LIQUID THERMOPLASTIC POLYMER APPLICATION FOR FOOTWEAR UPPERS

CROSS REFERENCE TO RELATED APPLICATIONS

[0001]This application claims priority to German Patent Application No. 10 2024 134 912.3, filed Nov. 26, 2024, which is incorporated by reference herein in its entirety.

TECHNICAL FIELD

[0002]The present disclosure relates to a method of manufacturing an upper for an article of foot-wear by dispensing strands of a liquefied polymer onto a substrate. The present disclosure further relates to a corresponding upper.

BACKGROUND

[0003]Articles of footwear generally comprise a sole and an upper. In traditional upper manufacturing, a flat two-dimensional raw upper is usually transformed into its desired three-dimensional shape of the final footwear by placing the raw upper or multiple components thereof on a last and stitching it together by one or more seams. This process mostly results in non-optimal fit in areas in which surfaces with two curvature directions are required, as for example on the forefoot vamp or the lateral quarter area. In recent years, footwear manufacturers developed a technique in which parts of an article of footwear are formed from an extruded member.

[0004]However, while extrusion methods as known in the art result in randomly distributed mats of fine fibers, a predefined arrangement of the fibers and therefore a predefined tuning of the properties of the manufactured mats of fibers is not applicable. On the other hand, while the known processes of extruding an extruded member may be utilized to generate a controlled geometric pattern, these patterns are usually relatively coarse compared to traditional knit or woven textile patterns and therefore lack the ability of creating fine mesh structures.

[0005]It is therefore the problem underlying the present disclosure to improve methods of manufacturing an upper for articles of footwear so that the above outlined disadvantages of the conventional manufacturing techniques are at least partly overcome.

BRIEF SUMMARY

[0006]The present disclosure is directed to a method for manufacturing an upper of an article of footwear. In some embodiments, the method may comprise producing a liquefied polymer by mixing a polymer with a solvent, and dispensing strands of the liquefied polymer onto a substrate to form a shape of a part of the upper.

[0007]Manufacturing an upper according to the methods described herein may provide the ability to form a three-dimensional shape of an upper without first forming a two-dimensional shape. Furthermore, strands with different properties can be used in different portions of the upper, thereby providing the ability to form an upper with distinct zones having properties suitable for a specific activity.

[0008]A first embodiment (I) of the present disclosure is directed to a method of manufacturing an upper for an article of footwear, the method comprising: providing a polymer; providing a solvent; mixing the polymer with the solvent, thereby producing a liquefied polymer; providing a substrate; dispensing strands of the liquefied polymer onto the substrate such that the strands form a shape of at least a part of the upper; curing the strands; and removing the cured strands from the substrate.

[0009]In a second embodiment (II), in the method of the first embodiment (I), the substrate comprises a three-dimensional shape of at least a part of a last.

[0010]In a third embodiment, (III), in the method of any one of embodiments (I)-(II), the substrate comprises a metallic surface, a textured surface, or a combination thereof.

[0011]In a fourth embodiment (IV), in the method of any one of embodiments (I)-(III), the dispensing comprises dispensing the liquefied polymer through a nozzle, such as by moving the nozzle with respect to the substrate.

[0012]In a fifth embodiment (V), in the method of any one of embodiments (I)-(IV), the dispensing comprises dispensing strands with a width of 1 mm-10 mm.

[0013]In a sixth embodiment (VI), in the method of any one of embodiments (I)-(V), a width of the strands after the curing is 0.3 mm-0.7 mm.

[0014]In a seventh embodiment (VII), in the method of any one of embodiments (I)-(VI), the dispensing comprises dispensing the strands in a first area of the substrate and a second area of the substrate such that a mechanical property of the cured strands in the first area differs from a mechanical property of the cured strands in the second area.

[0015]In an eighth embodiment (VIII), in the method of the seventh embodiment (VII), a magnitude of a mechanical property of the cured strands in a third area differs from a magnitude of the same mechanical property of the cured strands in a fourth area.

[0016]In a ninth embodiment (IX), in the method of any one of embodiments (VII)-(VIII), the mechanical property of the cured strands comprises density, width, strand diameter, elasticity, breathability, watertightness, tensile strength, shore hardness, traction, or a combination thereof.

[0017]In a tenth embodiment (X), in the method of any one of embodiments (I)-(IX), the dispensing comprises dispensing the strands in a strand pattern, such as by arranging individual strands on one or more of the substrate or a previously dispensed strand to form the strand pattern.

[0018]In an eleventh embodiment (XI), in the method of any one of embodiments (I)-(X), the method further comprises: heating at least a part of the cured strands; and attaching the part of the strands to a first component of the article of footwear.

[0019]In a twelfth embodiment (XII), in the method of the eleventh embodiment (XI), the first component comprises a sole component.

[0020]In a thirteenth embodiment (XIII), in the method of any one of embodiments (I)-(XII), the method further comprises arranging a second component on the substrate prior to the dispensing, wherein the dispensing further comprises dispensing the strands of the liquefied polymer at least partly onto the substrate and at least partly onto the second component.

[0021]In a fourteenth embodiment (XIV), in the method of the thirteenth embodiment (XIII), the second component comprises at least one of a reinforcing component, a padding component, a foil component, a mesh component, or a foam component.

[0022]In a fifteenth embodiment (XV), in the method of any one of embodiments (I)-(XIV), the polymer comprises polyurethanes (PU), thermoplastic polyamides (TPA), thermoplastic polyesters (TPE), thermoplastic styrenic block copolymers (TPS), thermoplastic polyurethanes (TPU), thermoplastic vulcanizates (TPV), rubber or ethylene-vinyl copolymer (EVA), thermoplastic polyurethanes (TPU), or combinations thereof.

[0023]In a sixteenth embodiment (XVI), in the method of any one of embodiments (I)-(XV), the solvent comprises a mixture of one or more of (C1-C6) ethers, (C1-C10) esters, (C1-C8) ketones, (C1-C8) alkanes.

[0024]In a seventeenth embodiment (XVII), in the method of any one of embodiments (I)-(XVI), the solvent comprises a mixture of one or more of tetrahydrofuran (THF), methyl ethyl ketone (MEK), cyclohexane (CYC), or ethyl acetate, butyl acetate.

[0025]In an eighteenth embodiment (XVIII), in the method of the seventeenth embodiment (XVII), a ratio of the mixture is in a range of 10 to 90 vol. %.

[0026]In a nineteenth embodiment (XIX), in the method of the seventeenth embodiment (XVII), a ratio of the mixture is in a range of 10 to 90 wt. %.

[0027]In a twentieth embodiment (XX), in the method of any one of embodiments (I)-(XIX), the liquefied polymer comprises a dynamic viscosity of 10000 to 50000 mPa·s.

[0028]In a twenty-first embodiment (XXI), in the method of any one of embodiments (I)-(XX), a ratio of the polymer to the solvent in the mixing step is in a range of 2:98 to 40:60 vol. %.

[0029]In a twenty-second embodiment (XXII), in the method of any one of embodiments (I)-(XXI), the liquefied polymer further comprises pigments, fibers, or a combination thereof.

[0030]In a twenty-third embodiment (XXIII), in the method of any one of embodiments (I)-(XXII), the liquefied polymer further comprises granulates.

[0031]In a twenty-fourth embodiment (XXIV), in the method of any one of embodiments (I)-(XXIII), the liquefied polymer further comprises a blowing agent.

[0032]In a twenty-fifth embodiment (XXV), in the method of any one of embodiments (I)-(XXIV), the curing comprises curing at a curing temperature of between 20° C. to 150° C. for a curing duration of between 2 min to 750 min.

[0033]In a twenty-sixth embodiment (XXVI), in the method of any one of embodiments (I)-(XXV), the dispensing comprises dispensing the liquefied polymer having a temperature in a range of 10° C. to 40° C.

[0034]A twenty-seventh embodiment (XXVII) of the present disclosure is directed to an upper for an article of footwear made by a method comprising the steps of any one of embodiments (I)-(XXVI).

BRIEF DESCRIPTION OF THE FIGURES

[0035]The accompanying figures, which are incorporated herein, form part of the specification and illustrate embodiments of the present disclosure. Together with the description, the figures further serve to explain the principles of and to enable a person skilled in the relevant art(s) to make and use the disclosed embodiments. These figures are intended to be illustrative, not limiting. Although the present disclosure is generally described in the context of these embodiments, it should be understood that it is not intended to limit the scope of the present disclosure to these particular embodiments. In the drawings, like reference numbers indicate identical or functionally similar elements.

[0036]Possible embodiments of the present disclosure will be further described in the following detailed description with reference to the following Figures:

[0037]FIG. 1 is a flow diagram illustrating a manufacturing method, according to some embodiments.

[0038]FIG. 2 is an illustration of an article of footwear comprising multiple strand patterns, according to some embodiments.

[0039]FIG. 3 is an illustration of a substrate, according to some embodiments.

[0040]FIG. 4A is an illustration of a liquefied polymer strand dispensed on a substrate, according to some embodiments.

[0041]FIG. 4B is an illustration of the liquefied polymer strand of FIG. 4A after a curing and removing of the strand from the substrate, according to some embodiments.

[0042]FIG. 5A is an illustration of a liquefied polymer strand before activation of a blowing agent, according to some embodiments.

[0043]FIG. 5B is an illustration of the polymer strand of FIG. 5A after curing and activating of the blowing agent, according to some embodiments.

[0044]FIG. 6 is an illustration of an article of footwear comprising multiple mechanical zones, according to some embodiments.

[0045]FIG. 7A is an illustration of an article of footwear comprising a low density strand pattern, according to some embodiments.

[0046]FIG. 7B is an illustration of an article of footwear comprising a high density strand pattern, according to some embodiments.

[0047]FIG. 8 is an illustration of an upper comprising components attached to the upper, according to some embodiments.

[0048]FIG. 9 is an illustration of an article of footwear comprising zones of differing mechanical stiffness, according to some embodiments.

DETAILED DESCRIPTION

[0049]In the following, exemplary embodiments of the present disclosure are described in more detail, with reference to an upper for an article of footwear. While specific feature combinations are described in the following with respect to the exemplary embodiments of the present disclosure, it is to be understood that the disclosure is not limited to such embodiments. In particular, not all features have to be present for realizing the disclosure, and the embodiments may be modified by combining certain features of one embodiment with one or more features of another embodiment.

[0050]The indefinite articles “a,” “an,” and “the” include plural referents unless clearly contradicted or the context clearly dictates otherwise.

[0051]The term “comprising” is an open-ended transitional phrase. A list of elements following the transitional phrase “comprising” is a non-exclusive list, such that elements in addition to those specifically recited in the list may also be present. The phrase “consisting essentially of” limits the composition of a component to the specified materials and those that do not materially affect the basic and novel characteristic(s) of the component. The phrase “consisting of” limits the composition of a component to the specified materials and excludes any material not specified.

[0052]The term “component” or “element” according to the present disclosure may refer to, but is not limited to, a unit or module that performs a specific function within a larger system. A component or element may be, for example, a component or element used in the manufacturing process of a sporting good, such as a sole unit, a midsole, an outsole, an outsole element, a film or foil material, a sole plate, a shoe upper, a functional element, etc.

[0053]Stated dimensions disclosed herein (for example, lengths, widths, thicknesses, etc.) include a range of +/−20% of the stated dimensions. For example, stated a dimension of 10 centimeters (cm) includes a range of dimensions greater than or equal to 8 cm and less than or equal to 12 cm.

[0054]In an embodiment, the present disclosure provides a method of manufacturing an upper for an article of footwear. The method may comprise the steps of providing a substrate, dispensing strands of a liquefied polymer onto the substrate such that the strands form a shape of at least a part of the upper, curing the strands, and removing the cured strands from the substrate.

[0055]In this manner, the present disclosure may enable a highly flexible method of manufacturing a part or even an entire upper, which at the same time may allow for a highly controlled dispensing of the strands onto the substrate. By this, footwear uppers with predefined characteristics and an improved shape can be provided. The term “dispensing” as used in the present disclosure is to be understood as a controlled extruding or outputting of a strand. The strand may be arranged or laid onto the substrate. In particular, the dispensing differentiates over a mere force spinning or jet extrusion of fibers as disclosed in conventional manufacturing methods, which merely provide a random distribution of fibers as a mat or web.

[0056]The method may further comprise the steps of providing a polymer, providing a solvent, and mixing the polymer with the solvent, thereby producing the liquefied polymer. In conventional manufacturing methods, the extruding of the extruded member, for example a sole for an article of footwear, usually is carried out by extruding a preheated thermoplastic polymer material, which can be solidified by reducing its temperature. The present disclosure is based on a different approach, namely, the production of a liquefied polymer by mixing the polymer and the solvent. The mixture can then be applied to and cured on the substrate. In this manner, the liquefied polymer can be applied more precisely and efficiently on the substrate, as no heating of the liquefied polymer is required.

[0057]A “polymer” according to present disclosure is to be understood but not limited to, a large molecule based on repeating subunits (monomers), which are bound together and form a network structure. Polymers may be classified as the following: synthetic polymers, natural polymers, biodegradable polymers, composite polymers.

[0058]A “solvent” according to present disclosure is to be understood but not limited to, a compound capable of dissolving, dispersing, or extracting other compounds. Solvents may be polar or nonpolar. Common solvents are in liquid form but may be also a gas or a solid.

[0059]“Mixing” according to present disclosure is to be understood but not limited to, as a process of combining to or more substances resulting in a mixture of the individual substances.

[0060]“Curing” according to present disclosure is to be understood but not limited to, as a chemical and/or physical process of a substance which typically promotes hardening, setting and/or solidification of the same. Curing is based on chemical reactions, heat influences and/or other external or internal factors.

[0061]In some embodiments, the substrate may comprise a three-dimensional shape of at least a part of a last. In some embodiments, the substrate may even be a last. By dispensing the liquefied polymer directly on a three-dimensional substrate or even a last, an upper or a part of the upper may already be formed in its required shape prior to the curing of the strands. Thus, additional steps of turning a two-dimensional part of an upper into a three-dimensional shape by stitching or gluing as required in conventional manufacturing methods can be omitted. This may result in a more efficient manufacturing technique of the part of the upper or the entire upper. The thus manufactured upper may also result in a higher wearing comfort, since less or even no seams are required.

[0062]In some embodiments, the substrate may comprise a metallic surface, a textured surface, or a combination thereof. Depending on the desired characteristics of the upper, a surface roughness of the substrate may be adapted to influence a tactile perception of the upper on a side that is facing towards the substrate. This side may correspond to an internal surface of a finished upper facing towards a wearer's foot. For example, a recess in the substrate may result in a protrusion on the upper inner side. A protrusion on the substrate, on the other hand, may result in a recess on the upper inner side. By this, a structured inner side of an upper may be provided. The structure may be used, for example, to reduce direct skin contact, imitate a more textile feel, improve a wearing comfort, or reduce slipping of the foot inside the upper.

[0063]In some embodiments, the dispensing may comprise dispensing the liquefied polymer through a nozzle. This may be achieved, for example, by moving the nozzle with respect to the substrate. By moving the substrate around a fixed nozzle, by moving a nozzle around a fixed substrate, or by moving a nozzle around a moving substrate, a preprogrammed strand dispensing resulting in a desired upper shape can be achieved.

[0064]In some embodiments, the dispensing may comprise dispensing strands with a width of 1-10 mm, a width of 2 mm-4 mm, or a width of 3 mm. In some embodiments, the liquefied polymer may enable the dispensing of strands having a specified width. The term “width” as used in the present disclosure is to be understood as a diameter in case of a round strand or the largest diameter or dimension in case of an oval or differently shaped strand. Based on the width as specified, an upper may be manufactured which has similar characteristics compared to a traditional textile upper while at the same time may be more easily adapted to specific needs. This is because instead of developing a complex knitting or weaving pattern, a dispensing pattern may be configured and optimized more efficiently.

[0065]In some embodiments, the width of the strands after the curing may be 0.3 mm-0.7 mm, or may be 0.5 mm. Thus, the present disclosure provides a manufacturing technique for uppers having a textile like feel without the disadvantages and limitations of a traditional textile pattern, such as a knitting or weaving pattern. The textile feel may be achieved based on the fine size of the individual strands used for manufacturing the part of the upper or the entire upper.

[0066]In some embodiments, the dispensing may comprise dispensing the strands in a first area of the substrate and a second area of the substrate such that a mechanical property of the cured strands in the first area differs from a mechanical property of the cured strands in the second area. Due to the high degree of freedom of movement during the dispensing of the liquefied polymer on the substrate, areas with different mechanical properties can efficiently be manufactured.

[0067]In some embodiments, a magnitude of a mechanical property of the cured strands in a third area may differ from a magnitude of the same mechanical property of the cured strands in a fourth area. By this, not only different mechanical properties can be achieved by the disclosed method but even the magnitude of a same mechanical property can be adjusted.

[0068]In some embodiments, the mechanical property of the cured strands may be at least one of density, width, strand diameter, elasticity, breathability, watertightness, tensile strength, Shore hardness, traction, or a combination thereof. Each of these properties may be optimized individually or in combination by adapting the dispensing of the liquefied polymer accordingly.

[0069]In some embodiments, the dispensing may comprise dispensing the strands in a strand pattern. In particular, the dispensing may comprise dispensing the strands in a strand pattern by arranging individual strands on the substrate and/or a previously dispensed strand to form the strand pattern. Depending on the strand pattern, a degree of a textile feel may be adjusted. The strand pattern may further define one or more of the mechanical properties described above.

[0070]In some embodiments, the method may further comprise the steps of heating at least a part of the cured strands and attaching the heated part of the strands to a first component of the article of footwear. By this, no stitching or gluing may be necessary for attaching the part of the upper to the first component. In some embodiments, the first component may comprise or even be a sole component. This method may enable a welding of the upper to the sole component without requiring stitches or gluing. In some embodiments, the first component may be a midsole. In this manner, a strobel board and/or a stitching of the upper to a strobel board may be avoided, which may result in a smooth and non-irritating transition from the upper to the midsole. Thus, a wearing comfort can be improved.

[0071]In some embodiments, the method may further comprise arranging a second component on the substrate prior to the dispensing, wherein the dispensing may further comprise dispensing the strands of the liquefied polymer at least partly onto the substrate and at least partly onto the second component. By this, no gluing or even heating treatments may be required for attaching the upper to the second component. Since the liquefied polymer may have a high sticking coefficient, the second component may adhere to the liquefied polymer and may be firmly attached after the curing step. In some embodiments, the second component may comprise at least one of a reinforcing component, a padding component, a foil component, a mesh component, or a foam component.

[0072]In some embodiments, the polymer may comprise one or more of polyurethanes (PU), thermoplastic polyamides (TPA), thermoplastic polyesters (TPE), thermoplastic styrenic block copolymers (TPS), thermoplastic polyurethanes (TPU), thermoplastic vulcanizates (TPV), rubber or ethylene-vinyl copolymer (EVA), thermoplastic polyurethanes (TPU), and/or combinations thereof. In some embodiments, the use of these polymers may allow for a time efficient and sustainable process in the production of the component. Suitable polymer materials may be elastic foam materials, such as thermoplastic elastomers and/or elastomers.

[0073]In some embodiments, the solvent may be a mixture of a group of solvent-borne and/or water-borne solvents, such as from the group of solvent-borne solvents, such as from the group of (C1-C6) ethers, (C1-C10) esters, (C1-C8) ketones, (C1-C8) alkanes, and/or combinations thereof. These solvents have shown to be compatible with the production method of the upper, while allowing for flexible adaptation of mechanical characteristics of the polymer to the requirements of the product and the process.

[0074]In some embodiments, the solvent may be a mixture of one or more of tetrahydrofuran (THF), methyl ethyl ketone (MEK), cyclohexane (CYC), or ethyl acetate, butyl acetate. These solvents have the advantage that they can be removed in a time efficient manner during the curing process and allow for a production process that is capable of adapting to various mechanical properties of the liquid polymer.

[0075]In some embodiments, a ratio of the mixture may be in the range of 10 to 90 vol. %., 20 to 80 vol. %, or 30 to 70 vol. %. Additionally or alternatively, the ratio of the mixture may be in the range of 10 to 90 wt. %., 20 to 80 wt. %, or 30 to 70 wt. %. In some embodiments, the disclosed ratios of the mixture of the solvent may be suitable for both mixing the polymer and changing/adapting the mechanical characteristics of the liquefied polymer to the special requirements of the product and the process.

[0076]In some embodiments, the liquefied polymer may comprise a dynamic viscosity of 10000 to 50000 mPa·s or a dynamic viscosity of 20000 to 40000 mPa·s. In some embodiments, a liquid polymer comprising the specific dynamic viscosity may allow for its use in automated and/or manual deposition processes.

[0077]In some embodiments, a ratio of the polymer to the solvent in the mixing step may be in the range of 2:98 to 40:60 vol. %, 5:95 to 30:70 vol. %, or 10:90 to 20:80 vol. %. In some embodiments, the specific ratio of solvent to the polymer may allow for convenient use in the dispensing process and flexible adaptation to the requirements of the product and/or process.

[0078]In some embodiments, the liquefied polymer may further comprise pigments. The pigments may allow for a color selection of the liquefied polymer. For example, some liquefied polymers, such as liquefied thermoplastic polyurethane, may have a glass-like transparency without color pigments. By adding pigments to the liquefied polymer in an amount up to 1 vol. %, a desired color effect can be achieved without negatively affecting the mechanical properties of the cured strands.

[0079]In some embodiments, the liquefied polymer may further comprise fibers. This may allow for an increased stiffness and durability in the selected areas of application. “Fibers” are to be understood but not limited to, as threads or filaments based on natural and/or synthetic materials. For example, adding glass-fibers in the amount of 2.5 to 5 wt. % to the liquefied polymer may improve the durability, in particular an abrasion resistance, of the upper.

[0080]In some embodiments, the liquefied polymer may further comprise granulates. The granulates may comprise various materials, e.g. finely ground rubber particles in the range of 0.1-0.3 mm. In this manner, traction and grip properties may be enhanced in selected areas of the upper based on the use of the granulates in the selected areas. Moreover, a visual appearance of the upper may be enhanced. “Granulates” are to be understood but not limited to, as particles with different size and shape which may have specific mechanical properties based on natural and/or synthetic materials.

[0081]In some embodiments, the liquefied polymer may further comprise a blowing agent. A “blowing agent” is to be understood but not limited to, as a substance which expands during the curing step and thereby produces a cellular structure via a foaming process in the upper. The cellular structure in a matrix reduces its density, thereby increasing relative stiffness of the original polymer. Accordingly, a surface roughness of the upper may be increased based on the amount of blowing agent used. In some embodiments, the surface roughness may increase a textile feel of the upper, resulting in a more pleasant wearing comfort.

[0082]In some embodiments, the curing may comprise curing at a curing temperature of between 20° C. to 150° C., between 30° C. to 100° C., or between 40° C. to 50° C., for a curing duration of between 2 min to 750 min, between 5 min to 390 min, or between 10 min to 30 min. In some embodiments, these curing conditions may allow for a cost-and energy-efficient process for the production of the upper.

[0083]In some embodiments, the dispensing may comprise dispensing the liquefied polymer having a temperature in the range of 10° C. to 40° C., 15° C. to 30° C., or ambient temperature. Conventional methods of manufacturing an upper based on a softening of a thermoplastic polymer by increasing its temperature above its glass transition temperature are mostly complex, time consuming, and inefficient. Instead, the present disclosure focuses on an alternative approach, namely the liquefied polymer. Based on the mixing of the polymer and the solvent, no elevated temperatures are required for the methods disclosed herein. This provides an improved and more flexible manufacturing method as compared to known techniques.

[0084]In some embodiments, the present disclosure provides an upper for an article of footwear made by a method comprising one or more steps as described above.

[0085]FIG. 1 presents a flow diagram illustrating method steps for a method 100 for manufacturing an upper 210, 610, 710, 760, 800, 950 (shown, for example, in FIGS. 2, 6, 7A, 7B, 8, and 9, respectively) for an article of footwear 200, 600, 700, 750, 900 (shown, for example, in FIGS. 2, 6, 7A, 7B, and 9, respectively) according to some embodiments of the disclosure. The method 100 may comprise the step 140 of providing a substrate 300, 400 (shown, for example, in FIGS. 3 and 4A, respectively). The substrate 300, 400 may have a three-dimensional shape of at least a part of a last. In some embodiments, a last may be used as substrate 300, 400. The substrate 300, 400 may comprise areas 310, 410, 420. In some embodiments, the areas 310, 410 may comprise metallic surfaces. In some embodiments, the area 420 may comprise a texture. In some embodiments, the substrate 300, 400 may comprise a combination of metallic and textured surfaces. Further details of an embodiment of a substrate 300, 400 are provided with reference to FIGS. 3 and 4 below.

[0086]The method 100 may further comprise the step 150 of dispensing strands 430, 500 (shown, for example, in FIGS. 4A and 5A, respectively) of the liquefied polymer onto the substrate 300, 400 such that the strands 430, 500 form a shape of at least a part of the upper 210, 610, 710, 760, 800, 950. Thus, after the dispensing, the liquefied polymer may essentially already be in its final shape as desired or intended for upper 210, 610, 710, 760, 800, 950. The term “essentially” refers to minor changes of the liquefied polymer strands 430, 500 which may occur during the curing step (see below). Thus, based on the advantageous dispensing, further steps of turning a two-dimensional part of an upper into a three-dimensional shape may not be required for the upper 210, 610, 710, 760, 800, 950 according to the present disclosure. In some embodiments, the dispensing in step 150 may comprise dispensing the liquefied polymer through a nozzle. The nozzle may be moved with respect to the substrate 300, 400. Thus, either the nozzle may be moved and the substrate 300, 400 may be fixed, or the substrate 300, 400 may be moved and the nozzle may be fixed. It may also be advantageous if both the substrate 300, 400 and the nozzle are moving at the same time during the dispensing. In this manner, practically no limitations are provided and all kinds of shapes of uppers 210, 610, 710, 760, 800, 950 may be manufactured based on the present disclosure.

[0087]Additionally or alternatively, the step 150 may comprise dispensing strands 430, 500 with a width of 1-10 mm, a width of 2 mm-4 mm, or a width of 3 mm. It may be noted that also varying widths within the same strand 430, 500 are possible based on the disclosure. For example, portions of varying width of a single strand 430, 500 may be achieved by changing a pressure applied to the liquefied polymer while pressing the liquefied polymer through a nozzle during the dispensing. Currently known manufacturing techniques are not capable of producing a single strand with a varying width as described.

[0088]The width of the strands 440, 510 (shown, for example, in FIGS. 4B and 5B, respectively) after the curing may be in the range of 0.3 mm-0.7 mm, or 0.5 mm. Currently known manufacturing techniques are not capable of producing a strand having widths of the dimensions described herein. A potential reason for this may be based on the higher viscosity of polymers used in known manufacturing techniques as compared to the lower viscosity of polymers that can be used in the manufacturing technique described herein. In some embodiments, a dynamic viscosity of the liquefied polymer may be in the range of 10000 to 50000 mPa·s, or in the range of 20000 to 40000 mPa·s. Method 100 enables a dispensing of the liquefied polymer having an advantageous small width. The fine strands 430, 440, 500, 510 as described provide an upper 210, 610, 710, 760, 800, 950 having similar or improved characteristics compared to a traditional textile upper. At the same time limitations of traditional textile uppers, such as knitting or weaving requirements, or the disadvantages resulting from the shape transformation from a two-dimensional textile into a three-dimensional shape of an upper do not limit uppers manufactured using the methods described herein.

[0089]Additionally or alternatively, in some embodiments the step 150 may comprise dispensing the strands 430, 500 in at least two areas 310, 410, 420 of the substrate 300, 400 such that a mechanical property of the cured strands 440, 510 differs in these areas 310, 410, 420. Additionally or alternatively, the dispensing may also be such that a same mechanical property may have different magnitudes. The mechanical property of the cured strands 440, 510 may be at least one of density, width, strand diameter, elasticity, breathability, watertightness, tensile strength, Shore hardness, traction, or a combination thereof.

[0090]Additionally or alternatively, the step 150 may comprise dispensing the strands 430, 500 in a strand pattern 230, 240, 250, 260 (shown for example in FIG. 2). This may be achieved by arranging individual strands 430, 500 on the substrate 300, 400 and/or a previously dispensed strand in the strand pattern 230, 240, 250, 260. Depending on the strand pattern 230, 240, 250, 260, a degree of a textile feel may be adjusted. In some embodiments, the strand pattern 230, 240, 250, 260 may at least partially determine the mechanical properties of the upper 210, 610, 710, 760, 800, 950. For example, a dense strand pattern (for example, strand patterns 240, 250, 260) may result in a higher tensile strength compared to a loose or less dense strand pattern (for example, strand pattern 230).

[0091]In addition to the mechanical properties of the upper 210, 610, 710, 760, 800, 950 provided by the strand pattern 230, 240, 250, 260, the softness and/or stiffness of the polymer used in the liquefied polymer may also influence the mechanical properties of the upper 210, 610, 710, 760, 800, 950. In this case the mechanical property of the upper 210, 610, 710, 760, 800, 950 may be based on the softness and/or stiffness of the individual strands. For example, a Shore A value of the polymer used may range from Shore A smaller than 50, resulting in soft and comforting strands, up to Shore A larger than 90, for highly stiff strands.

[0092]In some embodiments, the method 100 may further comprise a step of arranging a second component on the substrate 300, 400 prior to the dispensing, wherein the dispensing may further comprise dispensing the strands 430, 500 of the liquefied polymer at least partly onto the substrate 300, 400 and onto the second component. Using this method, no gluing or heating treatments may be required for attaching the upper 210, 610, 710, 760, 800, 950 to the second component. In some embodiments, the second component may comprise at least one of a reinforcing element 810 (shown for example in FIG. 8), a padding element 270, 820, 821 (shown for example in FIG. 2 and FIG. 8, respectively), a foil component (for example, a foil material used to improve scuff resistance, provide a decorative finish, provide a reflective surface, and/or for a logo or branding purposes), a mesh component (for example, a mesh material provided on various portions of a shoe for breathability, to reduce weight, and/or provide a comfortable fit), or a foam component (for example, a foam material for a midsole, a heel cushion, padding around a collar or tongue, etc.).

[0093]In some embodiments, the method 100 may further comprise the step 160 of curing the strands 430, 500. For example, the liquefied polymer having the shape of the substrate 300, 400 may be cured while at the same time the solvent(s) within the liquefied polymer is (are) removed. The solvent may be removed via condensation and the condensates may be recycled. The curing temperature in the curing step 160 may be between 20° C. to 150° C., between 30° C. to 100° C., or between 40° C. to 50° C., and the curing time may be between 2 min to 750 min, between 5 min to 390 min, or between 10 min to 30 min. In some embodiments the curing step 160 may be carried out using radiation. For example, curing step 160 may be performed using infrared radiation (IR). However, other types of radiation may be applicable. The width of the strands 440, 510 after the curing step 160 may be between 0.3 mm-0.7 mm, or 0.5 mm.

[0094]In some embodiments, prior to step 140, method 100 may comprise the step 110 of providing a polymer. The polymer may be selected from the group of elastomers and/or thermoplastic elastomers. Materials from the group of elastomers may comprise block foams, such as ethylene-vinyl-acetate (EVA), polyurethanes (PU) and/or rubber. Thermoplastic elastomers (TPE) may comprise bead-, block foams, crosslinked, and/or un-crosslinked and can be classified using the following groups: TPE-O or TPO; TPE-V or TPV; TPE-U or TPU; TPE-E or TPE or TPC; TPE-S or TPS; TPE-A or TPA. Polymer materials from the group of TPE-O or TPO may comprise polypropylene (PP), ethylene propylene diene rubber or ethylene propylene diene monomer rubber (EPDM). Polymer materials from the group of TPE-V or TPV may comprise thermoplastic vulcanizates such as Sarlink®. Polymer materials from the group of TPE-U or TPU may be further classified in ester based, ether based, or linear UP materials. For instance, an ester-based TPU material group may be HUNTSMAN-H FOAM® such as HUNTSMAN A6055AG®. For example, an ether-based TPU material group may be ELASTOLLAN® 11XX (BASF) such as ELASTOLLAN® 1170A. Polymer materials from the group of TPE-E or TPC may comprise HYTREL® (DuPont), KEYFLEX® (LG) and/or ARNITEL® (DSM). A polymer material from the group of TPE-S or TPS may be STYROFLEX® (BASF). Polymer materials from the group of TPE-A or TPA may be from the group of polyether block amides, such as PEBAX®, and/or VESTAMID®.

[0095]In embodiments in which the method 100 comprises the step 110, the method may further comprise the step 120 of providing a solvent. Suitable solvents may be solvents selected from the group of solvent-borne and/or water-borne solvents, such as from the group of solvent-borne solvents, such as from the group of (C1-C6) ethers, (C1-C10) esters, (C1-C8) ketones, (C1-C8) alkanes, and/or combinations thereof. In some embodiments, the solvent may be a mixture of one or more of tetrahydrofuran (THF), methyl ethyl ketone (MEK), cyclohexane (CYC), ethyl acetate, or butyl acetate. In some embodiments, the ratio of the mixture of the solvent is in the range of 10 to 90 vol %., 20 to 80 vol. %, or 30 to 70 vol. %.

[0096]In embodiments in which the method 100 comprises the steps 110, 120, the method 100 may further comprise the step 130 of mixing the polymer and the solvent, thereby producing the liquefied polymer. In some embodiments, the ratio of the polymer to the solvent in the mixing step may be in the range of 2:98 to 40:60 vol. %, 5:95 to 30:70 vol. %, or 10:90 to 20:80 vol. %. The ratio of the polymer to the solvent in the mixing step may be in the range of 10 to 90 wt. %., 20 to 80 wt. %, or 30 to 70 wt. %.

[0097]In some embodiments, the method 100 may further comprise the steps of heating at least a part of the cured strands 440, 510 and attaching the part of the cured strands 440, 510 to a first component of the article of footwear. The first component may comprise a sole component 220, 620, 625, 720, 770, 960 (shown, for example, in FIGS. 2, 6, 7A, 7B, and 9, respectively), for example a midsole, and outsole, etc.

[0098]In some embodiments, the liquefied polymer used in method 100 may comprise pigments, fibers, granulates and/or a blowing agent. The effect of the blowing agent will be described in more detail below with reference to FIG. 5.

[0099]FIG. 2 depicts an embodiment of an article of footwear 200 manufactured according to the methods described herein. For example, upper 210 of footwear 200 may be manufactured as described above with reference to method 100. Article of footwear 200 further comprises the sole component 220 attached to upper 210. For example, a part of the cured strands of upper 210 may be heated and attached to the sole component 220. In some embodiments, the sole component 220 may be a midsole the article of footwear 200. In some embodiments, heating the strands eliminates the need for stitching or gluing to attach the sole component 220 to the upper 210.

[0100]In some embodiments, the upper 210 may comprise various layers and distinct patterns 230, 240, 250, 260 of cured strands. A base layer of the upper 210 may comprise a first pattern 230. In some embodiments, the first pattern 230 may comprise a mesh-like pattern similar to a traditional knitted textile. The base layer may be manufactured by depositing the liquefied strands onto a substrate as described above. On the base layer, a second layer in a second pattern 240 may be deposited, for example, in a heel area. In some embodiments, the second pattern 240 may be a regular pattern of essentially parallel strands (for example, within ten percent of being parallel). In some embodiments, the strands of the second pattern 240 may be wider as compared to the strands of the base layer. In some embodiments, the second pattern 240 may be adapted to provide stability in specific areas of the article of footwear 200. For example, the second pattern 240 may be adapted to provide stability in the heel area of upper 210.

[0101]In some embodiments, upper 210 may comprise a third pattern 250 arranged on the base layer, for example, in a forefoot to midfoot area. In some embodiments, the third pattern 250 may be a regular pattern of strands arranged in a diamond shaped pattern or a rhomboidal pattern. In some embodiments, the third pattern 250 may be adapted to provide improved stretchability in specific areas of the article of footwear 200. For example, the third pattern 250 may be adapted to provide improved stretchability in the forefoot area and/or midfoot area.

[0102]In some embodiments, upper 210 may comprise a fourth pattern 260 arranged on the third pattern 250, for example, in a toe box area and/or on a medial side and/or a lateral side of upper 210. In some embodiments, the strands of the fourth pattern 260 may be irregularly dispensed, for example having a higher density in areas in which a higher traction or abrasion resistance may be required. The fourth pattern 260 may be advantageous for uppers for soccer shoes, for example, since the cured strands may provide a high friction or stickiness beneficial at areas which are used for ball control. Based on the various layers of cured strands which may be dispensed directly onto a substrate during manufacture (for example, cured strands that comprise the first pattern 230, the second pattern 240, the third pattern 250, the fourth pattern 260, or a combination thereof), upper 210 may comprise a surface close to the foot of a wearer while also providing a superior traction and grip to a ball, for example.

[0103]In some embodiments, upper 210 may comprise a padding component 270 in the heel area of the article of footwear 200. In some embodiments, the padding component 270 may be made from a traditional textile and may be attached to the upper 210 by heating the cured strands in this area. The padding component 270 may increase a wearing comfort for a wearer of article of footwear 200. In some embodiments, the padding component 270 may further stabilize the collar region of upper 210, thereby preventing it from collapsing in. The stabilization may facilitate the wearer stepping into footwear 200. In some embodiments, the padding component 270 may be formed by dispensing a liquefied polymer as described above. For example, a multilayer of cured strands having a mesh like pattern may provide similar cushioning properties as a padding from traditional textiles. It is even possible to manufacture an entire footwear upper exclusively based on the disclosed method of dispensing of liquefied polymer.

[0104]FIG. 3 depicts an embodiment of a substrate 300 having a shape of a last. Substrate 300 may even be a last. In some embodiments, the area 310 of the substrate 300 may comprise a smooth surface. In some embodiments, the area 310 may comprise a metallic surface. In some embodiments, the area 310 may comprise a smooth and metallic surface. In some embodiments, the smooth and/or metallic surface may facilitate removing of the cured strands from the substrate 300 after the curing step. In a forefoot and/or toe area 320 of substrate 300 two different layers 330, 340 of liquefied polymer strands are depicted. In some embodiments, layer 330 of liquefied polymer strands may be dispensed along a tip section of the forefoot and/or toe area 320 starting at the side of the first toe and extending to a side of the fifth toe. In some embodiments, if the substrate 300 would be placed on a ground with a sole section facing the ground, the strands of the layer 330 would essentially extend parallel to the ground (for example, within ten degrees of parallel to the ground). In some embodiments, a density of the dispensed strands of the first layer 330 may be highest in a central section 331 as compared to the edge sections 332, 333. In some embodiments, edge section 332 may be located closer to a sole of the substrate 300 than the central section 331 and the edge section 333. In some embodiments, central section 331 may be located between edge section 332 and edge section 333 such that edge section 333 is located further from the sole of the substrate 300 than edge section 332 and central section 331. Based thereon, the central section 331 may provide a higher degree of abrasion resistance, reinforcement and protection of the toes as compared to the less dense edge sections 332, 333. On the other hand, edge section 333 and edge section 332 may provide a higher degree of elasticity and breathability as compared to the denser central section 331.

[0105]In some embodiments, the layer 340 of liquefied polymer strands may be arranged on top of the layer 330. In some embodiments, the strands of the layer 340 may run essentially perpendicular (for example, within ten degrees of perpendicular) to the strands of the layer 330. In some embodiments, the strands of the layer 340 may start below the forefoot and/or toe area 320 on a side where a sole is to be attached and extend upwards in direction to a vamp area 321 of substrate 300. In some embodiments, the strands of the layer 340 may provide a directional tensile strength along the individual strands of the layer 340. In some embodiments, the directional tensile strength provided by the layer 340 may be smaller than a directional tensile strength provided by the layer 330 along the individual strands of the layer 330. In some embodiments, the difference in tensile strength may be based on the low density of the strands of the layer 340 as compared to the density of the strands of the layer 330.

[0106]As shown in FIG. 3, the layer 330 and the layer 340 of dispensed liquefied polymer strands are arranged in an area of the substrate 300 which is curved in various directions. These areas are difficult to manufacture using traditional methods in which a two-dimensional surface must be shaped into the required three-dimensional shape without introducing kinks or creases. The present disclosure overcomes these difficulties by allowing a three-dimensional shape to be generated without the need to first generate a two-dimensional shape. Thus, in some embodiments at least a part of an upper which is curved in various directions may be manufactured according to the methods disclosed herein.

[0107]FIG. 4A depicts an embodiment of a substrate 400 according to the present disclosure. Substrate 400 has two distinct surface areas, a first surface area 410 and a second surface area 420. In some embodiments, the first surface area 410 may be smooth and the second surface area 420 may have a textured surface. In FIG. 4A, the textured surface of the second surface area 420 may comprise quadratic protrusions 421 arranged in a regular configuration. Between the quadratic protrusions 421 recesses 422 are formed. Other shapes and forms of protrusions and corresponding recesses are also applicable and may be implemented in some embodiments.

[0108]In some embodiments, during the dispensing of the liquefied polymer strands 430 onto substrate 400, the two surface areas 410, 420 result in differently textured cured strands 440, as depicted in FIG. 4B. The section 450 of the cured strands 440 corresponds to the section of the strands 430 arranged on surface area 410, and section 460 of cured strands 440 corresponds to the section of the strands 430 arranged on surface area 420, respectively. Depending on the level of viscosity of the liquefied polymer, the side of the strands 430 facing the substrate 400 may at least partially flow into the recesses 422 in the second surface area 420. This flow may result in protrusions 442 on the side of the cured strands 440, which was facing the substrate 400 prior to the removing. The same side of the cured strands 440 in section 450 may have a flattened surface 411 based on having been dispensed on the smooth surface area 410.

[0109]In general, a section of a strand which has been dispensed and cured on a textured surface may have a rougher or textured surface as compared to a section dispensed and cured on a smooth(er) surface. In other words, the cured strands generally may have a roughness corresponding to a negative shape of the surface on which they are dispensed and cured. The term “negative” is to be understood that a recess in the substrate translates into a protrusion in the cured strand and vice versa. The different textures of the cured strand may provide different haptics or tactile perceptions to a wearer of an upper manufactured in accordance with the present disclosure. In some embodiments, the textured side of the strands may correspond to the side of the upper facing a wearer's foot. Such arrangements of the textured strands may be used for reducing the area of the upper with direct skin contact. Additionally or alternatively, the textured strands can be adapted to imitate a textile haptic or feel for the wearer.

[0110]FIG. 5A/5B depict a schematic illustration of strands 500, 510 in accordance with the present disclosure. In some embodiments, strands 500, 510 may comprise a blowing agent. FIG. 5A depicts strand 500 prior to a curing step. Thus, in strand 500 the blowing agent has not been activated yet and strand 500 has a smooth and closed surface 501.

[0111]FIG. 5B depicts strand 510, which corresponds to strand 500 after curing. During the curing process, the blowing agent gets activated and expands, thereby producing a cellular structure via a foaming process in strand 510. The cellular structure may create a surface roughness 511 of strand 510, the degree of which depends on the amount of blowing agent used in the liquefied polymer. For example, using more blowing agent in a strand will result in a higher surface roughness as compared to a strand in which less blowing agent is used. The surface roughness 511 may increase a textile feel of the upper manufactured in accordance with the present disclosure, thereby resulting in a more comfortable experience for a wearer. In some embodiments, the blowing agent may be adapted to not increase the width of the cured strand 510 more than 10% as compared to a cured strand with not blowing agent. In some embodiments, the blowing agent may be adapted to not increase the width of the cured strand 510 more than 5% as compared to a cured strand with no blowing agent.

[0112]FIG. 6 depicts an embodiment of an article of footwear 600 manufactured according to the methods described herein. For example, upper 610 of article of footwear 600 may be manufactured as described above with reference to method 100. In some embodiments, article of footwear 600 comprises a midsole 620 attached to upper 610. In some embodiments, a portion of the cured strands of upper 610 may be heated and attached to a midsole 620, thereby attaching the midsole 620 to the upper 610 after the strands are cooled. Thus, no stitching or gluing may be required for attaching the midsole 620 to the upper 610. In some embodiments, on an opposite side of midsole 620 an outsole 625 may be attached.

[0113]FIG. 6 further depicts the article of footwear 600 having three zones of different mechanical properties. These mechanical properties may be adapted for the article of footwear 600 in a laceless configuration. Thus, upper 610 should be provided with sufficient lockdown, to ensure that footwear 600 stays on the wearer's foot even when swinging the leg during a sprint or when hitting a ball, for example. On the other hand, upper 610 should also be provided with sufficient elasticity to ensure that a wearer can easily step in when putting on footwear 600.

[0114]These various mechanical properties can be efficiently provided based on the method as described herein. In a first zone, an omnidirectional or non-directional stretchability of upper 610 is provided (indicated by arrows 611). Such stretchability can be achieved based on strands made from a polymer material having one or more of: a Shore A hardness below 70, a high stretchability, low stiffness, etc. In a second zone a directional lockdown indicated by arrows 612 is provided while an essentially perpendicular stretchability (indicated by arrows 613) is also provided in a different direction. The directional lockdown indicated by arrows 612 can, for example, be achieved by utilizing a hard polymer material, thicker strands as compared to strands in the other zones, and/or stiffer strands as compared to strands in the other zones for the strands on the upper dispensed in a direction parallel to arrows 612. In some embodiments, the strands aligned with the direction indicated by arrows 612 may limit stretching in the direction indicated by arrows 612. At the same time, strands having similar properties as described with reference to the first zone may be dispensed on the substrate in direction of arrows 613 (e.g., the third zone). A dispensing of the different strands in the second zone and the third zone may be separated in alternating layers (e.g. first dispensing a layer of strands in direction of arrows 612, than dispensing a layer of strands in direction of arrows 613, etc.). In some embodiments, a mesh pattern may be dispensed in which a strand in direction parallel to arrows 612 is dispensed followed by a strand in direction parallel to arrows 613, followed by a strand in a direction parallel to arrows 612, and so forth. While FIG. 6 is to be understood as an exemplary embodiment, other arrangements of different zones having one or more of the above-described mechanical properties is also applicable based on the present disclosure.

[0115]FIG. 7A depicts an embodiment of an article of footwear 700 manufactured according to the methods described herein. For example, upper 710 of article of footwear 700 may be manufactured as described above with reference to method 100. Article of footwear 700 may comprise a sole 720 attached to upper 710. In some embodiments, a portion of the cured strands of upper 710 may be heated and attached to the sole 720, thereby attaching the sole 720 to the upper 710 after the strands are cooled. Thus, no stitching or gluing may be required for attaching the sole 720 to the upper 710. However, alternative attachment methods, like stitching or gluing, may also be in accordance with the present disclosure.

[0116]FIG. 7A depicts an embodiment of an upper 710 having a high degree of breathability provided by the strand pattern having openings 711. Upper 710 may also have various zones with distinct levels of breathability, which may be adapted to breathability perception zones of a human foot, for example. For this, a density of strands may be low (for example, as compared to a density of strands providing a closed surface as in upper 760 of FIG. 7B, for example) and arranged in a mesh-like pattern, such that multiple openings 711 are provided in upper 710. Upper 710 may be advantageous for articles of footwear adapted for running, for example.

[0117]FIG. 7B depicts an embodiment of an article of footwear 750 manufactured according to the methods described herein. For example, upper 760 of footwear 750 may be manufactured as described above with reference to method 100. Article of footwear 750 comprises a sole 770 attached to upper 760.

[0118]Contrary to footwear 700, article of footwear 750 depicts an embodiment of an upper 760 having a high degree of traction and/or watertightness. Upper 760 may also have various zones with distinct levels of traction, which may be adapted based on the respective usage or kind of sports for which upper footwear 750 is intended for, for example. For this, a density of strands is high (for example, higher as compared to upper 710) and arranged in a mesh-like pattern, such that no openings but instead a closed surface 761 is provided in upper 760. Upper 760 may be beneficial for articles of footwear adapted for playing soccer, for example.

[0119]FIG. 8 depicts a schematic illustration of an embodiment of an upper 800 manufactured according to the methods described herein. For example, upper 800 may be manufactured as described above with reference to method 100. Upper 800 comprises a reinforcing element 810 in a toe area 815. In some embodiments, the reinforcing element 810 may be arranged on a substrate prior to dispensing any liquefied polymer strands. Then, the liquefied polymer strands may be dispensed onto the substrate and onto the reinforcing element 810. Since the liquefied polymer strands can attached components together (as described above), the reinforcing element 810 and the dispensed strands may be attached to each other. The level of attachment between the reinforcing element 810 and the dispensed strands may be further increased and potentially made permanent by the curing step. Alternatively, the reinforcing element 810 may be attached to an upper after dispensing the strands but prior to the curing step such that, after curing, the reinforcing element 810 and the dispensed strands may be attached to the upper. In this manner it may be possible to have the reinforcing element 810 arranged on the outside of a finished upper, which is the side not in contact with a wearer's foot when wearing a corresponding article of footwear comprising upper 800.

[0120]Instead of or in addition to the reinforcing element 810, upper 800 may comprise a lateral padding element 820 and a medial padding element 821 in a collar area 825. In some embodiments, the padding elements 820, 821 may be attached to upper 800 in the same manner as described with reference to reinforcing element 810. While FIG. 8 depicts elements in the toe area 815 and the collar area 825 (for example, the reinforcing element 810 and the padding elements 820, 821), additional elements in different areas are also applicable and may be implemented using methods described herein.

[0121]FIG. 9 depicts an embodiment of an article of footwear 900 from a lateral point of view 910 and a medial point of view 920. Article of footwear 900 may be manufactured according to the methods described herein. For example, upper 950 of article of footwear 900 may be manufactured as described above with reference to method 100. Article of footwear 900 further may comprise a sole 960 attached to upper 950. For example, a portion of the cured strands of upper 950 may be heated and attached to a sole 960, thereby attaching the sole 960 to the upper 950 after the strands are cooled. Thus, no stitching or gluing may be required for attaching the sole 960 to the upper 950.

[0122]In FIG. 9, various zones having a different levels of mechanical stiffness may be provided. The different levels of mechanical stiffness may be achieved by varying a strand density accordingly. For example, a higher strand density may result in a higher mechanical stiffness. A lower strand density may result in a lower mechanical stiffness. While the indicated zones in FIG. 9 may be optimized for soccer shoes, other arrangement of zones may also be applicable based on requirements of other kinds of footwear.

[0123]While the above embodiments indicate various individual examples, one or more of these examples may also be combined together in an article of footwear 200, 600, 700, 750, 900 according to the present disclosure. For example, the textured strands 430, 440 as described with reference to FIG. 4 may be combined with any of the embodiments describing various mechanical properties in various zones. Moreover, an article of footwear 700 having openings 711 for improved breathability as described with reference to FIG. 7A may also have a closed surface 761 in another area of the upper 210, 610, 710, 760, 800, 950 with improved watertightness and abrasion resistance as described with reference to FIG. 7B.

[0124]While various embodiments have been described herein, they have been presented by way of example, and not limitation. It should be apparent that adaptations and modifications are intended to be within the meaning and range of equivalents of the disclosed embodiments, based on the teaching and guidance presented herein. It therefore will be apparent to one skilled in the art that various changes in form and detail can be made to the embodiments disclosed herein without departing from the spirit and scope of the present disclosure. The elements of the embodiments presented herein are not necessarily mutually exclusive, but can be interchanged to meet various situations as would be appreciated by one of skill in the art.

[0125]The examples are illustrative, but not limiting, of the present disclosure. Other suitable modifications and adaptations of the variety of conditions and parameters normally encountered in the field, and which would be apparent to those skilled in the art, are within the spirit and scope of the present disclosure.

[0126]It is to be understood that the phraseology or terminology used herein is for the purpose of description and not of limitation. The breadth and scope of the present disclosure should not be limited by any of the above-described exemplary embodiments, but should be defined in accordance with the following claims and their equivalents.