HK1184029B - Method of lasting an article of footwear - Google Patents

Description

Method of lasting an article of footwear

Background

The article of footwear generally includes two primary elements: an upper and a sole structure. The upper may be formed from a variety of material elements (e.g., textiles, polymer sheets, foam layers, leather, synthetic leather) that are stitched or adhesively bonded together to form a void within the footwear for comfortably and securely receiving a foot. The sole structure is secured to a lower portion of the upper and is generally positioned between the foot and the ground. In many articles of footwear, including athletic footwear styles, the sole structure generally includes an inner liner, a polymer foam midsole, and a rubber outsole.

A common method of manufacturing articles of footwear involves the use of a lasting process. More particularly, a majority of the upper is formed and disposed about a last having a general foot shape. Various methods are then utilized to tighten the upper around the last, thereby imparting a substantially foot-like shape to the void within the upper. To tighten the upper of a running shoe around a last, a strobel material, for example, is typically secured to the lower perimeter of the upper and extends across the area of the last corresponding to the underside of the foot. The sole structure is then secured to the lower perimeter of the upper and the strobel material, thereby substantially completing the manufacture.

Disclosure of Invention

Various aspects and variations of a method of manufacturing an article of footwear are disclosed below. The method may include assembling at least a portion of an upper of an article of footwear, the upper having a lower perimeter edge. Securing the lasting element to the upper. The lasting element includes (a) a first strip bonded to a lateral side (laterals) of the upper adjacent the lower peripheral edge, (b) a second strip bonded to a medial side (mediaside) of the upper adjacent the lower peripheral edge, and (c) at least one strand extending through the first strip and the second strip. The strands are tensioned and bond a sole structure of the article of footwear to the upper.

The method may further include placing at least a portion of an upper of the article of footwear on a last, the upper having a lower perimeter edge. Securing the lasting element to the upper. The lasting element includes (a) a first strip bonded to a lateral side (laterals) of the upper adjacent the lower peripheral edge, (b) a second strip bonded to a medial side (mediastines) of the upper adjacent the lower peripheral edge, and (c) at least one strand extending through and forming a w-shaped structure between the first strip and the second strip. The strand is tensioned to tighten the upper about the last, and a sole structure of the article of footwear is bonded to the upper.

Additionally, the method may include forming a lasting element having a unitary knit structure (unitaryknit construction) including (a) a pair of fabric strips, and (b) at least one strand that passes through the fabric strips and forms a w-shaped structure between the fabric strips. Placing at least a portion of an upper of an article of footwear on a last. The lasting element is secured to the upper, the strand is tensioned to tighten the upper around the last, and a sole structure of the article of footwear is joined to the upper.

The method of manufacturing an article of footwear also includes forming a knitted component defining an interior shoe cavity for receiving a foot, the knitted component including a pair of opposing sides and having at least one strand passing through the opposing sides and forming a w-shaped structure between the opposing sides. The knitted component is placed on the last, and the thread is tightened to tighten the knitted component around the last. The sole may then be bonded to the knitted component.

The advantages and features of novelty characterizing aspects of the present invention are pointed out with particularity in the appended claims. To gain an improved understanding of the advantages and features of novelty, however, reference may be made to the following descriptive matter and accompanying drawings that describe and illustrate various structures and concepts related to the invention.

Drawings

The foregoing summary, as well as the following detailed description, is better understood when read in conjunction with the appended drawings.

FIG. 1 is a perspective view of an article of footwear.

FIG. 2 is an exploded perspective view of the article of footwear.

FIG. 3 is a lateral (lateralside) elevational view of the article of footwear.

Fig. 4 is a medial (front) view of the article of footwear.

Figures 5A and 5B are cross-sectional views of the article of footwear defined by section lines 5A and 5B in figures 3 and 4, respectively.

FIG. 6 is a perspective view of a lasting element of the article of footwear.

FIG. 7 is a plan view of the lasting element.

FIGS. 8A and 8B are cross-sectional views of the lasting element, as defined by section lines 8A and 8B, respectively, in FIG. 7.

Fig. 9A-9H are perspective views of a manufacturing process for an article of footwear.

Fig. 10A-10G are cross-sectional views of the manufacturing process defined by section lines 10A-10G in fig. 9A-9G, respectively.

11A-11C are perspective views corresponding with FIG. 2 and illustrating other structures of the article of footwear.

Fig. 12A-12C are cross-sectional views corresponding with fig. 5A and illustrating other structures of the article of footwear.

FIGS. 13A-13C are plan views corresponding with FIG. 7 and illustrating additional features of the lasting element.

Figure 14 is a perspective view of a knitted component.

Detailed Description

The following discussion and accompanying figures disclose various structures of the article of footwear 10 and methods of making the article of footwear 10. Concepts associated with footwear 10 are disclosed with reference to configurations that are suitable for running, but may be utilized with a wide range of athletic footwear styles, including basketball shoes, cross-training shoes, cycling shoes, football shoes, soccer shoes, tennis shoes, and loafers, for example. Additionally, concepts associated with footwear 10 may also be utilized with styles that are generally considered to be non-athletic footwear, including dress shoes, loafers, slippers, and boots, for example. Accordingly, the concepts associated with footwear 10 may be applied to a variety of footwear structures and methods of manufacturing the footwear structures.

General shoe construction

Footwear 10 is illustrated in figures 1-5B as including a sole structure 20 and an upper 30. For reference, footwear 10 may be divided into generally three regions: a forefoot region 11, a midfoot region 12, and a heel region 13, as shown in fig. 3 and 4. Footwear 10 also includes a lateral side 14 and a medial side 15. Forefoot region 11 generally includes portions of footwear 10 corresponding with the toes and the joints connecting the metatarsals with the phalanges. Midfoot region 12 generally includes portions of footwear 10 corresponding with the arch area of the foot. Heel region 13 generally corresponds with the rear of the foot, including the calcaneus bone. Lateral side 14 and medial side 15 extend through each of regions 11-13 and correspond with opposite sides of footwear 10. Regions 11-13 and sides 14-15 are not intended to demarcate precise areas of footwear 10. Rather, regions 11-13 and sides 14-15 are intended to represent general areas of footwear 10 to aid in the following discussion. In addition to footwear 10, regions 11-13 and sides 14-15 may also be utilized for sole structure 20, upper 30, and their respective elements.

Sole structure 20 is secured to upper 30 and extends between the foot and the ground when footwear 10 is worn. The primary elements of sole structure 20 are a midsole 21 and an outsole 22. Midsole 21 is secured to a lower area of upper 30 and may be formed from a compressible polymer foam element (e.g., polyurethane or ethylvinylacetate foam) that reduces ground reaction forces (i.e., provides cushioning) as the element is compressed between the foot and the ground during walking, running, or ambulatory activities. In further configurations, midsole 21 may include plates, bumpers (modulators), fluid-filled chambers, lasting elements, or motion-control members that further reduce forces, improve stability, or affect the motion of the foot, or midsole 21 may be primarily formed from a fluid-filled chamber. Outsole 22 is secured to a lower surface of midsole 21 and may be formed from a wear-resistant rubber material that is textured to impart traction. An interior liner 23 may also be positioned within upper 30 and positioned to extend under a lower surface of the foot. Although this structure for sole structure 20 provides one example of a sole structure that may be used in connection with an upper, a variety of other conventional or non-conventional structures for sole structure 20 may also be used. Accordingly, the structure and features of sole structure 20, or any sole structure utilized with upper 30, may vary greatly.

Upper 30 defines a void within footwear 10 for receiving and securing a foot relative to sole structure 20. The shoe cavity is shaped to receive the foot and extends along the lateral side of the foot, along the medial side of the foot, over the foot, around the foot, and under the foot. Access to the footwear cavity is provided through an ankle opening 31 provided in at least heel region 13. Lace 32 extends through various apertures or other lace-receiving elements (e.g., D-rings, hooks) in upper 30 and allows the wearer to modify dimensions of upper 30 to accommodate portions of the foot. More specifically, lace 32 allows the wearer to tighten upper 30 around the foot, and lace 32 allows the wearer to loosen upper 30 to facilitate entry and removal of the foot from the void (i.e., through ankle opening 31). Upper 30 also includes a tongue 33 that extends between the interior void and lace 32. In addition, upper 30 may include a heel counter disposed in heel region 13 that limits heel motion or a wear-resistant toe guard disposed in forefoot region 11 that imparts wear-resistance, for example.

Various portions of upper 30 may be formed from one or more of a variety of material elements (e.g., textiles, polymer sheets, foam layers, leather, synthetic leather). A lower region or lower perimeter of upper 30 adjacent to sole structure 20 (i.e., the upper surface of midsole 21) defines a peripheral edge 34. As discussed in more detail below, at least a portion of lasting element 40 is secured to or disposed adjacent to lower region, lower peripheral edge or perimeter edge 34, and lasting element 40 is used in the manufacture (e.g., lasting) of footwear 10.

Lasting element structure

Lasting element 40 is illustrated in FIGS. 6-8B and includes a pair of straps 41 (e.g., a first strap and a second strap) and a strand 42. The strips 41 are generally spaced apart from one another and the wire 42 is alternated through each of the strips 41 to form a W-shaped structure between the strips 41. That is, the thread 42 passes through one of the belts 41 (e.g., a first belt), through another of the belts 41 (e.g., a second belt), and continues to repeatedly and alternately pass through each of the belts 41. In this manner, a portion of the wire 42 forms a w-like structure between the belts 41, which may also be described as forming a zigzag or wavy structure between the belts 41.

Bands 41 are disposed generally parallel to one another, but may be curved along the contour or shape of peripheral edge 34 when incorporated into footwear 10. Referring to fig. 6, a length 43, a width 44, and a thickness 45 of one of the strips 41 are defined. Generally, length 43 is substantially greater than either of width 44 and thickness 45. Also, width 44 is greater than thickness 45. This structure gives each of the strips 41 a generally rectangular and planar appearance. The line 42 extends through each of the straps 41. When strip 41 is formed from a polymeric sheet, for example, strip 41 may define holes or other apertures through which strip 42 passes. When the belt 41 is formed of, for example, a fabric, the threads 42 may pass between adjacent yarns.

A variety of materials may be used for various components of lasting element 40. For example, the belt 41 may be formed of fabric, a polymer sheet, leather, synthetic leather, or a combination of these materials (e.g., a thermoplastic polymer sheet bonded to fabric). The thread 42 may be formed from a variety of filaments, fibers, yarns, threads, cables, or cords made of, for example, rayon, nylon, polyester, polyacrylate, silk, cotton, carbon, glass, aramid (e.g., para-aramid and meta-aramid fibers), ultra-high molecular weight polyethylene, liquid crystal polymer, copper, aluminum, and steel. Accordingly, the materials and material combinations used for lasting element 40 (i.e., each of straps 41 and strands 42) may vary widely.

Although the different structures of lasting element 40 may be formed from a variety of materials, lasting element 40 may also be formed from a single piece element through a knitting process, such as flat-knitting. More specifically, lasting element 40 may be formed from a single knit structure via a flat knitting process. As an alternative to flat knitting, lasting element 40 may be formed by weaving or weft insertion warp knitting. As used herein, a knit element, such as lasting element 40, is defined as being formed from a single knit structure when constructed substantially as a single piece of the knit element by a knitting process. That is, the knitting process substantially forms and combines various features and structures of lasting element 40 (e.g., straps 41 and threads 42). In various examples of processes for forming lasting element 40 having a single knit structure, a knitting machine is used to (a) form each of bands 41 and (b) repeatedly and alternately thread 42 through each of bands 41. That is, the knitting process used to form lasting element 40 having a single knit structure generally involves (a) mechanically manipulating one or more yarns to form a series of stitches defining a lace 41 and (b) passing thread 42 through lace 41.

Forming lasting element 40 to have a single knit construction provides a number of advantages. For example, lasting element 40 may be effectively manufactured from yarns that are mechanically manipulated by a knitting machine. That is, the knitting machine may be automated to manufacture lasting element 40 from yarn components. Moreover, the particular yarns used for the band 41, the different regions of the band 41, and the threads 42 may be selected and positioned by the knitting process. In addition, the knitting process may also be used to form longer lengths of strap 41 and strand 42, and individual lasting elements 40 for different articles of footwear (including footwear 10) may then be cut from the longer lengths of strap 41 and strand 42. As yet another example, one knitting machine may be used to form different lasting elements 40 having different properties. That is, for example, length 43, width 44, thickness 45, spacing between bands 41, location of threads 42, and the yarns used for bands 42 and threads 42 may be varied by modifying the knitting process. Thus, using a knitting process to form lasting element 40 with a single knit structure may provide advantages over separately forming and assembling straps 41 and strands 42.

A variety of different types of yarns may be incorporated into lasting element 40 during the knitting process. Although the bands 41 and threads 42 may be formed from the same yarn or yarn type, the bands 41 and threads 42 may also be formed from separate yarns having different properties. By way of example, the yarns forming the bands 41 and threads 42 may include polyester, nylon, polyacrylate, rayon, cotton, wool, and silk. The yarns may be monofilament or multifilament yarns, and the yarns may comprise individual filaments each formed of a different material. Also, the yarn may include filaments that are each formed of two or more different materials. Yarns having different degrees of twist and crimp and different deniers may also be used for the belt 41 and the wire 42. The material of the yarns may also be selected to maintain a desired shape when heat set. Accordingly, various types of yarns and yarn materials may be incorporated into components of lasting element 40.

Any of the yarn materials discussed above may be used for thread 42. However, as discussed in more detail below, the strand 42 may be tightened or tensioned during the manufacturing process of the footwear 10. As such, the manufacturing process may be more beneficial due to the formation of threads 42 from relatively non-stretch yarns. Thus, the thread 42 may be formed from a variety of filaments, fibers, yarns, threads, cables, or ropes made of, for example, carbon fiber, glass fiber, aramid (e.g., para-aramid fiber and meta-aramid fiber), ultra-high molecular weight polyethylene material, liquid crystal polymer material, copper, aluminum, and steel. Accordingly, the thread 42 may be formed of a variety of materials having different structures.

In accordance with the above discussion, lasting element 40 may be secured to a lower area, lower perimeter, or perimeter edge 34 of upper 30, or disposed adjacent to a lower area, lower perimeter, or perimeter edge 34 of upper 30. In general, lasting element 40 may include a strap 41 and a strand 42. While the bands 41 are generally spaced apart from one another, the threads 42 alternate through each of the bands 41 to form a w-shaped structure, a saw tooth structure, or a wave-like structure between the bands 41. Although straps 41 and threads 42 may be formed separately and combined, lasting element 40 may also be formed with a single knit structure by a knitting process such as, for example, flat knitting. Moreover, the materials used in straps 41 and threads 42 (e.g., the materials of the yarns forming lasting element 40) may be varied to impart particular properties to lasting element 40.

Manufacturing process

A variety of techniques may be used to manufacture footwear 10. An example of a manufacturing process that includes the use of lasting element 40 is discussed below with respect to FIGS. 9A-9H and 10A-10G. Referring to FIG. 9A, a beginning step of the manufacturing process is shown in which a plurality of individual elements of footwear 10 (e.g., portions of sole structure 20, upper 30, and lasting element 40) are present and located proximate to last 50. At this step, upper 30 is generally formed from a combination of multiple material elements (e.g., textiles, polymer sheets, foam layers, leather, synthetic leather) that are stitched or adhesively bonded together. A lower area of upper 30, which faces upward in fig. 9A, defines a perimeter edge 34.

Last 50 may have a conventional last configuration and have a general foot shape and ankle portion. As oriented in fig. 9A, the portion of last 50 corresponding with the lower surface of the foot faces upward, the portion of last 50 corresponding with the upper surface of the foot faces downward, the portion of last 50 corresponding with the toe surface faces upward to the left, and the portion of last 50 corresponding with the heel surface faces downward to the right. Referring to fig. 10A, a cross-sectional view through a portion of last 50 corresponding with a forefoot region of the foot is illustrated. Although last 50 is depicted as having a solid core structure, last 50 may also be formed from a plurality of movable elements that change the overall shape of last 50.

Upper 30 is now placed on last 50, as shown in fig. 9B and 10B, and covers an area of last 50. More specifically, upper 30 covers portions of last 50 corresponding with the lateral and medial sides of the foot, the upper surface of the foot, and the heel area. However, in this step of the manufacturing process, the portion of last 50 corresponding to the lower surface of the foot is exposed. That is, peripheral edge 34 forms an aperture or opening in upper 30 that exposes a portion of last 50 that corresponds with the lower surface of the foot.

When upper 30 is placed on last 50, lasting element 40 is positioned adjacent to a lower area of upper 30, as shown in FIGS. 9C and 10C. Lasting element 40 is then secured to a lower area of upper 30, which forms peripheral edge 34 as depicted in FIGS. 9D and 10. Although a variety of methods may be used to join lasting element 40 with the lower area of upper 30, stitching, thermal bonding, adhesive bonding, or a combination of each of these methods may be used. Moreover, lasting element 40 is secured to a lower area of upper 30 such that (a) one of straps 41 is joined with a lateral side of upper 30 from forefoot region 11 to heel region 13 and (b) another of straps 41 is joined with medial side 15 of upper 30 from forefoot region 11 to heel region 13. It is further noted that strips 41 are illustrated as overlapping peripheral edge 34 such that (a) a portion of each of strips 41 is disposed against a surface of upper 30 and (b) another portion of each of strips 41 extends outwardly from peripheral edge 34, although a variety of other configurations may be used.

At this step of the manufacturing process, upper 30 extends over last 50 in a relatively loose manner. Referring to fig. 10D, for example, due to the loose fit configuration of upper 30 on last 50, a different gap is formed between upper 30 and last 50. To tighten upper 30 around last 50, however, strand 42 is pulled or otherwise tensioned, as shown in fig. 9E and 10E. By tensioning strands 42, upper 30 is drawn against the surface of last 50 to guide upper 30 to assume the shape of last 50. That is, tension strands 42 direct the void within upper 30 to assume the shape of the foot. Given that strands 42 extend through straps 41 and are able to move or slide through straps 41, tensioning strands 42 also has the effect of pulling straps 41 closer together along substantially the entire length of upper 30. Accordingly, tensioning strap 42 generally has the effect of (a) tightening upper 30 about last 50 and (b) pulling straps 41 closer together.

After tensioning straps 42, sole structure 20 is positioned adjacent to lasting element 40 and a lower area of upper 30, as shown in fig. 9F and 10F. Sole structure 20 is then secured to lasting element 40 and a lower area of upper 30, as shown in fig. 9G and 10G. Although a variety of methods may be used to join sole structure 20 with lasting element 40 and a lower area of upper 30, stitching, thermal bonding, adhesive bonding, or a combination of each of these methods may be used. When sole structure 20 is secured, footwear 10 may be removed from last 50, as shown in fig. 9H. Optionally, strand 42 may also be removed from footwear 10 through ankle opening 31. That is, strand 42 may be removed from strip 41 and removed from the cavity formed by upper 30 where last 50 was previously located. Moreover, inner liner 23 may be positioned within the void formed by upper 30, thereby substantially completing the manufacture of footwear 10.

In accordance with the above discussion, footwear 10 may be manufactured by a process that generally includes disposing at least a portion of upper 30 on last 50. Lasting element 40 is then secured to upper 30, and lasting element 40 may have been previously formed by knitting to have a single knit structure. More specifically, (a) one of straps 41 is coupled with lateral side 14 of upper 30 from forefoot region 11 to heel region 13, and (b) another of straps 41 is coupled with medial side 15 of upper 30 from forefoot region 11 to heel region 13. Strands 42 are then tensioned to tighten upper 30 around last 50, and sole structure 20 is bonded to one or both of lasting element 40 and upper 30.

Further structure

Aspects of footwear 10 including lasting element 40 and the manufacturing processes for the footwear may vary. Referring to FIG. 2, for example, lasting element 40 has a configuration in which the end regions of band 41 are unbonded and spaced apart from one another. Alternatively, fig. 11A illustrates a structure in which the end regions are joined. The arrangement of FIG. 2 also illustrates lasting element 40 as a single component that extends substantially the entire length of footwear 10. In some configurations, however, separate lasting elements 40 may be provided in different areas of footwear 10. For example, FIG. 11B illustrates a configuration in which three separate lasting elements 40 are provided in each of regions 11-13. One advantage of using lasting element 40 is the removal of the strobel lining from the manufacturing process and the final shoe. Although lasting element 40 effectively replaces the strobel sock, some manufacturing processes may use similar structures in at least a portion of footwear 10. Referring to FIG. 11C, for example, lasting element 40 is disposed in forefoot region 11, but strobel lining 51 extends through regions 12 and 13.

Referring to fig. 5A and 10D and 10E, strips 41 are illustrated as overlapping peripheral edge 34 such that (a) a portion of each of strips 41 is disposed against a surface of upper 30 and (b) another portion of each of strips 41 extends outward from peripheral edge 34. The placement of lasting element 40 with respect to peripheral edge 34 may vary. In a further construction, strips 41 may be secured to upper 30 such that (a) substantially all of strips 41 are disposed against a surface of upper 30, as shown in fig. 12A, (B) strips 41 are disposed adjacent an opposite surface of upper 30, as shown in fig. 12B, and (C) edges 34 of strips 41 are joined to peripheral edges 34, as shown in fig. 12C. It should also be noted that lines 42 are not illustrated in fig. 12A-12C, so that lines 42 may be removed in a later step of the fabrication process. Accordingly, the manner in which strap 41 is joined to upper 30 may vary.

Various aspects associated with lasting element 40 may also vary. For example, referring to fig. 13A, two threads 42 pass through each of the belts 41 and intersect each other between the belts 41. As another example, a plurality of threads 42 may be disposed along the length of the belt 41, as shown in fig. 13B. An advantage of this configuration is that the wire 42 can be independently tensioned during the manufacturing process. In addition to the modifications associated with thread 42, band 41 may also differ from the configurations discussed above. As an example, fig. 13C illustrates a configuration in which the width 44 varies along the length of the strip 41. More particularly, the width 44 is relatively small in the middle region of the belt 41 and larger in the end regions. The features and configuration of lasting element 40 may vary.

Knitted component

Knitted component 60 is illustrated in fig. 14 and may form a majority of another upper or upper 30. When incorporated into upper 30, knitted component 60 extends through each of regions 11-13, over forefoot region 11, along lateral side 14 and medial side 15, and around heel region 13. In addition, knitted component 60 may form an interior surface and an opposite exterior surface of upper 30. As such, knitted component 60 defines at least a portion of a void within upper 40.

Knitted component 60 includes a plurality of tubes 61 in which laces 62 are disposed. As such, knitted component 60 has a construction similar to that disclosed in U.S. patent application serial No. 12/338,726, entitled knitting component, for example, by the united states patent and trademark office, filed on 2008, 12, 18, which is incorporated herein by reference. Additionally, knitted component 60 includes threads 63 that alternately pass through opposite sides of a lower peripheral edge of knitted component 60 to form a w-like structure between the sides or lower peripheral edge. In this manner, a portion of wire 63 forms a w-like structure between the sides and lower peripheral edge of member 60, which can also be described as forming a saw-tooth or wave-like structure.

During the manufacturing of footwear 10 or other articles of footwear that include knitted component 60, threads 63 may be tensioned to draw the surface of knitted component 60 against the last. Accordingly, as with strand 42, strand 63 may be used to guide knitted component 60 to assume the shape of last 50 during the lasting of footwear 10. That is, tension wires 63 direct the shoe cavity within knitted component 60 to assume the shape of the foot. Given that strands 63 extend through and are able to move or slide past the side or lower peripheral edges of knitted component 60, tensioning strands 64 also have the effect of pulling the side or lower peripheral edges closer together along substantially the entire length of knitted component 60. Accordingly, in general, tensioning wires 63 have the effect of (a) tightening knitted component 60 about last 50 and (b) pulling the side or lower peripheral edges of knitted component 60 closer to one another. When tensioned, the sole structure may be secured to knitted component 60 and threads 63 may be removed from knitted component 60.

Knitted component 60 may be formed using a variety of manufacturing processes, including a flat knitting process, which imparts a unitary knit structure. When formed by a flat knitting process, knitted component 60 is formed in one operation to include tubes 61, laces 62, and strands 63, typically by a flat knitting machine, although hand knitting is also possible. An advantage of using a flat knitting process to manufacture knitted component 60 is that a variety of characteristics may be imparted to knitted component 60 by the flat knitting process. That is, the flat knitting process may form knitted component 60 to have, for example, (a) multiple knit types that impart different properties to individual regions of knitted component 60, (b) multiple yarn types that impart different properties to individual regions of knitted component 60, (c) overlapping knit layers that form tube 61, (d) material, such as lace 62, disposed within tube 61, and (e) threads 63 that alternate across opposite sides or lower peripheral edges of knitted component 60. In this manner, a flat knitting process may be utilized to substantially form knitted component 60 having different properties and structural characteristics, which may be advantageous for footwear 10.

The present invention is disclosed above and in the accompanying drawings by reference to a variety of structures. The purpose served by the disclosure is to provide an example of the various features and concepts related to the invention, not to limit the scope of the invention. One skilled in the relevant art will recognize that numerous variations and modifications may be made to the structures described above without departing from the scope of the present invention, as defined by the appended claims.

Claims (23)

1. A method of manufacturing an article of footwear, the method comprising:

assembling at least a portion of an upper of an article of footwear, the upper having a lower perimeter edge;

providing a lasting element that has been pre-formed separately from the upper, the lasting element comprising: (a) a first belt, (b) a second belt spaced apart from the first belt, and (c) at least one strand extending through the first and second belts;

securing the lasting element to the upper, wherein securing the lasting element further comprises (a) bonding a first strap to a lateral side of the upper adjacent to the lower perimeter edge, (b) bonding a second strap to a medial side of the upper adjacent to the lower perimeter edge, and (c) wherein the at least one strand is disposed through the first and second straps to extend between the lateral side of the upper and the medial side of the upper;

tensioning the at least one strand; and

a sole structure of an article of footwear is joined to an upper.

2. The method recited in claim 1, wherein the step of securing the lasting element to the upper includes extending the first strap and the second strap from a heel region to a forefoot region of the upper.

3. The method recited in claim 1, wherein the step of tensioning the strand includes drawing the first and second straps toward each other along substantially an entire length of the upper.

4. The method recited in claim 1, wherein the step of bonding the sole structure to the upper includes bonding the sole structure to the lower peripheral edge, the first strap, and the second strap.

5. The method recited in claim 1, further including a step of forming the lasting element to have a unitary knit construction such that the first strap, the second strap, and the at least one strand are a single piece element.

6. The method recited in claim 5, wherein the step of forming the lasting element includes a flat knitting process.

7. The method recited in claim 1, further including a step of forming the lasting element such that the strand alternates between the first strip and the second strip and forms a W-shaped structure between the first strip and the second strip.

8. The method recited in claim 1, further including a step of removing the strand from the lasting element after the step of bonding an outsole associated with the sole structure to the upper.

9. The method of claim 1, further comprising the step of placing the upper on a last having the shape of a foot, and wherein the step of tensioning the strand includes tightening the upper around the last.

10. A method of manufacturing an article of footwear, the method comprising:

placing at least a portion of an upper of an article of footwear on a last, the upper having a lower perimeter edge;

providing a lasting element that has been pre-formed separately from the upper, the lasting element comprising: (a) a first belt, (b) a second belt spaced apart from the first belt, and (c) at least one strand extending through the first and second belts;

securing the lasting element to the upper after the step of placing the upper on the last, wherein securing the lasting element further comprises (a) bonding a first strap to a lateral side of the upper adjacent to the lower perimeter edge, (b) bonding a second strap to a medial side of the upper adjacent to the lower perimeter edge, and (c) wherein at least one strand extends through the first and second straps and forms a W-shaped structure between the first and second straps to extend between the lateral side of the upper and the medial side of the upper;

tensioning the strand to tighten the upper around the last; and

a sole structure of an article of footwear is joined to an upper.

11. The method recited in claim 10, wherein the step of securing the lasting element to the upper includes extending the first strap and the second strap from a heel region to a forefoot region of the upper.

12. The method recited in claim 10, wherein the step of tensioning the strand includes drawing the first and second straps toward each other along substantially an entire length of the upper.

13. The method recited in claim 10, further including a step of forming the lasting element to have a unitary knit construction such that the first strap, the second strap, and the at least one strand are a single piece element.

14. The method recited in claim 13, wherein the step of forming the lasting element includes a flat knitting process.

15. The method recited in claim 10, further including a step of forming the lasting element such that the strand alternates between the first strip and the second strip.

16. The method recited in claim 10, further including a step of removing the strand from the lasting element after the step of bonding an outsole associated with the sole structure to the upper.

17. A method of manufacturing an article of footwear, the method comprising:

forming a lasting element having a unitary knit structure, the lasting element including (a) a pair of webbing straps, and (b) at least one strand that passes through the webbing straps and forms a W-like structure between the webbing straps, the unitary knit structure of the lasting element being such that the pair of webbing straps and the at least one strand are a single-piece element;

placing at least a portion of an upper of an article of footwear on a last, the upper being formed separately from the lasting element;

securing the lasting element to the upper after the upper has been placed on the last;

tensioning the strand to tighten the upper around the last; and

a sole structure of an article of footwear is joined to an upper.

18. The method recited in claim 17, wherein the step of forming the lasting element includes a flat knitting process.

19. The method recited in claim 17, wherein the step of securing the lasting element to the upper includes bonding the webbing to opposite sides of a lower peripheral edge of the upper.

20. The method recited in claim 19, wherein the step of securing the lasting element to the upper further includes extending the strap from a heel region to a forefoot region of the upper.

21. The method recited in claim 17, wherein the step of tensioning the strand includes drawing the strips of fabric closer together along substantially an entire length of the upper.

22. The method recited in claim 17, wherein the step of bonding the sole structure to the upper includes bonding the sole structure to the upper and the textile strip.

23. The method recited in claim 17, further including a step of removing the strand from the lasting element after the step of bonding an outsole associated with the sole structure to the upper.