Three-dimensionally thermo-molded footwear
Articles of footwear including a thermo-molded upper having a skin composed of one or more low melting point thermoplastic polymers. The skin may include at least one of: a base layer composed of a low melting point thermoplastic polymer and a grid layer including a yarn composed of a low melting point thermoplastic polymer. The uppers may be formed by placing a skin and an inflatable bladder into a mold cavity and heating the mold to a predetermined temperature. The inflatable bladder may be inflated such that the skin is pressed against an interior surface of the heated mold cavity to cause the skin to take on the shape of the internal surface of the mold cavity, thereby forming an upper for an article of footwear.
1. An article of footwear, comprising:
an upper comprising:
a single integrally bladder-molded skin comprising a bladder-molded three-dimensional shape defining an open space for receiving a human foot, a lateral forefoot portion, a medial forefoot portion, a lateral midfoot portion, a medial midfoot portion, a lateral rearfoot portion, and a medial rearfoot portion of the upper, the skin comprising:
a bladder-molded base layer defining at least part of the lateral forefoot portion, at least part of the medial forefoot portion, at least part of the lateral midfoot portion, at least part of the medial midfoot portion, at least part of the lateral rearfoot portion, and at least part of the medial rearfoot portion of the upper, the base layer comprising a low melting point thermoplastic polymer; and
a bladder-molded grid layer comprising a yarn comprising a low melting point thermoplastic polymer,
wherein the low melting point thermoplastic polymer of the base layer and the low melting point thermoplastic polymer of the grid layer have melting points of 200 degrees Celsius (C) or less; and
a midsole coupled to the upper,
wherein the grid layer wraps around at least part of a medial side of the midsole, at least part of a bottom surface of the midsole, and at least part of a lateral side of the midsole, such that the grid layer extends from the medial side of the midsole, across the bottom surface of the midsole, and to the lateral side of the midsole.
2. The article of footwear of claim 1 , comprising a bladder-molded shell layer comprising a low melting point thermoplastic polymer.
3. The article of footwear of claim 1 , wherein the single integrally bladder-molded skin further comprises a bottom portion that extends from a lateral side of the skin to a medial side of the skin.
4. The article of footwear of claim 1 , wherein the base layer comprises a mechanically isotropic material layer.
5. The article of footwear of claim 1 , wherein the base layer is a homogenous material.
6. The article of footwear of claim 1 , wherein the grid layer is at least partially embedded within the base layer.
7. The article of footwear of claim 1 , wherein the yarn of the grid layer comprises thermoplastic polyurethane.
8. The article of footwear of claim 1 , wherein the grid layer comprises a pattern comprising areas with different open pore densities configured to provide one or more different characteristics to different areas of the upper.
9. The article of footwear of claim 8 , wherein the characteristics are selected from the group consisting of: breathability, strength, thermal conductivity, and stretchability.
10. The article of footwear of claim 1 , wherein the grid layer is a woven layer.
11. The article of footwear of claim 10 , wherein the woven layer comprises a woven pattern comprising areas with different yarn densities configured to provide one or more different characteristics to different areas of the upper.
12. The article of footwear of claim 1 , wherein the grid layer is disposed over the base layer.
13. The article of footwear of claim 12 , comprising a plurality of bladder-molded shell layers comprising a low melting point thermoplastic polymer disposed over the grid layer.
14. The article of footwear of claim 13 , wherein the plurality of shell layers are configured to provide one or more different characteristics to different areas of the upper.
15. The article of footwear of claim 1 , wherein the skin comprises a bladder-molded shell layer comprising a low melting point thermoplastic polymer having a melting point of 200 degrees Celsius (C) or less, and wherein the shell layer wraps around at least part of the medial side of the midsole, at least part of the bottom surface of the midsole, and at least part of the lateral side of the midsole, such that the shell layer extends from the medial side of the midsole, across the bottom surface of the midsole, and to the lateral side of the midsole.
16. An article of footwear, comprising:
a midsole;
an upper coupled to the midsole, the upper comprising:
a single integrally bladder-molded skin comprising a bladder-molded three-dimensional shape defining an open space for receiving a human foot, a lateral forefoot portion, a medial forefoot portion, a lateral midfoot portion, a medial midfoot portion, a lateral rearfoot portion, and a medial rearfoot portion of the upper, the skin comprising:
a first bladder-molded layer defining at least part of the lateral forefoot portion, at least part of the medial forefoot portion, at least part of the lateral midfoot portion, at least part of the medial midfoot portion, at least part of the lateral rearfoot portion, and at least part of the medial rearfoot portion of the upper; and
a second bladder-molded layer comprising a low melting point thermoplastic polymer having a melting point of 200 degrees Celsius (C) or less,
wherein the second layer wraps around at least part of a medial side of the midsole, at least part of a bottom surface of the midsole, and at least part of a lateral side of the midsole, such that the second layer extends from the medial side of the midsole, across the bottom surface of the midsole, and to the lateral side of the midsole, and
wherein the second layer is directly fused to at least part of the medial side of the midsole, at least part of the bottom surface of the midsole, and at least part of the lateral side of the midsole.