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A method of manufacturing a multi-layer, composite footwear upper having a three-dimensional geometry includes the steps of forming a substantially planar composite sheet from two or more layers, heating the composite sheet, and compression molding the composite sheet into the three-dimensional geom

A method of manufacturing a multi-layer, composite footwear upper having a three-dimensional geometry includes the steps of forming a substantially planar composite sheet from two or more layers, heating the composite sheet, and compression molding the composite sheet into the three-dimensional geometry of the footwear upper. The composite sheet is formed by laminating a first layer of thermoplastic foam to a second layer of thermoplastic urethane (TPU), preferably in the form of a TPU film. A third layer of mesh fabric can be interposed between the first and second layers. The composite sheet is compressed after heating in a mold cavity to achieve the desired three-dimensional geometry. The composite sheet can be compression molded into separate sections which are assembled after molding to form the footwear upper. Alternatively, the composite sheet can be compression molded into a seamless, unitary footwear upper that requires minimal, if any, assembly for completion. The multi-layer composite upper can be applied to a sole to form performance footwear suitable for use in a wide range of conditions.

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A method of manufacturing a multi-layer, composite footwear upper having a three-dimensional geometry includes the steps of forming a substantially planar composite sheet from two or more layers, heating the composite sheet, and compression molding the composite sheet into the three-dimensional geom

A method of manufacturing a multi-layer, composite footwear upper having a three-dimensional geometry includes the steps of forming a substantially planar composite sheet from two or more layers, heating the composite sheet, and compression molding the composite sheet into the three-dimensional geometry of the footwear upper. The composite sheet is formed by laminating a first layer of thermoplastic foam to a second layer of thermoplastic urethane (TPU), preferably in the form of a TPU film. A third layer of mesh fabric can be interposed between the first and second layers. The composite sheet is compressed after heating in a mold cavity to achieve the desired three-dimensional geometry. The composite sheet can be compression molded into separate sections which are assembled after molding to form the footwear upper. Alternatively, the composite sheet can be compression molded into a seamless, unitary footwear upper that requires minimal, if any, assembly for completion. The multi-layer composite upper can be applied to a sole to form performance footwear suitable for use in a wide range of conditions. wherein the method comprises packaging the hygroscopic composition at a temperature between about 50° C. and about 80° C. 5. The method of claim 1 wherein the mono-layer has a thickness between 0.28 mm and 0.40 mm. 6. A method for packaging pellets of a hygroscopic composition wherein the method includes placing the pellets into a container and sealing the container, wherein the pellets have a temperature between about 50° C. and about 110° C. during the placing and wherein the container comprises a mono-layer of polypropylene resin free of a metal layer having a thickness between 0.25 mm and 0.60 mm and is effective to limit moisture pickup by the pellets to less than 0.15 weight percent after twenty weeks. 7. The method of claim 6 wherein the hygroscopic composition comprises at least one resin of the group consisting of polyurethanes, polycarbonates, polyesters, and polyamides. 8. The method of claim 6 wherein the mono-layer has a thickness between 0.28 mm and 0.40 mm. 9. A method of claim 1, wherein the hygroscopic composition has a moisture pick-up of about 0.12 weight percent water or less after 20 weeks. wood. The fiber reinforced plastic underlay is composed of glass and/or carbon fibers embedded in a polymeric resin such as epoxy, phenolic, vinyl ester, polyester, polypropylene or polyamide resin. Further, the fiber reinforced plastic underlay is substantially bonded to the wood member with a reactive hotmelt adhesive. The fiber reinforced plastic provides high fatigue resistance to the composite wood board and prevents water leakage into the trailer through the end joints of the wood segments.