing exterior side and is conformed to the contouring element along multiple interface edges of the backing and the contouring element. 
   
     
     
         15 . The upper portion of  claim 14 , wherein the porous outer panel comprises a mesh. 
     
     
         16 . The upper portion of  claim 14 , wherein the backing includes at least one opening defining a ventilation window, and wherein a portion of the outer panel spans the ventilation window and is bonded to regions of the backing exterior side at an edge of the ventilation window. 
     
     
         17 . The upper portion of  claim 14 , wherein
 the backing includes a plurality of openings defining ventilation windows,   each of the ventilation windows is spanned by a corresponding portion of the outer panel,   each of the window spanning outer panel portions is bonded to regions of the backing exterior side at edges of the corresponding ventilation window,   the upper portion includes a second contouring element located between the exterior side of backing and the interior side of the outer panel,   the second contouring element is surrounded by adjacent regions of the backing exterior side not contacting the second contouring element, and   the adjacent backing regions surrounding the second contouring element are bonded to the interior side of the outer panel.   
     
     
         18 . A method comprising:
 assembling a stack of components comprising a backing, a bonding agent, at least one contouring element and a porous outer panel, wherein the contouring element is located between the backing and the porous outer panel; and   heating and compressing the assembled stack so as to bond the backing, contouring element and outer panel and form a composite panel having a contour corresponding to the contouring element.   
     
     
         19 . The method of  claim 18 , wherein the stack of components comprises a contouring element having a thickness greater than a thickness of the porous outer panel.