# US 10,499,706 B2 · Molded footwear upper and method of making same > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 10,499,706 B2 - Document ID: US10499706B2 - Status: Granted - Kind: B2 - Application number: 13/849,386 - Filed: 2013-03-22 - Published: 2014-09-25 - Granted: 2019-12-10 - Earliest claimed: 2013-03-22 - Assignees: Reebok International Ltd. - Applicants: Reebok International Limited - Inventors: William Marvin; Kevin Leary; Paul E. Litchfield; Thomas Piacentini - Web page: https://patentgrep.com/patent/US10499706B2 ## CPC - A43B 23/0235: {Different layers of different material} - A43B 1/00: Footwear characterised by the material - A43B 23/0255: {assembled by gluing or thermo bonding} - A43B 23/026: {Laminated layers} - A43B 23/028: {Resilient uppers, e.g. shock absorbing} - B29D 35/146: {Uppers} - B29D 35/148: {Moulds or apparatus therefor} - A43B: CHARACTERISTIC FEATURES OF FOOTWEAR; PARTS OF FOOTWEAR - B29D: PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE (making granules B29B9/00; making preforms B29B11/00) ## Abstract A method for manufacturing an upper for an article of footwear includes: forming a foam layer; forming a preliminary upper by laminating an outer layer, an inner layer, and the foam layer intermediate to the outer layer and the inner layer; and molding the preliminary upper to a shape having a contour to substantially fit at least a portion of a foot to provide at least a portion of an upper for an article of footwear. ## Claims ### Claim 1 An article of footwear, comprising: a footwear upper comprising a single piece laminate including a pre-shaped contoured foam cushioning member, an innermost layer, and an outermost layer, wherein the foam cushioning member is disposed between the innermost layer and the outermost layer, wherein a first region of the single piece laminate corresponds to a portion of a lateral side of the foot and a second region of the single piece laminate corresponds to a portion of a medial side of the foot, wherein the outermost layer of the upper comprises an elastic material, and wherein the foam cushioning member comprises asymmetrical cross-sections such that an outer surface of the upper includes a protrusion and an inner surface of the upper includes a protrusion; and a footwear lower attached to the footwear upper to provide a sole supporting member to the article of footwear. ### Claim 2 (depends on 1) The article of footwear according to claim 1, wherein the innermost layer is an elastic material. ### Claim 3 (depends on 2) The article of footwear according to claim 2, wherein the innermost layer and the outermost layer are two-way stretch materials. ### Claim 4 (depends on 2) The article of footwear according to claim 2, wherein the innermost layer and the outermost layer are four-way stretch materials. ### Claim 5 (depends on 2) The article of footwear according to claim 2, wherein the innermost layer and the outermost layer are the same material. ### Claim 6 (depends on 2) The article of footwear according to claim 2, wherein the innermost layer and the outermost layer comprise an elastic polyurethane fiber, elastane, or both. ### Claim 7 (depends on 1) The article of footwear according to claim 1, wherein the foam cushioning member is in contact with both the innermost layer and the outermost layer. ### Claim 8 (depends on 1) The article of footwear according to claim 1, wherein the innermost layer contacts the outermost layer over a portion of the single piece laminate. ### Claim 9 An upper for an article of footwear, comprising: a first molded laminate piece contoured for a forward portion of a foot, extending from a toe region to a midfoot region and including a first medial side portion and a first lateral side portion; and a second molded laminate piece contoured for a rearward portion of the foot, extending from a heel region to the midfoot region and including a second medial side portion and a second lateral side portion, wherein the first medal side portion is attached to the second medial side portion, and wherein the first lateral side portion is attached to the second lateral side portion, the first molded laminate piece and the second molded laminate piece each comprising: an innermost layer comprising a four-way stretch elastic material, an outermost layer comprising a four-way stretch elastic material, and a foam cushioning member disposed between and contacting both the innermost layer and the outermost layer, wherein the foam cushioning member has a perimeter smaller than perimeters of the innermost layer and the outermost layer, such that the perimeter of the foam cushioning member is enveloped by the innermost layer and the outermost layer. ### Claim 10 (depends on 9) The upper for an article of footwear according to claim 9, wherein the first molded laminate piece or the second molded laminate piece further comprises a reinforcing layer disposed between the innermost layer and the outermost layer. ### Claim 11 (depends on 9) The upper for an article of footwear according to claim 9, wherein the second molded laminate piece further comprises a plurality of eyelets. ### Claim 12 (depends on 9) The upper for an article of footwear according to claim 9, wherein the foam cushioning member of the first molded laminate piece or the second molded laminate piece is contoured for a portion of a foot. ### Claim 13 (depends on 9) The upper for an article of footwear according to claim 9, wherein the innermost layer contacts the outermost layer over a portion of the first molded laminate piece or the second molded laminate piece. ### Claim 14 (depends on 9) The article of footwear according to claim 9, wherein the innermost layer and the outermost layer are the same material. ### Claim 15 (depends on 9) The article of footwear according to claim 9, wherein the innermost layer and the outermost layer comprise an elastic polyurethane fiber, elastane, or both. ### Claim 16 An article of footwear, comprising: a footwear upper, comprising: a first molded laminate piece contoured for a forward portion of a foot, extending from a toe region to a midfoot region and including a first medial side portion and a first lateral side portion, and a second molded laminate piece contoured for a rearward portion of the foot, extending from a heel region to the midfoot region and including a second medial side portion and a second lateral side portion, wherein the first medal side portion is attached to the second medial side portion, and wherein the first lateral side portion is attached to the second lateral side portion, the first molded laminate piece and the second molded laminate piece each comprising: an innermost layer comprising a four-way stretch elastic material, an outermost layer comprising a four-way stretch elastic material, and a foam cushioning member disposed between and contacting both the innermost layer and the outermost layer, wherein the foam cushioning member has a perimeter smaller than perimeters of the innermost layer and the outermost layer, such that the perimeter of the foam cushioning member is enveloped by the innermost layer and the outermost layer; and a footwear lower attached to the footwear upper to provide a sole supporting member to the article of footwear. ### Claim 17 (depends on 16) The article of footwear according to claim 16, wherein the first molded laminate piece or the second molded laminate piece further comprises a reinforcing layer disposed between the innermost layer and the outermost layer. ### Claim 18 (depends on 16) The article of footwear according to claim 16, wherein the second molded laminate piece further comprises a plurality of eyelets. ### Claim 19 (depends on 16) The article of footwear according to claim 16, wherein the foam cushioning member of the first molded laminate piece or the second molded laminate piece is contoured for a portion of a foot. ### Claim 20 (depends on 16) The article of footwear according to claim 16, wherein the innermost layer contacts the outermost layer over a portion of the first molded laminate piece or the second molded laminate piece. ### Claim 21 (depends on 1) The article of footwear according to claim 1, wherein the foam cushioning member comprises at least one rib extending from the first region, around a heel region, and to the second region. ### Claim 22 (depends on 16) The article of footwear according to claim 16, wherein the innermost layer and the outermost layer are the same material. ### Claim 23 (depends on 16) The article of footwear according to claim 16, wherein the innermost layer and the outermost layer comprise an elastic polyurethane fiber, elastane, or both. ### Claim 24 An upper for an article of footwear, comprising: a lateral side laminate piece extending from a heel region to a toe region of the upper; and a medial side laminate piece extending from the heel region to the toe region of the upper the lateral side laminate piece and the medial side laminate piece each comprising: an innermost layer comprising a four-way stretch elastic material, an outermost layer comprising a four-way stretch elastic material, and a foam cushioning member disposed between and contacting both the innermost layer and the outermost layer, wherein the foam cushioning member has a perimeter smaller than perimeters of the innermost layer and the outermost layer, such that the perimeter of the foam cushioning member is enveloped by the innermost layer and the outermost layer. ### Claim 25 (depends on 24) The upper for an article of footwear according to claim 24, wherein the lateral side laminate piece and the medial side laminate piece are coupled at a first seam in the heel region and at a second seam in the toe region. ### Claim 26 (depends on 24) The upper for an article of footwear according to claim 24, wherein the lateral side laminate piece or the medial side laminate piece further comprises a reinforcing layer disposed between the innermost layer and the outermost layer. ### Claim 27 (depends on 24) The upper for an article of footwear according to claim 24, wherein the lateral side laminate piece or the medial side laminate piece further comprises a plurality of eyelets. ### Claim 28 (depends on 24) The upper for an article of footwear according to claim 24, wherein the foam cushioning member of the lateral side laminate piece or the medial side laminate piece is contoured for a portion of a foot. ### Claim 29 (depends on 24) The upper for an article of footwear according to claim 24, wherein the innermost layer contacts the outermost layer over a portion of the lateral side laminate piece or the medial side laminate piece. ### Claim 30 (depends on 24) The article of footwear according to claim 24, wherein the innermost layer and the outermost layer are the same material. ### Claim 31 (depends on 24) The article of footwear according to claim 24, wherein the innermost layer and the outermost layer comprise an elastic polyurethane fiber, elastane, or both. ### Claim 32 An upper for an article of footwear, comprising: one or more molded laminate pieces, comprising: an innermost layer comprising a four-way stretch elastic material, an outermost layer comprising a four-way stretch elastic material, and a foam cushioning member disposed between and contacting both the innermost layer and the outermost layer, wherein the foam cushioning member has a perimeter smaller than perimeters of the innermost layer and the outermost layer, such that the perimeter of the foam cushioning member is enveloped by the innermost layer and the outermost layer, and wherein the molded laminate piece further comprises a plurality of eyelets. ### Claim 33 (depends on 32) The upper for an article of footwear according to claim 32, comprising: a first molded laminate piece contoured for a forward portion of a foot, extending from a toe region to a midfoot region and including a first medial side portion and a first lateral side portion; and a second molded laminate piece contoured for a rearward portion of the foot, extending from a heel region to the midfoot region and including a second medial side portion and a second lateral side portion, wherein the first medal side portion is attached to the second medial side portion, wherein the first lateral side portion is attached to the second lateral side portion, and wherein the plurality of eyelets are disposed in the second molded laminate piece. ### Claim 34 (depends on 32) The upper for an article of footwear according to claim 32, comprising: a lateral side laminate piece extending from a heel region to a toe region of the upper; and a medial side laminate piece extending from the heel region to the toe region of the upper. ### Claim 35 (depends on 34) The upper for an article of footwear according to claim 34, wherein the lateral side laminate piece and the medial side laminate piece are coupled at a first seam in the heel region and at a second seam in the toe region. ### Claim 36 (depends on 32) The upper for an article of footwear according to claim 32, wherein a portion of the upper further comprises a reinforcing layer disposed between the innermost layer and the outermost layer. ### Claim 37 (depends on 32) The upper for an article of footwear according to claim 32, wherein the foam cushioning member is contoured for a portion of a foot. ### Claim 38 (depends on 32) The upper for an article of footwear according to claim 32, wherein the innermost layer contacts the outermost layer over a portion of the molded laminate piece. ### Claim 39 (depends on 32) The article of footwear according to claim 32, wherein the innermost layer and the outermost layer are the same material. ### Claim 40 (depends on 32) The article of footwear according to claim 32, wherein the innermost layer and the outermost layer comprise an elastic polyurethane fiber, elastane, or both. ### Claim 41 An article of footwear, comprising: a footwear upper, comprising: a lateral side laminate piece extending from a heel region to a toe region of the upper, and a medial side laminate piece extending from the heel region to the toe region of the upper, the lateral side laminate piece and the medial side laminate piece each comprising: an innermost layer comprising a four-way stretch elastic material, an outermost layer comprising a four-way stretch elastic material, and a foam cushioning member disposed between and contacting both the innermost layer and the outermost layer, wherein the foam cushioning member has a perimeter smaller than perimeters of the innermost layer and the outermost layer, such that the perimeter of the foam cushioning member is enveloped by the innermost layer and the outermost layer; and a footwear lower attached to the footwear upper to provide a sole supporting member to the article of footwear. ### Claim 42 (depends on 41) The article of footwear according to claim 41, wherein the lateral side laminate piece and the medial side laminate piece are coupled at a first seam in the heel region and at a second seam in the toe region. ### Claim 43 (depends on 41) The article of footwear according to claim 41, wherein the lateral side laminate piece or the medial side laminate piece further comprises a reinforcing layer disposed between the innermost layer and the outermost layer. ### Claim 44 (depends on 41) The article of footwear according to claim 41, wherein the lateral side laminate piece or the medial side laminate piece further comprises a plurality of eyelets. ### Claim 45 (depends on 41) The article of footwear according to claim 41, wherein the foam cushioning member of the lateral side laminate piece or the medial side laminate piece is contoured for a portion of a foot. ### Claim 46 (depends on 41) The article of footwear according to claim 41, wherein the innermost layer contacts the outermost layer over a portion of the lateral side laminate piece or the medial side laminate piece. ### Claim 47 (depends on 41) The article of footwear according to claim 41, wherein the innermost layer and the outermost layer are the same material. ### Claim 48 (depends on 41) The article of footwear according to claim 41, wherein the innermost layer and the outermost layer comprise an elastic polyurethane fiber, elastane, or both. ### Claim 49 An article of footwear, comprising: a footwear upper, comprising: one or more molded laminate pieces, comprising: an innermost layer comprising a four-way stretch elastic material, an outermost layer comprising a four-way stretch elastic material, and a foam cushioning member disposed between and contacting both the innermost layer and the outermost layer, wherein the foam cushioning member has a perimeter smaller than perimeters of the innermost layer and the outermost layer, such that the perimeter of the foam cushioning member is enveloped by the innermost layer and the outermost layer, and wherein the molded laminate piece further comprises a plurality of eyelets; and a footwear lower attached to the footwear upper to provide a sole supporting member to the article of footwear. ### Claim 50 (depends on 49) The article of footwear according to claim 49, comprising: a first molded laminate piece contoured for a forward portion of a foot, extending from a toe region to a midfoot region and including a first medial side portion and a first lateral side portion; and a second molded laminate piece contoured for a rearward portion of the foot, extending from a heel region to the midfoot region and including a second medial side portion and a second lateral side portion, wherein the first medal side portion is attached to the second medial side portion, wherein the first lateral side portion is attached to the second lateral side portion, and wherein the plurality of eyelets are disposed in the second molded laminate piece. ### Claim 51 (depends on 49) The article of footwear according to claim 49, comprising: a lateral side laminate piece extending from a heel region to a toe region of the upper; and a medial side laminate piece extending from the heel region to the toe region of the upper. ### Claim 52 (depends on 51) The article of footwear according to claim 51, wherein the lateral side laminate piece and the medial side laminate piece are coupled at a first seam in the heel region and at a second seam in the toe region. ### Claim 53 (depends on 49) The article of footwear according to claim 49, wherein a portion of the upper further comprises a reinforcing layer disposed between the innermost layer and the outermost layer. ### Claim 54 (depends on 49) The article of footwear according to claim 49, wherein the foam cushioning member is contoured for a portion of a foot. ### Claim 55 (depends on 49) The article of footwear according to claim 49, wherein the innermost layer contacts the outermost layer over a portion of the molded laminate piece. ### Claim 56 (depends on 49) The article of footwear according to claim 49, wherein the innermost layer and the outermost layer are the same material. ### Claim 57 (depends on 49) The article of footwear according to claim 49, wherein the innermost layer and the outermost layer comprise an elastic polyurethane fiber, elastane, or both.