U.S. patent application number 11/362248 was filed with the patent office on 2007-08-30 for compression molded footwear and methods of manufacture.
This patent application is currently assigned to The Timberland Company. Invention is credited to Peter Dillon, David L. Vattes.
Application Number | 20070199210 11/362248 |
Document ID | / |
Family ID | 38042826 |
Filed Date | 2007-08-30 |
United States Patent
Application |
20070199210 |
Kind Code |
A1 |
Vattes; David L. ; et
al. |
August 30, 2007 |
Compression molded footwear and methods of manufacture
Abstract
An article of footwear having an upper, which includes a first
foam layer having a first surface and a second surface remote from
the first surface, a second foam layer having a first surface and a
second surface remote from the first surface, and a middle layer
having a first surface and a second surface remote from the first
surface. The first surface of the middle layer is affixed to the
second surface of the first foam layer, and the second surface of
the middle layer is affixed to the first surface of the second foam
layer. The upper defines at least a portion of a foot receiving
cavity for the article of footwear.
Inventors: |
Vattes; David L.;
(Londonderry, NH) ; Dillon; Peter; (Topsfield,
MA) |
Correspondence
Address: |
LERNER, DAVID, LITTENBERG,;KRUMHOLZ & MENTLIK
600 SOUTH AVENUE WEST
WESTFIELD
NJ
07090
US
|
Assignee: |
The Timberland Company
Stratham
NH
|
Family ID: |
38042826 |
Appl. No.: |
11/362248 |
Filed: |
February 24, 2006 |
Current U.S.
Class: |
36/45 |
Current CPC
Class: |
A43B 7/085 20130101;
B32B 5/32 20130101; B32B 25/045 20130101; B32B 2307/54 20130101;
B32B 2266/0214 20130101; B32B 2266/0207 20130101; B32B 2266/0221
20130101; B29D 35/146 20130101; A43B 23/0235 20130101; B32B
2266/0264 20130101; A43B 23/0255 20130101; B32B 2307/724 20130101;
B32B 5/18 20130101; A43B 23/042 20130101; B32B 25/00 20130101; B32B
7/12 20130101; B32B 1/00 20130101; B32B 2307/738 20130101; A43B
13/12 20130101; B29D 35/142 20130101; A43B 23/022 20130101; B32B
2437/02 20130101; B32B 5/245 20130101; B32B 2266/06 20130101; B32B
2255/102 20130101 |
Class at
Publication: |
036/045 |
International
Class: |
A43B 23/00 20060101
A43B023/00 |
Claims
1. An article of footwear, comprising an upper including: a first
foam layer having a first surface and a second surface remote from
said first surface thereof; a second foam layer having a first
surface and a second surface remote from said first surface
thereof; and a middle layer having a first surface and a second
surface remote from said first surface thereof; wherein said first
surface of said middle layer is affixed to said second surface of
said first foam layer and said second surface of said middle layer
is affixed to said first surface of said second foam layer, and
said upper defines at least a portion of a foot receiving cavity
for the article of footwear.
2. The upper of claim 1, wherein at least one of said first and
second foam layers comprises an open-cell foam.
3. The upper of claim 1, wherein at least one of said first and
second foam layers comprises a thermoformable foam.
4. The upper of claim 3, wherein at least one of said first and
second foam layers comprises a thermoset foam.
5. The upper of claim 3, wherein at least one of said first and
second foam layers comprises a thermoplastic foam.
6. The upper of claim 5, wherein said thermoplastic foam is an EVA
foam.
7. The upper of claim 1, wherein said first foam layer further
includes a feature affixed to said first surface thereof.
8. The upper of claim 7, wherein said feature is a protective
feature and is located in a toe region of said upper.
9. The upper of claim 7, wherein said feature is a supportive
feature and is located in an ankle region of said upper.
10. The upper of claim 9, wherein said feature is integrally formed
with said first foam layer.
11. The upper of claim 8, wherein said feature comprises a coating
applied to at least a portion of said first surface of said first
foam layer.
12. The upper of claim 11, wherein said coating comprises a latex
paint.
13. The upper of claim 11, wherein said coating comprises a
lacquer.
14. The upper of claim 1, wherein: said first foam layer, said
second foam layer, and said middle layer form a unitary piece of
layered material having a first seam and a second seam; said
unitary piece of layered material defines a first substantially
seamless portion on a medial side of said upper between said first
seam and said second seam; and wherein said upper defines a second
substantially seamless portion on a lateral side of said upper
between said first seam and said second seam.
15. The upper of claim 14, wherein said first seam is positioned at
a heal section of said upper, and wherein said second seam is
positioned at a toe section of said upper.
16. An article of footwear comprising: a sole; and a unitary upper
affixed to said sole and formed of a layered material having: a
first foam layer; a second foam layer; and a middle layer
interposed between said first and second foam layers, said upper
defining at least a portion of a foot-receiving cavity of said
article of footwear.
17. The article of claim 16, wherein said middle layer is
adhesively affixed between said first and second foam layers.
18. The article of claim 16, wherein said middle layer is a mesh
textile material.
19. The article of claim 16, wherein said first and second foam
layers each comprise a thermoformable foam.
20. The article of claim 19, wherein said thermoformable foam is a
thermoplastic foam.
21. The article of claim 20, wherein said thermoplastic foam is an
EVA foam.
22. The article of claim 21, wherein said EVA foam comprises an
open-cell foam.
23. The article of claim 19, wherein said thermoformable foam
comprises a polyester foam.
24. The article of claim 19, wherein said thermoformable foam
comprises a polyether foam.
25. The article of claim 19, wherein said thermoformable foam
comprises a latex foam.
26. A method for making an article of footwear, comprising:
providing a first foam layer, a second foam layer and a middle
layer and integrally forming said first foam layer, said second
foam layer and said middle layer by interposing said middle layer
between said first foam layer and said second foam layer to form a
blank defining a profile having first and second mating portions;
and forming an upper defining a portion of a foot receiving cavity
from said blank by aligning said first and second mating
portions.
27. The method of claim 26, wherein integrally forming said first
foam layer, second foam layer and middle layer includes compression
molding said first and second foam layers and said middle layer
together.
28. The method of claim 27, wherein said compression molding
includes the use of a mold, said mold being used to form a sole for
said article of footwear concurrently with said integrally forming
said first foam layer, second foam layer and middle layer.
29. The method of claim 27, wherein integrally forming said first
foam layer, second foam layer and middle layer further includes
adhesively affixing said middle layer between said first foam layer
and said second foam layer.
30. The method of claim 26, wherein said integrally forming said
first foam layer, second foam layer and middle layer includes cold
molding of the first and second foam layers and the middle
layer.
31. The method of claim 30, wherein said cold molding includes
using rollers.
32. The method of claim 31, wherein said cold molding includes
using plates, said plates being substantially flat.
33. The method of claim 26, further including trimming said layered
material to form a blank.
34. The method of claim 26, further including applying a coating to
said first surface of said first foam layer after said step of
compression molding.
35. The method of claim 26 further including forming a first seam
from said first mating portion, and forming a second seam from said
second mating portion.
36. The method of claim 26 further including: affixing an insole to
said upper at an outside edge thereof so as to define a foot
receiving cavity therebetween; inserting a last into said foot
receiving cavity; heating said upper so as to form said upper to a
shape of said last; allowing said upper to cool; and removing said
last from said foot receiving cavity.
37. An article of footwear having a unitary upper formed from a
layered material, and a sole, said upper forming at least a portion
of a foot receiving cavity of said article of footwear, and said
sole being affixed to said upper, said article of footwear being
formed by the process of: providing a first foam layer, a second
foam layer and a middle layer and integrally forming said first
foam layer, said second foam layer and said middle layer by
interposing said middle layer between said first foam layer and
said second foam layer to form a blank defining a profile having
first and second mating portions; and forming said upper from said
blank by forming first and second seams from said first and second
mating portions; and affixing said sole to said upper.
38. The article of claim 37, wherein integrally forming said first
foam layer, second foam layer and middle layer includes compression
molding of the first and second foam layers and the middle
layer.
39. The article of claim 38, wherein said middle layer is formed of
a textile material defining a plurality of open portions such that
said process step of compression molding forces said first foam
layer and said second foam layer into mutual contact within said
open portions so as provide tensile strength to said layered
material.
40. The article of claim 39, wherein said process step of
integrally forming said first foam layer, second foam layer and
middle layer includes adhesively affixing said middle layer between
said first foam layer and said second foam layer.
41. The article of claim 40, wherein said process step of
adhesively affixing includes applying a heat-activated adhesive to
a surface of said middle layer and applying heat thereto.
42. An article of footwear comprising: a sole; and a unitary upper
affixed to said sole so as to define a foot receiving cavity
therein, said unitary upper being formed of a layered material
consisting essentially of: a first layer of a thermoformable foam
and having a first surface and a second surface remote from said
first surface thereof; and a second layer having a first surface
and a second surface remote from said first surface thereof;
wherein said second surface of said first layer is affixed to said
first surface of said second layer, said upper defining at least a
portion of a foot-receiving cavity.
43. The article of claim 42, wherein said second layer is a textile
material.
44. The article of claim 43, wherein said first surface of said
first layer is disposed toward said foot receiving cavity such that
said second surface of said second layer is spaced apart from said
foot receiving cavity.
45. The article of claim 42 wherein said first layer further
includes a feature affixed to said first surface thereof.
46. The upper of claim 45, wherein said feature is integrally
formed with said first foam layer.
47. An article of footwear comprising: an upper; and a bottom
affixed to said upper; wherein said upper and said bottom are
formed from a unitary piece of layered material including: a first
layer of thermoformable foam having a first surface and a second
surface remote from said first surface thereof; and a second layer
having a first surface and a second surface remote from said first
surface thereof; said second surface of said first layer being
affixed to said first surface of said second layer.
48. The article of claim 47, wherein said second layer includes a
first region and a second region, said first region comprising a
first material and said second region comprising a second
material.
49. The article of claim 48, wherein said first material is a
rubber and said second material is a textile.
Description
BACKGROUND OF THE INVENTION
[0001] The present invention relates generally to articles of
footwear and, more particularly, to articles of footwear having
multilayer molded uppers.
[0002] Typically, many types of footwear are made by what is known
as a cut and sew method, in which individual pieces of material are
cut out and sewn together to form the three dimensional ("3-D")
shape of a footwear upper. In such a process, individual pieces of
material are cut out according to a pattern, in which individual
pieces are designated to form specified portions of the shoe upper.
When the pieces are cut out, they are typically marked according to
the portion of the upper which they are intended to form. The
individual pieces are bonded, stitched and then lasted, giving the
shoe the necessary 3-D shape. Other portions of the shoe may then
be attached to the upper, such as an outsole, midsole, footbed,
etc.
[0003] Such a method requires a large number of steps, each
requiring a skilled person for completion thereof. This increases
the overall manufacturing cost and can lead to throughput problems
arising from bottlenecks in one step of the process. For example,
the absence of the person responsible for one step in the process
can shut down an entire production line of footwear. Furthermore,
the use of such complicated individual pieces leads to a product
that is more difficult to design, requiring the design of both the
individual pieces and how the pieces will fit together to form the
shape of the shoe upper. This further contributes to increased
costs of the finished product, and increases lead time when
designing the shoe.
[0004] Alternative methods of shoe production have been developed
which use various molding techniques to create the shoe upper. Such
methods generally use a type of thermoformable polymeric material,
such as plastic, to create individual parts of the shoe upper or
the upper as a whole. One such method includes injection molding of
a thermoplastic into a non-planar 3-D mold to form the shape of the
shoe upper. This decreases the time needed to form the shoe.
However, the injection molding method presents significant
additional problems. Specifically, the complicated molds necessary
to form the 3-D shape of a shoe upper increase costs and lead time
due to the time required to manufacture these molds. Furthermore,
although molding creates advantages such as faster forming of the
basic shape of the shoe upper, such benefits can be outweighed by
the fact that additional process steps must be performed after
molding of the shoe in order to control material creep. Creep is
when the foaming reaction to heat energy continues causing
expansion of the foam material. If not controlled, creep can result
in continued expansion of the polymer. This causes the shoe upper
to stretch, which affects the fit quality of the shoe.
Additionally, because the majority of the shoe upper is formed in a
single process step, there are no available intermediate steps that
can control factory defects in the upper of the shoe. Such defects
typically arise due to the difficulty in controlling the expansion
of foam after injection into the mold, particularly during cooling.
In order to control such defects, tolerances within the molds need
to be widened, which can lead to overall fit problems with the
finished product.
[0005] An alternative method includes forming a 3-D footwear upper
by compression molding a sheet of material, including a layer of
thermoplastic polyurethane (TPU) having a predetermined thickness,
into a 3-D form. However, this method does not alleviate the
expense required by complex 3-D molds or the increased product lead
time associated therewith. In addition to being able to control
expansion of the polymer during molding, this method allows
additional materials to be added to shoe upper during formation
thereof, which helps to control creep and stretching of the
product. This is typically accomplished by interposing between two
moldable, thermoplastic layers, a fabric or other suitable material
that possess appropriate tensile properties.
[0006] Limitations in such a process arise, particularly from the
materials, namely TPU, that are used in the 3-D compression
molding. Such materials are often somewhat thick or dense,
resulting in shoe uppers that are too rigid or inflexible for
practical purposes of footwear. The relative weight of TPU can also
make it less desirable for use in a shoe upper. For example, the
specific gravity of TPU can be approximately 1.0 to 1.1 where other
materials, such as EVA foam, can be up to five times lighter.
Additionally, footwear made from material including TPU retains
heat and can make the foot hot, causing discomfort to the
wearer.
[0007] Additionally, it is difficult to mold a 3-D shape from a
single sheet of material having both thermoplastic and fabric
materials, fabric not being thermoplastic. This causes difficulty
in molding the complex 3-D shape of the shoe upper because
thermoplastic and non-thermoplastic materials conform to the mold
differently. This can tend to separate the materials during
forming. All of the materials to be molded in such a process must
possess thermoformable properties. The use of non-thermoformable
materials can cause problems in the overall integrity of the
product or the reliability of the process, leading to increased
factory defects from the difficulty to control the molding process.
Additionally, compression molding of a 3-D form from a flat
substrate of material can lead to thinning of certain layers of the
material during formation because the material must stretch to
conform to the mold. This can weaken the overall material or
diminish the foot protective properties of the materials used to
form the upper. It also limits the ability of the shoe to be formed
with decorative or protective features on the shoe upper.
Stretching can also make it difficult to control the overall
compression of the foam, which is desirous in compression molding
because compression helps to bond the layers of material
together.
[0008] Therefore, it is necessary to provide footwear uppers that
possess the advantages of foam, particularly with respect to
protection of the foot, durability, and other such properties,
while providing a shoe with acceptable flexibility and ease of
manufacture. Additionally, with the use of foam and compression
molding process, there is a reduction in manufacturing cost, an
increase in versatility of design and an increase in the number of
various materials which may be used. The shoe, particularly the
upper should be structured to utilize the desired properties of
foam while minimizing creep and stretching in an effective manner,
or to provide other additional beneficial properties to the foam
material from which the upper is constructed. It is further
desirous to provide a shoe upper that has features formed thereon,
but which may be formed from an otherwise planar piece of material.
Such features can provide an enhanced, more secure fit to the
amorphous shape of the foot and/or provide additional protection.
It is also desirous to provide a method for making such footwear
that can be carried out in a limited number of process steps while
compensating for defects that may arise during other molding
processes. Such a method should utilize materials and methods
already employed in the art. It is further desired to provide a
method for manufacturing such footwear that eliminates the need for
complex 3-D molds, while taking advantage of the benefits present
in compression molded products.
SUMMARY OF THE INVENTION
[0009] The present invention relates to an article of footwear
having an upper which includes a first foam layer having a first
surface and a second surface remote from the first surface, a
second foam layer having a first surface and a second surface
remote from the first surface, and a middle layer having a first
surface and a second surface remote from the first surface. The
first surface of the middle layer is affixed to the second surface
of the first foam layer, and the second surface of the middle layer
is affixed to the first surface of the second foam layer. The upper
defines at least a portion of a foot receiving cavity for the
article of footwear.
[0010] Preferably, at least one of the first and second foam layers
of the upper is made from an open-cell foam. Additionally, least
one of the first and second foam layers preferably comprises a
thermoformable foam, which can include either a termoset foam or a
thermoplastic foam. A thermoplastic foam used in the article of
footwear may be an EVA foam.
[0011] In an upper according to an embodiment of the present
invention the first foam layer further includes a feature affixed
to the first surface thereof. The feature may be in the form of a
protective feature located in, for example, the toe region of the
upper. Alternatively, the feature can be a supportive feature
located in, for example, the ankle region of the upper. The feature
is preferably integrally formed with the first foam layer or the
second foam layer. In an alternative embodiment, the feature
comprises a coating applied to at least a portion of the first
surface of the first foam layer. Such a coating can comprise a
latex paint or a lacquer.
[0012] In one embodiment of the present invention, the first foam
layer, the second foam layer, and the middle layer form a unitary
piece of layered material having a first seam and a second seam.
The unitary piece of layered material may define a first
substantially seamless portion on a medial side of the upper
between the first seam and the second seam. The upper may further
define a second substantially seamless portion on a lateral side of
the upper between the first seam and the second seam. In a
preferred embodiment, the first seam is positioned at the heal
section of the upper, and the second seam is positioned at the toe
section of the upper.
[0013] An alternative embodiment of the present invention relates
to an article of footwear having a sole and a unitary upper that is
formed of a layered material and affixed to the sole. The layered
material has a first foam layer, a second foam layer, and a middle
layer interposed between the first and second foam layers. The
upper defines at least a portion of a foot-receiving cavity of the
article of footwear. Preferably, the middle layer is adhesively
affixed between the first and second foam layers. The middle layer
is preferably a mesh textile material.
[0014] It is preferred that the first and second foam layers each
comprise a thermoformable foam. Preferably, the thermoformable foam
is a thermoplastic foam, and, more preferably, thermoplastic foam
is an EVA foam. The EVA foam may comprise an open-cell foam.
Alternatively, the thermoformable foam may comprise a polyester, a
polyether or a latex foam.
[0015] A further embodiment of the present invention relates to a
method for making an article of footwear. The method includes
providing a first foam layer, a second foam layer and a middle
layer, and integrally forming the first foam layer, the second foam
layer and the middle layer by interposing the middle layer between
the first foam layer and the second foam layer to form a blank
defining a profile having first and second mating portions. The
method further includes forming an upper defining a portion of a
foot receiving cavity from the blank by aligning the first and
second mating portions. Integrally forming the first foam layer,
second foam layer and middle layer may include compression molding
the first and second foam layers and the middle layer together. A
first seam can be formed from the first mating portion, and a
second seam can be formed from the second mating portion.
[0016] In the method according to the present embodiment of the
invention, the compression molding may include the use of a mold.
The mold can further be used to form a sole for the article of
footwear concurrently with the integral forming of the first foam
layer, second foam layer and middle layer. Preferably, integrally
forming the first foam layer, second foam layer and middle layer
further includes adhesively affixing the middle layer between the
first foam layer and the second foam layer. In an alternative
embodiment, integrally forming the first foam layer, second foam
layer and middle layer may include cold molding of the first and
second foam layers and the middle layer. Cold molding can be
carried out using rollers or plates which may be substantially
flat. The method of the present embodiment can further include
trimming the layered material after molding thereof. In a further
embodiment of the present invention, the method includes applying a
coating to the first surface of the first foam layer after
compression molding thereof.
[0017] Additionally, the method of the present embodiment may
further include affixing an insole to the upper at an outside edge
thereof so as to define a foot receiving cavity therebetween. A
last may then be inserted into the foot receiving cavity of the
article of footwear. The upper may then be reheated so as to form
the upper to the shape of the last. The upper may then be allowed
to cool and the last can be removed from the foot receiving
cavity.
[0018] A further embodiment of the present invention relates to an
article of footwear having a unitary upper and a sole. The upper is
formed from a layered material, forms at least a portion of a foot
receiving cavity of the article of footwear, and is affixed to the
upper. The article of footwear of the present embodiment is formed
by the process of providing a first foam layer, a second foam layer
and a middle layer and integrally forming the first foam layer, the
second foam layer and the middle layer by interposing the middle
layer between the first foam layer and the second foam layer to
form a blank. The blank preferably defines a profile having first
and second mating portions. An upper is formed from the blank by
forming first and second seams from the first and second mating
portions. The sole is then affixed to the upper.
[0019] In a preferred embodiment the first foam layer, second foam
layer and middle layer are integrally formed by compression
molding. Additionally, the step of integrally forming may include
adhesively affixing the middle layer between the first foam layer
and the second foam layer. The adhesive used in the step of
integrally forming is preferably heat activated. In a further
embodiment, the middle layer is formed of a textile material
defining a plurality of open portions such that the step of
compression molding forces the first foam layer and the second foam
layer into mutual contact within the open portions so as provide
tensile strength to the layered material.
[0020] An additional embodiment of the present invention relates to
an article of footwear comprising a sole, and a unitary upper
affixed to the sole so as to define a foot receiving cavity
therein. The unitary upper is formed of a layered material
consisting essentially of a first layer of a thermoformable foam
having a first surface and a second surface remote from the first
surface thereof, and a second layer having a first surface and a
second surface remote from the first surface thereof. The second
surface of the first layer is affixed to the first surface of the
second layer. The upper defines at least a portion of a
foot-receiving cavity. The second layer may be formed from a
textile material.
[0021] The first surface of the first layer may be disposed toward
the foot receiving cavity such that the second surface of the
second layer is spaced apart from the foot receiving cavity.
Further, the first layer may include a feature affixed to the first
surface thereof, which may be integrally formed with the first foam
layer.
[0022] An alternative embodiment of the present invention relates
to an article of footwear including an upper and a bottom affixed
to the upper, wherein the upper and the bottom are formed from a
unitary piece of layered material. The layered material includes a
first layer of thermoformable foam having a first surface and a
second surface remote from the first surface thereof and a second
layer having a first surface and a second surface remote from the
first surface thereof. The second surface of the first layer is
affixed to the first surface of the second layer. The second layer
may include a first region and a second region, the first region
comprising a first material and the second region comprising a
second material. The first material may be a rubber and the second
material may be a textile.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] The present invention will be better understood on reading
the following detailed description of non-limiting embodiments
thereof, and on examining the accompanying drawings, in which:
[0024] FIG. 1 is a perspective view of a shoe according to an
embodiment of the present invention;
[0025] FIG. 2 is a cross-section of a footwear upper according to
an embodiment of the present invention;
[0026] FIG. 3 is a cross-section of a layered material according to
an embodiment of the present invention;
[0027] FIG. 4 is a perspective view of materials which may be used
in forming a footwear upper according to one embodiment of the
present invention;
[0028] FIG. 5 shows an example of a shoe blank according to one
embodiment of the present invention and an example of a mold that
can be used to form a desired shape for materials according to one
embodiment of the present invention;
[0029] FIG. 6 shows a compression molded shoe blank according to
one embodiment of the invention;
[0030] FIG. 7 shows a step in the assembly of a footwear upper
according to one embodiment of the present invention;
[0031] FIG. 8 is an assembly view of a shoe according to one
embodiment of the present invention; and
[0032] FIG. 9 is a flow chart illustrating a method of making a
shoe according to an embodiment of the present invention;
[0033] FIG. 10 shows an example of a shoe upper according to an
alternative embodiment of the present invention; and
[0034] FIG. 11 shows an example of a shoe upper according to an
alternative embodiment of the present invention.
DETAILED DESCRIPTION
[0035] In describing the preferred embodiments of the subject
matter illustrated and to be described with respect to drawings,
specific terminology will be employed for the sake of clarity.
However, the invention is not intended to be limited to the
specific terms so selected, and it is to be understood that each
specific term includes all technical equivalents which operate in a
similar manner to accomplish a similar purpose.
[0036] Referring to the drawings, wherein like reference numerals
represent like elements, there is shown in FIG. 1, in accordance
with one embodiment of the present invention, a shoe designated
generally by reference numeral 10. Shoe 10 is generally constructed
of an upper 12, an insole 14 (see FIG. 8), and an outsole 16. Upper
12 is designed to receive the foot of a wearer by defining a
portion of foot receiving cavity 13 therein. The bottom portion of
foot receiving cavity 13 is defined by insole 14, which is
generally structured to support the foot of the wearer of shoe 10.
Outsole 16 is structured to provide further support for the foot of
the wearer and makes contact with the ground underneath shoe 10.
Additionally, outsole 16 provides cushioning and traction for the
wearer. Although the particular shoe 10 illustrated is in the form
of an athletic or hiking shoe, those having reasonable skill in the
art will understand that the invention described herein can be
applied to other types of footwear, including dress shoes, sandals
or any other type of footwear.
[0037] Upper 12 is structured to securely hold the foot of a wearer
and, to the extent possible, maintain the foot in contact with
insole 14. Upper 12 is also preferably designed to provide support
for the foot and to protect the foot from injury. Preferably, upper
12 covers the metatarsal and toe region of the foot as well as the
instep portion and the heel portion of the foot. Optionally, upper
12 extends over the ankle of the wearer, providing support and
protection thereto. Accordingly, upper 12 includes sections that
correspond to the areas of the foot. These areas include the toe
portion 20, the instep portion 25 and the heel portion 22. Instep
portion 25 is further divided into medial 26 and lateral 28
portions, respectively. As discussed above, in typical shoe
construction the individual portions of the shoe are generally
formed from one or more separate, cut-out pieces of material per
section. For example, medial and lateral portions 26, 28 of instep
portion 25 are typically formed from quarter panels. Such a
construction, results in the typical shoe upper being composed of
numerous parts that are sewn and/or glued together.
[0038] Referring now to FIG. 4, upper 12 according to aspects of
the present invention is shown as being constructed of fewer
individual pieces of material than a typical shoe. Upper 12
according to one embodiment of the present invention is desirably
made from a single unitary piece of material, which may be
generally planar prior to the molding process. However, the
advantages of such a shoe construction could be realized by a shoe
formed from two or more pieces of material.
[0039] Upper 12 is desirably made from a layered material 44. As
shown in FIGS. 2 and 3, layered material 44 preferably includes
three separate layers, including a first layer 46, a second layer
48, and a middle layer 50. When layered material 44 is assembled
into the form of upper 12, first layer 46 faces the innermost part
of foot receiving cavity 13, while second layer 48 is remote from
first layer 46 in a direction away from the foot receiving cavity
13. The separate layers are preferably integrally formed into the
unitary layered material 44 by subjecting the layers to a
compression molding process, as will be discussed in detail below.
First layer 46 and second layer 48 are preferably formed from a
foam material, and more preferably an open-cell foam; however, the
foam may be either open or closed cell. The use of foam in
connection with upper 12 provides basic protection for the foot,
over non-foam materials such as TPU, by having air cells embedded
therein to provide cushioning characteristics that can help
attenuate forces that are applied to the outside of the shoe. This
can serve as injury protection for blunt force trauma that might
cause bruising or other injury.
[0040] Preferably, a foam having thermoformable properties is
selected so that the foam is compatible with compression molding to
form layered material 44. Desired thermoformable properties include
both thermoset and thermoplastic properties as are understood in
the art. Such a foam may preferably be formed form a sheet stock
foam, which is understood in the art to include rolled goods,
having thermoformable properties. Thermoformable foams can be
molded into various shapes using compression molding. Features may
also be incorporated into the layered material 44, which is
otherwise generally planar in form. As shown in FIGS. 1 and 3,
upper 12 can include a number of such features 32, which can be
protective, decorative, and can provide enhanced foot security.
Protective features may provide additional cushioning to desired
areas of the foot, while decorative features are designed simply to
enhance the aesthetic appeal of the shoe. An alternative to forming
features 32 during compression molding includes providing features
in the stock sheet of foam from which second layer 48 or first
layer 46 is formed. As shown in FIG. 3, features 32 may be formed
by providing a layer of foam that is thicker in the area of the
feature 32 than other areas of the upper. The use of EVA foam when
making an upper 12 having such features 32 is particularly
advantageous because of the cushioning properties and
thermoformable properties which EVA possess. Protective features 32
are particularly useful, for example, along the lateral side 28 and
medial side of the foot as well as on the heel section 18 for,
e.g., ankle protection, or toe section 20 of the upper 12.
Additional structurally protective elements 32 can be provided
around eyelets 30 which provide protection for the laces 31 which
pass through eyelets 30. This protects laces 31 from abrasion or
tearing during use due to objects that may be encountered in the
environment in which the shoes are used. This also can protect the
upper from stretching or tearing. Furthermore, according to an
alternative embodiment of the present invention shown in FIGS. 10
and 11, eyelets can be formed as loops 33 attached to upper 12
extending into eyestay 29. Loops 33 can be affixed to upper 12
during compression molding, or can be affixed after compression
molding by stitching, by using adhesive or by other bonding
processes.
[0041] Similarly, as shown in FIG. 3, features 32 can be formed on
the first layer 46 of upper 12. While exterior features 32 are
generally formed to provide protection or decorative designs,
interior features 32 may be added to one or more sections of the
upper 12 to provide a more comfortable or secure fit for the foot
within upper 12 by more closely matching the shape of the shoe
interior to that of the foot. By way of example, such interior
features could be placed on the inside of the arch region of the
foot or in the ankle region. Additional features and placement
thereof would be reasonably understood by those having skill in the
art. Such features 32 may be strategically placed on areas of the
upper 12 to provide the desired function thereof, e.g., protection
or decoration, without affecting the desired properties of the
shoe, such as flexibility or breathability.
[0042] In addition to having thermoformable properties, the foam(s)
used in the layered material 44 is preferably hydrolytically stable
and does not absorb or breakdown in the presence of water.
Additionally, the foam(s) selected should be lightweight, e.g.,
having a specific gravity of about 0.20 or less than 0.50.
Preferably, the specific gravity is between 0.15 and 0.30, and more
preferably, between 0.20 and 0.25. Most preferably, the foam(s)
selected has a specific gravity of about 0.22. EVA foam is
particularly suitable for first 46 and second 48 layers of layered
material 44 because it falls within such parameters. Other
materials that can be used for first 46 and second 48 layers
include polyester, polyether and latex. Polyester and polyether are
useful due to their stability in the presence of water. TPU is not
suitable for the layers at the layered material 44 according to the
present invention because it holds in heat, may discolor in the
presence of water, can take permanent length if stretched, and, is
generally less flexible than thermoformable foams.
[0043] It is not necessary that first layer 46 and second layer 48
be composed of the same material. In one particular embodiment of
shoe 10, first layer 46 and second layer 48 may be formed of
different materials, or the same material having different
properties, such as specific gravity or durometer, in order to
provide specified features for each of these layers, such as
insulation for warmth, breathability, protection of the foot,
rigidity and/or flexibility, pressure distribution and comfort.
Selection of such properties will be understood by those having
reasonable skill in the art. Further, each of the layers 46, 48 may
be formed of one or more layers of material, which may have
different properties, e.g., insulation, breathability, protection,
durability, rigidity, flexibility, color, etc.
[0044] Middle layer 50 is interposed between first layer 46 and
second layer 48. Middle layer 50 may be selected in order to lend
an additional property to layered material 44, such as
breathability, waterproofing, and/or tensile support. Generally,
the types of foams used to form first layer 46 and second layer 48
have a low modulus of elasticity, such that they are susceptible to
migration, tearing, or stretching while in use. The materials in a
shoe upper are generally under tensile stress while in use.
Therefore, when materials such as foam are used to form a shoe
upper, the stress from tightening of the shoe onto the foot can
cause the foam to stretch, significantly affecting the fit and
performance of the shoe. Providing a middle layer 50 having a high
tensile strength alleviates the problem of material deformation or
elongation. Additionally, the middle layer 50 may also provide
benefits such as breathability of the shoe upper 12, while
maintaining the advantageous properties of the foam layers 46, 48.
Optionally, middle layer 50 may be interposed between first and
second layers 46, 48 throughout the entire upper 12 or throughout
only a portion thereof, including instep portion 25, heel portion
18 or toe portion 20. Further, different materials for middle layer
50 can be used in different regions of upper 12. Middle layer 50
may be partly or completely interposed between the layers 46 and
50, e.g., covering some or all of the surfaces of layers 46 and 48
which face one another.
[0045] In one embodiment, middle layer 50 is composed of a textile
mesh material. Such construction is further advantageous because it
allows layered material 44 to be integrally formed via a
compression molding process such that a fiber matrix is formed in
which first layer 46 and second layer 48 extend between and fill
spaces between fibers composing the mesh textile material. Such a
structure greatly increases the tensile strength of the layered
material 44, without reducing the overall flexibility of layered
material 44. Alternative materials may be used to form middle layer
50 including leathers, non-woven fabrics and/or waterproof
materials such as rubber or, more preferably, PFTE or other such
waterproof, breathable membranes such as Gore-Tex.RTM. brand
membranes. A combination of different materials may also be used in
middle layer 50, combining properties thereof. For example, rubber
and mesh can be used in combination to provide both waterproof and
high-tensile properties to layered material 44. Middle layer 50 may
also have multiple layers or regions of the same or different
materials.
[0046] Breathability of the shoe upper 12 can be further enhanced
by providing a breathable middle layer 50 for layered material 44.
When such material is used for middle layer 50, it is advantageous
to provide a number of ventilation windows 33 in upper 12 through
both first layer 46 and second layer 48 of layered material 44. By
not cutting a window in middle layer 50, the general shape of the
upper is maintained due to the tensile properties of the middle
layer 60. The degree of ventilation can be adjusted by the size and
number of ventilation windows placed in upper 12. Such would be
understood by those having reasonable skill in the art. Preferably,
windows are formed from layered material by cutting out matching
sections of first layer 46 and second layer 48 prior to being
integrally formed into layered material with middle layer 50.
Alternatively, the first and second layers do not need to match, as
long as there are substantially breathable windows in each
layer.
[0047] Additional features which may be incorporated into shoe 10
include a tongue and/or gusset 38, which extends along the instep
portion of the wearer's foot underneath laces 31 and can be
fastened to upper 12 near the metatarsal section of upper 12 at the
end of the eyestay 29. Collar 36 can be affixed with or without a
liner running from the heel section to the front of the ankle
section. Additionally, an inner boot or bootie (not shown) can be
fitted within upper 12 such that it partially or fully envelops the
foot of wearer of the shoe 10, providing additional support or
protection therefore. An inner boot is typically made from neoprene
or similar material and may be provided within foot receiving
cavity 13. A footbed (not shown) may be utilized with or without
the inner boot.
[0048] In an alternative embodiment of the present invention, the
layered material 44 used to form upper 12 consists essentially of
two layers of material. One layer of the material 44 may be a
suitable thermoformable foam material, which, as discussed above,
is desirably selected to have properties and characteristics
similar to those of EVA foam. The other layer of material may be
any material which is suitable for middle layer 50, as discussed
above, e.g., a textile mesh, non-woven fabric or a leather, but not
TPU. The two layers of material can be arranged such that the foam
layer is disposed adjacent to the foot receiving cavity 13 with the
other layer being spaced apart therefrom and facing the outside of
the shoe. Alternatively, the non-foam layer can be disposed
adjacent to the foot receiving cavity with the foam layer being
spaced apart therefrom and facing the outside of the shoe 10. While
the layered material 44 in this embodiment is said to consist
essentially of two layers, other elements may optionally be present
in layered material 44, although they are not essential to the
present aspect of the invention. For example, layered material 44
can include interior or exterior features 32 or partial coverings
or coatings thereon.
[0049] Referring now, generally, to FIG. 9, a further embodiment of
the present invention includes a method for making shoe 10 having
upper 12 formed of a unitary piece of layered material 44, wherein
optional method steps are included in boxes having a broken line.
The process begins at S10 and, as shown in S20, the materials used
in forming the upper are cut into the general shape of a blank 70.
An adhesive may be applied to the materials, as shown in S30. The
materials are then combined in S50 into layered material 44.
Layered material is then subjected to a compression molding process
S50 wherein the heat and pressure from the mold activate the
adhesive, cause bonding of the materials and effect compression
molding of the foam layers. If necessary, in S60 blank 70 may be
further trimmed to form the desired shape therefor. If a gusset or
tongue 38 is to be incorporated into shoe 10, it may optionally be
assembled with blank 70 in S70. Heel and toe seams 22, 24 are then
formed by stitching or other processes in S80 to form blank 70 into
the desired shape of upper 12. An insole 14 may be attached to
upper 12, as shown in S90. In a preferred embodiment upper 12 is
then attached to a lasting insole 14 by a lasting technique known
to those having reasonable skill in the art as a Strobel. Slip
lasting may also be employed with this type of upper construction.
The shape of upper 12 can be further formed by inserting a last
into the foot receiving cavity 13 and reheating the upper in S100.
Optionally, in S110 a film can be applied to upper 12. Sole 16 is
then affixed to upper 12, as shown in S110. Optionally, a heel
counter and/or a toe cap can be affixed to the shoe in step S120. A
sockliner may be inserted into foot receiving cavity 13 in
S130.
[0050] The structure of upper 12 results in upper 12 having
appreciably fewer stitched or cemented areas than a typical shoe
upper. A preferred embodiment of the present invention has only two
stitched areas (or seams) therein, which are sewn into upper 12 to
form the 3-D geometry of upper 12 from a unitary, flat piece of
material referred generally herein as blank 70 (FIG. 5).
Preferably, the seams included in the structure of upper 12 are
located in the portion 20 and the heel portion 18 of upper 12. More
preferably, toe seam 24 runs along approximately the ceneterline of
upper 12 from the outer edge of the shoe to near the instep portion
25. In an alternative embodiment of upper 12, toe seam 24 extends
through toe portion 20 and around the eyestay 29 for the tongue
and/or gusset. This may result in an upper that is formed of two
separate pieces of material rather than a single, unitary
piece.
[0051] The reduced number of seams present in upper 12 results in
upper 12 defining portions thereof that are substantially seamless.
A preferred embodiment of upper 12, having seams only in the toe 20
and heal 18 portions, has two substantially seamless portions
extending between the toe seam 24 and the heel seam 23. When
referring to a portion of shoe 10 as substantially seamless, a seam
is understood to be made between adjoining sections of upper 12.
For example, upper 12, may be stitched or otherwise affixed along
the outer edge thereof to for example, a lasting insole 14 as in
strobel or strip lasting, outsole 16 when the method of attachment
is, for example, stitch out, or another portion of shoe 10 along a
portion of upper 12 that is nonetheless considered substantially
seamless. The first substantially seamless portion runs along the
medial side 28 of the upper 12, while the other substantially
seamless portion runs along the lateral side 28 of the upper 12. It
is beneficial to reduce the number of seams within upper 12 not
only for ease of assembly and reduced production cost, but also
because doing so results in a stronger, more durable upper.
Alternative arrangements of seams within the design of upper 12
will result in different locations for the substantially seamless
portions. For example, seams could be included in the instep 25
portion of the upper, particularly in the medial 26 and lateral 28
portions, extending from the eyestay 29 or collar 35 portions to
the nearest outside edge of upper 12. Such an arrangement would
result in the heel 18 and toe 20 portions being substantially
seamless. Additional arrangements of seams and substantially
seamless portions would be apparent to those having reasonable
skill in the art upon reading this disclosure.
[0052] In a preferred embodiment of the present invention, blank 70
is formed from layered material 44, as described above with respect
to steps S10-S70. While layered material 44 can be formed in a
first stage as shown in steps S30-S60, and then blank 70 can be
formed by cutting layered material 44 to the appropriate
dimensional, step S70, it is preferred that the two are formed
simultaneously by cutting the stock material layers used to form
the layered material into the approximate shape for blank 70 and
then compression molding the layers together. Compression molding
is ideal for assembly of the individual layers into layered
material 44, because it allows complex shapes to be formed into the
surfaces of layered material 44, as discussed above. Further,
compression molding can, in certain embodiments of the present
invention, further enhance the integral forming of layered material
44, compared to conventional methods, by forming a fiber matrix
from first and second foam layers 46, 48 and a mesh middle layer
50.
[0053] Preferably, the materials used to form layered material 44
are prepared separately before being combined into layered material
44. This may include cutting the individual layers 46, 48, 50 into
the approximate shape desired for blank 70 as shown in step S20. An
example of the desired shape for blank 70 is shown in FIG. 5 and
will generally be such that it can be formed from a generally
planar shape into the approximate 3-D shape of upper 12.
[0054] In the example shown in FIG. 5, the shape used for blank 70
includes a left portion 62 and a right portion 63, wherein each of
the right and left portions will be bent in a generally downward
direction to form medial 26 and lateral 28 sides of the shoe upper
12. The medial and lateral sides 26, 28 may or may not be
symmetrical, depending upon the specific design of the article of
footwear 10. The shape also has portions that, once left 62 and
right 63 portions have been appropriately situated, can be bent
together to form heel 23 and toe 25 portions. A section along the
front end of the profile is preferably cut such that it can form
toe seam 24 when the upper is shaped into a 3-D form. Further, a
section is preferably cut out from the middle of the pattern that
forms the shape of collar 36 and eyestay 29. The pattern to which
middle layer 50 is cut can be the same as that of second and first
layers, or it can optionally be uncut in middle section 37, which
can be cut out after compression molding. Middle layer 50,
preferably, is uncut in the middle section 37 to aid in the
alignment of parts while compression molding.
[0055] First layer 46 and second layer 48 can, optionally, include
features 32 preformed therein, preferably during extrusion of the
stock from which first layer and second layer are cut.
Alternatively, features 32 can be formed into first layer 46 and/or
second layer 48 after extrusion. Such formation of features 32
could require the design of mold 100 to accommodate such features.
As a further alternative, features 32 may be formed from an
additional piece of foam or other material that is affixed to
layered material 44 in desired portions thereof. Such features can
be decorative and, thus could be refined in shape during
compression molding of layered material 44, which is discussed
below. Additionally, one or both of first layer 46 and second layer
48 can include a plurality of windows 42 cut out therein which are
desirably located in substantially the same position in the first
layer 46 and second layer 48. The materials used to form layered
material 44 can be cut to the exact dimensions of the final
product, step 20. Conversely, a "rough-cut" can be used to give an
approximate size in length, width, and thickness of the material.
The use of a rough cut is preferred because it allows the final
cut, as seen in step S70, to be used to correct irregularities in
alignment and ensures an edge for the visible parts of upper where
all layers are aligned and allows for wider tolerance for the
compression mold.
[0056] First layer 46, second layer 48, and middle layer 50 are
next prepared for compression molding. It is possible that, simply
compression molding the materials will not properly adhere the
materials together to integrally form layered material 44. Thus, an
adhesive is preferably applied before compression molding to
provide additional bonding between the layers at step S30. The
particular adhesive used is preferably heat activated and is used
by first applying a primer to the inside surface of first layer and
the inside surface 56 of second layer 48 as well as to both sides
of middle layer 50. A coating of cement may then be applied to all
primed areas of first layer 46, second layer 48, and middle layer
50 in step S40. The cement is preferably composed of a synthetic
resin co-polymer that is heat activated, although other
alternatives are known in the art, such as urethane cement. After
application of the adhesive, heat is applied to the cement, thereby
activating the adhesive properties thereof at step S40. The three
layers are combined in step 50 such that middle layer 50 is
interposed between first layer 46 and second layer 48.
[0057] The combined layers are then placed in a heated compression
mold at step S60 in order to complete the integral forming of
layered material 44 and for forming of any desired features 32
within or on layered material 44. The time needed for compression
molding will vary with the materials and the geometry of any
features to be formed, but can typically take about 7-8 minutes. A
preferred embodiment of mold 100 is shown in FIG. 5, and is
preferably made up of a top portion 102 and a bottom portion 104,
each section preferably having a cavity 106, 108 formed therein.
Alternatively, a single cavity can be included on only one of
either top 102 or bottom 104 portion of mold 100. Cavities 106, 108
should be structured to provide pressure to both the second layer
48 and the first layer 46 when they are placed within mold 100.
This will generally mean that cavity 106 and cavity 108 are
dimensioned to form an approximate predetermined thickness for
compression molded layer material 44. Accordingly, the second foam
layer 48, first foam layer 46, and middle layer 50 will be selected
so as to have a thickness that is greater than the predetermined
thickness of the finished layered material 44 so that the three
layers are compressed together when placed in mold 100. Preferably,
in one example, layered material 44 has a thickness of at least
about 1.5 mm after compression molding. In another example, it is
preferred that layered material 44 has a thickness of no more than
15 mm after compression molding. Desirably, layered material 44 has
a thickness between 2 mm and 6 mm after compression molding. To
achieve this, the assembled layers will have a thickness that is
greater than the desired thickness of layered material 44 after
compression molding. A majority of this additional thickness will
be attributable to the first and second foam layers 46, 48, the
middle layer preferably having little compression set compared to
the foam layers. If features 32 are to be included on the surfaces
of layered material 44, the desired thickness of the features 32
should be taken into account in determining the thickness of the
materials prior to molding.
[0058] Mold 100 may be configured to receive layered material 44,
which may have a generally planar shape. However, as previously
discussed, it may be desired to add features 32 to the second or
first surface of upper 12, which can be accomplished by forming
corresponding receptacles 110 into cavity 106 and cavity 108 of
mold 100. The use of such receptacles 110 within mold 100 results
in areas of the foam layers which are not compressed at all, or are
compressed less than the majority of the layered material 44.
Additionally, mold 100 can include a cavity (not shown) for forming
the sole 16 of shoe 10 concurrently with the compression molding of
upper 12.
[0059] Alternative variations for compression mold 100 include the
use of flat plates or rolling. The flat plates used in such
compression molding may have a similar structure to the outside 102
and inside portions 104 illustrated in FIG. 5, except that they
need not include cavities 106 and 108, the assembled layers being
placed directly on the plates. Such plates can include receptacles
110 formed therein. The rollers used in an alternative variation of
the compression molding process are simply two opposed rollers
having a predetermined distance therebetween. The assembled layers
are first heated and then fed through the rollers, which are
rotated in opposite directions to facilitate such feeding. Both of
these variations provide a layered material 44 with a substantially
constant cross-section. Further, both of these options allow for
variation in the thickness of layered material 44, and can
accommodate stock materials of varying thickness. Alternatively,
non-flat rollers ban be used to add varying cross section
dimensions to the layered material. Such non-flat rollers can
include features 100, which would require proper alignment of the
assembled layers prior to feeding.
[0060] Once the appropriate time has elapsed for compression
molding of layered material 44, e.g., between seven to eight
minutes, compression mold 110 is desirably placed in a cooling
press (not shown) such that the resulting layered material 44 is
allowed to cool and become substantially impliable. Such a process
may take between 3 and 7 minutes, but will preferably take between
4 and 6 minutes. Most preferably cooling takes on the order of
about 5 minutes, but will vary with the materials used, the
thickness thereof, and the temperature of the mold. For example, in
an embodiment of the present invention, first and second layers 46,
48 are made from EVA foam, each layer having a thickness of about 3
mm. The combined layers are placed in a compression mold at a
temperature of between 145 and 165 degrees, Celsius, for between 6
and 8 minutes, which requires a cooling time of between 3 and 7
minutes, and preferably of about 5 minutes. Once the time needed
for cooling has elapsed, mold 100 is removed from the cooling press
and opened. Then blank 70, made of integrally formed layered
material 44, is removed from compression mold 100. If necessary,
the outer edges of layered material are trimmed to meet the exact
guidelines of the upper pattern and to remove any defects or
irregularities arising during the formation of layered material 44.
The trimming step desirably includes removal of a portion of middle
layer 50 from within collar portion 36 of upper 12, and may also
include cutting exactly the outer perimeter of the layered material
44 in order to form blank 70.
[0061] Alternatively, mold 100 can be unheated, or "cold," meaning
that the mold will be at or near the ambient air temperature. In
such a variation of the process of the current invention, referred
to herein as "cold molding," layered material 44 is heated prior to
being placed in mold 100. Layered material can be heated in, for
example, an oven or using a heat gun. Such a process is useful
because it reduces cycle time and improves productivity. Another
benefit is that it reduces fabric exposure to high temperatures and
direct contact with a hot metal mold. With the use of cold molding,
non-textile materials may be introduced into the process for
variation of the material or fabric layer(s). This variation can be
a benefit both functionally and aesthetically. Such benefits are
also realized when using a mold in the form of rollers, as
discussed above.
[0062] Optionally, other features can be added to the layered
material 44 after compression molding, S110. Such features may
include coatings such as of latex paint, lacquer or polymeric film.
These post-compression molding coatings can be decorative, such as
by providing a color or design for the layered material, or can be
functional, such as by increasing the abrasion-resistance of the
layered material 44 in desired areas. Further such features can be
both decorative and protective. Again, these features are
preferably strategically placed on layered material 44 so as to
provide the desired characteristics, without affecting the overall
characteristics of shoe 10, such as breathability or
flexibility.
[0063] In a preferred embodiment, additional features in the form
of a material coating are applied to upper 12 by a process
generally known in the art as a "cubic dipping," "water transfer,"
or "transfer printing." In this process, upper 12 is provided
according to an embodiment of the present invention. The desired
coating material is applied to a film that is specifically designed
for such a process and is known in the art. Preferably, the film
may be urethane based. In the example of adding a graphic, image or
design to the upper, "artwork" is preprinted or applied to the
dipping film. The film is then set on the surface of a water bath
and prepped by smoothing film across surface of water. The film or
coating material is sprayed with a solvent to activate the release
of the ink design from the film. Additionally, upper 12 can be
primed to further adhesion between the coating and upper 12. Upper
12 is dipped into the bath, where the film conforms to the shape of
the upper due to the pressure from the water. This adheres the
coating to upper 12, allowing the coating to adhere to the variant
shape of upper 12 with minimal quality or cosmetic issues, such as
gaps or wrinkles. The film will preferably break down in the
presence of water, leaving the coating applied to upper 12. The
coating is then allowed to dry on upper 12. A finishing coating,
such as a lacquer to seal and protect design, may also be applied
and then upper 12 can be inserted into an oven for drying.
[0064] Suitable materials for this coating process include latex
paint, lacquer or ink. If ink is used, the process allows for
various designs to be printed using the ink onto the film prior to
application to upper 12. This allows a specific decorative design
to be applied to upper 12. This decorative design can be
predetermined or can be supplied by a consumer in the form of a
digital image, including a JPEG image. In one embodiment, the
consumer can supply the design through a specially-designed,
internet-based interface, which allows the user to create custom
footwear including an image which the consumer selects or provides.
The user can choose from stock images displayed on the interface or
may submit the consumer's own image for placement on upper 12.
Additionally, the consumer could be allowed to select how the image
is applied to upper 12 including image size, color and location on
upper 12.
[0065] In a preferred embodiment in the present invention a liner
(not shown) can be incorporated into the region of blank 70 that
forms the collar 36 of the shoe 10 by, for example, stitching.
Optionally, the shoe 10 can include a tongue 38 which is preferably
stitched onto the end of the eyestay 29 section, extending beneath
laces 31 toward collar 36. Alternatively, a gusset may be used in
lieu of tongue 38.
[0066] As shown in FIG. 8, blank 70 is preferably formed into the
3-D geometry of a shoe upper 12 by stitching closed heel section 18
to form heel seam 22, and by stitching closed toe section 20 to
form toe seam 24, step 90. A lasting insole may be added by
stitching the bottom portion of the upper to the lasting insole,
step 90. In an alternative embodiment, heel seam and toe seam are
not stitched together but are rather bonded using bonding cement or
other sealing means. Some types of such bonding may require overlap
portions to be included in the design of the outer profile of blank
70. An insole 14, preferably in the form of a lasting insole is
then stitched or otherwise affixed to the base of the shoe upper 12
such that the appropriate shoe receiving cavity 13 is formed
therebetween, step 90.
[0067] In a preferred embodiment of the present invention, the 3-D
shoe upper 12 formed in the previous steps, described in relation
to FIG. 9, is further formed to better conform to the shape of a
foot, thereby allowing a well-fitting shoe to be formed from
unitary blank 70. To accomplish this, a last is inserted into upper
12, eyestay 29 may be laced closed and upper 12 reheated at step
S100 by placing the lasted upper into a heat oven at approximately
70 degrees Celsius. Because of the thermoformable properties of
first foam layer 46 and second foam layer 48, heating will form the
upper 12 to the shape of the last. The adhesive included in between
layers of the layered material 44 will prevent the reheating of the
upper 12 from causing the materials to separate. Depending on the
temperature used for re-heating, it may be preferable to use a
non-heat activated adhesive. Furthermore, selection of a middle
layer 50 having an appropriate tensile strength will prevent
stretching of the heated, plyable, inner layer 46 and second layer
48. After heating, the upper 12 is allowed to cool and the last is
removed.
[0068] Once the desired shape for the shoe upper 12 is achieved, a
sole unit 16 may be attached to the strobel sock 14 at step S120.
This may be done by cementing or another appropriate bonding
operation, which can include stitching. Sole 16 may be of any
configuration, and may include an outsole, midsole and/or other
components such as arch support, etc. Additionally, toe cap 34 may
be affixed to toe section 20 to cover toe seam 22. In the
alternative, sole 16 may extend in a generally upward direction to
cover toe seam 22. Optionally, a sock liner (not shown) is inserted
into the foot receiving cavity 13.
[0069] In an alternative embodiment of the present invention, shoe
10 including upper 12 and at least a portion of outsole 16 can be
formed from a unitary piece of layered material 44 including at
least one foam layer and at least one material layer 50. In this
embodiment, a blank having a medial portion, lateral portion, and a
bottom portion may be formed from the layered material in a unitary
fashion. The bottom portion can be affixed to either the medial or
lateral portion at an area thereof or alternatively may be attached
to both portions wherein the bottom portion may be formed with a
center seam, This lasting technique is commonly known as center
seam slip lasting.
[0070] Although the invention herein has been described with
reference to particular embodiments, it is to be understood that
these embodiments are merely illustrative of the principles and
applications of the present invention. It is therefore to be
understood that numerous modifications may be made to the
illustrative embodiments and that other arrangements may be devised
without departing from the spirit and scope of the present
invention as defined by the appended claims.
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