UPPER WITH ENGINEERED SUPPORT STRUCTURE FOR ARTICLE OF FOOTWEAR

BACKGROUND

[0001]The present embodiments relate to articles of footwear and more particularly to an upper with an engineered support structure for an article of footwear.

[0002]Conventional articles of footwear generally include two primary elements: an upper and a sole assembly. The upper is secured to the sole assembly and forms a void within the footwear for comfortably and securely receiving a foot. The sole assembly is secured to a lower surface of the upper so as to be positioned between the upper and the ground.

[0003]Various materials are conventionally utilized in manufacturing the upper. The materials may be selected based upon various properties, including stretch-resistance, wear-resistance, flexibility, air-permeability, compressibility, and moisture-wicking, for example, with each material imparting different properties to the upper.

[0004]There is a need in the art for an article of footwear having an upper with an engineered support structure that provides an improved fit and feel to a wearer.

SUMMARY

[0005]In one aspect, the disclosure provides an upper for an article of footwear with an engineered support structure. The upper includes a first layer, a second layer, and an engineered support structure. The engineered support structure includes an adhesive dot matrix pattern disposed between the first layer and the second layer. The engineered support structure having at least one first zone with a first level of support defined by a first adhesive dot density or a first size of adhesive dots in the adhesive dot matrix pattern and at least one second zone with a second level of support defined by a second adhesive dot density or a second size of the adhesive dots in the adhesive dot matrix pattern. The first level of support being different from the second level of support.

[0006]In another aspect, the disclosure provides a method of forming an upper with an engineered support structure. The method includes providing a first layer of the upper having an inner face and an opposite outer face. The method also includes providing a second layer of the upper having a first face and an opposite second face. The method further includes depositing a plurality of adhesive dots onto one of the inner face of the first layer or the first face of the second layer according to an adhesive dot matrix pattern to form the engineered support structure. The engineered support structure includes at least one first zone with a first level of support defined by a first adhesive dot density or a first size of adhesive dots in the adhesive dot matrix pattern and at least one second zone with a second level of support defined by a second adhesive dot density or a second size of the adhesive dots in the adhesive dot matrix pattern. The first level of support being different from the second level of support

[0007]In another aspect, the disclosure provides an engineered support structure for an upper. The engineered support structure includes a plurality of adhesive dots deposited onto a face of a layer of the upper according to an adhesive dot matrix pattern. The adhesive dot matrix pattern provides the engineered support structure with at least one first zone with a first level of support defined by a first adhesive dot density or a first size of adhesive dots in the adhesive dot matrix pattern and at least one second zone with a second level of support defined by a second adhesive dot density or a second size of the adhesive dots in the adhesive dot matrix pattern. The first level of support being different from the second level of support.

[0008]Other systems, methods, features and advantages of the disclosure will be, or will become, apparent to one of ordinary skill in the art upon examination of the following figures and detailed description. It is intended that all such additional systems, methods, features and advantages be included within this description and this summary, be within the scope of the disclosure, and be protected by the following claims.

BRIEF DESCRIPTION OF THE DRAWINGS

[0009]The disclosure can be better understood with reference to the following drawings and description. Throughout the drawings, reference numbers may be re-used to indicate correspondence between referenced elements. The drawings are provided to illustrate example embodiments described herein and are not intended to limit the scope of the disclosure. Sizes and relative positions of elements in the drawings are not necessarily drawn to scale. For example, the shapes and sizes of various elements and angles are not drawn to scale, and some of these elements are arbitrarily enlarged and positioned to improve drawing legibility.

[0010]FIG. 1 is an isometric view of an example embodiment of an article of footwear including an upper with an engineered support structure;

[0011]FIG. 2 is a schematic plan view of an example embodiment of an upper with an engineered support structure;

[0012]FIG. 3 is an exploded view of the example embodiment of the upper with an engineered support structure;

[0013]FIG. 4 is a representative view of an example embodiment of an adhesive dot matrix pattern for an upper;

[0014]FIG. 5 is a representative view of an example embodiment of a process of applying an adhesive dot matrix pattern to a portion of an upper;

[0015]FIG. 6 is a representative cross-sectional view of an example embodiment of an outer layer and an inner layer joined by an adhesive dot matrix pattern;

[0016]FIG. 7A is a schematic view of an example embodiment of an adhesive dot matrix arrangement that allows for four way stretch;

[0017]FIG. 7B is a schematic view of an example embodiment of an adhesive dot matrix arrangement that allows for two way stretch;

[0018]FIG. 8 is a schematic view of an example embodiment of an upper with various areas having four way stretch or two way stretch;

[0019]FIG. 9 is a representative view of an alternate embodiment of an adhesive dot matrix pattern for an upper; and

[0020]FIG. 10 is a representative view of another alternate embodiment of an adhesive dot matrix pattern for an upper.

DETAILED DESCRIPTION

[0021]Articles of footwear having an upper with an engineered support structure are described herein. The techniques of the present embodiments provide an upper for an article of footwear that distributes pressure in a way that is comfortable for the wearer while also effectively supporting movement of the wearer's foot. In some aspects, the upper of the present embodiments includes an engineered support structure having varied zones of support throughout areas of the upper to allow for support of the wearer's foot.

[0022]For consistency and convenience, directional adjectives are employed throughout this detailed description corresponding to the illustrated embodiments. For purposes of this disclosure, the following directional terms, when used in reference to an article of footwear, shall refer to the article of footwear when sitting in an upright position, with the sole facing the ground, that is, as it would be positioned when worn by a wearer standing on a substantially level surface. The terms “medial,” “lateral,” “anterior,” “posterior,” and the like are intended to refer to anatomical directions corresponding to a human on whom an article is configured to be placed or worn. For example, “medial” refers to a relative position disposed toward the center of the human body, while “lateral” refers to a relative position disposed away from the center of the human body. With respect to footwear, the term “anterior” refers to a relative position closer to the toe of a wearer and “posterior” refers to a relative position closer to the heel of the wearer. In the absence of a wearer, the same directional terms may be used as if the article of footwear is being worn in its expected configuration.

[0023]The term “longitudinal” as used throughout this detailed description and in the claims refers to a direction extending a length of an article. In some cases, the longitudinal direction may extend from a forefoot region to a heel region of the article. Also, the term “lateral” as used throughout this detailed description and in the claims refers to a direction extending a width of an article. In other words, the lateral direction may extend between a medial side and a lateral side of an article.

[0024]Terms such as “up,” “down,” “vertical,” “horizontal,” and the like should be understood in the context of the particular article in question. For example, an article may be oriented around defined X, Y, and Z axes, with the X axis corresponding to the longitudinal direction and the Y axis corresponding to the lateral direction. In those examples, the X-Y plane will define horizontal, with up being defined as the positive Z direction and down being defined as the negative Z direction. Furthermore, the term “vertical” as used throughout this detailed description and in the claims refers to a direction generally perpendicular to the X-Y plane and/or the lateral and longitudinal directions. For example, in cases where an article is planted flat on a ground surface, the vertical direction may extend from the ground surface upward. It will be understood that each of these directional adjectives may be applied to individual components of an article, such as an upper and/or a sole assembly.

[0025]The Figures illustrate an example embodiment of an article of footwear 100. For clarity, the following detailed description discusses an example embodiment, in the form of a casual shoe, but it should be noted that the techniques described herein could be applied to any form of an article of footwear including, but not limited to: sneakers, running shoes, training shoes, yoga shoes, soccer shoes, football shoes, basketball shoes, baseball shoes, rugby shoes, other types of sports shoes, casual shoes, hiking boots, as well as other kinds of footwear. As shown in FIGS. 1 through 10, article of footwear 100, also referred to simply as article 100, is intended to be used with a right foot; however, it should be understood that the following discussion may equally apply to a mirror image of article of footwear 100 that is intended for use with a left foot.

[0026]Referring to FIGS. 1 through 10, for purposes of reference, article 100 may include forefoot region 10, midfoot region 20 and heel region 30. Forefoot region 10 may be generally associated with the toes and joints connecting the metatarsals with the phalanges. Midfoot region 20 may be generally associated with the arch of a foot. Likewise, heel region 30 may be generally associated with the heel of a foot, including the calcaneus bone. In addition, article 100 may include medial side 40 and lateral side 50. In particular, medial side 40 and lateral side 50 may be opposing sides of article 100. Furthermore, both medial side 40 and lateral side 50 may extend through forefoot region 10, midfoot region 20 and heel region 30.

[0027]It will be understood that forefoot region 10, midfoot region 20 and heel region 30 are only intended for purposes of description and are not intended to demarcate precise regions of article 100, but rather, to describe relative positions. Likewise, medial side 40 and lateral side 50 are intended to represent generally two sides of an article, rather than precisely demarcating article 100 into two halves. In addition, forefoot region 10, midfoot region 20 and heel region 30, as well as medial side 40 and lateral side 50, can also be applied to individual components of an article, such as a sole assembly and/or an upper.

[0028]Article 100 may include an upper 110 and a sole assembly 120. In some embodiments, sole assembly 120 may be configured to provide traction for article 100. In addition to providing traction, sole assembly 120 may attenuate ground reaction forces when compressed between the foot and the ground during walking, running or other ambulatory activities. The configuration of sole assembly 120 may vary significantly in different embodiments to include a variety of conventional or non-conventional structures. In some cases, the configuration of sole assembly 120 can be configured according to one or more types of ground surfaces on which sole assembly 120 may be used. Examples of ground surfaces include, but are not limited to: dirt, concrete, pavement, natural turf, synthetic turf, as well as other surfaces.

[0029]Sole assembly 120 is secured to upper 110 and extends between the foot and the ground when article 100 is worn. In different embodiments, sole assembly 120 may include different components. For example, sole assembly 120 may include an outsole, a midsole, and/or an insole. In some cases, one or more of these components may be optional. Moreover, in some cases, sole assembly 120 may itself be optional.

[0030]Upper 110 may be generally configured to receive and cover a foot. To this end, upper 110 may include an opening 112 that provides entry to an interior of upper 110 and/or article 100. In an example embodiment, upper 110 may be configured as a slip on upper that does not include laces or fastening members to secure article 100 to the foot of a wearer. In other embodiments, upper 110 may include provisions for tightening or otherwise fastening upper 110 and article 100 to a foot of a wearer. In some embodiments, for example, upper 110 may be provided with lace receiving members, which may include a plurality of eyelets that are configured to receive a lace. Although not shown in the present embodiments, some embodiments of article 100 may include a lace or other fastening member that may be used to adjust the size of opening 112 and therefore the fit of upper 110 around a foot of a wearer.

[0031]In this embodiment, upper 110 of article 100 includes a vamp area 114 that is configured to cover over the instep on the top of the foot of the wearer. As shown in FIG. 1, vamp area 114 extends from a toe end 116 of upper 110 at the front of article 100 to a front collar edge 118 at opening 112. Some embodiments of upper 110 may include a tongue to facilitate comfort and fit of upper 110 and/or article 100. For example, embodiments of upper 110 may have a tongue that extends longitudinally from opening 112 through vamp area 114 of upper 110 in a direction towards forefoot region 10. In these embodiments, the tongue is configured to cover the instep of the foot of a wearer of article 100.

[0032]Referring now to FIG. 2, a planar or flat configuration of upper 110 is shown. In this embodiment, upper 110 includes an outer periphery 200 that extends around a perimeter of upper 110 in the flat configuration. As shown in FIG. 2, outer periphery 200 of upper 110 includes a front edge 202 that extends from the front of upper 110 in either direction (e.g., towards medial side 40 and lateral side 50) from toe end 116. Outer periphery 200 includes a lateral side edge 204 on lateral side 50 and continues to a heel edge 206 that will form a heel of upper 110 when upper 110 is formed into article of footwear 100 (as shown in FIG. 1). Outer periphery 200 also includes a medial side edge 208 on medial side 40 on the opposite side of upper 110 from lateral side edge 204 on lateral side 50.

[0033]In this embodiment, upper 110 has an asymmetric arrangement with a heel portion 210 of upper 110 extending from lateral side edge 204 on lateral side 50. In one embodiment, heel portion 210 of upper 110 includes a first rear edge 212 extending from heel edge 206 that is configured to be joined or mated with a second rear edge 214 extending from medial side edge 208. That is, first rear edge 212 and second rear edge 214 are configured to be brought together and joined via stitching, adhesive, or other attachment mechanism to close the rear of upper 110 and form opening 112 in upper 110 (as shown in FIG. 1). With this arrangement, when rear of upper 110 is closed to form opening 112, an inner peripheral edge of opening 112 is defined by medial inner edge 216 on medial side 40, front collar edge 118, and lateral inner edge 218 on lateral side 50.

[0034]Referring now to FIG. 3, an exploded view of upper 110 is shown. In some embodiments, upper 110 of article 100 may include multiple layers, including an outer layer 300 forming at least a portion of an exterior of article 100 and an inner layer 302 forming at least a portion of an interior of article 100 and configured to face towards the foot of a wearer when article 100 is worn. Each layer of upper 110 may be made from a separate fabric or textile. In an example embodiment, the fabrics or textiles forming outer layer 300 and/or inner layer 302 may have 2-way stretch capabilities, 4-way stretch capabilities, wicking properties, quick drying characteristics, and combinations thereof. In one embodiment, outer layer 300 and inner layer 302 may be made from a knit textile. In some cases, the fabric or textile of outer layer 300 may be different from inner layer 302. For example, outer layer 300 may be made from a knit textile that has a greater amount or percentage of stretchable fibers or yarns (e.g., elastane or similar fibers/yarns) than inner layer 302. In other cases, the fabric or textile of outer layer 300 may be the same as inner layer 302. In still other cases, outer layer 300 and inner layer 302 may be made from any type or kind of fabric or textile, including combinations of textiles and/or fabrics.

[0035]In an example embodiment, outer layer 300 of upper 110 includes an outer face 304 on the exterior of upper 110 and an opposite inner face 306 facing inwards towards the foot of the wearer. Inner face 306 of outer layer 300 faces towards a first face 308 of inner layer 302 when inner layer 302 and outer layer 300 are joined together to form upper 110. Inner layer 302 also includes a second face 310 opposite first face 308 that faces towards the foot of the wearer when article 100 including upper 110 is worn. In some embodiments, second face 310 of inner layer 302 is within the interior of upper 110.

[0036]According to the techniques of the present embodiments, an upper, including upper 110, may be provided with an engineered support structure that allows the upper to have zones of varying support (i.e., stretch resistance) in different areas of the upper and the article including the upper (e.g., article 100). In some embodiments, the engineered support structure may be formed by selectively applying drops or dots of adhesive in between the layers of the upper in different patterns to create the zones of varying support. When the layers forming the upper are joined, the patterns of adhesive allow the upper to stretch to varying degrees or amounts, depending on the separation distance between the drops or dots of adhesive forming each zone. With this arrangement, an upper with an engineered support structure that provides zones of varying support for a foot of a wearer of an article of footwear may be formed.

[0037]As shown in FIG. 3, an adhesive dot matrix pattern 312 joins or bonds outer layer 300 and inner layer 302 together to form upper 110. As will be described in more detail below, adhesive dot matrix pattern 312 includes a plurality of adhesive dots arranged with varying densities (e.g., by varying separation distances and/or adhesive dot sizes) that provides zones of varying support to upper 110. In this embodiment, outer layer 300 of upper 110 may be joined with inner layer 302 by aligning first face 308 of inner layer 302 with inner face 306 of outer layer 300 and bringing the opposing faces (e.g., 308, 306) together to join outer layer 300 and inner layer 302 to form upper 110.

[0038]In one embodiment, an engineered support structure may include two or more layers of an adhesive dot matrix pattern, including, for example, adhesive dot matrix pattern 312. Each of the two or more layers may be applied on top or over another layer or beneath or below another layer so as to create a multi-layered adhesive dot matrix pattern. In some cases, the adhesive dot matrix pattern in each layer of the multi-layered adhesive dot matrix pattern may be the same or different than the pattern underneath and/or above it. The multiple layers of the multi-layered adhesive dot matrix patterns may partially or completely overlap to create zones with varying properties throughout different areas or regions of upper 110 and/or article 100.

[0039]Referring now to FIG. 4, an example embodiment of adhesive dot matrix pattern 312 is shown for forming an engineered support structure for upper 110. In this embodiment, adhesive dot matrix pattern 312 includes four levels of adhesive dot density (e.g., associated with varying separation distances and/or adhesive dot sizes) arranged in different areas of upper 110 to provide zones having different levels of support. As shown in FIG. 4, adhesive dot matrix pattern 312 includes a first adhesive dot density 400 that is associated with a minimum adhesive dot density having a largest separation distance and/or a smallest adhesive dot size to provide a smallest level of support. That is, first adhesive dot density 400 bonds the opposite layers (e.g., outer layer 300 and inner layer 302 shown in FIG. 3) such that the areas of upper 110 having first adhesive dot density 400 provide the least stretch resistance.

[0040]In this embodiment, first adhesive dot density 400 may be used in at least a center portion of upper 110 in forefoot region 10 in an area corresponding to a toe box of article 100. First adhesive dot density 400 may also be used in areas along front collar edge 118 and heel portion 210 of upper 110. With this arrangement, these areas of upper 110 may be configured to allow the greatest amount of stretch (i.e., provide the least stretch resistance).

[0041]Adhesive dot matrix pattern 312 also includes a second adhesive dot density 402 that is associated with a low adhesive dot density having a separation distance that is smaller than the separation distance of first adhesive dot density 400 (and/or an adhesive dot size that is larger than the adhesive dot size of first adhesive dot density 400) to provide a level of support that is greater than the level of support provided by first adhesive dot density 400. That is, second adhesive dot density 402 bonds the opposite layers (e.g., outer layer 300 and inner layer 302 shown in FIG. 3) such that the areas of upper 110 having second adhesive dot density 402 provide an amount or degree of stretch resistance that is greater than the amount or degree of stretch resistance provided by first adhesive dot density 400.

[0042]In this embodiment, second adhesive dot density 402 may be used in at least an area around the center portion of upper 110 in forefoot region 10 surrounding the area corresponding to the toe box of article 100 having first adhesive dot density 400. As shown in FIG. 4, second adhesive dot density 402 extends through at least a portion of vamp area 114 of upper 110, including areas adjacent to medial side edge 208 on medial side 40, lateral side edge 204 on lateral side 50, and front edge 202 at the front of upper 110.

[0043]Adhesive dot matrix pattern 312 further includes a third adhesive dot density 404 that is associated with a medium adhesive dot density having a separation distance that is smaller than the separation distance of second adhesive dot density 402 and first adhesive dot density 400 (and/or an adhesive dot size that is larger than the adhesive dot size of second adhesive dot density 402 and first adhesive dot density 400) to provide a level of support that is greater than the level of support provided by second adhesive dot density 402 and first adhesive dot density 400. That is, third adhesive dot density 404 bonds the opposite layers (e.g., outer layer 300 and inner layer 302 shown in FIG. 3) such that the areas of upper 110 having third adhesive dot density 404 provide an amount or degree of stretch resistance that is greater than the amount or degree of stretch resistance provided by second adhesive dot density 402 and first adhesive dot density 400.

[0044]In this embodiment, third adhesive dot density 404 may be used in at least a portion of vamp area 114 on medial side 40 and lateral side 50. Third adhesive dot density 404 may also be used in at least areas extending along lateral inner edge 218 of opening 112 and above heel portion 210 having first adhesive dot density 400. With this arrangement, third adhesive dot density 404 along lateral inner edge 218 may limit stretch (i.e., a greater amount of stretch resistance) around opening 112 to keep a foot of a wearer of article 100 secured within upper 110.

[0045]In this embodiment, adhesive dot matrix pattern 312 also includes a fourth adhesive dot density 406 that is associated with a high adhesive dot density having a separation distance that is smaller than the separation distance of third adhesive dot density 404, second adhesive dot density 402, and first adhesive dot density 400 (and/or an adhesive dot size that is larger than the adhesive dot size of third adhesive dot density 404, second adhesive dot density 402, and first adhesive dot density 400) to provide a level of support that is greater than the level of support provided by third adhesive dot density 404, second adhesive dot density 402, and first adhesive dot density 400. That is, fourth adhesive dot density 406 bonds the opposite layers (e.g., outer layer 300 and inner layer 302 shown in FIG. 3) such that the areas of upper 110 having fourth adhesive dot density 406 provide an amount or degree of stretch resistance that is greater than the amount or degree of stretch resistance provided by third adhesive dot density 404, second adhesive dot density 402, and first adhesive dot density 400.

[0046]In this embodiment, fourth adhesive dot density 406 may be used in at least an area extending along a majority of outer periphery 200 of upper 110, including along front edge 202 that extends from the front of upper 110 and further in either direction (e.g., towards medial side 40 and lateral side 50) along lateral side edge 204 on lateral side 50 to heel portion 210 and along medial side edge 208 on medial side 40 to second rear edge 214. Fourth adhesive dot density 406 may also be used in at least an area extending laterally across the top of vamp area 114 from medial side 40 to lateral side 50. With this arrangement, fourth adhesive dot density 406 in this area may form a band-like structure over the top of the foot of the wearer that limits lateral (i.e., side to side) stretch of upper 110 when article 100 is worn. Additionally, fourth adhesive dot density 406 may be used in an area extending from heel portion 210 to first rear edge 212. With this arrangement, adhesive dot matrix pattern 312 forms an engineered support structure between outer layer 300 and inner layer 302 of upper 110 for providing an improved fit and feel to article 100.

[0047]In one embodiment, the adjacent adhesive dots of first adhesive dot density 400 are separated by a first separation distance D1. For example, as shown in FIG. 4, a first adhesive dot 410 and a second adhesive dot 412 in a zone having first adhesive dot density 400 are spaced apart from each other by first separation distance D1. The adjacent adhesive dots of second adhesive dot density 402 are separated by a second separation distance D2 that is smaller than first separation distance D1. For example, as shown in FIG. 4, a third adhesive dot 414 and a fourth adhesive dot 416 in a zone having second adhesive dot density 402 are spaced apart from each other by second separation distance D2. The adjacent adhesive dots of third adhesive dot density 404 are separated by a third separation distance D3 that is smaller than first separation distance D1 and second separation distance D2. For example, as shown in FIG. 4, a fifth adhesive dot 418 and a sixth adhesive dot 420 in a zone having third adhesive dot density 404 are spaced apart from each other by third separation distance D3.

[0048]In an example embodiment, the separation distances of the adjacent adhesive dots of each zone decrease from the center portion of upper 110 in forefoot region 10 surrounding the area corresponding to the toe box outwards towards outer periphery 200 at toe end 116 such that first separation distance D1 is greater than second separation distance D2 and third separation distance D3 and second separation distance D2 is greater than third separation distance D3. In one embodiment, first separation distance D1 is approximately 6 millimeters (mm), second separation distance D2 is approximately 4 mm, and third separation distance D3 is approximately 3 mm. In other embodiments, the specific separation distances may vary. The same variation in adjacent adhesive dot separation distances may also be applied in different directions. For example, the same effect may be achieved by changing the separation distances between the adjacent adhesive dots in a direction following along an area of different zones, (e.g., the adjacent adhesive dots in each area have the same separation distance in the zone having first adhesive dot density 400 and are further separated from the neighboring adhesive dots in adjacent zones having the same separation distance in the zone having second adhesive dot density 402).

[0049]Additionally, in some embodiments, a zone having fourth adhesive dot density 406 may surround the zones having first adhesive dot density 400, second adhesive dot density 402, and third adhesive dot density 404 around at least a portion of outer periphery 200 of upper 110 In an example embodiment, the separation distances of the adhesive dots in the zone having fourth adhesive dot density 406 may be smaller than each of first separation distance D1, second separation distance D2, and third separation distance D3. For example, in the embodiment shown in FIG. 4, the separation distances between the adhesive dots in the zone having fourth adhesive dot density 508 may be approximately 1 mm or less.

[0050]With this arrangement, the areas of upper 110 having zones with an adhesive dot density that has a larger separation distance between the adhesive dots provides a lower amount or degree of stretch resistance (e.g., allowing more stretch) than the areas of breast support garment 100 having zones with an adhesive dot density that has a smaller separation distance between the adhesive dots provides a higher amount or degree of stretch resistance (e.g., allowing less stretch). That is, as shown in FIG. 4, the zone of upper 110 having first adhesive dot density 400 associated with first separation distance D1 provides less support and allows more stretch than the zones having second adhesive dot density 402 associated with second separation distance D2 and third adhesive dot density 404 associated with third separation distance D3. The zone of upper 110 having second adhesive dot density 402 associated with second separation distance D2 provides more support and allows less stretch than the zone having first adhesive dot density 400, but provides less support and allows more stretch than the zone having third adhesive dot density 404 associated with third separation distance D3. With this arrangement, areas of upper 110 may be provided with an engineered support structure having varying levels of support determined by the specific adhesive dot matrix pattern applied between the layers of upper 110 (e.g., outer layer 300 and inner layer 302).

[0051]Additionally, by providing engineered support structure between the layers forming upper 110 (e.g., outer layer 300 and inner layer 302) progressive stretch may be provided in a single material. That is, the stretchability of outer layer 300 and/or inner layer 302 may be selectively adjusted for more stretch or less stretch in particular areas of upper 110 without using a different material or textile to form those areas of upper 110. For example, in some embodiments, one of outer layer 300 or inner layer 302 may be made of a knit material with a large degree or amount of stretch. Applying the techniques of the present embodiments to form an engineered support structure, selected areas of the knit material may have a greater amount of stretch resistance (e.g., exhibiting less stretch) than the knit material on its own without the engineered support structure. In this manner, the techniques of the present embodiments allow for additional stretch resistance to be provided to fabrics or textiles.

[0052]Referring now to FIG. 5, a process 500 for forming an engineered support structure on upper 110 is shown. In some embodiments, process 500 may be implemented using a glue or adhesive deposition printer that allows individual drops or dots of glue or adhesive to be deposited directly onto a surface of a fabric, such upper 110, in a predetermined pattern. In this embodiment, process 500 is implemented by adhesive deposition printer 502 includes a nozzle 504 that deposits a droplet or dot 506 of glue or adhesive at specific locations on first face 308 of inner layer 302.

[0053]The printer 502 can be pre-programmed to apply a pre-determined pattern of adhesive dots to upper 110 to form adhesive dot matrix pattern 312, as well as other adhesive dot matrix patterns, including but not limited to adhesive dot matrix pattern 900 (shown in FIG. 9) and adhesive dot matrix pattern 1000 (shown in FIG. 10). In an example embodiment, each droplet or dot 506 of glue or adhesive may have a predetermined volume. For example, droplet or dot 506 of glue or adhesive may have a volume of approximately 0.5 cubic millimeters. In other embodiments, the volume of each droplet or dot may vary. Additionally, in some embodiments, the size or volume of each droplet or dot 506 of glue or adhesive may be varied as described below to change or modify a support level of areas of the upper where the adhesive dots are applied.

[0054]FIG. 5 shows the adhesive dots being distributed by printing or deposition in different areas of upper 110, however persons skilled in the art would understand that adhesive dot placement can be random without departing from the scope of protection and the level of support provided in each zone will be defined by the size and/or the density of adhesive dots in such zone. In one embodiment, multiple layers of adhesive dots can be printed or deposited one on top of another.

[0055]As shown in FIG. 5, printer 502 has deposited a plurality of adhesive dots 508 in a specific pattern on first face 308 of inner layer 302 in an area corresponding to one or more zones of adhesive dot matrix pattern 312. Each adhesive dot of plurality of adhesive dots 508 is spaced apart by a separation distance that may vary in different areas of upper 110 to provide an engineered support structure that has zones of varying levels of support (i.e., different levels of stretch resistance). Process 500 may continue by using printer 502 to cover all, substantially all, or a majority of first face 308 of inner layer 302 with adhesive dots with varying separation distances to form the engineered support structure with different zones of support.

[0056]In one embodiment, printer 502 can deposit plurality of adhesive dots 508 in a specific first pattern on first face 308 of inner layer 302 in an area corresponding to one or more zones of an adhesive dot matrix pattern (e.g., adhesive dot matrix pattern 312) and then printer 502 can deposit a specific second pattern of a plurality of adhesive dots in another adhesive dot matrix pattern on top of the first pattern such that at least some of the adhesive dots in the second pattern at least partially overlap with adhesive dots of the first pattern (i.e., at least one adhesive dot in the second pattern is deposited on top of the adhesive dot from the first pattern underneath it) to form a multi-layered adhesive dot pattern.

[0057]In these embodiments, the first pattern applied in the first layer of the multi-layered adhesive dot matrix pattern may be the same or different than the second pattern applied in the second layer of the multi-layered adhesive dot matrix pattern. Printer 502 can be preprogrammed to include a number of different adhesive dot matrix patterns in a single layer configuration or a multiple layer configuration. The multiple layers of the multi-layered adhesive dot matrix patterns may be aligned (one on top of another) or offset from one another. In one implementation, the first pattern of adhesive dots deposited on first face 308 of inner layer 302 forming the first layer may be allowed time to set up before applying the second layer of adhesive dots in the second pattern.

[0058]In one implementation of process 500, once process 500 has been completed (e.g., printer 502 has deposited plurality of adhesive dots 508 according to a predetermined dot matrix pattern or multiple layers of the multi-layered adhesive dot matrix pattern), the material layers of upper 110 may be joined together by aligning and bringing together the opposing faces of the respective layers together to form upper 110. It should be understood that the adhesive dot matrix pattern may be applied to different faces of the various layers in one or more implementations of process 500. For example, as shown here, first face 308 of inner layer 302 may be joined with inner face 306 of outer layer 300 such that adhesive dot matrix pattern 312 is deposited between outer layer 300 and inner layer 302 to form upper 110 (as shown in FIG. 3).

[0059]In other implementations, each droplet or dot 506 of an adhesive dot matrix pattern can be deposited on either side or face of either layer of the two layers that are to be joined together by the adhesive dot matrix pattern. That is, for example, in the implementation of upper 110 shown in FIG. 3 where adhesive dot matrix pattern 312 is located between outer layer 300 and inner layer 302, process 500 may be used to apply adhesive dot matrix pattern 312 to first face 308 of inner layer 302 or inner face 306 of outer layer 300. Additionally, in the case of the multi-layered adhesive dot matrix patterns, each layer of the adhesive dot matrix pattern may be applied on either side or face of either layer of the material layers forming the upper (e.g., upper 110). It should be understood that the same principles apply to the various embodiments and implementations of uppers described herein so that where an adhesive dot matrix pattern is disposed between two layers, the adhesive dot matrix pattern may be applied to either or both of the two opposing faces.

[0060]The adhesive dots (e.g., plurality of adhesive dots 508) arranged in the dot matrix pattern bonds together the two layers (e.g., outer layer 300 and inner layer 302) at the locations corresponding to the pattern of the drops or dots of adhesive to form the engineered support structure between outer layer 300 and inner layer 302 of upper 110. At the locations where the adhesive is present, outer layer 300 and inner layer 302 are bonded to each other and relative movement of the layers at that location is constrained, thereby limiting stretch. By varying the separation distance between the discrete drops or dots of adhesive that bonds the two layers, the amount or degree of stretch resistance may be correspondingly varied. That is, in areas where the separation distance between the drops or dots of adhesive is smaller (i.e., the drops or dots of adhesive are spaced closer together), the stretch resistance will be greater (i.e., permitting less stretching) in these areas to provide a greater amount of support. Conversely, in areas where the separation distance between the drops or dots of adhesive is larger (i.e., the drops or dots of adhesive are spaced farther apart), the stretch resistance will be less (i.e., permitting more stretching) in these areas to provide a lesser amount of support.

[0061]Additionally, in some embodiments, the amount or degree of stretch resistance may also be varied by changing a size or volume of the adhesive dots forming the adhesive dot matrix pattern. For example, by using adhesive dots of a first size that are larger than adhesive dots of a second size, the larger sized adhesive dots bond more material of the opposing layers together, thereby permitting less stretch in those areas where the adhesive dot size is larger than in the areas where the adhesive dot size is smaller. In still other embodiments, the engineered support structure may utilize variations in separation distance and adhesive dot size to change the level of support (e.g., stretch resistance) in different areas of upper 110.

[0062]In one embodiment, each droplet or dot 506 of an adhesive dot matrix pattern may have a round or circular shape, for example, as shown in FIG. 5. In other embodiments, the shape or configuration of each droplet or dot of an adhesive dot matrix pattern may be different, including, but not limited to ovals, lines, dashes, and other regular or irregular shapes. In some cases, an adhesive dot matrix pattern may include droplets or dots having the same shape or configuration. In other cases, an adhesive dot matrix pattern may include droplets or dots of varying shapes and configurations throughout the pattern.

[0063]In some embodiments, the adhesive dots of the adhesive dot matrix pattern forming the engineered support structure of upper 110 (e.g., adhesive dot matrix pattern 312) may infiltrate or permeate into the fabric or textile forming the opposite layers of upper 110, for example, outer layer 300 and inner layer 302, to join or bond the opposing faces together. Referring now to FIG. 6, outer layer 300 and inner layer 302 of upper 110 are shown joined or bonded together with a plurality of adhesive dots 600 arranged according to adhesive dot matrix pattern 312 having first adhesive dot density 400, second adhesive dot density 402, and third adhesive dot density 404, as described above. In an example embodiment, outer layer 300 includes outer face 304 that forms an exterior surface of upper 110 and second face 310 of inner layer 302 faces towards the foot of the wearer in the interior of upper 110 when article 100 is worn.

[0064]As shown in FIG. 6, plurality of adhesive dots 600 are bonded or attached to the opposite faces of outer layer 300 and inner layer 302. In this embodiment, plurality of adhesive dots 600 are directly bonded between first face 308 of inner layer 302 and inner face 306 of outer layer 300. That is, plurality of adhesive dots 600 are arranged in thin layers between opposite faces of outer layer 300 and inner layer 302. With this arrangement, plurality of adhesive dots 600 form the engineered support structure between outer layer 300 and inner layer 302 of upper 110.

[0065]In this embodiment, the separation distance between plurality of adhesive dots 600 having first adhesive dot density 400 (e.g., first separation distance D1) is greater than the separation distance between plurality of adhesive dots 600 having second adhesive dot density 402 (e.g., second separation distance D2), and the separation distance between plurality of adhesive dots 600 having second adhesive dot density 402 (e.g., second separation distance D2) is greater than the separation distance between plurality of adhesive dots 600 having third adhesive dot density 404 (e.g., third separation distance D3).

[0066]In some embodiments, the arrangement of each adhesive dot in the adhesive dot matrix pattern (e.g., adhesive dot matrix pattern 312) may be varied to provide either four way stretch or two way stretch to zones of upper 110. In an example embodiment, four way stretch or two way stretch may be provided by varying the separation distances of the adhesive dots in one orientation within each area or zone of adhesive dot density so as to allow four way stretch or two way stretch. FIGS. 7A and 7B illustrate example embodiments of adhesive dot arrangements that allow four way stretch and two way stretch. Referring first to FIG. 7A, a schematic view of an example embodiment of an adhesive dot matrix arrangement 700 that allows for four way stretch is shown.

[0067]In this embodiment, adhesive dot matrix arrangement 700 allows four way stretch so that upper 110 may stretch in a first longitudinal direction 702 and an opposite second longitudinal direction 704 as well as stretching in a first lateral direction 706 and an opposite second lateral direction 708. For example, in one embodiment, first longitudinal direction 702 and second longitudinal direction 704 may be aligned or oriented along a longitudinal length of upper 110 and article 100 (e.g., from toe end 116 to the heel end at the opposite end of upper 110 and article 100). Similarly, first lateral direction 706 and second lateral direction 708 may be aligned or oriented along a lateral width of upper 110 and article 100 (e.g., between medial side 40 and lateral side 50). As shown in FIG. 7A, the four way stretch of adhesive dot matrix arrangement 700 is provided by arranging the adhesive dots such that a longitudinal separation distance (D_LONG) is equal to a lateral separation distance (D_LAT) in the area of upper 110.

[0068]That is, each adhesive dot in the plurality of adhesive dots forming the zones of the adhesive dot matrix pattern (e.g., adhesive dot matrix pattern 312) may have equal separation distances (D_LONG=D_LAT) from each neighboring or adjacent adhesive dot in both the longitudinal direction (702, 704) and the lateral direction (706, 708) throughout the various areas of upper 110 where four way stretch is desired. Thus, adhesive dot matrix arrangement 700 allows four way stretch so that upper 110 may stretch longitudinally and laterally.

[0069]Referring now to FIG. 7B, a schematic view of an example embodiment of an adhesive dot matrix arrangement 710 that allows for two way stretch is shown. In this embodiment, adhesive dot matrix arrangement 710 allows two way stretch so that upper 110 may stretch in first lateral direction 706 and opposite second lateral direction 708, but stretch in first longitudinal direction 702 and opposite second longitudinal direction 704 is substantially constrained or prevented. As shown in FIG. 7B, the two way stretch of adhesive dot matrix arrangement 710 is provided by arranging the adhesive dots such that lateral separation distance (D_LAT) is greater than longitudinal separation distance (D_LONG) in the area of upper 110 (e.g., D_LAT>D_LONG).

[0070]Similarly, adhesive dot matrix arrangement 710 may be configured to allow two way stretch so that upper 110 may stretch in first longitudinal direction 702 and opposite second longitudinal direction 704, while stretch in first lateral direction 706 and opposite second lateral direction 708 is substantially constrained or prevented by arranging the adhesive dots in adhesive dot matrix arrangement 710 such that longitudinal separation distance (D_LONG) is greater than lateral separation distance (D_LAT) in the area of upper 110 (e.g., D_LONG>D_LAT).

[0071]That is, each adhesive dot in the plurality of adhesive dots forming the zones of the adhesive dot matrix pattern (e.g., adhesive dot matrix pattern 312) may have unequal separation distances (D_LAT>D_LONG Or D_LONG>D_LAT) from each neighboring or adjacent adhesive dot in either the lateral direction (706, 708) as shown in FIG. 7B or the longitudinal direction (702, 704) throughout the various areas of upper 110 where two way stretch is desired. By arranging the adhesive dots of the adhesive dot matrix pattern closer together in one direction, the layers of the fabric bonded together at the locations of the closer arranged adhesive dots are limited or prevented from stretching relative to each other in that direction. Thus, adhesive dot matrix arrangement 710 allows two way stretch so that upper 110 may stretch only longitudinally or laterally.

[0072]While the four way stretch of adhesive dot matrix arrangement 700 and the two way stretch of adhesive dot matrix arrangement 710 have been described relative to longitudinal and lateral directions of upper 110 and/or article 100, it should be understood that similar arrangements may be provided to allow or limit stretch in other specific directions relative to upper 110 and/or article 100, for example, diagonally or offset angles that are not substantially aligned with either the longitudinal or lateral directions.

[0073]FIG. 8 illustrates an example embodiment of an upper with various areas having four way stretch or two way stretch. In this embodiment, upper 110 is provided with different areas or zones having four way stretch and two way stretch. For example, as shown in FIG. 8, a first area 800 may be provided with two way stretch by arranging the adhesive dots of adhesive dot matrix pattern 312 according to adhesive dot matrix arrangement 710. A second area 802 and a third area 804 may each be provided with four way stretch by arranging the adhesive dots of adhesive dot matrix pattern 312 according to adhesive dot matrix arrangement 700. Additionally, in this embodiment, a fourth area 806 of upper 110 may be provided with limited or no stretch.

[0074]In this embodiment, first area 800 is associated with the toe box in forefoot region 10 of upper 110. Providing two way stretch in first area 800 allows the toe box of upper 110 to stretch laterally between medial side 40 and lateral side 50 but stretch in the longitudinal direction between the heel and toe is limited. In this embodiment, second area 802 is associated with medial side 40 in midfoot region 20 and a portion of forefoot region 10. Providing four way stretch in second area 802 allows medial side 40 of upper 110 to accommodate motion of the foot of the wearer during activities so that upper 110 can stretch both laterally and longitudinally. In this embodiment, third area 804 is associated with an area of upper 110 that extends over the top of the foot of the wearer. Providing four way stretch in third area 802 allows the top of upper 110 covering the wearer's foot to accommodate motion of the foot of the wearer during activities so that upper 110 can stretch both laterally and longitudinally.

[0075]Additionally, as shown in FIG. 8, fourth area 806 is associated with lateral side 50 extending from heel region 30 into midfoot region 20 and around the front of upper 110 in forefoot region 10. Fourth area 806 also includes a portion that extends laterally over the top of the foot in forefoot region 10 between first area 800 and third area 804. By providing fourth area 806 with limited or no stretch, additional support may be provided to upper 110 during activities.

[0076]In some embodiments, different engineered support structures providing zones having varying levels of support to an upper may be provided by using different adhesive dot matrix patterns applied between the layers of the upper. FIGS. 9 and 10 illustrate some alternate embodiments of adhesive dot matrix patterns that provide zones of varying levels of support to areas of an upper.

[0077]Referring now to FIG. 9, an alternate embodiment of an adhesive dot matrix pattern 900 is shown for forming an engineered support structure for upper 110. In this embodiment, adhesive dot matrix pattern 900 includes three levels of adhesive dot density (e.g., associated with varying separation distances and/or adhesive dot sizes) arranged in different areas of upper 110 to provide zones having different levels of support. As shown in FIG. 9, adhesive dot matrix pattern 900 includes a first adhesive dot density 902 that is associated with a minimum adhesive dot density having a largest separation distance and/or a smallest adhesive dot size to provide a smallest level of support. That is, first adhesive dot density 902 bonds the opposite layers (e.g., outer layer 300 and inner layer 302 shown in FIG. 3) such that the areas of upper 110 having first adhesive dot density 902 provide the least stretch resistance.

[0078]In this embodiment, first adhesive dot density 902 may be used in at least a center portion of upper 110 in forefoot region 10 in an area corresponding to a toe box of article 100. First adhesive dot density 902 may also be used in areas along front collar edge 118 and heel portion 210 of upper 110. With this arrangement, these areas of upper 110 may be configured to allow the greatest amount of stretch (i.e., provide the least stretch resistance).

[0079]Adhesive dot matrix pattern 900 also includes a second adhesive dot density 904 that is associated with a low adhesive dot density having a separation distance that is smaller than the separation distance of first adhesive dot density 902 (and/or an adhesive dot size that is larger than the adhesive dot size of first adhesive dot density 902) to provide a level of support that is greater than the level of support provided by first adhesive dot density 902. That is, second adhesive dot density 904 bonds the opposite layers (e.g., outer layer 300 and inner layer 302 shown in FIG. 3) such that the areas of upper 110 having second adhesive dot density 904 provide an amount or degree of stretch resistance that is greater than the amount or degree of stretch resistance provided by first adhesive dot density 902.

[0080]In this embodiment, second adhesive dot density 904 may be used in at least an area around the center portion of upper 110 in forefoot region 10 surrounding the area corresponding to the toe box of article 100 having first adhesive dot density 902. As shown in FIG. 9, second adhesive dot density 904 extends through at least a portion of vamp area 114 of upper 110, including extending to areas along medial side edge 208 on medial side 40 and lateral side edge 204 on lateral side 50.

[0081]Adhesive dot matrix pattern 900 further includes a third adhesive dot density 906 that is associated with a medium adhesive dot density having a separation distance that is smaller than the separation distance of second adhesive dot density 904 and first adhesive dot density 902 (and/or an adhesive dot size that is larger than the adhesive dot size of second adhesive dot density 904 and first adhesive dot density 902) to provide a level of support that is greater than the level of support provided by second adhesive dot density 904 and first adhesive dot density 902. That is, third adhesive dot density 906 bonds the opposite layers (e.g., outer layer 300 and inner layer 302 shown in FIG. 3) such that the areas of upper 110 having third adhesive dot density 906 provide an amount or degree of stretch resistance that is greater than the amount or degree of stretch resistance provided by second adhesive dot density 904 and first adhesive dot density 902.

[0082]In this embodiment, third adhesive dot density 906 may be used in at least a center portion of vamp area 114 and extending around the front of upper 110 along outer periphery 200 closer to toe end 116 than second adhesive dot density 904 and first adhesive dot density 902. Third adhesive dot density 906 may also be used in at least areas extending along lateral inner edge 218 of opening 112 and above heel portion 210 having first adhesive dot density 902. With this arrangement, third adhesive dot density 906 along lateral inner edge 218 may limit stretch (I.e., a greater amount of stretch resistance) around opening 112 to keep a foot of a wearer of article 100 secured within upper 110.

[0083]Referring now to FIG. 10, another alternate embodiment of an adhesive dot matrix pattern 1000 is shown for forming an engineered support structure for upper 110. In this embodiment, adhesive dot matrix pattern 1000 includes four levels of adhesive dot density (e.g., associated with varying separation distances and/or adhesive dot sizes) arranged in different areas of upper 110 to provide zones having different levels of support. As shown in FIG. 10, adhesive dot matrix pattern 1000 includes a first adhesive dot density 1002 that is associated with a minimum adhesive dot density having a largest separation distance and/or a smallest adhesive dot size to provide a smallest level of support. That is, first adhesive dot density 1002 bonds the opposite layers (e.g., outer layer 300 and inner layer 302 shown in FIG. 3) such that the areas of upper 110 having first adhesive dot density 1002 provide the least stretch resistance. In this embodiment, first adhesive dot density 1002 may be used in at least a center portion of upper 110 in forefoot region 10 in an area corresponding to a toe box of article 100. With this arrangement, this area of upper 110 may be configured to allow the greatest amount of stretch (i.e., provide the least stretch resistance).

[0084]Adhesive dot matrix pattern 1000 also includes a second adhesive dot density 1004 that is associated with a low adhesive dot density having a separation distance that is smaller than the separation distance of first adhesive dot density 1002 (and/or an adhesive dot size that is larger than the adhesive dot size of first adhesive dot density 1002) to provide a level of support that is greater than the level of support provided by first adhesive dot density 1002. That is, second adhesive dot density 1004 bonds the opposite layers (e.g., outer layer 300 and inner layer 302 shown in FIG. 3) such that the areas of upper 110 having second adhesive dot density 1004 provide an amount or degree of stretch resistance that is greater than the amount or degree of stretch resistance provided by first adhesive dot density 1002.

[0085]In this embodiment, second adhesive dot density 1004 may be used in at least an area around the center portion of upper 110 in forefoot region 10 surrounding the area corresponding to the toe box of article 100 having first adhesive dot density 1002. As shown in FIG. 10, second adhesive dot density 1004 extends through at least a portion of an area adjacent to medial side edge 208 on medial side 40, lateral side edge 204 on lateral side 50, and front edge 202 at the front of upper 110. Second adhesive dot density 1004 may also be used in an area on lateral side 50 adjacent to front collar edge 118 and at heel portion 210 of upper 110.

[0086]Adhesive dot matrix pattern 1000 further includes a third adhesive dot density 1006 that is associated with a medium adhesive dot density having a separation distance that is smaller than the separation distance of second adhesive dot density 1004 and first adhesive dot density 1002 (and/or an adhesive dot size that is larger than the adhesive dot size of second adhesive dot density 1004 and first adhesive dot density 1002) to provide a level of support that is greater than the level of support provided by second adhesive dot density 1004 and first adhesive dot density 1002. That is, third adhesive dot density 1006 bonds the opposite layers (e.g., outer layer 300 and inner layer 302 shown in FIG. 3) such that the areas of upper 110 having third adhesive dot density 1006 provide an amount or degree of stretch resistance that is greater than the amount or degree of stretch resistance provided by second adhesive dot density 1004 and first adhesive dot density 1002.

[0087]In this embodiment, third adhesive dot density 1006 may be used in at least across a portion of vamp area 114 extending between medial side 40 and lateral side 50. Third adhesive dot density 1006 may also be used in at least an area extending along lateral inner edge 218 of opening 112 above heel portion 210 having second adhesive dot density 1004. With this arrangement, third adhesive dot density 1006 along lateral inner edge 218 may limit stretch (i.e., a greater amount of stretch resistance) around opening 112 to keep a foot of a wearer of article 100 secured within upper 110.

[0088]In this embodiment, adhesive dot matrix pattern 1000 also includes a fourth adhesive dot density 1008 that is associated with a high adhesive dot density having a separation distance that is smaller than the separation distance of third adhesive dot density 1006, second adhesive dot density 1004, and first adhesive dot density 1002 (and/or an adhesive dot size that is larger than the adhesive dot size of third adhesive dot density 1006, second adhesive dot density 1004, and first adhesive dot density 1002) to provide a level of support that is greater than the level of support provided by third adhesive dot density 1006, second adhesive dot density 1004, and first adhesive dot density 1002. That is, fourth adhesive dot density 1008 bonds the opposite layers (e.g., outer layer 300 and inner layer 302 shown in FIG. 3) such that the areas of upper 110 having fourth adhesive dot density 1008 provide an amount or degree of stretch resistance that is greater than the amount or degree of stretch resistance provided by third adhesive dot density 1006, second adhesive dot density 1004, and first adhesive dot density 1002.

[0089]In this embodiment, fourth adhesive dot density 1008 may be used in at least an area extending along a majority of outer periphery 200 of upper 110, including along the front edge that extends from the front of upper 110 and further in either direction (e.g., towards medial side 40 and lateral side 50) along lateral side edge 204 on lateral side 50 to heel portion 210 and along medial side edge 208 on medial side 40 to second rear edge 214. Fourth adhesive dot density 1008 may also be used in at least an area extending around front collar edge 118 at opening 112. Additionally, fourth adhesive dot density 1008 may be used in an area extending from heel portion 210 to first rear edge 212. With this arrangement, adhesive dot matrix pattern 1000 forms an engineered support structure between outer layer 300 and inner layer 302 of upper 110 for providing an improved fit and feel to article 100.

[0090]The present embodiments have been described herein in reference to upper 110 for article 100 having two layers with an engineered support structure formed by an adhesive dot matrix pattern disposed between the two layers. In other embodiments, an upper having a different number of layers that are joined or bonded using one or more adhesive dot matrix patterns according to the techniques described herein may be provided. For example, an adhesive dot matrix pattern or a multi-layered adhesive dot matrix pattern may be applied between one or more pairs of adjacent layers of a multi-layer upper formed from any number of layers using the techniques described herein.

[0091]Additionally, in some embodiments, the techniques described herein for applying the adhesive dot matrix pattern between layers of the upper may be further used as a methodology to customize the internal fit between the interior lining and upper of an article of footwear for a foot of a wearer. For example, the adhesive dot matrix pattern may be applied to the inner face of the material forming the upper (i.e., facing inwards towards an interior void of the article of footwear) and/or to the outer face of lining material within the interior void of the article of footwear (i.e., facing outwards away from the interior).

[0092]In such embodiments, the adhesive dots of the adhesive dot matrix pattern may be made from an adhesive material that would not be activated during the footwear manufacturing process so as to remain unbonded to the adjacent layers where the adhesive dot matrix pattern is located. After the article of footwear has been constructed, a custom foot form (i.e., customized to a foot of a wearer) may be inserted into the interior void of the article of footwear and the article of footwear with the custom foot form inside may be further heated and pressed during a separate process. This second heat and press process would activate the adhesive material of the adhesive dot matrix pattern to bond the adjacent layers together, for example, to bond the material forming the upper to the lining material only in the areas where they come in contact with each other. This customized process creates a form-fitting internal lining for the article of footwear and can also provide an engineered support structure to areas or regions of the upper and article of footwear where the foot of the wearer may have a greater circumference than a generic or conventionally shaped article of footwear.

[0093]In some embodiments, an additional liner layer may be provided between the adhesive dot matrix pattern and the opposing layers so as to define a pocket or void between the layers. In these embodiments, the additional liner layer may be smaller than each of the opposing layers. For example, by adding an additional liner layer between the opposing layers, the adhesive dot matrix pattern will join the opposing layers at areas surrounding the liner layer, but the liner layer will prevent a portion of one of the opposing layers from being joined with the other.

[0094]For example, referring again to FIG. 3, an additional liner layer formed of a textile material may be disposed between layer 300 and adhesive dot matrix pattern 312 and/or between inner layer 310 and adhesive dot matrix pattern 312. At the location corresponding to this additional liner layer, adhesive dot matrix pattern 312 will bond or join layer 300 to the additional liner layer while inner layer 310 remains unattached to either layer 300 or the additional liner layer at this location. Therefore, a pocket or void may be formed between one face of the additional liner layer and first face 308 of inner layer 302. Similarly, if the additional liner layer is located between adhesive dot matrix pattern 312 and inner layer 302, at the location corresponding to this additional liner layer, adhesive dot matrix pattern 312 will bond or join inner layer 302 to the additional liner layer while layer 300 remains unattached to either inner layer 310 or the additional liner layer at this location. Therefore, a pocket or void may be formed between one face of the additional liner layer and inner face 306 of layer 300.

[0095]A pocket or void between layers of the upper may also be formed in another manner. In some embodiments, one or more areas of the adhesive dot matrix pattern may be substantially free of adhesive dots so as to define areas where opposing layers are not joined or attached to each other by the adhesive dot matrix pattern. For example, by leaving areas of the adhesive dot matrix pattern substantially free of adhesive dots, the layers of the upper may remain unattached in those areas to form pockets or voids between the layers forming the upper.

[0096]For example, referring again to FIG. 3, at least one area of adhesive dot matrix pattern 312 may be left substantially free of adhesive dots. Accordingly, when layer 300 of upper 110 is joined with inner layer 302 by adhesive dot matrix pattern 312, the at least one area of adhesive dot matrix pattern 312 that is substantially free of adhesive dots will form a void or pocket between layer 300 and inner layer 302. That is, while adhesive dot matrix pattern 312 joins or bonds first face 308 of inner layer 302 with inner face 306 of outer layer 300 at areas where adhesive dot matrix pattern 312 includes adhesive dots, the at least one area substantially free of adhesive dots will leave first face 308 of inner layer 302 unattached to inner face 306 of outer layer 300.

[0097]By providing one or more areas of the adhesive dot matrix pattern substantially free of adhesive dots, voids or pockets between layers of the upper may be formed at different portions of the upper. For example, a pocket may be formed in this manner along one or both of the medial and lateral sides of the upper (e.g., medial side 40 and/or lateral side 50 of upper 110). Pockets may also be formed at other locations on the upper, including but not limited to portions of forefoot region 10 and/or heel region 30. In some cases, a pocket formed in this manner in heel region 30 may have a rigid support member inserted within the pocket to provide additional rigidity to the upper to provide support to the heel of a wearer.

[0098]In some embodiments, the pocket or void formed in this manner between the layers forming the upper may include a spacer fabric and/or spacer yarns within the pocket or void. In this manner, the spacer fabric or spacer yarns may provide a substantially three-dimensional structure to areas of the upper. With this arrangement, pockets or voids including spacer fabric or spacer yarns disposed within the pocket or void between the layers of the upper may provide cushioning or padding to areas of the upper. For example, areas of the upper surrounding an ankle or a heel of a wearer may be provided with spacer fabric or spacer yarns within pockets or voids in the upper to give additional cushioning or padding to the ankle or heel of a wearer when an article of footwear including the upper is worn. It should be understood that spacer fabric or spacer yarns may be provided within pockets or voids located in other areas of the upper.

[0099]Additionally, in some embodiments, spacer yarns disposed within the void or pocket between the layers of the upper may be secured or fused together using an adhesive dot matrix pattern, as described above, to form zones having varying amounts or degrees of stretch resistance. For example, the fused zones of spacer yarns may be varied by changing or varying an adhesive dot density or a size of the adhesive dots in the adhesive dot matrix pattern in the desired areas to create the zones.

[0100]While various embodiments of the disclosure have been described, the description is intended to be exemplary, rather than limiting and it will be apparent to those of ordinary skill in the art that many more embodiments and implementations are possible that are within the scope of the disclosure. Accordingly, the disclosure is not to be restricted except in light of the attached claims and their equivalents. Also, various modifications and changes may be made within the scope of the attached claims.