A last for forming an upper of an article of footwear includes an exterior surface, where the exterior surface includes a plurality of three dimensional structural surface components disposed over at least 50% of the exterior surface of the last.

The invention relates to systems and methods for creating wound material portions for incorporation into an article of footwear. More particularly, one method of manufacturing at least a portion of an upper for an article of footwear, in accordance with the invention, includes the steps of providing a support structure, providing a fiber delivery system, tacking a first end of a first fiber onto the support structure, moving the support structure with respect to the fiber delivery system to wind the first fiber around the support structure, cutting a second end of the first fiber upon positioning of the first fiber onto the support structure, and treating at least a portion of the first fiber to fixedly hold it in a wound arrangement and form a fabric layer for incorporation into an article of footwear.

The invention relates to systems and methods for creating wound material portions for incorporation into an article of footwear. More particularly, one method of manufacturing at least a portion of an upper for an article of footwear, in accordance with the invention, includes the steps of providing a support structure, providing a fiber delivery system, tacking a first end of a first fiber onto the support structure, moving the support structure with respect to the fiber delivery system to wind the first fiber around the support structure, cutting a second end of the first fiber upon positioning of the first fiber onto the support structure, and treating at least a portion of the first fiber to fixedly hold it in a wound arrangement and form a fabric layer for incorporation into an article of footwear.

The invention provides a method for assisting a joining of a vamp and a sole by vacuum positioning. Initially, the method is that placing a shoe last in a vamp to be joined, coating a liquid medium to a side of the vamp to be joined with a sole or a side of the sole to be joined with the vamp, and combining the vamp with the sole. Afterward, placing the vamp and the sole in a bag, performing a vacuum operation on the bag to press the vamp and the sole, performing a microwave heating operation on the bag to heat the liquid medium to make the vamp join with the sole, and finally taking out the joined vamp and sole from the bag to obtain a finished product.

In some embodiments, a shoe assembly comprises a vamp and a sole. The vamp includes a middle section, and the vamp and the middle section are formed of a continuous piece of a first molded material. The vamp also includes a first aperture and a second aperture. The sole includes a forefoot section and a heel section that are joined by a midfoot section. The forefoot section, the heel section, and the midfoot section are formed of a continuous piece of a second molded material. The second molded material is an EVA-based material. The first aperture of the vamp receives a part of the forefoot section and the second aperture receives a part of the heel section. When the shoe assembly is placed on a flat surface, the forefoot section is in direct contact with the flat surface.

In some embodiments, a shoe assembly comprises a vamp and a sole. The vamp includes a middle section, and the vamp and the middle section are formed of a continuous piece of a first molded material. The vamp also includes a first aperture and a second aperture. The sole includes a forefoot section and a heel section that are joined by a midfoot section. The forefoot section, the heel section, and the midfoot section are formed of a continuous piece of a second molded material. The second molded material is an EVA-based material. The first aperture of the vamp receives a part of the forefoot section and the second aperture receives a part of the heel section. When the shoe assembly is placed on a flat surface, the forefoot section is in direct contact with the flat surface.

An article of footwear flat pattern upper (126, 300, 302) having an upper portion (302) and a footbed portion (304) is provided. The upper portion (302) and the footbed portion (304) are integrally coextensive, such that the upper portion (302) lateral side (317) converges with the footbed lateral side (317). The footbed portion (304) includes a concave edge (319) extending between the footbed toe end (312) and the footbed heel end (314) along the footbed medial side (315) and a plurality of forming apertures along the medial side (315). The upper portion (302) also includes a plurality of forming apertures extending along the medial side (315).

An article of footwear flat pattern upper (126, 300, 302) having an upper portion (302) and a footbed portion (304) is provided. The upper portion (302) and the footbed portion (304) are integrally coextensive, such that the upper portion (302) lateral side (317) converges with the footbed lateral side (317). The footbed portion (304) includes a concave edge (319) extending between the footbed toe end (312) and the footbed heel end (314) along the footbed medial side (315) and a plurality of forming apertures along the medial side (315). The upper portion (302) also includes a plurality of forming apertures extending along the medial side (315).

Present aspects are directed to a braided article of footwear comprising a mechanical lock structure. The braided upper comprises a tubular braided structure with a plurality of apertures. The midsole comprises a plurality of protruding studs that are configured to receive the plurality of apertures. The midsole receives the braided upper and the plurality of protruding studs extend below a bottom surface of the braided upper via the plurality of apertures, locking or securing the braided upper and midsole together, thereby creating a mechanical lock structure.

Present aspects are directed to a braided article of footwear comprising a mechanical lock structure. The braided upper comprises a tubular braided structure with a plurality of apertures. The midsole comprises a plurality of protruding studs that are configured to receive the plurality of apertures. The midsole receives the braided upper and the plurality of protruding studs extend below a bottom surface of the braided upper via the plurality of apertures, locking or securing the braided upper and midsole together, thereby creating a mechanical lock structure.