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1. (WO2019032311) BASE LAYER FOR FOOTWEAR AND METHOD OF MANUFACTURING SAME
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What is claimed is:

1. A strobe! for an article of footwear comprising:

a base layer having a forefoot portion, a midfoot portion, and a heel portion; and

an upper layer formed of a polymer material covering at least a portion of the top surface of the base layer;

wherein the upper layer is directly bonded to the base layer in each of the forefoot portion, the midfoot portion, and the heel portion without any fastening members.

2. The strobel of claim 1, wherein the base layer is in the form of a ring having a central aperture extending therethrough.

3. The strobel of claim 1, wherein the polymer material is polyurethane.

4. The strobel of claim 1, wherein the base layer is formed of a non-woven polymer.

5. The strobel of claim 4, wherein the polymer is polyester.

6. The strobel of claim 1, wherein another portion of the top surface of the base layer remains exposed about an entire periphery of the base lay er.

7. The strobel of claim 1 , wherein the upper layer covers the entire top surface of the base layer extending fully to, and coextensively with, the peripheral edges of base layer.

8. A method of forming a strobel comprising:

positioning a base layer on a first mold portion, the base layer having a first central aperture extending therethrough;

positioning a second mold portion having a second central aperture extending therethrough in contact with the base layer such that a portion of a top surface of the base layer about its entire outer perimeter is covered by the second moid portion;

disposing a polymer material into the first and second central apertures such that the polymer material covers a portion of the top surface of the base layer not covered by the second mold portion;

positioning a third mold portion in contact with the second mold portion; and

subjecting the polymer material and base layer to heat such that the polymer material bonds directly to the base layer,

9. The method of claim 8, wherein the polymer material is polyurethane.

10. The method of claim 8, wherein the step of disposing is performed by pouring the polymer material.

11. The method of claim 8, wherein the base layer is formed of a non-woven polymer.

12. The method of claim 1 1 , wherein the polymer is polyester.

13. The method of claim 8, wherein a thickness of the polymer material is approximately 3.8 mm.

14. The method of claim 8, wherein a thickness of the base layer is approximately 1 mm.

15. The method of claim 8, wherein the portion of the base layer covered by the second moid portion defines a peripheral flange having a width between approximately 4 mm and approximately 6 mm.

16. The method of claim 15, wherein the portion of the base layer covered by the polymer material has a width between approximately 6 mm and approximately 9 mm.

17. The method of claim 15, wherein the base layer is formed of two separate pieces.

18. The method of claim 17, wherein the pieces of the base layer are secured to one another prior to the base layer being positioned on the first moid portion.

19. The method of claim 8, wherein the first mold portion includes a plurality of projections extending upwardly from a top surface of the first mold portion, the base layer being engaged with the projections when the base layer is positioned on the first mold portion.

20. A method of forming a strobel comprising:

positioning a base layer on a first moid portion, the base layer including first and second portions that together form a ring having a central aperture extending therethrough, a plurality of projections extending upwardly from a top surface of the first mold portion, the base layer being engaged with the projections when the base layer is positioned on the first moid portion;

positioning a second mold portion having a second central aperture extending therethrough in contact with the base layer such that a portion of a top surface of the first and second portions about their entire outer perimeters are covered by the second mold portion;

pouring polyurethane into the first and second central apertures such that the polyurethane fills the first and second central apertures and covers portions of the top surfaces of the first and second portions of the base layer not covered by the second mold portion, and

subjecting the polymer material and the first and second base layer portions to heat such that the polymer material bonds directly to the first and second base layer portions.

21. The method of claim 20, wherein the base layer is formed of a non-woven polyester.

22. The method of claim 20, wherein a thickness of the polymer material is approximately 3.8 mm.

23. The method of claim 20, wherein a thickness of the base layer is approximately 1 mm.

24. The method of claim 20, wherein the portions of the top surface of the first and second portions of the base layer covered by the second mold portion define a peripheral flange area having a width between approximately 4 mm and approximately 6 mm.

25. The method of claim 20, wherein the fi rst and second portions of the base layer are secured to one another prior to being positioned on the first mold portion.