TONGUE FOR AN ARTICLE OF FOOTWEAR

BACKGROUND

[0001] The current embodiment relates generally to footwear, and in particular to a method of assembling a tongue for an article of footwear.

[0002] Articles of footwear can include fastening systems such as laces, straps and zippers. Laces are generally attached to the top of an upper, and help to tighten an opening around a foot. Typically, a tongue is provided along the upper, which rests between a foot and the laces. The tongue can help in adjusting the lacing system. The tongue can act to cover the top of the foot in the region of the opening. The tongue can also provide comfort to the wearer from the lace or closure pressure of the fastening system on the foot of a wearer.

SUMMARY

[0003] In one aspect, the invention includes an article of footwear comprising: an upper; a tongue, the tongue including a top layer and a bottom layer; an attachment region associated with a portion of the upper and the top layer of the tongue; and wherein the bottom layer is attached to the top layer of the tongue with a staggered attachment that is displaced from the attachment region by a distance.

[0004] In another aspect, the invention includes a method for assembling a tongue for an article of footwear, comprising: providing at least a portion of an upper, the portion of the upper including a first portion configured to be associated with a forefoot region of the article of footwear and a second portion disposed opposite the first portion; providing a portion of a tongue, the portion of the tongue including a top layer having a front edge and a rear edge; attaching the second portion of the upper and the front edge of the top layer of the tongue at an attachment region; and attaching a bottom layer to the top layer of the tongue, the bottom layer having a staggered attachment that is displaced from the attachment region by a distance.

[0005] In another aspect, the invention includes a method for assembling a tongue for an article of footwear, comprising: providing an upper, the upper including a first portion configured to be associated with a majority of an exterior of the article of footwear and a second portion configured to be associated with a top layer of a tongue, the first portion and the second portion being integrally formed at an attachment region; providing a bottom layer of the tongue, the bottom layer being initially separate from the upper; and attaching the bottom layer to the top layer of the tongue, the bottom layer having a staggered attachment that is displaced from the attachment region by a distance.

[0006] Other systems, methods, features and advantages will be, or will become, apparent to one of ordinary skill in the art upon examination of the following figures and detailed description. It is intended that all such additional systems, methods, features and advantages be included within this description and this summary, be within the scope of the embodiments, and be protected by the following claims.

BRIEF DESCRIPTION OF THE DRAWINGS

[0007] The embodiments can be better understood with reference to the following drawings and description. The components in the figures are not necessarily to scale, emphasis instead being placed upon illustrating the principles of the embodiments. Moreover, in the figures, like reference numerals designate corresponding parts throughout the different views.

[0008] FIG. 1 is an isometric view of an embodiment of an article of footwear including a tongue;

[0009] FIG. 2 is an isometric view of an embodiment of an article of footwear including a tongue, in which the upper and sole are shown in phantom;

[0010] FIG. 3 is a plan view of an embodiment of a portion of an upper and a portion of a tongue;

[0011] FIG. 4 is a plan view of an embodiment of a portion of an upper attached to a portion of a tongue;

[0012] FIG. 5 is a plan view of an embodiment of a portion of an upper including an attached top layer of a tongue;

[0013] FIG. 6 is an exploded view of an embodiment of a portion of an upper including an attached tongue with a top layer, a padding material, and a back layer;

[0014] FIG. 7 is a top down view of an embodiment of a back side of a portion of an upper including an attached assembled tongue;

[0015] FIG. 8 is a cross-sectional view of an embodiment of an article of footwear including a tongue shown in FIG. 1 ;

[0016] FIG. 9 is an enlarged view of a cross-section of an embodiment of a tongue;

[0017] FIG. 10 is a plan view of an embodiment of an upper integrally formed with a portion of a tongue; [0018] FIG. 1 1 is an exploded view of an embodiment of an upper including a tongue with an integrally formed top layer, a padding material and a back layer; and

[0019] FIG. 12 is a top down view of an embodiment of a back side of an upper including an integrally formed tongue.

DETAILED DESCRIPTION

[0020] FIGS. 1 and 2 illustrate views of an embodiment of an article of footwear 100. For clarity, the following detailed description discusses an exemplary embodiment, in the form of a sports shoe, but it should be noted that the present embodiments could take the form of any article of footwear including, but not limited to: hiking boots, soccer shoes, football shoes, sneakers, rugby shoes, basketball shoes, baseball shoes as well as other kinds of shoes. Articles of footwear may also take the form of any non-athletic shoe, including, but not limited to: dress shoes, loafers, sandals, and boots. An individual skilled in the relevant art will appreciate, therefore, that the concepts disclosed herein apply to a wide variety of footwear styles, in addition to the specific style discussed in the following material and depicted in the accompanying figures. As shown in FIGS. 1 and 2, article of footwear 100, also referred to simply as article 100, is intended to be used with a left foot; however, it should be understood that the following description may equally apply to a mirror image of article of footwear 100 that is intended for use with a right foot.

[0021] Referring to FIGS. 1 and 2, for purposes of reference, article 100 may be divided into forefoot region 10, midfoot region 12 and heel region 14.

Forefoot region 10 may be generally associated with the toes and joints connecting the metatarsals with the phalanges. Midfoot region 12 may be generally associated with the arch of a foot. Likewise, heel region 14 may be generally associated with the heel of a foot, including the calcaneus bone. In addition, article 100 may include lateral side 16 and medial side 18. In particular, lateral side 16 and medial side 18 may be opposing sides of article 100. Furthermore, both lateral side 16 and medial side 18 may extend through forefoot region 10, midfoot region 12 and heel region 14.

[0022] It will be understood that forefoot region 10, midfoot region 12 and heel region 14 are only intended for purposes of description and are not intended to demarcate precise regions of article 100. Likewise, lateral side 16 and medial side 18 are intended to represent generally two sides of an article, rather than precisely demarcating article 100 into two halves. In addition, forefoot region 10, midfoot region 12 and heel region 14, as well as lateral side 16 and medial side 18, can also be applied to individual components of an article, such as a sole structure and/or an upper.

[0023] For consistency and convenience, directional adjectives are employed throughout this detailed description corresponding to the illustrated embodiments. The term "longitudinal" as used throughout this detailed description and in the claims refers to a direction extending a length of an article. In some cases, the longitudinal direction may extend from a forefoot portion to a heel portion of the article. Also, the term "lateral" as used throughout this detailed description and in the claims refers to a direction extending a width of an article. In other words, the lateral direction may extend between a medial side and a lateral side of an article. Furthermore, the term "vertical" as used throughout this detailed description and in the claims refers to a direction generally perpendicular to a lateral and longitudinal direction. For example, in cases where an article is planted flat on a ground surface, the vertical direction may extend from the ground surface upward. In addition, the term "proximal" refers to a portion of a footwear component that is closer to a portion of a foot when an article of footwear is worn. Likewise, the term "distal" refers to a portion of a footwear component that is further from a portion of a foot when an article of footwear is worn. It will be understood that each of these directional adjectives may be applied to individual components of an article, such as an upper and/or a sole structure.

[0024] Article 100 may include upper 102 and sole structure 1 10.

Generally, upper 102 may be any type of upper. In particular, upper 102 may have any design, shape, size and/or color. For example, in embodiments where article 100 is a basketball shoe, upper 102 could be a high top upper that is shaped to provide high support on an ankle. In embodiments where article 100 is a running shoe, upper 102 could be a low top upper. [0025] In some embodiments, upper 102 may be comprised of one or more components. In an exemplary embodiment, upper 102 may include a vamp 104. Vamp 104 may be a portion of upper 102 that is associated generally with forefoot region 10. In other embodiments, vamp 104 also may extend into a portion of upper 102 associated with midfoot region 12. In another embodiment, upper 102 may be made of additional portions associated with one or more of forefoot region 10, midfoot region 12, and/or heel region 14. In still other embodiments, upper 102 may be made of a single portion comprising a substantially majority of upper 102.

[0026] In some embodiments, upper 102 may include one or more elements disposed on an outer surface of upper 102. In an exemplary embodiment, upper 102 may include one or more overlay elements, including a vamp overlay 106 and/or an eyelet overlay 108. In various embodiments, overlay elements may be attached to the outer surface of upper 102 using any known process. In some embodiments, overlay elements may be disposed on the outer surface of upper 102 using one or more of the processes described below.

[0027] In some embodiments, sole structure 1 10 may be configured to provide traction for article 100. In addition to providing traction, sole structure 1 10 may attenuate ground reaction forces when compressed between the foot and the ground during walking, running or other ambulatory activities. The configuration of sole structure 1 10 may vary significantly in different embodiments to include a variety of conventional or non-conventional structures. In some cases, the configuration of sole structure 1 10 may be configured according to one or more types of ground surfaces on which sole structure 1 10 may be used. Examples of ground surfaces include, but are not limited to: natural turf, synthetic turf, dirt, as well as other surfaces.

[0028] Sole structure 1 10 is secured to upper 102 and extends between the foot and the ground when article 100 is worn. In different embodiments, sole structure 1 10 may include different components. For example, sole structure 1 10 may include an outsole, a midsole, and/or an insole. In some cases, one or more of these components may be optional. In some cases, a midsole may be attached directly to upper 102. In other cases, a midsole may be attached to a sockliner associated with upper 102. In different embodiments, a midsole may have different material characteristics to provide various levels of comfort, cushioning and/or shock absorption. Examples of different materials that could be used for a midsole include, but are not limited to: foam, rubber, plastic, polymers, as well as any other kinds of materials.

[0029] In some cases, sole structure 1 10 may also include an outsole. The outsole may be configured to provide traction for sole structure 1 10 and article 100. An outsole may include one or more tread elements and/or ground penetrating members such as cleats. The outsole can have different material characteristics to provide varying levels of traction with a ground surface. Examples of different materials that could be used for an outsole include, but are not limited to: plastic, rubber, polymers as well as any other kinds of materials that are both durable and wear resistant.

[0030] In some embodiments, upper 102 further includes an opening 120 at heel region 14 for inserting a wearer's foot into article 100, and a fastening region 122. Opening 120 may be limited to heel region 14 of article 100 or may extend along the top of upper 102 into, and including, fastening region 122. Thus, in one embodiment upper 102 may be integrated with fastening region 122. In another embodiment fastening region 122 may be separately affixed to upper 102.

Fastening region 122 may be situated along the midfoot region 12 of upper 102 as shown in FIGS. 1 and 2, or may be situated at other parts of article 100, as would be apparent to those of skill in the art.

[0031] In some embodiments, fastening region 122 may further include lateral fastening portion 132 and medial fastening portion 134. Lateral fastening portion 132 may be disposed along a lateral edge of fastening region 122. Medial fastening portion 134 may be disposed along a medial edge of fastening region 122. Moreover, lateral fastening portion 132 and/or medial fastening portion 134 may include provisions for associating with a fastening system. In an exemplary embodiment, lateral fastening portion 132 and/or medial fastening portion 134 may include eyelets for receiving portions of a lace or other fastener.

[0032] Fastening region 122 may include a fastening system for tightening article 100 around a wearer's foot. Examples of different fastening systems that could be used within fastening region 122 include, but are not limited to: lacing systems, strap systems as well as any other kinds of systems. Thus, fastening region 122 may be configured in a variety of ways to accommodate different types of fastening systems. In some embodiments, fastening region 122 may be provided with laces. Laces could be any type of laces configured for use with an article of footwear.

[0033] In one embodiment, the laces may be configured to engage with fastening region 122. In some cases, laces may be inserted through eyelets disposed on lateral fastening portion 132 and/or medial fastening portion 134 in an alternating manner. This arrangement allows fastening region 122, and upper 102, to be tightened by pulling on the laces. In an exemplary embodiment, the eyelets may be associated with eyelet overlay 108 disposed on lateral side 16 and medial side 18.

[0034] Upper 102 may further include one or more separate provisions configured to be associated with upper 102. In some embodiments, upper 102 may include a tongue 124. In some embodiments, a portion of tongue 124 may be associated with upper 102 adjacent to fastening region 122. In an exemplary embodiment, a portion of tongue 124 may be attached to upper 102. In some cases, a portion of tongue 124 may be rigidly attached only at a toe end of fastening region 122 that is associated with forefoot region 10 of upper 102. In an exemplary embodiment, a portion of tongue 124 may be rigidly attached to vamp 104 of upper 102. In other cases, one or more portions of tongue 124 may be additionally rigidly attached along other portions of the fastening region 122. In still other cases, one or more portions of tongue 124 may be attached at toe end portion of fastening region 122 near forefoot region 10 and along the entirety of fastening region 122 extending through midfoot region 12 towards heel region 14. Depending on the attachment of one or more portions of tongue 124 to upper 102, opening 120 may be of varying sizes when tongue 124 is lifted up from fastening region 122.

[0035] In an exemplary embodiment, one or more overlay elements, including vamp overlay 106, may be disposed over the location where a portion of tongue 124 is rigidly attached to a portion of upper 102 at the toe end portion of fastening region 122. In other embodiments, a portion of tongue 124 may be configured as an integral portion of upper 102. With these arrangements, tongue 124 may be configured to present a stitchless visible attachment to upper 102 when viewed by a wearer from the outside of article of footwear 100. In other words, upper 102 will present a smooth appearance between the transition from vamp 104 to tongue 124 extending through fastening region 122.

[0036] In some embodiments, tongue 124 may include additional components and/or elements disposed on an outer surface. In one embodiment, tongue 124 may include a tongue overlay 136 disposed on a top end 202 of tongue 124. Top end 202 of tongue 124 is associated with opening 120 of article 100 and is located opposite a front end 200 of tongue 124. Front end 200 of tongue 124 is associated with the portion of tongue 124 that is disposed closer to forefoot region 10 than top end 202. In some embodiments, front end 200 of tongue 124 may be associated with the toe end of fastening region 122. Tongue overlay 136 may include a provision for engaging with portions of a fastening system of article 100. In an exemplary embodiment, tongue overlay 136 may include one or more eyelets or anchors that are configured to engage with laces. With this arrangement, tongue overlay 136 may assist with keeping tongue 124 disposed within fastening region 122. In other embodiments, tongue overlay 136 is optional and may be omitted.

[0037] In some embodiments, tongue 124 may be comprised of one or more components. In an exemplary embodiment, tongue 124 may include a top layer and a bottom layer. The top layer and the bottom layer may be attached to form tongue 124 in a manner as described in the various embodiments below. In an exemplary embodiment, the components of tongue 124 may be rigidly attached using stitching. As shown in FIG. 2, a stitch line 210 connecting one or more components of tongue 124 may be visible from the outside of article of footwear 100. In an exemplary embodiment, stitch line 210 may be disposed at a distance apart from front end 200 of tongue 124, as more fully described below.

[0038] In some embodiments, a tongue for an article of footwear may be assembled using a method configured to provide a smooth surface in contact with a foot of a wearer on the inside of the article of footwear and/or to present a stitchless visible tongue to the wearer on the outside of the article of footwear. In an

exemplary embodiment, a method of using a staggered attachment to assemble a tongue for an article of footwear may be configured to provide a smooth inside surface and/or a stitchless visible exterior appearance. By using a staggered attachment, stacking and bunching of seams attaching a tongue to an article that may irritate or rub against a foot of a wearer inside the article and/or present an undesired appearance on exterior of the article may be avoided. FIGS. 3 through 7 illustrate an exemplary process for assembling a tongue to be attached to a portion of an upper using a staggered attachment to present a smooth inside surface and/or a stitchless visible exterior appearance.

[0039] FIG. 3 illustrates a portion of an upper and a portion of a tongue that may be assembled together using the process described herein to form a tongue with a staggered attachment. In an exemplary embodiment, the process may include providing a portion of an upper and a portion of a tongue for attachment to each other. In some cases, the portion of the upper and the portion of the tongue may be formed from separate materials using processes known to one in the art. In other cases, the portion of the upper and the portion of the tongue may be formed as individual pieces from the same or similar materials.

[0040] In this embodiment, the portion of the upper is a vamp 300. Vamp 300 may include a toe portion 302 associated with the toe area of forefoot region 10 of article 100, a medial portion 304 associated with medial side 18 of article 100, and a lateral portion 306 associated with lateral side 16 of article 100. In this

embodiment, vamp 300 may form a majority or substantially all of the portion of the upper that is associated with forefoot region 10 and/or portions of midfoot region 12. In other embodiments, however, vamp 300 and/or the portion of the upper may include additional or different components, including in some cases, components forming a substantially majority of the upper extending through forefoot region 10, midfoot region 12, and/or heel region 14.

[0041] Vamp 300 may further include a cut-out portion 308. Cut-out portion 308 may be associated with an end of vamp 300 opposite toe portion 302. In some embodiments, cut-out portion 308 may be configured to form part of the fastening region of article 100. In an exemplary embodiment, cut-out portion 308 may be associated with a portion of a tongue. In this embodiment, a top layer 310 of a tongue may be configured to be attached to vamp 300. Top layer 310 may be a first piece of material that may form an outer or exterior surface of an assembled tongue. Top layer 310 may act as a cover for one or more inner layers. Inner layers may be configured to provide cushioning along the top of a foot. In some

embodiments, top layer 310 could comprise a substantially similar material to the material used in constructing the upper.

[0042] In this embodiment, top layer 310 may have a front edge 312 that is configured to be associated with vamp 300 and a rear edge 318 that is configured to be located near opening 120 of article 100 near heel region 14. Top layer 310 may also include a medial edge 314 that is configured to be associated with medial side 18 of article 100 and a lateral edge 316 that is configured to be associated with lateral side 16 of article 100. In an exemplary embodiment, top layer 310 may have a generally elongated trapezoidal shape with the dimensions of front edge 312 being associated with a narrower or smaller width than the dimensions of rear edge 318. In other embodiments, top layer 310 may have any shape, including, but not limited to rectangular, elliptical, triangular, as well as any other regular or irregular shape.

[0043] FIG. 4 illustrates an embodiment of a portion of an upper that has been attached to a portion of a tongue. In this embodiment, top layer 310 is rigidly attached to vamp 300. In an exemplary embodiment, top layer 310 may be rigidly attached to vamp 300 using stitching 400. Generally, stitching 400 may be any kind of stitching that may be used to accomplish the attachment of top layer 310 to vamp 300. In some cases, simple stitches may be used. In other cases, more complex stitches may be used. Examples of various stitches that may be used include, but are not limited to: backstitches, basting stitches, blind stitches, buttonhole stitches, chain stitches, cross-stitches, embroidery stitches, feather stitches, hemming stitches, lock stitches, padding stitches, running stitches, serge stitches, slip stitches, stretch stitches, top stitches, whip stitches, zigzag stitches as well as any other types of machine or manual stitches. In this embodiment, stitching 400 is a serge stitch.

[0044] In some embodiments, top layer 310 may be attached to vamp 300 at an attachment region. In an exemplary embodiment, the attachment region may correspond approximately to a portion of vamp 300 that is at or near cut-out portion 308. In some cases, front edge 312 of top layer 310 may be attached to a portion of vamp 300 at the attachment region that is displaced a distance from cut-out portion 308 in the direction of toe portion 302. In other cases, front edge 312 of top layer 310 may be attached adjacent to, or along, the edge of cut-out portion 308 at the attachment region. In this embodiment, front edge 312 may be attached to vamp 300 at the attachment region using stitching 400. Stitching 400 may secure top layer 310 to vamp 300 in such a way so as to form a live hinge. With this arrangement, top layer 310 may be configured to allow the assembled tongue to pivot or move within fastening region 122 of article 100. In other embodiments, other methods may be used to attach top layer 310 to vamp 300, including, but not limited to adhesives, other types of stitching, as described above, as well as other permanent or nonpermanent attachment mechanisms.

[0045] Referring now to FIG. 5, an assembly 500 that includes a vamp attached with a top layer of a tongue is shown. In some embodiments, one or more overlay elements may be attached to assembly 500. In an exemplary embodiment, overlay elements may be attached to portions of assembly 500, including vamp 300 and/or top layer 310 of the tongue. In some cases, overlay elements, including vamp overlay 106 and/or tongue overlay 136, may be heat pressed to one or more portions of assembly 500, including vamp 300 and /or top layer 310 of the tongue. With a heat press application, hot melt adhesive, including, but not limited to a thermoplastic polymer, may be used to attach the overlay elements to the outer surface of portions of vamp 300 and/or top layer 310. In other cases, overlay elements, including vamp overlay 106 and/or tongue overlay 136, may be stitched to one or more portions of assembly 500. In still other cases, other methods may be used to attach an overlay element to a portion of assembly 500 and/or an upper, including, but not limited to adhesives and/or stitching, as described above, as well as other permanent or nonpermanent attachment mechanisms, including one or more attachment mechanisms used in combination.

[0046] In an exemplary embodiment, the process of applying the overlay elements using a heat pressing technique may include aligning the overlay elements over assembly 500 where the overlay elements are desired. In some embodiments, the location of one or more of the overlay elements may be configured to assist with providing the stitchless visible exterior appearance and/or engaging with a fastening system. In an exemplary embodiment, vamp overlay 106 may be located on assembly 500 so as to substantially cover stitching 400 attaching top layer 310 to vamp 300. With this arrangement, assembly 500 may present a smooth appearance between the transition from vamp 300 to top layer 310 of the tongue on article 100.

[0047] In some cases, a jig or a pattern may be used to align the overlay elements with the portion of assembly 500. In some cases, the overlay elements may be temporarily attached to assembly 500, for example by using pins or a tacky material to hold the overlay elements in place. Generally, assembly 500 may be laid flat together with the overlay elements in an apparatus that applies heat and/or pressure. The applied heat and/or pressure may melt the adhesive disposed on the overlay elements to attach the overlay elements to assembly 500 at the desired locations. With this arrangement, vamp overlay 106 and/or tongue overlay 136 may be attached to portions of assembly 500, including vamp 300 and/or top layer 310 of the tongue.

[0048] In an exemplary embodiment, eyelet overlay 108, discussed above, may be attached to portions of upper 102 associated with lateral fastening portion 132 and/or medial fastening portion 134 using a similar heat pressing technique. In addition, a similar process may be used to attach additional overlay elements to other portions of article 100, including other portions of upper 102.

[0049] In other embodiments, one or more overlay elements, including vamp overlay 106, tongue overlay 136, and/or eyelet overlay 108, as well as any other overlay elements, may be applied to portions of upper 102 using a screening process. With a screening process, layers of overlay material, including, but not limited to rubber, plastic, polymers, or other materials, may be applied to the outer surface of portions of upper 102. The screening process may be repeated multiple times to achieve an overlay element with a desired thickness. In addition, the screening process may be used to apply graphic elements and/or tactile elements to portions of upper 102.

[0050] Referring now to FIG. 6, an exploded view of components of the tongue are shown being configured for attachment to assembly 500. In some embodiments, a process for assembling components of a tongue may be assembled using a staggered attachment to present a smooth inside surface and/or a stitchless visible exterior appearance on article 100. In an exemplary embodiment, one or more components of a tongue may be provided for attachment with top layer 310 that has been attached to vamp 300 to form assembly 500, as described above. In one embodiment, the components for forming the tongue may include a bottom layer 600. Bottom layer 600 may be configured to be attached to top layer 310 to form an assembled tongue. In some embodiments, an inside surface of bottom layer 600 may be associated with an interior of article 100. The inside surface of bottom layer 600 may be configured to be in contact with a foot of a wearer when disposed within the interior of article 100.

[0051] Bottom layer 600 may include a proximal edge 602 disposed in a direction associated with forefoot region 10 of article 100. Bottom layer 600 may include a distal edge 604 located opposite proximal edge 602 and disposed in a direction associated with opening 120 of article 100 near heel region 14. Bottom layer 600 may further include a lateral edge and a medial edge disposed around the perimeter of bottom layer 600 between proximal edge 602 and distal edge 604. In an exemplary embodiment, bottom layer 600 may be configured with a similar shape as top layer 310. In this embodiment, bottom layer 600 may be associated with a generally elongated trapezoidal shape, with the dimensions of proximal edge 602 being associated with a narrower or smaller width than the dimensions of distal edge 604. In other embodiments, bottom layer 600 may have a dissimilar shape from top layer 310. In various embodiments, bottom layer 600 may have any shape, including, but not limited to rectangular, elliptical, triangular, as well as any other regular or irregular shape.

[0052] In some embodiments, the components of the tongue may include an intermediate layer 610. Intermediate layer 610 may be provided between top layer 310 and bottom layer 600. In some embodiments, intermediate layer 610 may be a cushioning material configured to provide padding to the assembled tongue. Cushioning material may include foam, rubber, plastic, or other padding material. In different embodiments, the thickness of cushioning material disposed in intermediate layer 610 may vary. In some embodiments, the thickness of intermediate layer 610 may vary according to the amount of cushioning required. In particular, regions of increased thickness may provide increased cushioning, while regions of reduced thickness may provide less cushioning. In addition, in this embodiment, intermediate layer 610 may be associated with a shape that is similar to top layer 310 and/or bottom layer 600. In other embodiments, however, intermediate layer 610 may have any shape, including, but not limited to rectangular, elliptical, triangular, as well as any other regular or irregular shape. In an exemplary embodiment, the dimensions associated with intermediate layer 610 may be configured to be smaller than top layer 310 and/or bottom layer 600 so that intermediate layer 610 may fit within the assembled tongue.

[0053] In an exemplary embodiment, a process for assembling the components of the tongue may use a staggered attachment to attach bottom layer 600 and/or intermediate layer 610 to top layer 310 to form the assembled tongue. Referring now to FIG. 7, a back side 700 of an exemplary embodiment of a portion of an upper including an assembled tongue that is attached using a staggered attachment is shown. In this embodiment, back side 700 of assembly 500 is shown with an assembled tongue that includes bottom layer 600 attached to top layer 310. In some cases, intermediate layer 610 may be disposed between top layer 310 and bottom layer 600 within the assembled tongue.

[0054] In some embodiments, bottom layer 600 may be attached to top layer 310 using an attachment that is staggered from the attachment region associated with top layer 310 and the portion of the upper. In an exemplary embodiment, the attachment region may be stitching 400, as described above, attaching top layer 310 to the vamp to form assembly 500. In an alternate

embodiment, the attachment region may be associated with a top layer of a tongue formed integral with an upper, as more fully described in the alternate embodiments below. In other embodiments, the attachment region may be associated with any type of rigid or removable connection between a portion of the tongue and a portion of the upper that anchors one end of the tongue in place to the upper.

[0055] In some embodiments, bottom layer 600 may be rigidly attached to top layer 310 to form the assembled tongue using stitching. The stitching that rigidly attaches top layer 310 and bottom layer 600 to each other may be simple stitches or complex stitches, including any of the types of stitches described above. In an exemplary embodiment, a row stitch may be used. As shown in FIG. 7, bottom layer 600 may be rigidly attached to top layer 310 using a row stitch that extends around the perimeter of top layer 310 and bottom layer 600. In this embodiment, the row stitch includes a back stitch portion 702, a front stitch portion 704, a lateral side stitch portion 706, and a medial side stitch portion 708.

[0056] In an exemplary embodiment, front stitch portion 704 may be used to rigidly attach proximal edge 602 of bottom layer 600 to top layer 310 at a distance that is staggered from front edge 312 of top layer 310. In this embodiment, front stitch portion 704 attaches bottom layer 600 to top layer 310 at a first distance D1 from the attachment region where front edge 312 of top layer 310 is attached to the vamp using stitching 400. In some embodiments, first distance D1 may be from 5 mm to 30 mm. In other embodiments, first distance D1 may be larger than 30 mm. In still other embodiments, first distance D1 may be smaller than 5 mm. With this arrangement, front stitch portion 704 may be staggered from stitching 400 by first distance D1 to prevent stacking and bunching of the stitches and to present a smooth inside surface on back side 700 of assembly 500. In addition, this staggered attachment may also assist with presenting a stitchless visible exterior appearance on article 100. In various embodiments, first distance D1 associated with the staggered attachment of the bottom layer 600 to top layer 310 may be varied based on the type of article, the size of article, the materials associated with one or more portions of the article, including top layer 310, bottom layer 600, and/or upper 102, as well as other factors.

[0057] In some embodiments, back stitch portion 702 may be used to rigidly attach distal edge 604 of bottom layer 600 near or adjacent to rear edge 318 of top layer 310. In this embodiment, back stitch portion 702 may rigidly attach distal edge 604 of bottom layer 600 a second distance D2 from rear edge 318 of top layer 310. In an exemplary embodiment, second distance D2 is substantially smaller than first distance D1 . In other embodiments, second distance D2 may be negligible and back stitch portion 702 may rigidly attach bottom layer 600 and top layer 310 along distal edge 604 and rear edge 318. Similarly, lateral side stitch portion 706 and/or medial side stitch portion 708 may be used to rigidly attach lateral and/or medial edges of bottom layer 600 near or adjacent to lateral edge 316 and/or medial edge 314 of top layer 310.

[0058] In some embodiments, once bottom layer 600 and top layer 310 have been rigidly attached using the method described herein to form the assembled tongue, assembly 500 may be then combined with one or more additional

components to form the assembled article 100, as shown in FIGS. 1 and 2 described above. In an exemplary embodiment, assembly 500 may include vamp and an assembled tongue that is then attached to a portion of an upper to form upper 102. In addition, one or more overlay elements may be provided on upper 102 as described above. The upper 102 may then be attached to sole structure 1 10 using any method known in the art to complete article 100. [0059] While the embodiments herein have been described as being rigidly attached using stitching, in different embodiments, other methods of attaching one or more portions of the upper, including the vamp, to portions of the tongue, including a top layer of the tongue, may be used, including, but not limited to various types of adhesives or other attachment mechanisms. In addition, the method of assembling the components of the tongue have been described above in a particular order, however, in other embodiments, the order of assembly may be varied. For example, in some cases, a bottom layer of a tongue may be attached to a portion of an upper and a top layer of the tongue may be attached to the combined assembly. In other cases, the top layer and the bottom layer of the tongue may be attached using the methods described herein to form the assembled tongue and the assembled tongue may be attached to the portion of the upper.

[0060] Referring now to FIGS. 8 and 9, article 100, including tongue 124 assembled using the process described above in reference to FIGS. 3 through 7, is shown in cross section. As shown in FIGS. 8 and 9, top layer 310 of tongue 124 may be attached to upper 102 at an attachment region that includes stitching 400 to rigidly attach front end 200 of tongue 124 to vamp 104. In this embodiment, front end 200 of tongue 124 may abut against the edge of vamp 104 at the attachment region. In other embodiments, front end 200 of tongue 124 may be disposed on top of, or overlapping, vamp 104 at the attachment region.

[0061] In some embodiments, front stitch portion 704 may be used to rigidly attach bottom layer 600 to top layer 310 at a distance that is staggered from stitching 400. Front stitch portion 704 may extend through top layer 310 to appear on the exterior surface as stitch line 210. Similarly, back stitch portion 702 may be used to rigidly attach bottom layer 600 near or adjacent to rear edge 318 of top layer 310. In some embodiments, intermediate layer 610 may be disposed between top layer 310 and bottom layer 600 to provide cushioning to tongue 124.

[0062] In an exemplary embodiment, vamp overlay 106 may be provided on upper 102 in a location corresponding to the attachment region between top layer 310 and vamp 104. In this embodiment, vamp overlay 106 covers all or substantially all of stitching 400. In cases where vamp overlay 106 is attached using a hot melt adhesive, adhesive material may penetrate into one or more of vamp 104, top layer 310 and/or stitching 400 to attach vamp overlay 106 to upper 102. In cases where vamp overlay is attached using a screening process, material may be deposited in one or more layers directly onto one or more of vamp 104, top layer 310 and/or stitching 400 to form vamp overlay 106 on upper 102. With this arrangement, the staggered attachment between stitching 400 and front stitch portion 704, together with optional vamp overlay, may present a smooth inside surface and/or a stitchless visible exterior appearance on article 100. In addition, in cases where laces are associated with the fastening region, the stitchless visible exterior appearance may be further enhanced.

[0063] In an alternate embodiment, an upper or a portion of an upper may be integrally formed with a portion of a tongue. FIGS. 10 through 12 illustrate an alternate process for assembling a tongue that has a portion of the tongue formed integrally from the material of a portion of the upper to present a stitchless visible appearance. Referring now to FIG. 10, an upper assembly 800 may include an upper 802 that is formed with an integral tongue top layer 804. In an exemplary embodiment, upper assembly 800 may include a piece of material that is formed with integral tongue top layer 804. In this embodiment, integral tongue top layer 804 may extend from an attachment region associated with upper 802 to a top edge 806 associated with an opening near a heel region of the article.

[0064] In this embodiment, upper assembly 800 may comprise a substantial majority or substantially all of an upper for an article. Upper assembly 800 may include a toe end 808 that is configured to be associated with a forefoot region of an article. Upper assembly may also include a lateral heel end 816 and a medial heel end 814 that are configured to be associated with a heel region of an article. In an exemplary embodiment, lateral heel end 816 and medial heel end 814 may be attached to each other at the heel region of the article.

[0065] In some embodiments, upper assembly 800 may include one or more provisions for associating with a fastening system. In an exemplary embodiment, upper assembly 800 may include integrated eyelets, including lateral eyelets 810 and medial eyelets 812, that are disposed within the material of upper assembly 800. Lateral eyelets 810 and/or medial eyelets 812 may be configured to engage with laces for tightening an article. In other embodiments, upper assembly 800 may include one or more overlay elements disposed on portions of upper assembly, as described above.

[0066] Referring now to FIG. 1 1 , an exploded view of components of the tongue are shown being configured for attachment to upper assembly 800. In some embodiments, a process for assembling components of a tongue may be assembled using a staggered attachment to present a smooth inside surface and/or a stitchless visible exterior appearance on an article. In an exemplary embodiment, one or more components of a tongue may be provided for attachment with integral tongue top layer 804 of upper assembly 800. In one embodiment, the components for forming the assembled tongue may include a bottom layer 900. Bottom layer 900 may be configured to be attached to integral tongue top layer 804 to form an assembled tongue. In some embodiments, an inside surface of bottom layer 900 may be associated with an interior of an article. The inside surface of bottom layer 900 may be configured to be in contact with a foot of a wearer when disposed within the interior of the article.

[0067] Bottom layer 900 may be similar to bottom layer 600, described above. In an exemplary embodiment, bottom layer 900 may be configured with a similar shape as a portion of integral tongue top layer 804. In this embodiment, bottom layer 900 may be associated with a generally elongated trapezoidal shape. In other embodiments, bottom layer 900 may have a dissimilar shape from integral tongue top layer 804. In various embodiments, bottom layer 900 may have any shape, including, but not limited to rectangular, elliptical, triangular, as well as any other regular or irregular shape.

[0068] In some embodiments, the components of the tongue may further include an intermediate layer 902. Intermediate layer 902 may be similar to intermediate layer 610, described above. In this embodiment, intermediate layer 902 may be provided between integral tongue top layer 804 and bottom layer 900. In an exemplary embodiment, the dimensions associated with intermediate layer 902 may be configured to be smaller than integral tongue top layer 804 and/or bottom layer 900 so that intermediate layer 902 may fit within the assembled tongue.

[0069] In an exemplary embodiment, a process for assembling the components of the tongue may use a staggered attachment to attach bottom layer 900 and/or intermediate layer 902 to integral tongue top layer 804 to form the assembled tongue. The process for using the staggered attachment may be similar to the process described above with regard to the embodiments shown in FIGS. 3 through 7. Referring now to FIG. 12, a back side 1000 of an exemplary embodiment of an upper including an integral tongue top layer that is assembled using a staggered attachment is shown. In this embodiment, back side 1000 of upper assembly 800 is shown with an assembled tongue that includes bottom layer 900 attached to integral tongue top layer 804. In some cases, intermediate layer 902 may be disposed between integral tongue top layer 804 and bottom layer 900 within the assembled tongue.

[0070] In some embodiments, bottom layer 900 may be attached to integral tongue top layer 804 using an attachment that is staggered from the attachment region associated with integral tongue top layer 804 and upper 802. In an exemplary embodiment, the attachment region may the region of upper assembly 800 where upper 802 transitions to integral tongue top layer 804, as described above.

[0071] In some embodiments, bottom layer 900 may be rigidly attached to integral tongue top layer 804 to form the assembled tongue using stitching. In an exemplary embodiment, stitching may be similar to any kind of stitching described above in regard to attaching top layer 310 and bottom layer 600 to each other. As shown in FIG. 12, bottom layer 900 may be rigidly attached to integral tongue top layer 804 using a stitch that extends around the perimeter of integral tongue top layer 804 and bottom layer 900. In this embodiment, the stitch includes a back stitch portion 1002, a front stitch portion 1004, a lateral side stitch portion 1006, and a medial side stitch portion 1008.

[0072] In an exemplary embodiment, front stitch portion 1004 may be used to rigidly attach a proximal edge of bottom layer 900 to integral tongue top layer 804 at a distance that is staggered from the attachment region. In this embodiment, front stitch portion 1004 attaches bottom layer 900 to integral tongue top layer 804 at a third distance D3 from the attachment region associated with integral tongue top layer 804 and upper 802. In some embodiments, third distance D3 may be similar to first distance D1 , described above. In an exemplary embodiment, third distance D3 may be smaller than first distance D1 . With this arrangement, front stitch portion 1004 may be staggered from the attachment region by third distance D3 to present a smooth inside surface on back side 1000 of upper assembly 800. In addition, this staggered attachment may also assist with presenting a stitchless visible exterior appearance on an article. In various embodiments, third distance D3 may be varied as described above in reference to first distance D1 .

[0073] In some embodiments, back stitch portion 1002 may be used to rigidly attach a distal edge of bottom layer 900 near or adjacent to top edge 806 of integral tongue top layer 804. In an exemplary embodiment, back stitch portion 1002, lateral side stitch portion 1006, and/or medial side stitch portion 1008 may rigidly attach portions of bottom layer 900 to portions of integral tongue top layer 804, as described above with reference to the stitching attaching bottom layer 600 and top layer 310.

[0074] In some embodiments, once bottom layer 900 and integral tongue top layer 804 have been rigidly attached using the method described herein to form the assembled tongue, upper assembly 800 may be then combined with one or more additional components to form an assembled article, similar to article 100 shown in FIGS. 1 and 2.

[0075] Generally, any materials known in the art for use with footwear can be used with the tongues discussed above. Examples of materials include, but are not limited to: plastic, foam, fabric, canvas, leather, wood, rubber, metal as well as any other materials known in the art.

[0076] While various embodiments of the have been described, the description is intended to be exemplary, rather than limiting and it will be apparent to those of ordinary skill in the art that many more embodiments and implementations are possible. Accordingly, the embodiments are not to be restricted except in light of the attached claims and their equivalents. Also, various modifications and changes may be made within the scope of the attached claims.