Composite footwear upper and method of manufacturing a composite footwear upper

摘要

A method of manufacturing a multi-layer, composite footwear upper having a three-dimensional geometry includes forming a substantially planar composite sheet from two or more layers, heating the composite sheet, and shaping the composite sheet into the three-dimensional geometry of the footwear upper. The composite sheet can be formed by laminating a first layer of thermoplastic foam to a second layer of thermoplastic urethane (TPU). A third layer of mesh fabric can be interposed between the first and second layers. The composite sheet can be shaped by compression molding in a mold cavity or by lasting to achieve the desired three-dimensional geometry.