FOOTWEAR PROVIDED WITH A FOOTWEAR-UPPER MADE

ACCORDING TO SAID METHOD

CROSS-REFERENCE TO RELATED APPLICATIONS

This patent application claims priority from Italian patent application no. 102020000003760 filed on 24/02/2020, the entire disclosure of which is herein incorporated by reference.

TECHNICAL FIELD

The present invention relates to a production method of a footwear-upper and to a footwear provided with a footwear- upper made according to said method.

More in detail, the present invention relates to a production method of a thermoformed upper with a sock-like structure for mountain footwear. Use to which the following description will make explicit reference without thereby losing generality.

BACKGROUND ART

As is known, the most recent and sophisticated sports shoes are provided with a thermoformed upper with a sock like structure, which is obtained starting from a seamless tubular knitted fabric, made in one piece by a circular knitting machine.

More in detail, the footwear-upper of these sports shoes is obtained starting from a tubular knitted fabric, which is at least partially made with yarns of hot-melt polymeric material, and is longitudinally divided into two seamlessly joined, tubular segments contiguous to one another, which are roughly shaped like a sock and are folded back and laid over one another so as to form, respectively, the inner layer and the outer layer of the footwear-upper. The production of the footwear-upper involves closing the end of the tubular knitted fabric corresponding to a first tubular segment, and then slipping/fitting the tubular knitted fabric onto a rigid last that copies the shape of the footwear-upper to be made, so as to fit and spread out the first tubular segment of the tubular knitted fabric over said rigid last.

After the first tubular segment has been fitted on the rigid last, the production of the footwear-upper involves folding back the tubular knitted fabric at the boundary line between the first and second tubular segments, so as to superimpose and spread out the second tubular segment over the first tubular segment; and then subjecting the tubular knitted fabric folded back over the rigid last to a thermo forming thermal treatment, so that the tubular knitted fabric permanently assumes the shape of the rigid last. Unfortunately, while allowing the creation of more comfortable footwear, the thermoformed footwear-upper with the sock-like structure has not yet been used for making mountain shoes, because it is intrinsically poorly resistant to the scratches and abrasions to which the upper of a mountain shoe is usually subjected.

Experimental tests, in fact, has shown that sharp stones and shrubs can tear the yarns of the footwear-upper with relative ease, and that even the tearing of a small number of yarns rapidly impairs the structural integrity and containing capacity of the footwear-upper, with all the problems that this entails.

DISCLOSURE OF INVENTION

Aim of the present invention is to provide a thermo- formed footwear-upper with a sock-like structure that is capable of effectively resisting the scratches and abrasions to which a mountain shoe is usually subjected.

In accordance with this aims, according to the present invention there is provided a production method of a footwear-upper as defined in Claim 1 and preferably, though not necessarily, in any one of the claims dependent thereon.

According to the present invention, there is also provided a footwear as defined in Claim 15.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention will now be described with reference to the accompanying drawings, which illustrate a non-limiting embodiment thereof, wherein:

- Figure 1 is a partially exploded, perspective view of a mountain shoe provided with a footwear-upper realized according to the teachings of the present invention;

- Figures 2 to 6 schematically illustrate a few steps of the production method of the footwera-upper shown in Figure 1.

BEST MODE FOR CARRYING OUT THE INVENTION With reference to Figure 1, number 100 denotes, as a whole, a sports footwear which is particularly suitable for walking along scree slopes, mountain paths and rough terrain in general, i.e. a mountain shoe or the like.

The sports footwear 100 basically comprises: a substantially sock-shaped, thermoformed footwear-upper 1 which is shaped so as to accommodate and protect the user's foot, including the sole of the foot, preferably up to the height of the tibio-tarsal joint; and a sole 2 preferably with a treaded profile, which is preferably made of vulcanized rubber or other soft and flexible polymeric material with a high friction coefficient, and is firmly fixed to the lower part of the footwear-upper 1 preferably by sewing and/or gluing. Preferably, the sole 2 is moreover dimensioned so as to cover the entire sole of the user's foot. With reference to Figures 1 to 6, in particular, the thermoformed footwear-upper 1 has a double-layer structure, and comprises a preferably seamless, tubular knitted fabric 11 which is at least partly realized with hot-melt yarns and is longitudinally divided into two tubular segments 12 and 13 contiguous and substantially complementary shaped to one other, which are folded back and superimposed over one another so as to form, respectively, the inner layer and the outer layer of the footwear-upper 1. In other words, the tubular knitted fabric 11 is folded back on itself at the boundary line t between the tubular segments 12 and 13, so that the tubular segment 12 of the tubular knitted fabric 11 forms the inner layer of footwear- upper 1, and that the tubular segment 13 of the tubular knitted fabric 11 overlaps the tubular segment 12 and forms the outer layer of footwear-upper 1.

The term hot-melt yarns refers to yarns made of a hot- melt polymeric material, preferably of the thermoplastic type, with a melting/softening temperature lower than 150°C and preferably ranging between 90°C and 130°C.

With reference to Figure 1, the thermoformed footwear- upper 1 additionally includes at least one, and more conveniently a plurality of reinforcement plates with a rigid or semi-rigid structure, which are made of hot-melt polymeric material, and are applied to as many areas/portions of the tubular knitted fabric 11, so as to emerge outside of the footwear-upper 1 while incorporating inside thereof at least the yarns of the outer tubular segment 13 of the tubular knitted fabric 11. In other words, similarly to the hot-melt yarns of the tubular knitted fabric 11, the reinforcement plate(s) is/are made of a preferably thermoplastic, polymeric material with a melting/softening temperature lower than 150°C and preferably ranging between 90°C and 130°C. In addition, the reinforcement plate(s) of the thermoformed footwear-upper 1 preferably has/have a thickness greater than the local thickness of the outer tubular segment 13 of the tubular knitted fabric 11.

More in detail, in the example shown, the reinforcement plate(s) made of hot-melt polymeric material preferably has/ have a thickness ranging between 0,2 and 3 mm (millimetres).

Optionally, the hot-melt polymeric material which the reinforcement plate(s) of the thermoformed footwear-upper 1 is/are made of is moreover the same as the hot-melt polymeric material which the hot-melt yarns of the tubular knitted fabric 11 are made of.

Clearly, in a different embodiment the hot-melt polymeric material which the reinforcement plate(s) is/are made of may differ in polymeric composition and/or density and/or hardness from the hot-melt polymeric material which the hot-melt yarns of the tubular knitted fabric 11 are made of.

In the example shown, in particular, the tubular segments 12 and 13 of the tubular knitted fabric 11 are preferably made of natural and/or artificial and/or synthetic yarns, combined with hot-melt yarns preferably made of hot-melt nylon and/or hot-melt polyester.

In addition, the tubular knitted fabric 11 is preferably made in one piece and seamlessly by a circular knitting machine.

Optionally, the natural and/or artificial and/or synthetic yarn(s) used to make the inner tubular segment 12 of the tubular knitted fabric 11 may also be different from the yarns used to make the outer tubular segment 13. With reference to Figure 1, in the example shown, in particular, the thermoformed footwear-upper with a sock-like structure 1 is preferably provided with an oblong-shaped front reinforcement plate 14, which is U-bent and is placed on the tip of the footwear-upper 1, so as to embrace and protect the front part of the suitably folded-back tubular knitted fabric 11, and therefore the front part of the user's foot.

Moreover, the front reinforcement plate 14 preferably has a thickness ranging between 0,5 and 2 mm (millimetres), and is applied on the tubular knitted fabric 11 so as to emerge outside of the footwear-upper 1, while incorporating inside itself at least the yarns of the outer tubular segment 13 of the tubular knitted fabric 11.

In addition, the front reinforcement plate 14 preferably also extends/prolongs along the inner and/or outer lateral side of the footwear-upper 1 so that one or both ends 14e of the front reinforcement plate 14 reach(es), and optionally also go beyond, the boundary line between the tarso-phalangeal portion and the arch-plantar portion of the user's foot.

In addition, the central part of the front reinforcement plate 14 is preferably also provided with a protruding lobe like appendage, which rises along the upper front part of the footwear-upper 1, towards the instep of the user's foot, preferably substantially remaining astride of the midplane of footwear-upper 1, so as to cover and protect the upper- front part of the folded-back tubular knitted fabric 11, and therefore the upper part of the tarso-phalangeal portion of the user's foot. With reference to Figure 1, the thermoformed footwear- upper with a sock-like structure 1 is preferably moreover provided with a rear reinforcement plate 15 preferably substantially in the shape of a concave half-shell, which is placed on the rear part of the footwear-upper 1, so as to cover and protect the heel portion of the folded-back tubular knitted fabric 11, and therefore the heel of the user's foot.

Moreover, the rear reinforcement plate 15 preferably has a thickness ranging between 1 and 2 mm (millimetres), and is applied on the tubular knitted fabric 11 so as to emerge outside of the footwear-upper 1, while incorporating inside itself at least the yarns of the outer tubular segment 13 of the tubular knitted fabric 11.

Preferably, the thermoformed footwear-upper with a sock-like structure 1 is also provided with an additional, oblong-shaped reinforcement plate 16, which is U-bent and is placed astride the rear part of the footwear-upper 1 so as to cover the area of the substantially sock-shaped, tubular knitted fabric 11 above the calcaneus of the user's foot, and thus the rear reinforcement plate 15, and then extend obliquely along the inner and outer lateral sides of the footwear-upper 1, towards the two ends 14e of the front reinforcement plate 14.

Moreover, the reinforcement plate 16 preferably has a thickness ranging between 0,5 and 1,5 mm (millimetres), and is applied on the tubular knitted fabric 11 so as to emerge outside of the footwear-upper 1, while incorporating inside itself at least the yarns of the outer tubular segment 13 of the tubular knitted fabric 11.

Preferably, the front reinforcement plate 14, the rear reinforcement plate 15 and the additional reinforcement plate 16 are also made of the same hot-melt polymeric material.

More in detail, in the example shown the reinforcement plates 14, 15 and 16 are preferably made of hot-melt nylon or hot-melt polyester.

Obviously, in a different embodiment, the reinforcement plate 14 and/or the reinforcement plate 15 and/or the reinforcement plate 16 may be made of polymeric materials that differ from each other in the polymeric composition and/or the density and/or the hardness.

With reference to Figures 1, 2, 3 and 4, preferably the weave (i.e. the interlacing pattern of the weft and warp yarns) of the outer tubular segment 13 of tubular knitted fabric 11 moreover changes according to the position on the footwear-upper 1.

Similarly, the weave (i.e. the interlacing pattern of the weft and warp yarns) of the inner tubular segment 12 of tubular knitted fabric 11 preferably changes according to the position on the footwear-upper 1. More in detail, the outer tubular segment 13 of the tubular knitted fabric 11 preferably has, in at least one, and more conveniently all the areas embedded in the reinforcement plate(s) of the footwear-upper 1, a looser and/or thinner weave than the remaining areas of the outer tubular segment 13. Even more in detail, the outer tubular segment 13 of the tubular knitted fabric 11 preferably has a first weave in the area(s) which is/are embedded in the hot-melt polymeric reinforcement plate(s) of the footwear-upper 1, and at least a second weave in all or some of the areas that directly overlap the inner tubular segment 12. Preferably, the second weave moreover has a denser spacing of the weft and warp yarns than that of the first weave and/or a greater nominal thickness than that of the first weave. With reference to Figures 2 and 3, in the example shown, in particular, the outer tubular segment 13 of the tubular knitted fabric 11 is preferably provided, at the reinforce ment plates 14, 15 and 16, with as many sectors 14a, 15a and 16a having a looser and/or thinner weave than the remaining part of the outer tubular segment 13.

In other words, the sectors 14a, 15a and 16a of the outer tubular segment 13 of tubular knitted fabric 11 that are embedded in the reinforcement plates 14, 15 and 16, preferably have a looser and/or thinner weave than the remaining part of the outer tubular segment 13.

Preferably, the sectors 14a, 15a and 16a of the outer tubular segment 13 moreover have a shape that substantially copies that of the corresponding reinforcement plate 14, 15 and 16.

In contrast, the inner tubular segment 12 of tubular knitted fabric 11 preferably has, in at least one and more conveniently all the areas covered/overlapped by the reinforcement plate(s) of the footwear-upper 1, a tighter weave and/or a thickness greater than the remaining areas of the inner tubular segment 12.

Even more in detail, the inner tubular segment 12 of the tubular knitted fabric 11 preferably has a first weave at the area(s) which is/are covered by the hot-melt polymeric reinforcement plate(s) of the footwear-upper 1, and at least a second weave at the area(s) which is/are covered by the outer tubular segment 13 alone.

Preferably, the second weave moreover has a nominal thickness lower than that of the first weave and/or a wider spacing of the weft and warp yarns than that of the first weave.

Preferably, the first weave (i.e. the interlacing pattern of the weft and warp yarns) of the inner tubular segment 12 is moreover different from the first and/or second weave of the outer tubular segment 13. Similarly, the second weave (i.e. the interlacing pattern of the weft and warp yarns) of the inner tubular segment 12 is preferably different from the first and/or second weave of the outer tubular segment 13.

In other words, the inner tubular segment 12 of the tubular knitted fabric 11 is preferably made with a weave, i.e. the interlacing pattern of the weft and warp yarns, totally or partially different from that of the outer tubular segment 13.

Clearly, the weaves of the tubular segments 12 and 13 of tubular knitted fabric 11 are seamlessly connected to one another.

With reference to Figures 2 and 3, in the example shown, in particular, the inner tubular segment 12 of tubular knitted fabric 11 is preferably provided, at the reinforcement plates 14, 15 and 16, with as many sectors

14b, 15b and 16b having a tighter weave and/or a thickness greater than the remaining part of the inner tubular segment 12.

In other words, the sectors 14b, 15b and 16b of the outer tubular segment 12 of tubular knitted fabric 11 that are covered by the reinforcement plates 14, 15 and 16, preferably have a tighter and/or thicker weave than the remaining part of the inner tubular segment 12.

Preferably, the sectors 14b, 15b and 16b of the inner tubular segment 12 moreover have a shape that substantially copies that of the corresponding reinforcement plate 14, 15 and 16.

With reference to Figures 2 to 6, the production of the thermoformed footwear-upper 1 firstly comprises the step of manufacturing, preferably by means of a circular knitting machine, a tubular knitted fabric 11 which is longitudinally divided into two, contiguous and preferably seamlessly joined together, tubular segments 12 and 13 that are preferably substantially sock-shaped, and intended to form, respectively, the inner layer and the outer layer of the footwear-upper 1.

After completing the tubular knitted fabric 11, the production method of the thermoformed footwear-upper 1 preferably also comprises the step of closing, preferably by sewing and/or welding, the end/mouth 12a of the tubular segment 12 of tubular knitted fabric 11, that is the tubular segment intended to form the inner layer of the footwear- upper 1.

In the example shown, in particular, the end 12a of tubular segment 12 is preferably closed by ultrasonic welding.

With reference to Figure 2, after having optionally closed the end/mouth 12a of the tubular segment 12 of tubular knitted fabric 11, the production method of the thermoformed footwear-upper 1 provides for slipping the tubular knitted fabric 11 on a rigid last 200 substantially in the shape of a stylized foot and which copies the shape of the footwear- upper to be made, so as to fit the tubular segment 12 of the tubular knitted fabric 11 directly onto the rigid last 200, forcing it to assume the shape of the rigid last 200. With reference to Figures 3 and 4, after fitting the tubular segment 12 of the tubular knitted fabric 11 onto the rigid last 200, the production method of the thermoformed footwear-upper 1 comprises the step of placing/fixing on the tubular segment 12, in the area or areas of the tubular segment 12 where the reinforcement plate or plates of the footwear-upper will be located, as many sheets/patches of hot-melt material of given thickness, which are made of hot- melt polymeric material preferably of the thermoplastic type, and which substantially copy the shape of the reinforcement plates to be made.

Preferably, the portion(s) of the tubular segment 12 that is/are covered/overlapped by the sheet(s)/patch(es) of hot-melt material preferably has/have a tighter weave and/or a greater thickness than the remaining areas of the tubular segment 12.

In other words, the production method of the thermo formed footwear-upper 1 provides for placing the sheet(s)/ patch(es) of hot-melt material over corresponding sectors of the tubular segment 12 having a tighter weave and/or a greater thickness.

In addition, the sheet(s)/patch(es) of hot-melt material preferably has/have a thickness ranging between 0,2 and 3 mm (millimetres).

In the example shown, in particular, the production method of the thermoformed footwear-upper 1 preferably provides for placing/fixing a first sheet/patch of hot-melt material 214 on the front part of the rigid, substantially foot-shaped last 200, preferably immediately above the thicker sector 14b of the tubular segment 12 of tubular knitted fabric 11. Preferably, the sheet/patch of hot-melt material 214 moreover substantially copies the shape of the sector 14b of tubular segment 12.

In addition, the production method of the thermoformed footwear-upper 1 preferably provides for placing/fixing a second sheet/patch of hot-melt material 215 on the rear part of the rigid last 200, preferably immediately above the thicker sector 15b of the tubular segment 12 of tubular knitted fabric 11. Preferably, the sheet/patch of hot-melt material 215 moreover substantially copies the shape of the sector 15b of tubular segment 12.

Lastly, the production method of the thermoformed footwear-upper 1 preferably provides for placing/fixing a third sheet/patch of hot-melt material 216 around the heel area of the rigid last 200, preferably immediately above the thicker sector 16b of the tubular segment 12 of tubular knitted fabric 11. Preferably, the sheet/patch of hot-melt material 216 moreover substantially copies the shape of the sector 16b of the tubular segment 12.

Preferably , the sheets/patches of hot-melt material 214, 215, 216 are furthermore made of hot-melt nylon or polyester.

With reference to Figures 4 and 5, after fixing/placing the sheet(s)/patch(es) of hot-melt material on the tubular segment 12 of tubular knitted fabric 11, the production method of the thermoformed footwear-upper 1 comprises the step of folding back the tubular knitted fabric 11, roughly at the boundary line £ between the tubular segments 12 and 13, so as to spread out the tubular segment 13 of tubular knitted fabric 11 over the tubular segment 12 and the sheet(s)/patch(es) of hot-melt material.

Preferably, the portion(s) of tubular segment 13 that overlap the sheet(s)/patch(es) of hot-melt material moreover has/have a looser and/or thinner weave than the remaining areas of the tubular segment 13.

In other words, the production method of the thermo formed footwear-upper 1 provides for folding back the tubular knitted fabric 11 so as to arrange the sectors of tubular segment 13 having a looser and/or thinner weave above the corresponding sheets/patches of hot-melt material located on the tubular segment 12.

Preferably, the thickness of the sheet(s)/patch(es) of hot-melt material is also greater than the thickness of the portion(s) of the tubular segment 13 that locally overlap the same sheet(s)/patch(es) of hot-melt material. In the example shown, in particular, the production method of the thermoformed footwear-upper 1 preferably provides for folding back the tubular knitted fabric 11 substantially at the boundary line £ between the tubular segments 12 and 13, so as to arrange the sectors 14a, 15a and 16a of the tubular segment 13 above the corresponding sheets/patches of hot-melt material 214, 215 and 216.

In addition, the sheet/patch of hot-melt material 214 preferably has a thickness greater than the thickness of the corresponding sector 14a of the tubular segment 13 having a looser and/or thinner weave. The sheet/patch of hot-melt material 215 preferably has a thickness greater than the thickness of the corresponding sector 15a of the tubular segment 13 having a looser and/or thinner weave. The sheet/ patch of hot-melt material 216 preferably has a thickness greater than the thickness of the corresponding sector 16a of the tubular segment 13 having a looser and/or thinner weave.

At the end of this operation, the sheet(s)/patch(es) of hot-melt material 214, 215 and 216 are interposed and trapped between the tubular segments 12 and 13 of the tubular knitted fabric 11.

Moreover, the tubular segment 13 of tubular knitted fabric 11 is preferably spread out over the tubular segment 12 so as to place its end/mouth at the area of the tubular segment 12 that covers the tarso-phalangeal portion of the sole of the user's foot, so as to be subsequently covered by the sole 2 of the footwear 100.

With reference to Figure 6, after completely spreading out the tubular segment 13 of tubular knitted fabric 11 over the tubular segment 12 and the sheet(s)/patch(es) of hot- melt material, the production method of the thermoformed footwear-upper 1 comprises the step of thermoforming, directly on the rigid last 200, the article formed by the suitably folded-back, tubular knitted fabric 11 and by the sheet(s)/patch(es) of hot-melt material trapped in the tubular knitted fabric 11, so that the tubular knitted fabric 11 permanently assumes the shape of the rigid last 200, and that the sheet(s)/patch(es) of hot-melt material emerge outside of the tubular segment 13 while incorporating inside thereof the parts of the second tubular segment 13 that are located at the same sheet(s)/patch(es) of hot-melt material, thus forming the reinforcement plate(s) of the footwear- upper. More in detail, the production method of the thermo formed footwear-upper 1 provides for subjecting the article formed by the tubular knitted fabric 11 suitably folded-back over the rigid last 200 and by the sheet(s)/patch(es) of hot-melt material to a thermoforming thermal treatment that causes the temporary softening of the hot-melt yarns of the tubular knitted fabric 11, so as to permanently join/attach the tubular segment 13 of the tubular knitted fabric 11 to the underlying tubular segment 12. In addition, the same thermoforming thermal treatment moreover causes the temporary softening of the sheet(s)/patch(es) of hot-melt polymeric material, so as to permanently join/attach the sheet(s)/patch(es) to the tubular segments 12 and 13 of the tubular knitted fabric 11, further causing the parts of the tubular segment 13 which are located at the sheet(s)/ patch(es) of hot-melt material to be incorporated into the same sheets/patches of hot-melt material and to form the reinforcement plate(s) of the thermoformed footwear-upper 1.

More in detail, during the thermoforming thermal treatment, the article formed by the tubular knitted fabric 11 suitably folded back over the rigid last 200 and by the sheets/patches of hot-melt polymeric material 214, 215 and

216, is brought for a given time (for example 3 minutes) to a predetermined thermoforming temperature (for example 120°C) that causes the softening of the polymeric material forming the hot-melt yarns of the tubular knitted fabric 11 and the softening of the polymeric material forming the sheets/patches of hot-melt material 214, 215 and 216, so that the hot-melt yarns and the hot-melt sheets/patches are melted for a few seconds/minutes, thus permanently gluing the tubular segments 12 and 13 and the sheets/patches of hot-melt material 214, 215 and 216 firmly together.

At the end of the thermoforming thermal treatment, the production method of the thermoformed footwear-upper 1 finally provides the step of taking off/removing the resulting article from the rigid last 200, thereby obtaining a thermoformed footwear-upper 1 with a sock-like structure, wherein the inner layer of the footwear-upper corresponds to the tubular segment 12 of the tubular knitted fabric 11, and the outer layer of the footwear-upper corresponds to the tubular segment 13 of the tubular knitted fabric 11. In addition, the resulting thermoformed footwear-upper 1 is moreover provided with one or more reinforcement plates 14, 15, 16 emerging outside of the upper.

With reference to Figure 1, the footwear 100 is then completed by fixing/attaching, preferably by sewing and/or gluing, the sole 2 to the lower part of the thermoformed footwear-upper 1, preferably so that the sole 2 covers and hides from sight the end/mouth of the tubular segment 13 of the tubular knitted fabric 11. Obviously, the elasticity and/or stiffness of the thermoformed footwear-upper 1 depend both on the thickness and/or shape of the reinforcement plates, and on the type of yarns used to manufacture the tubular knitted fabric 11 and the related yarn-counts. The elastic properties of the elastic yarns possibly present in the tubular knitted fabric 11, in fact, are generally not impaired by the thermoforming thermal treatment.

The advantages connected to the presence of the reinforcement plate(s) 14, 15, 16 are noteworthy. By being located in the areas of the footwear-upper that are most exposed to scratches and abrasions and by incorporating inside themselves the yarns of the outer tubular segment 13 of the tubular knitted fabric 11, the reinforcement plate(s) 14, 15, 16 prevent(s) the yarns of the tubular knitted fabric 11 from coming into direct contact with sharp stones and/or shrubs, and thus from tearing and impairing the structural integrity of the footwear-upper.

It is finally clear that modifications and variations may be made to the thermoformed footwear-upper 1 and the production method thereof without however departing from the scope of the present invention.

For example, in a more sophisticated not-shown embodiment, the two ends 14e of the front reinforcement plate 14 can extend along the two inner and outer lateral sides of the thermoformed footwear-upper 1 up to reach and optionally join the rear reinforcement plate 15, so as to form a perimeter band/collar of a given height, with a rigid or semi-rigid structure, which emerges outside of the footwear- upper 1 along the entire perimeter of the user's foot, incorporating inside itself at least the yarns of the outer tubular segment 13 of the tubular knitted fabric 11. In addition, the production method of the thermoformed footwear-upper 1 may furthermore comprise the step of also placing, at one or more of said sheets/patches of hot-melt material 214, 215 and/or 216, at least one, preferably plate- like and preferably made of plastic, metal or composite material, reinforcement insert that is subsequently at least partially incorporated into the polymeric material that forms the same sheet(s)/patch(es) of hot-melt material 214, 215 and/or 216, so as to stiffen and/or strengthen the resulting reinforcement plate 14, 15 or 16.

More in detail, the reinforcement insert preferably has a shape that approximates by defect the shape of the related sheet/patch of hot-melt material 214, 215 or 216, and is preferably located immediately above or beneath the same sheet/patch of hot-melt material 214, 215 or 216.

Finally, the production method of the thermoformed footwear-upper 1 may comprise the step of pushing/pressing, during the thermoforming thermal treatment, the two tubular segments 12 and 13 of the tubular knitted fabric 11 one against the other, so as to facilitate/speed up the exit of the polymeric material forming the sheet(s)/patch(es) of hot-melt material 214, 215 and/or 216 from the corresponding areas of the outer tubular segment 13.