U.S. patent application number 13/122702 was filed with the patent office on 2011-09-22 for shoe with a flat formed shoe upper.
This patent application is currently assigned to Nike, Inc.. Invention is credited to Thomas Berend, Anthony Dean, Ciro Fusco.
Application Number | 20110225845 13/122702 |
Document ID | / |
Family ID | 42060126 |
Filed Date | 2011-09-22 |
United States Patent
Application |
20110225845 |
Kind Code |
A1 |
Dean; Anthony ; et
al. |
September 22, 2011 |
Shoe With A Flat Formed Shoe Upper
Abstract
Shoes specifically designed to facilitate production via
efficient shoe manufacturing methods and systems are described. In
embodiments, the shoe upper is designed by way of a flat forming
process, whereby the upper pattern is kept in a two-dimensional
shape for most of the upper assembly and then stitched or otherwise
affixed into a three-dimensional form in the final stage of upper
assembly.
Inventors: |
Dean; Anthony; (Newberg,
OR) ; Fusco; Ciro; (Portland, OR) ; Berend;
Thomas; (Beaverton, OR) |
Assignee: |
Nike, Inc.
Beaverton
OR
|
Family ID: |
42060126 |
Appl. No.: |
13/122702 |
Filed: |
September 28, 2009 |
PCT Filed: |
September 28, 2009 |
PCT NO: |
PCT/US09/58623 |
371 Date: |
June 10, 2011 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61194403 |
Sep 26, 2008 |
|
|
|
Current U.S.
Class: |
36/83 ; 36/47;
36/48 |
Current CPC
Class: |
A43B 23/07 20130101;
B29D 35/146 20130101; A43D 25/20 20130101; A43B 23/026 20130101;
A43D 111/00 20130101; A43B 23/042 20130101; A43B 23/24 20130101;
A43D 8/02 20130101; A43B 23/0235 20130101; A43B 3/0078 20130101;
A43B 23/028 20130101 |
Class at
Publication: |
36/83 ; 36/48;
36/47 |
International
Class: |
A43B 3/00 20060101
A43B003/00; A43B 23/00 20060101 A43B023/00 |
Claims
1. A shoe designed to facilitate a system for manufacturing shoes
customized to an order placed by a customer, the shoe comprising:
an upper, where the upper is manufactured by a flat forming
construction process, the flat forming construction process
comprising: layering a plurality of upper elements and hot-melt
films in between a lining layer and an external layer; heat
pressing the upper elements and the hot-melt films between the
lining layer and the external layer to generate one or more basic
laminated upper forms; and cutting out along pattern perimeters of
the basic laminated upper forms.
2. The shoe of claim 1, wherein the hot-melt film is thermoplastic
polyurethane (TPU).
3. The shoe of claim 1, wherein one or more of the upper elements
are formed of polyurethane foam.
4. The shoe of claim 1, wherein the upper elements include one or
more of internal foams, a lining foam, and reinforcement
pieces.
5. The shoe of claim 4, wherein the internal foams are shaped
consistent with various portions of the shoe, and include one or
more of a collar, a vamp, a quarter, and a tongue of the shoe.
6. The shoe of claim 4, wherein the lining foam forms a barrier
between the lining layer and the external layer to enhance comfort
and provide a three-dimensional form of the shoe.
7. The shoe of claim 4, wherein the reinforcement pieces include
one or more of a vamp reinforcement or an eyestay
reinforcement.
8. The shoe of claim 1, wherein the external layer is made from one
or more of synthetic leather or polyester mesh.
9. The shoe of claim 1, wherein the external layer forms an outer
surface of the upper and allows for customization of an appearance
of the upper in that various customization processes can be
performed to the upper including one or more of dying, digital
printing, embossing, or embroidering.
10. An upper portion of a shoe assembled using a flat forming
construction process according to a method comprising: while
maintaining a two-dimensional shape, layering a lining layer, one
or more upper components, and an external layer to form the upper
portion of the shoe, wherein a size and a shape of the upper
components vary based on one or more of which portion of the shoe
is being assembled, a type of shoe, and a size of shoe being
assembled; adhering the lining layer, the upper components, and the
external layer together by way of a heat press, wherein hot-melt
films are also layered in between the lining layer and the external
layer to bond the layers together; and cutting out the upper
portion of the shoe along an upper perimeter.
11. The method of claim 10, wherein the upper components are in the
shape of one or more of a collar, a vamp, a quarter or a tongue of
the shoe.
12. The method of claim 10, wherein one or more reinforcement
pieces are also layered in between the lining layer and the
external layer to provide more support for the upper portion of the
shoe.
13. The method of claim 10, further comprising forming a
three-dimensional upper by affixing two or more upper portions of
the shoe, wherein the two or more upper portions of the shoe
include one or more of a heel-quarter element or a tongue-toe
element.
14. The method of claim 13, further comprising inserting a last
into the three-dimensional upper.
15. The method of claim 14, further comprising attaching the
three-dimensional upper to a sole unit, wherein the sole unit
includes a midsole and an outsole.
16. A shoe designed to facilitate a system for manufacturing
customizable shoes, the shoe comprising: an upper whose components
are manufactured by way of a flat forming process wherein the
components of the upper maintain a two-dimensional shape throughout
their formation, and wherein the upper comprises: a heel-quarter
element that includes a heel area and multiple quarter panels; and
a tongue-toe element that includes a tongue and a toe-box region,
wherein the tongue-toe element is secured to the heel-quarter
element to form a three-dimensional upper form.
17. The shoe of claim 16, wherein the tongue-toe element is secured
to the heel-quarter element by way of one or more of stitching,
gluing, RF welding, or ultrasonic welding.
18. The shoe of claim 16, wherein the heel-quarter element and the
tongue-toe element are manufactured by a method comprising:
layering a plurality of upper elements and hot-melt films in
between a lining layer and an external layer; heat pressing the
upper elements and the hot-melt films between the lining layer and
the external layer to generate one or more basic laminated upper
forms; and cutting out along pattern perimeters of the basic
laminated upper forms.
19. The shoe of claim 18, wherein the external layer may be
customized using a customization process that includes one or more
of dying, digital printing, embossing, or embroidering.
20. The shoe of claim 18, wherein the upper elements include
internal foams, a lining foam, and reinforcement pieces.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional
Patent Application No. 61/194,403, filed Sep. 26, 2008, entitled
"Shoe With a Flat Formed Shoe Upper."
TECHNICAL FIELD
[0002] The present invention relates to athletic footwear. More
particularly, the present invention relates to a shoe with a flat
formed shoe upper.
BACKGROUND OF THE INVENTION
[0003] Shoes, especially shoe uppers, have traditionally been
assembled from a relatively large number of three-dimensional
components. Both the large number and the three-dimensional nature
of these components have required a great deal of labor to assemble
a single shoe. Decreasing the labor required to manufacture a shoe
by a meaningful amount is not possible with standard shoe
designs.
SUMMARY OF THE INVENTION
[0004] The present invention relates to a shoe specifically
designed to facilitate production via efficient shoe manufacturing
methods and systems. These shoe designs and/or manufacturing
methods reduce the specialized individual labor required for shoe
production, while avoiding high costs associated with highly
automated manufacturing equipment. Shoes in accordance with the
present invention may further permit a customer to select a
particular model of shoe, select functional options for the shoe
and/or select aesthetic options for the shoe.
BRIEF DESCRIPTION OF THE DRAWING
[0005] FIG. 1A illustrates the initial layering step for upper
creation, in accordance with the present invention;
[0006] FIG. 1B illustrates examples of upper components associated
with the layering step depicted in FIG. 1A, in accordance with the
present invention;
[0007] FIG. 2 illustrates a step for upper creation involving a
heat press, in accordance with the present invention;
[0008] FIG. 3 illustrates a step for upper creation involving
cutting out a pattern perimeter, in accordance with the present
invention;
[0009] FIG. 4 illustrates a step for thermoforming shoe
construction involving the attachment of a heel-quarter element to
a tongue-toe element, in accordance with an embodiment of the
present invention;
[0010] FIG. 5 illustrates a step for thermoforming shoe
construction involving lasting, in accordance with an embodiment of
the present invention;
[0011] FIG. 6 illustrates a step for thermoforming shoe
construction involving sole laying, in accordance with an
embodiment of the present invention;
[0012] FIG. 7 is a perspective view of a finished thermoform
construction basketball shoe, in accordance with an embodiment of
the present invention;
[0013] FIGS. 8A-C are lateral side elevational views of examples of
thermoform construction basketball shoes, in accordance with an
embodiment of the present invention;
[0014] FIG. 9A is a top plan view of a finished thermoform
construction skate shoe, in accordance with an embodiment of the
present invention;
[0015] FIG. 9B is a lateral side elevational view of a finished
thermoform construction skate shoe, in accordance with an
embodiment of the present invention;
[0016] FIG. 9C is a front view of a tongue associated with the
skate shoe depicted in FIG. 9A, in accordance with an embodiment of
the present invention; and
[0017] FIG. 9D is a profile view of a tongue associated with the
skate shoe depicted in FIG. 9A, in accordance with an embodiment of
the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0018] Shoes, in accordance with the present invention, are
designed to enable efficient manufacturing, and optionally,
customization. Shoe model options in accordance with the present
invention may include, for example, a running shoe model, a
basketball shoe model, and a skate shoe model. In accordance with
the present invention, upper forms of shoes may be manufactured by
a flat forming construction process, whereby the upper pattern is
kept in a two-dimensional shape for a substantial amount of the
upper assembly and is then stitched or otherwise affixed into a
three-dimensional form in the final stage of upper assembly. The
flat forming process minimizes the amount of labor, such as labor
intensive stitching traditionally needed to assemble a
three-dimensional upper form. The upper forms are then coupled with
midsole and/or outsole structures designed to permit efficient shoe
production.
[0019] Referring now to FIG. 1A, the initial layering step 100 for
upper creation, in accordance with the present invention, is
illustrated. In step 100, shoe upper components (e.g., upper
elements) and hot-melt films (not shown) may be cut and arranged in
between a lining layer 105 and an external layer 110. The upper
components layered in between lining layer 105 and external layer
110 may include: internal foams 115, 117, and 119; a lining foam
120; and reinforcement pieces 125, 127, and 129. Lining layer 105
may include a moisture-wicking textile for removing excess moisture
from the area immediately surrounding the foot. Suitable materials
for lining layer 105 include polyester and recycled polyester,
although other types of materials, including natural materials may
be used. Other suitable materials for lining layer 105 will become
readily apparent to those skilled in the art, given the benefit of
this disclosure.
[0020] In step 100, internal foams 115, 117, and 119 of different
shapes and sizes as illustrated in FIG. 1A may be placed upon
lining layer 105. Internal foams 115, 117, and 119 may be cut into
shapes consistent with conventional shoe design and may include,
for example, a collar, vamp, quarter, and tongue. Internal foams
115, 117, and 119 may enhance the structure and comfort of the
upper and can be formed of material such as polyurethane foam.
[0021] Lining foam 120 may be layered over the internal foams 115,
117, and 119 in step 100. Lining foam 120 forms a barrier between
lining layer 105 and external layer 110, and may enhance the
comfort and three-dimensional form of the shoe. In alternative
embodiments of the invention, lining foam 120 may be replaced by a
forming foam or other reinforcement materials conventionally used
in shoe upper manufacture.
[0022] In step 100, reinforcement pieces 125, 127, and 129 of
different shapes and sizes as illustrated in FIG. 1A may be placed
upon lining foam 120. Reinforcement pieces 125, 127, and 129 may be
cut into shapes consistent with conventional shoe design and may
include vamp and eyestay reinforcements. External layer 110 may be
placed above the reinforcement pieces 125, 127, and 129 in step
100. External layer 110 forms the outer surface of the upper and
may include textile elements for resisting abrasion and providing
breathability. To enable the customer to customize the appearance
of the upper, the external layer 110 may be altered by various
dying, digital printing, embossing and embroidering techniques.
Suitable materials for external layer 110 include synthetic leather
and polyester mesh, although other materials including natural
materials, may be used in accordance with the present invention.
Other suitable materials for external layer 110 will become readily
apparent to those skilled in the art, given the benefit of this
disclosure.
[0023] In step 100, hot-melt films (not shown) may be layered
amongst the upper components between lining layer 105 and external
layer 110. Upon heat pressing, these films act to adhesively bond
the upper components between lining layer 105 and external layer
110. The hot-melt films may be composed of materials such as
thermoplastic polyurethane (TPU) film. The TPU film(s) may be
integral to one or more sides of the other layers, such as lining
layer 105 and for external layer 110.
[0024] Referring now to FIG. 1B, examples of various upper
components associated with step 100 are illustrated and designated
generally as reference number 150. Upper components 150 may be cut
into shapes consistent with conventional shoe design and may
include, for example, a collar, vamp, quarter, tongue, and heel
counter. Specifically, vamp 160, is a part of the shoe that covers
the instep and may extend over the toe. The vamp overlay 162 may
cover at least a portion of the vamp. The quarter 164 is part of
the shoe's upper, and may cover the sides and back of the foot. In
many cases, the quarter is attached by some means (e.g., sewn,
glued) to the vamp. The collar lining and tongue lining, as shown
by 166 and 168, simply provide a lining for these parts of the shoe
and may be made out of a variety of materials, such as TPU, as
discussed above. The eyestay shown in 168 allows for the shoe to be
laced. The collar and tongue foam 170 are simply pieces of
material, here foam, that are formed or placed into the collar and
tongue to give these parts of the shoe shape and also to provide
comfort to the wearer of the shoe. The tongue 172 is a piece of
material that typically is placed in the top-center of the shoe and
sits on the top part of the foot. The tongue 172 also may protect
the top part of the foot. A tongue made from TPU and a vamp
reinforcement 174 are also illustrated in FIG. 1B, as well as an
eyestay reinforcement 176.
[0025] Referring now to FIG. 2, the heat press step 200 for upper
creation in accordance with the present invention is illustrated.
In heat press step 200, the layers from step 100 may be heat
pressed together to form a basic laminated upper form, designated
generally as 205. Upper form 205 is formed when the layers from
step 100 are heated under pressure. The specific temperature,
pressure, and time needed to laminate the upper form may vary
according to the upper component being treated. For example, proper
lamination of the quarter upper component may occur when treated at
a pressure of 25 bars at 135 degrees Celsius for thirty seconds,
and proper lamination of the tongue upper component may occur when
treated at a pressure of 25 bars at 130 degrees Celsius for
forty-five seconds.
[0026] Referring now to FIG. 3, the third step 300 for upper
creation in accordance with the present invention is illustrated.
In step 300, the pattern perimeter 310 of basic laminated upper
form 205 is cut out to form upper component 305. Step 300 may be
performed using any type of cutting device such as a cutting die,
shears, and the like.
[0027] As FIGS. 1-3 have not been described, a method for
constructing a shoe using a flat forming process will be disclosed.
The upper portion of a shoe may be constructed by first layering a
plurality of upper elements and hot-melt films in between a lining
layer and an external layer, as shown in FIGS. 1A and 1B. These
upper elements may include, for example, internal foams, a lining
foam, and reinforcement pieces. In one embodiment, one or more of
these upper elements are formed of polyurethane foam. The hot-melt
film may be thermoplastic polyurethane, in one embodiment, but in
other embodiments, may be made of another material. The upper
elements and hot-melt films may be heat pressed between the lining
and external layers to generate one or more basic laminated upper
forms, as further shown in FIG. 2. Additionally, the pattern
perimeters of the upper may be cut out of the basic laminated upper
forms, shown in FIG. 3.
[0028] Referring now to FIG. 4, the step 400 for thermoforming shoe
construction involving attachment of the heel-quarter element to a
tongue-toe element in accordance with an embodiment of the present
invention is illustrated. In step 400, a heel-quarter element 405
may be attached to a tongue-toe element 420 to form a
three-dimensional upper form 440. Heel-quarter element 405 is a
single, laminated upper component constructed according to steps
100, 200, and 300 illustrated in FIGS. 1-3.
[0029] Heel-quarter element 405 may include a heel area 410 and
quarter panels 415. To properly form heel area 410, heel-quarter
element 405 may be subject to thermoform heel-forming processes.
The thermoform heel-forming processes may involve heat pressing the
heel counter upper component, as shown in FIG. 1A, into a heel
shape, then chilling the heel counter component. A dart (not shown)
may be inserted at the top or bottom of heel area 410 of
heel-quarter element 405 to facilitate the formation of a smooth
heel. This thermoform heel-forming process may give the
heel-quarter element 405 a three-dimensional shape.
[0030] Similar to the formation of heel-quarter element 405,
tongue-toe element 420 may be a single piece made from steps
100-300 of FIGS. 1-3. Tongue-toe element 420 includes a tongue 425
attached to a toe-box region 430. In step 400, upper form 440 may
be constructed by affixing the toe-box region 430 to the heel area
410 by, for example, stitching, gluing, RF welding, ultrasonic
welding, or any other technique. Upper form 440 may then be fitted
with a strobel (not shown), such as a last, for further
construction and to shape the upper.
[0031] Referring now to FIG. 5, the lasting step 500 for
thermoforming shoe construction in accordance with an embodiment of
the present invention is illustrated. In lasting step 500, last 510
may be inserted into upper form 505 to properly shape the
upper.
[0032] Referring now to FIG. 6, the sole laying step 600 for
thermoforming shoe construction in accordance with an embodiment of
the present invention is illustrated. In sole laying step 600,
upper form 605 may be aligned and attached to sole unit 620. Sole
unit 620 may include a phylon midsole 610, a rubber outsole 615,
and a flange(s) (not shown). For example, upper form 605 may be
attached to the flange of midsole 610 using conventional shoe
manufacture techniques such as, for example, stitching, gluing or a
combination thereof. The attachment flange may surround the entire
perimeter of midsole 610, or may be at a plurality of points or
regions around the perimeter of midsole 610. The flange may be of a
different hardness than other portions of midsole 610. Upper form
605 may be attached to sole unit 620 by stitching, gluing, etc.
[0033] Referring now to FIG. 7, a perspective view of a finished
thermoform construction basketball shoe 700 in accordance with an
embodiment of the present invention is illustrated. Basketball shoe
700 includes an upper 705 attached to a sole unit 710. Sole unit
710 is comprised of phylon midsole 715 attached to an outsole 720,
as further described above in the discussion of FIG. 6.
[0034] Referring now to FIGS. 8A-C, lateral side elevational views
800 of examples of thermoform construction basketball shoes in
accordance with an embodiment of the present invention are
illustrated and designated generally as 810, 820, and 830
respectively. FIGS. 8A-C illustrate different options available in
accordance with the present invention. For example, a shoe can
include a standard graphic design as depicted in FIG. 8A, or the
shoe can be decorated with varsity designs as depicted in FIG.
8B-C.
[0035] Referring now to FIGS. 9A-B, top plan and lateral side
elevational views of a finished thermoform construction skate shoe
in accordance with an embodiment of the present invention are
illustrated and designated generally as reference numeral 900.
Skate shoe 900 includes an upper 905 attached to a sole unit 910.
Sole unit 910 is comprised of midsole 915 attached to an outsole
920. Skate shoe 900 may be further comprised of perforations 925 in
upper 905, emboss eyelets 930, a thick foam collar 935, an overlay
durable synthetic toe tip 940, and eyestay reinforcements 945.
[0036] Referring now to FIGS. 9C-D, front and profile views of a
tongue associated with the skate shoe depicted in FIG. 9A are
illustrated and designated generally as reference numeral 950. In
one embodiment, tongue 950 may be comprised of a thick 20 mm foam.
The exterior layer 955 of tongue 950 may be decorated with a
debossed logo 960.
[0037] The present invention has been described in relation to
particular embodiments, which are intended in all respects to be
illustrative rather than restrictive. Alternative embodiments will
become apparent to those of ordinary skill in the art to which the
present invention pertains without departing from its scope.
[0038] From the foregoing, it will be seen that this invention is
one well adapted to attain all the ends and objects set forth
above, together with other advantages which are obvious and
inherent to the system and method. It will be understood that
certain features and sub-combinations are of utility and may be
employed without reference to other features and sub-combinations.
This is contemplated by and is within the scope of the claims.
* * * * *