Laminated article and method of forming the same

Abstract

A laminated article particularly useful for forming shoe upper and a method of forming the same. The method generally comprises applying a thin and relatively uniform thickness layer of pressure sensitive adhesive to a release coated surface of a first thin and flexible sheet of material. The adhesive is applied in a regular discontinuous pattern having a multiplicity of small areas separated by pressure sensitive adhesive coated areas. The adhesive is allowed to cure or dry on the first sheet and, thereafter, the adhesive coated face of the first sheet is aligned with a second sheet of foam material and brought into contact therewith under sufficient pressure to bond the adhesive to the foam sheet. The release coated first sheet is left in place on the cured adhesive until it is desired to bond the sheet of foam material to a third sheet of flexible material, such as a sheet of shoe upper material. With the first sheet removed, the sheet of foam material can be aligned with the third sheet and bonded thereto through the application of pressure either manually or with squeeze rolls. Because the adhesive is applied in a discontinuous pattern with a multiplicity of small open areas and then dried or cured on the release sheet, it is neither absorbed into the foam sheet nor does it affect the flexibility or breathability of the foam sheet. The foam sheet thus retains the proper feel, and when joined to the third sheet, results in a composite or laminate structure having the desired characteristics.