GB2607876A

GB2607876A - Method of manufacturing an article of footwear

Info

Publication number: GB2607876A
Application number: GB2108298.7A
Authority: GB
Inventors: Bettles Ruth
Original assignee: Uk11yo Ltd
Current assignee: Uk11yo Ltd
Priority date: 2021-06-10
Filing date: 2021-06-10
Publication date: 2022-12-21
Also published as: GB202108298D0

Abstract

A method of manufacturing a single-piece upper and lining for an article of footwear and an article of footwear manufactured in accordance with such a method. The method comprising the steps of forming an enclosed volume from a continuous sheet of material 100, the enclosed volume comprising a first part 101 and a second part 102, the first part and the second part shaped such that when the second part is folded into the first part, the first part provides an upper of an article of footwear and the second part provides a lining of the article of footwear. The material may be knitted material, and the enclosed volume of material is created using a 3d knitting machine. A counter region 103,104 may be formed in the first and/or second part from a first material, and the remainder of the first and second arts are made from a second material. The first material may comprise a low melt yarn, and the counter region may be heated to create a stiffened part. The first part may comprise a planar base unit when the second part is folded into it, to create a surface for attaching to a sole.

Description

Method of Manufacturing an Article of Footwear

Technical Field

The present invention relates to methods of manufacturing articles of footwear and to 5 articles of footwear manufactured in accordance with such methods.

Background

Knitted trainers are a popular type of shoe. Knitted trainers include an upper made from a knitted material along with other components which may include an outsole, a midsole, a strobel insole or conventional insole, a lining, a counter stiffener, a counter lining, a toe puff, a toe lining, an insock and an insock lining. A well-known type of knitted trainer is the Nike Flyknit Racer.

A conventional process of manufacturing a knitted trainer is the two-dimensional cut and stitch technique. This process involves first manufacturing the separate components that make up the trainer. For example, a knitted upper is typically manufactured as a flat or tubular piece of material using an industrial knitting machine. The separate components of the trainer are then assembled via a series of stitching, cutting and gluing steps to form the final trainer.

This process of manufacturing a knitted trainer has several disadvantages. The process is complex because it involves manufacturing multiple separate components and performing multiple processing steps to assemble the components into the final trainer. This complexity increases the cost and time required to manufacture knitted trainers. Further, certain steps in the assembly process are typically performed manually, making the process labour intensive and prone to error. Still further, the process involves material wastage because components such as the upper lining, counter lining, toe lining, strobel insole, insock and insock lining are cut from a larger piece of material the remainder of which is typically left to waste.

It is an object of certain embodiments of the present invention to provide methods of manufacturing articles of footwear and articles of footwear manufactured in accordance with such methods that obviate or mitigate some or all of the above-described disadvantages.

Summary of the Invention

In accordance with a first aspect of the invention there is provided a method of manufacturing a single-piece upper and lining for an article of footwear. The method comprises: forming an enclosed volume from a continuous sheet of material, said enclosed volume comprising a first part and a second part, the first part and the second part shaped such that when the second pad is folded into the first pad, the first part provides an upper of an article of footwear and the second part provides a lining of the article of footwear. The method further comprises: folding the second part into the first part.

Optionally, the continuous sheet of material is a knitted material.

Optionally, the step of forming an enclosed volume from a continuous sheet of material is performed by a 3D knitting machine.

Optionally, the step of forming an enclosed volume from a continuous sheet of material further comprises forming a counter region of the first part and/or the second part from a first material or combination of materials and forming at least a substantial portion of the remainder of the first part and the second part from a second material or combination of materials, and wherein the first material or combination of materials has a lower melting temperature than the second material or combination of materials.

Optionally, the first material or combination of materials comprises low melt yarn.

Optionally, the step of forming an enclosed volume from a continuous sheet of material further comprises forming at least a substantial portion of the first part and the second part from a first material or combination of materials, wherein the first material or combination of materials comprises low melt yarn.

Optionally, the method further comprises the step of heating at least the counter region of the first part and/or the second part to cause the first material or combination of materials to melt and thereby forming a stiffened part of the single-piece upper and lining at the counter region.

Optionally, the first part and the second part are shaped such that when the second part is folded into the first part, the first part comprises a substantially planar base surface securable to a surface of a sole unit.

Optionally, the method further comprises securing the base surface of the first pad to the surface of the sole unit.

Optionally, the base surface of the first part is secured directly to the surface of the sole unit.

Optionally, the surface of the sole unit that is secured to the base surface of the first pad is shaped to provide a cupped heel.

Optionally, the surface of the sole unit that is secured to the base surface of the first part is shaped to provide a metatarsal dome.

Optionally, the surface of the sole unit that is secured to the base surface of the first part is shaped to provide a region of arch support.

In accordance with a second aspect of the invention there is provided an article of footwear comprising: a sole unit; and a single-piece upper and lining comprising an enclosed volume formed from a continuous sheet of material, said enclosed volume comprising a first part and a second part, the first part and the second part shaped such that when the second part is folded into the first part, the first part provides an upper of an article of footwear and the second part provides a lining of the article of footwear, and wherein the second part is folded into the first part.

Optionally, the continuous sheet of material is a knitted material.

Optionally, a counter region of the first part and/or the second part is composed of a first material or combination of materials and at least a substantial portion of the remainder of the first part and the second part is composed of a second material or combination of materials, and wherein the first material or combination of materials has a lower melting temperature than the second material or combination of materials.

Optionally, at least a substantial portion of the first part and the second part is composed of a first material or combination of materials, wherein the first material or combination of materials comprises low melt yarn.

Optionally, the first material or combination of materials present in the counter region of the first part and/or the second part forms a stiffened part of the single-piece upper and lining at the counter region.

Optionally, the first part comprises a substantially planar base surface secured to a surface of the sole unit.

Optionally, the base surface of the first part is secured directly to the sole unit.

Optionally, the surface of the sole unit that the first part is secured to is shaped to provide a cupped heel.

Optionally, the surface of the sole unit that the first part is secured to is shaped to provide a metatarsal dome.

Optionally, the surface of the sole unit that the first part is secured to is shaped to provide a region of arch support.

Advantageously, embodiments of the present invention provide an enclosed volume formed from a continuous sheet of material shaped such that it can be folded to form a single-piece upper and lining for an article of footwear. In certain embodiments, the single-piece upper and lining also functions as a counter stiffener, counter lining, strobel insole, toe puff, toe lining, insock and insock lining.

Advantageously, the entire single-piece upper and lining can be manufactured in a single production step, for example using a 3D knitting machine. This can simplify manufacture and reduce material wastage.

Advantageously, the single-piece upper and lining can be directly secured to a sole unit. In this way, an article of footwear can be provided that includes just two components, namely a single-piece upper and lining, and a sole unit.

Advantageously, the process of manufacturing an article of footwear, such as a knitted trainer or ballerina shoe, can be made less complex than conventional processes because it involves fewer components and requires fewer manufacturing steps. Advantageously, this means that the process is quicker, more reliable, lower cost and less labour intensive. The process can also substantially eliminate waste that arises in conventional "cut and stitch" techniques from cutting components from a larger piece of material.

Advantageously, the process can be used to manufacture an article of footwear, such as a knitted trainer or ballerina shoe, that is more comfortable, ergonomic, lightweight, breathable, flexible, and environmentally sustainable than conventional knitted footwear. Advantageously, the lining part of the single-piece upper and lining can act as a built-in sock to improve comfort by preventing rubbing between the article of footwear and the wearer's foot. Further, in contrast with certain existing articles of footwear that include a centre back seam, articles of footwear in accordance with embodiments of the invention can be seamless. This can improve comfort by reducing rubbing of a seam on the wearer's foot.

Various further features and aspects of the invention are defined in the claims.

Brief Description of the Drawings

Embodiments of the present invention will now be described by way of example only with reference to the accompanying drawings where like parts are provided with corresponding reference numerals and in which: Figure 1 is a simplified schematic diagram showing a single-piece upper and lining prior to folding in accordance with certain embodiments of the invention; Figures 2a -2d are simplified schematic diagrams showing a sequence of steps as to the upper arrangement of Figure 1 is folded in accordance with certain embodiments of the invention; Figures 3a -3d are simplified schematic diagrams showing the steps shown in Figures 2a -2d viewed from above the upper arrangement; Figures 4a -4c show further steps in the manufacture of an article of footwear that includes an upper arrangement of a type described herein in accordance with certain embodiments of the invention; Figure 5 is a diagram showing top and bottom views of a sole unit that can be secured to an upper arrangement of the type disclosed herein to form an article of footwear in accordance with embodiments of the invention; Figures 6a and 6b are simplified schematic top and side views of an article of footwear in the form of a ballerina shoe in accordance with embodiments of the invention; and Figures 7a -7d are simplified schematic diagrams showing cross sections of the ballerina shoe of Figure 6a and 6b in accordance with embodiments of the invention.

Detailed Description

Figure 1 is a simplified schematic diagram showing a first side of an upper arrangement prior to folding in accordance with certain embodiments of the invention. Figure 1 also shows a cross-sectional view through the centre of the upper arrangement 100. As described herein, when folded, the upper arrangement 100 can provide a single-piece upper and lining for an article of footwear such as a trainer or ballerina shoe.

The upper arrangement 100 comprises an enclosed volume that is formed from a continuous sheet of material. The continuous sheet of material is composed of a knitted material. The entire upper arrangement 100 is typically manufactured in a single step using a three-dimensional (3D) knitting machine. As will be understood, 3D knitting machines are machines that can be used to manufacture single-piece three-dimensional knitted articles. Suitable types of 3D knitting machine that can be used to manufacture the upper arrangement 100 include the Stoll-Knit or Shima Seiki VVHOLEGARMENT machines.

The upper arrangement 100 is formed from a continuous piece of material such that there are substantially no gaps in the upper arrangement 100 other than those present 20 between fibres of the material that the upper arrangement 100 is composed of.

The enclosed volume comprises a first part 101 and a second part 102. The first part 101 is shaped such that when the second part 102 is folded within the first part 101, the first part 101 forms an upper. As will be understood, an upper is an outermost surface of an article of footwear that surrounds a subject's foot and is located above the sole unit.

The first part 101 is a substantially concave portion of the continuous sheet of material. In use, the first part 101 is shaped to cover a subject's foot and to define a top outermost surface of an article of footwear. The first part 101 includes a first counter region 103 (denoted schematically on Figure 1 by dashed lines) located at the heel of the first part 101 and shaped to accommodate a subject's heel. The first part 101 also includes a central region 105, which is shaped to accommodate a subject's mid-foot, and a toe region 106, which is shaped to accommodate a subject's forefoot and toes. In this manner, the first part 101 has a substantially sock-like shape.

The second part 102 is shaped to provide a lining within the first part 101 when folded within the first part 101. The second part 102 typically substantially corresponds in shape with the first part 101 and is typically slightly smaller in size than the first part 101 such that it can be folded inside the first part 101 to form a lining therein. In use, the second part 102 is arranged to form an inner surface of an article of footwear that makes contact with a subject's foot.

The second part 102 is a further substantially concave portion of the continuous sheet of material. This means that when the second part 102 is folded inside the first part 101, the second part 102 acts as a lining within the first part 101. The second part 102 comprises a second counter region 104 (denoted schematically on Figure 1 via dashed lines) located at the heel of the second part 102. The second part 102 also includes a central region 107 and a toe region 108. As described above, typically the second part 102 is slightly smaller in size than the first part 101 so that, when folded, the second part 102 fits within the first part 101.

As shown in the cross-sectional view of Figure 1, the upper arrangement 100 includes a second side that substantially corresponds with the first side. Prior to folding, the upper arrangement 100 is typically substantially flat as shown in Figure 1 The first counter region 103 and the second counter region 104 are composed of a first material or combination of materials and the remainder of the upper arrangement 100 is composed of a second material or combination of materials. The first material or combination of materials typically has a lower melting temperature than the second material or combination of materials.

In certain embodiments, the first material or combination of materials extends approximately 40mm from the back of the upper arrangement 100 (i.e. the part of the upper arrangement that lies adjacent to a subject's heel in use) towards the toe region.

The first material or combination of materials includes low melt yarn. As will be understood, low melt yarn is arranged to melt during manufacture. Low melt yarn is also known as hotmelt yarn.

In certain embodiments, the first material or combination of materials is composed of approximately 90% low melt yarn and 10% polyester. In certain embodiments, the low melt yarn is a transparent polymer element fibre. In certain embodiments the low melt yarn comprises a suitable type of polyester, nylon or another suitable polymer.

to In certain embodiments, the first material or combination of materials has a melting temperature of between approximately 60°C and 110°C.

The second material or combination of materials includes no or a substantially small amount of low melt yarn such that the second material or combination of materials has a significantly higher melting temperature than the first material or combination of materials. In certain embodiments, the second material or combination of materials is composed of 100% polyester.

In certain embodiments, the second material or combination of materials has a melting 20 temperature of between approximately 250°C and 255°C.

In this manner, all or at least a substantial portion of low melt yarn present in the upper arrangement 100 is provided in the first counter region 103 and the second counter region 104. As described, in certain embodiments, no low melt yarn is provided outside of the counter regions 103 104. As described in more detail herein, the low melt yarn in the counter regions 103 104 is melted during manufacture to form a hardened counter region that can support a subject's heel and secure the first part 101 and second part 102 together at the counter region.

It will be understood that in certain embodiments the first material or combination of materials and/or the second material or combination of materials can include other suitable types of yarn.

In certain embodiments, the toe regions 106 108 of the first and second parts 101 102 can also be composed of the first material or combination of materials. As described in more detail herein, the low melt yarn in the toe regions 106 108 can be melted during manufacture to secure the first part 101 and second part 102 together at the toe region.

This can prevent the second part 102 from being pulled out of the first part 101 when the subject removes the article of footwear from their foot.

In certain embodiments, only one of the first counter region 103 and the second counter region 104 is composed of the first material or combination of materials.

Alternatively, in certain embodiments, the whole upper arrangement 100 is composed of the same material or combination of materials. For example, in certain embodiments, the entire upper arrangement 100 is composed of approximately 79% polyester yarn, 13.5% nylon yarn, 1.5% spandex yarn and 6% low melt yarn.

In embodiments where the whole upper arrangement 100 is composed of the same material or combination of materials, at least the counter area of the upper arrangement 100 (and in certain embodiments also the toe area of the upper arrangement 100) can be selectively heated during manufacture to form a stiffened counter region as described in more detail herein and for example with reference to Figure 4c.

Figures 2a -2d are simplified schematic diagrams showing a sequence of steps as the upper arrangement 100 of Figure 1 is folded to form a single-piece upper and 25 lining. Figures 3a -3d show a corresponding sequence of steps viewed from above the upper arrangement 100.

As shown in Figure 2a, an upper arrangement 100 is provided. The upper arrangement 100 includes a first part 101 and a second part 102. As described with reference to Figure 1, typically the upper arrangement 100 is formed as a single piece on a 3D knitting machine. Prior to folding, the upper arrangement 100 is substantially flat.

Subsequently, as denoted by the arrows in Figure 2b, the opposing sides of the upper arrangement 100 are pulled apart from a position or positions on either side of the upper arrangement 100 at or close to the boundary between the first part 101 and the second part 102. The second part 102 is also pushed towards the first pad 101.

Subsequently, as denoted by the arrow in Figure 2c, the second part 102 continues to be moved towards the first part 101 The second part 102 begins to be folded inside the first part 101.

Subsequently, as shown in Figure 2d, the second part 102 continues to be folded inside the first part 101 until the second part 102 is fully enclosed within the first part 101 as shown in Figure 2d. In this arrangement, the first part 101 provides an upper and the second part 102 provides a lining. The upper arrangement 100 includes two layers provided by the first part 101 and the second part 102. When the upper arrangement 100 is folded as shown in Figure 2d, the first part 101 includes a substantially planar base surface 200. The surface 200 can be secured to a sole unit as described in more detail herein.

The upper arrangement 100 can be used as part of an article of footwear for example by securing it directly to a sole unit as described in more detail herein.

Figures 4a to 4c are simplified schematic diagrams showing further steps in the manufacture of an article of footwear that includes an upper arrangement 100 of a type described herein. The further steps can be performed after the steps described with reference to Figures 2a -2d. In certain embodiments, the further steps form part of the same manufacturing process as the process described with reference to Figures 2a -2d.

Typically, the upper arrangement 100 is placed onto a last (not shown). As will be understood, a last is a foot shaped piece of material that is used to provide shape to an article of footwear.

A heat source 400 is then applied to at least the counter region 401 of the upper arrangement 100. Various suitable heat sources can be used. For example, hot air can be directed on the counter region 401or the entire upper arrangement 100 can be placed in an oven or heated tunnel.

Alternatively, as shown in Figure 4c, a counter forming machine 403 (also known as a counter moulding machine or back part moulding machine) can be used to apply heat to the counter region 401 of the upper arrangement 100. The counter forming machine 403 comprises a heated plate or mould that makes contact with the counter region 401 to selectively heat and thereby melt material in the counter region 401.

Returning to Figure 4a, the heat source 400 is of a suitable temperature and is applied in a suitable manner to cause melting of the material in the counter region 401 without melting the remainder of the upper arrangement 100. In certain embodiments, the temperature of the heat source 400 is approximately 70°C.

The application of the heat source 400 to the counter region 401 causes melting of the material in the counter region 401. Heat is then removed to allow the counter region 401 to cool. The melting and subsequent cooling of the counter region 401 causes the material present in the counter region 401 to stiffen. This is advantageous because, in use, the stiffened counter region 401 improves grip with a subject's heel to ensure an article of footwear that the upper arrangement 100 forms part of stays on the subject's foot. The stiffened counter region also means that a separate counter stiffener is not required.

In embodiments where low melt yarn is provided in the counter region 401 of both the first part 101 and second part 102, the melting of the low melt yarn causes the first part 101 and the second pad 102 at the counter region 401 to coalesce. This secures the first part 101 and the second part 102 parts together at the counter region 401.

In embodiments where low melt yarn is also provided in the toe region of both the first part 101 and second part 102, the low melt yarn in the toe region is also heated as part of the process described above such that the low melt yarn melts. Melting of the low melt yarn causes the first part 101 and the second part 102 at the toe region to coalesce. This secures the first part 101 and the second pad 102 together at the toe region to ensure the toe region of the second pad 102 is not pulled out of the first pad 101 when a subject removes the article of footwear from their foot. The melting and subsequent cooling of the toe region causes the material present in the toe region to stiffen. In this way, the toe region can act as a toe puff.

As shown in Figure 4b, the upper arrangement 100 is then secured to a sole unit 402, comprising a midsole and an outsole, using a suitable securing technique. As will be understood, an outsole is an outer layer of an article of footwear that contacts the ground. It will be understood that any suitable arrangement of sole unit can be used.

In certain embodiments, the upper arrangement 100 is secured directly to the midsole of the sole unit 402. In such embodiments, a suitable adhesive such as a water-based adhesive can be used to secure the base surface of the first part 101 with a surface of the midsole. Advantageously, in such embodiments the surface of the midsole that is secured to the base surface of the first part 101 can be shaped to provide ergonomic features to improve the comfort of the shoe. Such a modified sole unit is described in more detail with reference to Figure 5.

Figure 5 is a diagram showing top and bottom views of a sole unit that can be secured to an upper arrangement of the type disclosed herein to form an article of footwear in accordance with embodiments of the invention. Typically, the sole unit 500 is secured directly to an upper arrangement such that ergonomic features of the sole unit 500 are felt by a subject's foot. In this way, the sole unit 500 also acts as an insock.

The sole unit 500 comprises a midsole and an outsole. The sole unit 500 includes a top surface 501 forming part of a midsole that is arranged to be secured directly to a 25 base surface of an upper arrangement.

The top surface 501 includes a metatarsal dome 502, which is a dome shaped region located in the central part of the midfoot of the sole unit 500. The metatarsal dome 502 provides support and cushioning for a subject's metatarsal area by spreading the load across the forefoot and guiding movement of a subject's foot during walking or running.

The metatarsal dome 502 also lifts and separates the metatarsal bones to alleviate forefoot pain.

The top surface 501 includes an arch support region 503 provided by a raised portion located on the inside edge of the top surface 501. The arch support region 503 provides support for a subject's arch thereby improving comfort and foot stability. The arch support region 503 helps to prevent plantar fasciitis by supporting the plantar fascia tendon and can help prevent over pronation and posterior tibial tendonitis.

The top surface 501 includes a cupped heel region 504 located at the heel area. The cupped heel region 504 is a concave dome shaped region that is shaped to support a subject's heel. The cupped heel region 504 provides support for a subject's heel and helps to prevent movement of the sole unit 500 relative to the subject's foot. The cupped heel region 504 is formed to the shape of a subject's heel to stabilise and support the heel thereby helping to prevent over pronation and supination which can lead to posterior tibial tendonitis.

The top surface 501 typically includes a slight incline from front to back. For example, the back of the top surface 501 can be approximately 8mm higher than the front of the top surface 501 relative to the ground in use. This incline can help prevent Achilles heel pain.

The sole unit 500 includes a bottom surface 505 forming part of an outsole that is arranged to contact the ground in use. It will be understood that the bottom surface 505 can take any suitable form.

It will be understood that the sole unit 500 can be composed of any suitable material.

In certain embodiments, the sole unit 500 is composed of blown polyurethane (PU).

Alternatively, in certain embodiments the sole unit 500 can be injection moulded with blown ethylene vinyl acetate (EVA).

It will be understood that in certain embodiments the sole unit can comprise one or 30 more of a metatarsal dome, arch support region and cupped heel region as described herein in any combination.

Figures 6a and 6b are simplified schematic top and side views of an article of footwear in the form of a ballerina shoe 600 in accordance with embodiments of the invention.

The shoe 600 can be manufactured in accordance with the techniques described herein and can include corresponding features as described.

The shoe 600 comprises an upper arrangement comprising a first part 601 and a second part 602 formed from a continuous sheet of material. The first part 601 covers the top of a subject's foot and acts as an outer surface of the shoe 600 while the second part 602 acts as a lining within the shoe 600.

A portion of the first part 601 and second part 602 at the counter region 603 of the shoe 600 is stiffened while the remainder of the first part 601 and second part 602 is unstiffened. This ensures the shoe 600 is comfortable to wear while also ensuing the shoe 600 stays on a subject's foot during use. The first part 601 and second part 602 are also joined at the counter region 603 of the shoe 600 to hold the first part 601 and the second part 602 together.

The shoe 600 includes a sole unit 604. The sole unit 604 includes a midsole which is secured directly to a base surface of the first part 601.

As shown in Figure 6b, in certain embodiments, when the shoe 600 is not being worn, it has a substantially curved shape along its length. This is due to the elastic properties of the material that the first part 601 and second part 602 are composed of as well as the flexibility of the outsole. It will however be understood that in other embodiments the shoe can be substantially flat (i.e., not curved) along its length.

Advantageously, the shoe 600 can be composed of only two components, namely a single-piece upper arrangement and a sole unit. This means that the shoe 600 can be more lightweight and less complex to manufacture than conventional knitted shoes that include more components.

Advantageously, in contrast with conventional knitted shoes, the shoe 600 has a double layer of knitted material (provided by the upper and the lining). This can make the shoe 600 more comfortable to wear because friction during wear is created between the two knitted layers rather than between the upper and the subject's foot.

This can reduce the likelihood of a subject's foot getting blisters caused by friction between the subject's foot and the shoe 600.

Figures 7a to 7d are simplified schematic diagrams showing cross sections of the ballerina shoe 600 of Figures 6a and 6b.

Figure 7b shows a cross section of the counter region of the shoe 600. As shown, the heat applied to the counter region has caused the first part 601 and second part 602 to melt together such that there is no gap between them.

Figure 7c shows a cross section through the centre of the shoe 600. As shown, at the centre of the shoe the first part 601 and the second part 602 are not connected such that they are free to move relative to each other. A small gap is present between the first part 601 and second part 602, although the first part 601 and second part 602 will usually be in direct contact when the shoe 600 is being worn due to the subject's foot forcing the second part 602 into contact with the first part 601.

Figure 7d shows a cross section through the front (i.e. toe region) of the shoe 600. As shown, in the front of the shoe 600 the second part 602 is enclosed within the first part 20 601.

Advantageously, the second part 602 is secured to the first part 601 in the counter region but is free to move relative to the first part 601 in the remainder of the shoe 600. This can reduce the friction between the subject's foot and the shoe 600.

As described herein, in other embodiments the first part 601 can also be secured to the second part 602 at the toe region (i.e. in addition to the first part 601 being secured to the second part 602 in the counter region). This can help retain the second part 602 within the first part 601 when the shoe 600 is removed.

It will be understood that the techniques disclosed herein can be used to manufacture any suitable type of article of footwear including ballerina shoes, trainers, boots, heeled pumps, heeled boots, lace-less shoes, ballerina shoes with a high vamp, amongst others.

All of the features disclosed in this specification (including any accompanying claims, abstract and drawings), and/or all of the steps of any method or process so disclosed, may be combined in any combination, except combinations where at least some of such features and/or steps are mutually exclusive. Each feature disclosed in this specification (including any accompanying claims, abstract and drawings) may be replaced by alternative features serving the same, equivalent or similar purpose, unless expressly stated otherwise. Thus, unless expressly stated otherwise, each feature disclosed is one example only of a generic series of equivalent or similar features. The invention is not restricted to the details of the foregoing embodiment(s).

The invention extends to any novel one, or any novel combination, of the features disclosed in this specification (including any accompanying claims, abstract and drawings), or to any novel one, or any novel combination, of the steps of any method or process so disclosed.

With respect to the use of substantially any plural and/or singular terms herein, those having skill in the art can translate from the plural to the singular and/or from the singular to the plural as is appropriate to the context and/or application. The various singular/plural permutations may be expressly set forth herein for sake of clarity.

It will be understood by those within the art that, in general, terms used herein, and especially in the appended claims are generally intended as "open" terms (e.g., the term "including" should be interpreted as "including but not limited to," the term "having" should be interpreted as "having at least," the term "includes" should be interpreted as "includes but is not limited to," etc.). It will be further understood by those within the art that if a specific number of an introduced claim recitation is intended, such an intent will be explicitly recited in the claim, and in the absence of such recitation no such intent is present. For example, as an aid to understanding, the following appended claims may contain usage of the introductory phrases "at least one" and "one or more" to introduce claim recitations. However, the use of such phrases should not be construed to imply that the introduction of a claim recitation by the indefinite articles "a" or "an" limits any particular claim containing such introduced claim recitation to embodiments containing only one such recitation, even when the same claim includes the introductory phrases "one or more" or "at least one" and indefinite articles such as "a" or "an" (e.g., "a" and/or "an" should be interpreted to mean "at least one" or "one or more"); the same holds true for the use of definite articles used to introduce claim recitations. In addition, even if a specific number of an introduced claim recitation is explicitly recited, those skilled in the art will recognize that such recitation should be interpreted to mean at least the recited number (e.g., the bare recitation of "two recitations," without other modifiers, means at least two recitations, or two or more recitations).

It will be appreciated that various embodiments of the present disclosure have been described herein for purposes of illustration, and that various modifications may be made without departing from the scope of the present disclosure. Accordingly, the various embodiments disclosed herein are not intended to be limiting, with the true scope being indicated by the following claims.

Claims

CLAIMS1. A method of manufacturing a single-piece upper and lining for an article of footwear, said method comprising: forming an enclosed volume from a continuous sheet of material, said enclosed volume comprising a first part and a second part, the first part and the second part shaped such that when the second part is folded into the first part, the first part provides an upper of an article of footwear and the second part provides a lining of the article of footwear; and folding the second part into the first part.
2. A method of manufacturing a single-piece upper and lining for an article of footwear according to claim 1, wherein the continuous sheet of material is a knitted material.
3. A method of manufacturing a single-piece upper and lining for an article of footwear according to claim 2, wherein the step of forming an enclosed volume from a continuous sheet of material is performed by a 3D knitting machine.
4. A method of manufacturing a single-piece upper and lining for an article of footwear according to claim 2 or claim 3, wherein the step of forming an enclosed volume from a continuous sheet of material further comprises forming a counter region of the first part and/or the second part from a first material or combination of materials and forming at least a substantial portion of the remainder of the first part and the second part from a second material or combination of materials, and wherein the first material or combination of materials has a lower melting temperature than the second material or combination of materials.
5. A method of manufacturing a single-piece upper and lining for an article of footwear according to claim 4, wherein the first material or combination of materials comprises low melt yarn.
6. A method of manufacturing a single-piece upper and lining for an article of footwear according to claim 2 or claim 3, wherein the step of forming an enclosed volume from a continuous sheet of material further comprises forming at least a substantial portion of the first part and the second part from a first material or combination of materials, wherein the first material or combination of materials comprises low melt yarn.
7. A method of manufacturing a single-piece upper and lining for an article of footwear according to any of claims 4 to 6, wherein the method further comprises the step of heating at least the counter region of the first part and/or the second part to cause the first material or combination of materials to melt and thereby forming a stiffened part of the single-piece upper and lining at the counter region.
8. A method of manufacturing a single-piece upper and lining for an article of footwear according to any previous claim, wherein the first part and the second part are shaped such that when the second part is folded into the first part, the first part comprises a substantially planar base surface securable to a surface of a sole unit.
9. A method of manufacturing a single-piece upper and lining for an article of footwear according to claim 8, wherein the method further comprises securing the base surface of the first part to the surface of the sole unit.
10. A method of manufacturing a single-piece upper and lining for an article of footwear according to claim 8 or claim 9, wherein the base surface of the first part is secured directly to the surface of the sole unit.
11. A method of manufacturing a single-piece upper and lining for an article of footwear according to claim 9 or claim 10, wherein the surface of the sole unit that is secured to the base surface of the first part is shaped to provide a cupped heel.
12. A method of manufacturing a single-piece upper and lining for an article of footwear according to claim 10 or claim 11, wherein the surface of the sole unit that is secured to the base surface of the first part is shaped to provide a metatarsal dome.
13. A method of manufacturing a single-piece upper and lining for an article of footwear according to any of claims 10 to 12, wherein the surface of the sole unit that is secured to the base surface of the first part is shaped to provide a region of arch support.
14. An article of footwear comprising: a sole unit; and a single-piece upper and lining comprising an enclosed volume formed from a continuous sheet of material, said enclosed volume comprising a first part and a second part, the first part and the second part shaped such that when the second part is folded into the first part, the first part provides an upper of an article of footwear and the second part provides a lining of the article of footwear, and wherein the second part is folded into the first part.
15. An article of footwear according to claim 14, wherein the continuous sheet of material is a knitted material.
16. An article of footwear according to claim 15, wherein a counter region of the first part and/or the second part is composed of a first material or combination of materials and at least a substantial portion of the remainder of the first part and the second part is composed of a second material or combination of materials, and wherein the first material or combination of materials has a lower melting temperature than the second material or combination of materials.
17. An article of footwear according to claim 16, wherein the first material or combination of materials comprises low melt yarn.
18. An article of footwear according to claim 15, wherein at least a substantial portion of the first part and the second part is composed of a first material or combination of materials, wherein the first material or combination of materials comprises low melt yarn.
19. An article of footwear according to any of claims 16 to 18, wherein the first material or combination of materials present in the counter region of the first part and/or the second part forms a stiffened part of the single-piece upper and lining at the counter region
20. An article of footwear according to any of claims 14 to 19, wherein the first part comprises a substantially planar base surface secured to a surface of the sole unit.
21. An article of footwear according to claim 20, wherein the base surface of the first part is secured directly to the sole unit.
22. An article of footwear according to claim 20 or 21, wherein the surface of the sole unit that the first part is secured to is shaped to provide a cupped heel.
23. An article of footwear according to any of claims 20 to 22, wherein the surface of the sole unit that the first part is secured to is shaped to provide a metatarsal dome.
24. An article of footwear according to any of claims 20 to 23, wherein the surface of the sole unit that the first part is secured to is shaped to provide a region of arch support.