An upper may include a plurality of knit elements linked together by a molded thermoplastic polymer element comprising a thermoplastic polymer, each of the knit elements being discrete, where each of the knit elements comprises a border that is at least partially surrounded by the molded thermoplastic polymer element. Further, an article of footwear may include a plurality of knit elements linked together by a molded thermoplastic polymer element comprising a thermoplastic polymer, each of the knit elements being discrete, where each of the knit elements comprises a border that is at least partially surrounded by the molded thermoplastic polymer element.

Articles of wear having one or more textiles that include a low processing temperature polymeric composition and a high processing temperature polymeric composition, and methods of manufacturing the same are disclosed. The low processing temperature polymeric composition and the high processing temperature polymeric composition can be selectively incorporated into a textile to provide one or more structural properties and/or other advantageous properties to the article. The textile can be thermoformed to impart such structural and/or other advantageous properties to the article of wear. This abstract is intended as a scanning tool for purposes of searching in the particular art and is not intended to be limiting of the present disclosure.

An upper for an article of footwear, the upper including a base layer defining a least a portion of the upper and polymer threads stitched to the base layer. The polymer threads may include a core composed of a first material and a coating composed of a second material, where the melting point of the first material is higher than the melting point of the second material. The polymer threads may be bonded to the base layer by the coating of the polymer threads. The polymer threads may include one or more polymer thread sets stitched in pattern(s) on area(s) of an outer surface of the base layer to provide targeted characteristics to area(s) on the upper. In some embodiments, the polymer threads may be bonded to the base layer with heat and/or pressure.

A last for forming an upper of an article of footwear includes a first portion including a lateral side and a medial side that opposes the lateral side, and a second portion connected with and extending upward and transversely outward in an angled manner away from the first portion such that a terminal end of the second portion is distanced from the first portion. An exterior surface of the last can include a plurality of three dimensional structural surface components disposed over at least 50% of the exterior surface of the last.

Articles of wear having one or more textiles that include a low processing temperature polymeric composition and a high processing temperature polymeric composition, and methods of manufacturing the same are disclosed. The low processing temperature polymeric composition and the high processing temperature polymeric composition can be selectively incorporated into a textile to provide one or more structural properties and/or other advantageous properties to the article. The textile can be thermoformed to impart such structural and/or other advantageous properties to the article of wear. This abstract is intended as a scanning tool for purposes of searching in the particular art and is not intended to be limiting of the present disclosure.

An upper for an article of footwear, the upper including a base layer defining a least a portion of the upper and polymer threads stitched to the base layer. The polymer threads may include a core composed of a first material and a coating composed of a second material, where the melting point of the first material is higher than the melting point of the second material. The polymer threads may be bonded to the base layer by the coating of the polymer threads. The polymer threads may include one or more polymer thread sets stitched in pattern(s) on area(s) of an outer surface of the base layer to provide targeted characteristics to area(s) on the upper. In some embodiments, the polymer threads may be bonded to the base layer with heat and/or pressure.

Processes and systems for thermoforming articles of wear are disclosed. The process can include utilizing a negative pressure generation system to seal an article in a forming material thereby compressing the forming material onto the outer surface of the article. The process can also include exposing the sealed article to an increased temperature followed by exposure to a decrease temperature, while maintaining the compressive force of the forming material on the outer surface of the article. A positive pressure can also be applied to the sealed article while undergoing the heating and/or cooling steps, which can facilitate the removal of bubbles from the article during thermoforming as well as apply additional compressive force to the outer surface of the article.

Articles of footwear including a thermo-molded upper having a skin composed of one or more low melting point thermoplastic polymers. The skin may include at least one of: a base layer composed of a low melting point thermoplastic polymer and a grid layer including a yarn composed of a low melting point thermoplastic polymer. The uppers may be formed by placing a skin and an inflatable bladder into a mold cavity and heating the mold to a predetermined temperature. The inflatable bladder may be inflated such that the skin is pressed against an interior surface of the heated mold cavity to cause the skin to take on the shape of the internal surface of the mold cavity, thereby forming an upper for an article of footwear.

A process for thermo-adhesive bonding of semi-finished products includes preparing an inner sock, an outer sock and an impermeable membrane provided with a thermo-adhesive disposed on an inner surface and/or an outer surface of the membrane; fitting the inner sock onto a rigid reference shape; fitting the membrane over the inner sock; fitting the outer sock over the membrane; heating the outer sock, the membrane and the inner sock arranged on the rigid reference shape in an oven until at least partial melting of the thermo-adhesive; cooling the outer sock, the membrane and the inner sock arranged on the rigid reference shape until cross-linking of the thermo-adhesive and stable bonding of the membrane to the outer sock and/or the inner sock. Also, exerting a substantially uniform pressure on the outer sock, the membrane and the inner sock disposed on the rigid reference shape during cooling, so as to compact them.

Processes and systems for thermoforming articles of wear are disclosed. The process can include utilizing a negative pressure generation system to seal an article in a forming material thereby compressing the forming material onto the outer surface of the article. The process can also include exposing the sealed article to an increased temperature followed by exposure to a decrease temperature, while maintaining the compressive force of the forming material on the outer surface of the article. A positive pressure can also be applied to the sealed article while undergoing the heating and/or cooling steps, which can facilitate the removal of bubbles from the article during thermoforming as well as apply additional compressive force to the outer surface of the article.