Smooth Shoe Uppers And Methods For Producing Them
Shoe uppers having smooth seams and methods for producing them are disclosed. In one embodiment the upper uses thermoplastic seam tape which forms bonds between contiguous upper sections after being subjected to heat and/or pressure. In another embodiment, different parts of the shoe can be joined using hidden seams. Close seams can also be covered with a transfer material adapted to give the interior and/or exterior of the upper a smooth surface. In yet another embodiment, a method is disclosed which allows three-dimensional upper sections to be bonded on a last using thermoplastic seam tape.
1 . An upper for an article of footwear comprising: an exterior portion, wherein said exterior portion further comprises a plurality of exterior panels; and wherein at least two contiguous exterior panels are joined at least partially to one another by at least one close seam in a stitchless manner.
2 . The upper according to claim 1 wherein said at least one close seam comprises thermoplastic seam tape adapted to join said contiguous exterior panels at the close seam.
3 . The upper according to claim 2 wherein said thermoplastic seam tape comprises a material selected form the group consisting of polyurethane, polyamide, polyester, nylon, polyolefin, vinyl, polypropylene, thermoplastic urethane, tricot, acrylic, and PVC.
4 . The upper according to claim 2 wherein said thermoplastic seam tape comprises two sided thermoplastic adhesive.
5 . The upper according to claim 1 wherein said close seam is covered with a transfer material adapted to give the exterior portion of said shoe a smooth look and feel.
6 . The upper according to claim 1 further comprising an interior portion; wherein the interior portion has an interior portion upper edge and said exterior portion has an exterior portion upper edge; wherein the exterior portion is attached to the interior portion at least partially by stitching at a hidden seam located along the juncture of the interior portion upper edge and the exterior portion upper edge.
7 . The upper according to claim 6 further comprising a tongue pad, wherein the tongue pad is attached to the upper at least partially by the hidden seam located along the juncture of the interior portion upper edge and the exterior portion upper edge.
8 . The upper according to claim 6 further comprising a plurality of shoelace eyelets, wherein the shoelace eyelets are attached to the upper at least partially by the hidden seam located along the juncture of the interior portion upper edge and the exterior portion upper edge.
9 . The upper according to claim 1 wherein said upper farther comprises a toe region, a vamp region, and a heel region; said vamp region being divided into a rear vamp region and a forward vamp region; each of said toe region, rear vamp region, forward vamp region and heel regions have respective medial and lateral sides; said exterior panels comprising: a toe panel, a medial heel panel, a lateral heel panel, a medial rear vamp panel, a lateral rear vamp panel, a medial forward vamp panel, and a lateral forward vamp panel.
10 . The upper of claim 9 wherein said at least one close seam comprises close seams at the junctures of
(a) the toe section and the medial forward vamp section,
(b) the toe section and the lateral forward vamp section,
(c) the medial forward vamp section to the medial rear vamp section,
(d) the lateral forward vamp section to the lateral rear vamp section,
(e) the medial rear vamp section to the medial heel section, and
(f) the lateral rear vamp section to the lateral heel section.
11 . The upper according to claim 1 wherein one or more of said exterior panels are made of a mesh material.
12 . The upper according to claim 11 wherein said mesh material is overlaid with at least one adhesive film adapted to give the upper an aesthetically pleasing appearance.
13 . The upper according to claim 12 wherein said at least one adhesive film has a plurality of openings therein.
14 . The upper according to claim 1 wherein one or more of said exterior panels comprises an inflatable bladder.
15 . A method of making a shoe upper having a plurality of upper sections comprising the steps of:
(a) overlaying a portion of a thermoplastic seam tape on a portion of a first upper section;
(b) forming a first bond between the first upper section and the thermoplastic seam tape;
(c) overlaying a portion of a second upper section on said portion of said thermoplastic seam tape;
(d) forming a second bond between the second upper section and the thermoplastic seam tape such that a close seam is formed between the first and second upper sections.
16 . The method according to claim 15 further comprising the steps of:
(e) placing a blocking surface on top of the thermoplastic seam tape before forming the first bond; and
(f) removing the blocking surface after forming the first bond.
17 . The method according to claim 15 , wherein said first and second upper sections are exterior upper sections.
18 . The method according to claim 15 , wherein said first and second upper sections are interior upper sections.
19 . A method of making a shoe upper having a plurality of upper sections comprising the steps of:
(a) overlapping a portion of a first upper section and a portion of a second upper section thereby defining an overlap region;
(b) positioning a thermoplastic seam tape over at least a portion of said overlap region such that the thermoplastic seam tape is in direct contact with a surface of said first upper section and a surface of said second upper section;
(c) forming a first bond between the surface of the first upper section and the thermoplastic seam tape and a second bond between the surface of the second upper section and the thermoplastic tape such that a close seam is formed between the first and second upper sections.
20 . The method according to claim 19 further comprising steps of:
(d) placing a blocking surface on top of the thermoplastic seam tape before forming the first and second bonds;
(e) removing the blocking surface after forming the first and second bonds.