U.S. patent application number 13/122712 was filed with the patent office on 2011-09-29 for method for efficient and localized production of shoes.
This patent application is currently assigned to Nike, Inc.. Invention is credited to Melody Crisp.
Application Number | 20110232008 13/122712 |
Document ID | / |
Family ID | 42060129 |
Filed Date | 2011-09-29 |
United States Patent
Application |
20110232008 |
Kind Code |
A1 |
Crisp; Melody |
September 29, 2011 |
Method For Efficient And Localized Production Of Shoes
Abstract
Methods and systems relating to efficient shoe manufacturing
that reduce the specialized human labor required to manufacture a
pair of shoes while avoiding the high costs and special maintenance
requirements often associated with highly automated manufacturing
equipment are provided. Systems and methods in accordance with the
present invention may be used to produce multiple models of custom
shoes at a single shoe manufacturing facility using overlapping
workflows, thereby reducing the physical footprint of the
manufacturing facility. Additionally, embodiments of the invention
may provide methods and systems for efficiently producing shoes to
meet the demands of a particular geographic location, thereby
eliminating the need to import shoes produced in other
locations.
Inventors: |
Crisp; Melody; (Beaverton,
OR) |
Assignee: |
Nike, Inc.
Beaverton
OR
|
Family ID: |
42060129 |
Appl. No.: |
13/122712 |
Filed: |
September 28, 2009 |
PCT Filed: |
September 28, 2009 |
PCT NO: |
PCT/US2009/058628 |
371 Date: |
June 1, 2011 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61194496 |
Sep 26, 2008 |
|
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|
Current U.S.
Class: |
12/18.1 ;
12/142R; 36/136 |
Current CPC
Class: |
A43B 9/00 20130101; A43D
2200/20 20130101; G06Q 10/06 20130101 |
Class at
Publication: |
12/18.1 ; 36/136;
12/142.R |
International
Class: |
A43D 95/00 20060101
A43D095/00; A43B 23/24 20060101 A43B023/24; A43D 8/02 20060101
A43D008/02 |
Claims
1. A system for producing and assembling shoe components, the
system comprising: a receiving module for receiving a customer
input; a market that provides at least one temporary storage bin of
a first shoe component; a first shoe component-manufacturing module
that produces at least the first shoe component upon receiving an
indication from the marketplace, wherein the marketplace
temporarily stores the contents of the first shoe component and
provides the indication to the first component-manufacturing module
upon one of the at least one temporary storage bins of the
marketplace dropping below a predefined threshold amount of the
first shoe component; a second shoe component-manufacturing module
that produces one or more second shoe components upon receiving the
customer input; and a third component-manufacturing module that
assembles the one or more of the first shoe components and the one
or more of the second shoe components to produce a shoe
article.
2. The system of claim 1 wherein the one or more first shoe
components are processed after the first shoe component is removed
from said inventory.
3. The system of claim 1 wherein the first shoe component
manufacturing module produces outsoles.
4. The system of claim 1 wherein the first shoe component
manufacturing module produces midsoles.
5. The system claim 1 wherein the second shoe component
manufacturing module produces custom upper shoe components.
6. The system of claim 1 wherein the custom shoe component is
processed before being coupled to the first shoe component.
7. The system of claim 1 wherein the custom shoe component is
comprised of two or more coupled custom shoe components.
8. The system of claim 1 wherein the second shoe manufacturing
module comprises a plurality of customization sub-modules.
9. A processing facility for the modularized production of
composite custom shoe components, said processing facility
comprising: a cutting and kitting module that cuts shoe upper
components from an inventory of raw upper materials, at least one
of the raw upper materials comprising a customizable gray good,
that then assembles the cut shoe upper materials into kits that
comprise all of the upper elements necessary to form an entire shoe
upper, and that then temporarily stores the kits; a customization
module that retrieves temporarily stored kits from the cutting and
kitting module, that layers the shoe upper components of the kit
into a flat framed assembly with multiple layers, and that
customizes at least a portion of the shoe upper components by
applying decoration to the shoe upper components; a forming and
stitching module that receives the customized shoe upper
components, that forms the customized shoe upper components into a
three-dimensional shoe upper, that affixes a strobel to the formed
shoe upper, and that lasts the formed shoe upper and strobel; a
midsole and outsole fabrication module that fabricates shoe
midsoles and shoe outsoles; and a stockfit and assembly module that
receives the lasted and formed shoe upper and strobel from the
forming and stitching module, that receives the shoe midsoles and
shoe outsoles from the midsole and outsole module, and that
assembles the shoe midsole, the shoe outsole, and the lasted and
formed shoe upper and strobel into a shoe.
10. The processing facility of claim 9, wherein the cutting and
knitting module comprises a material storage component that holds
the raw upper materials, a component cutting machine, and a market
that holds the kits after assembly.
11. The processing facility of claim 9, wherein the customization
module comprises a hot melt lamination press, an eco-solvent
printer, a digital printing dye sublimation station, a trim
clicker, and an embroidery station.
12. The processing facility of claim 9, wherein the forming and
stitching module comprises a radio frequency press that joins the
layers of the shoe upper, a cutting press that removes the joined
shoe upper from excess upper material, a toe-forming component that
forms the toe of the shoe upper, a heel-forming component that
forms the heel of the shoe upper, and a strobel-stitch component
that stitches a strobel to the formed shoe upper.
13. The processing facility of claim 9, wherein the forming and
stitching module comprises a heat press that joins the layers of
the shoe upper, a cutting press that removes the joined shoe upper
from excess upper material, a toe-forming component that forms the
toe of the shoe upper, a heel-forming component that forms the heel
of the shoe upper, and a strobel-stitch component that stitches a
strobel to the formed shoe upper.
14. The processing facility of claim 9, wherein the stockfit and
assembly module comprises applies at least one adhesive to assemble
the shoe outsole, the shoe midsole and the lasted and formed shoe
upper and strobel into a shoe.
15. The processing facility of claim 14, wherein the stockfit and
assembly module further comprises a press that applies pressure to
the shoe outsole, the shoe midsole, and the lasted and formed shoe
upper and strobel after at least one adhesive has been applied
between the lasted and formed shoe upper and strobel and the shoe
midsole and at least one adhesive has been applied between the shoe
midsole and the shoe outsole.
16. A shoe manufactured through a process, the steps of the process
comprising: in a cutting and kitting module, providing a plurality
of raw materials required for a multilayered shoe upper, cutting
the raw materials into the components of the multilayered shoe
upper and placing the components necessary to make a single
multilayered shoe upper into kits; in a customization module,
receiving a kit and assembling the shoe upper components into
multiple layers aligned on a flat frame, and customizing the
multilayer upper components by applying decoration to at least one
layer of the multilayer shoe upper components while the multilayer
shoe upper components are on the flat frame; in a forming module,
joining the multilayer upper components to form one integral shoe
upper while the multilayer shoe upper components are on the frame,
removing the joined shoe upper from the frame by cutting the shoe
upper from excess upper material, forming joined shoe upper into a
three-dimensional shoe upper, and stitching a strobel to the formed
shoe upper; in an outsole and midsole module, forming a shoe
midsole and forming a shoe outsole; and in a stockfit and assembly
module, attaching the shoe midsole to the shoe upper and attaching
the shoe outsole to the shoe upper to form a completed shoe.
17. The shoe of claim 16, wherein the joined upper is cut from the
excess upper material using a press.
18. The shoe of claim 16, wherein the kits of shoe upper components
each includes the components necessary to make a shoe upper for a
shoe having a predetermined size.
19. The shoe of claim 16, wherein the multilayer upper components
are joined by a heat press.
20. The shoe of claim 16, wherein the multi-layer upper components
are joined by a radio frequency welder.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional
Patent Application No. 61/194,496, filed Sep. 26, 2008, entitled
"Method for Efficient and Localized Production of Shoes."
BACKGROUND OF THE INVENTION
[0002] Shoe production is a labor-intensive process that has
changed little despite advancements in automation over the past 100
years. Thus, most shoe manufacturing operations today require a
significant amount of manual input. For example, one worker may
cut, form, align, and stitch an upper piece of a shoe. While this
process may utilize a number of machines, there is still a
significant amount of human input required that can introduce
variation between any two different uppers. This upper shoe piece
may then be passed to another worker who may then add embroidery or
other embellishments, which also require a significant amount of
human input. These high levels of human input can introduce
undesired variations in the finished shoe-product. Further, the
large amount of human labor required in the making of shoes has
limited the ability to produce on-demand custom shoes at a price
deemed acceptable by most customers.
SUMMARY OF THE INVENTION
[0003] This Summary is provided to introduce a selection of
concepts in a simplified form that are further described below in
the Detailed Description. This Summary is not intended to identify
key features or essential features of the claimed subject matter,
nor is it intended to be used as an aid in determining the scope of
the claimed subject matter. The present invention offers several
practical applications in the technical arts, not limited to
methods for the production of specific types of shoes that are
herein described.
[0004] The present invention relates to efficient shoe
manufacturing methods and systems that reduce the specialized human
labor required to manufacture a pair of shoes while avoiding the
high costs and special maintenance requirements often associated
with highly automated manufacturing equipment. Systems and methods
in accordance with the present invention may be used to produce
multiple models of custom shoes at a single shoe manufacturing
facility. For example, one customer may order a particular model of
shoe while a second customer may order a different model of shoe,
yet both shoe models may be manufactured at the same facility by
utilizing overlapping workflows.
BRIEF DESCRIPTION OF THE DRAWING
[0005] The present invention is described in detail below with
reference to the attached drawing figures, wherein:
[0006] FIG. 1 illustrates a diagram of a shoe
component-manufacturing facility for the manufacture of custom shoe
components in accordance with an embodiment of the present
invention;
[0007] FIG. 2 illustrates a flowchart of a method of efficiently
manufacturing multiple models of custom shoes at a single
manufacturing facility in accordance with an embodiment of the
present invention;
[0008] FIG. 3 illustrates a flowchart of an outsole manufacturing
workflow for a running shoe for the outsole/midsole module in
accordance with an embodiment of the present invention;
[0009] FIG. 4 illustrates a flowchart of a midsole manufacturing
workflow for a running shoe for the outsole/midsole module in
accordance with an embodiment of the present invention;
[0010] FIG. 5 illustrates a flowchart of a workflow for a running
shoe for the priming and adhesive module in accordance with an
embodiment of the present invention;
[0011] FIG. 6 illustrates a flowchart of a workflow for joining an
outsole and a midsole into a midsole-outsole on a running shoe in
accordance with an embodiment of the present invention;
[0012] FIG. 7 illustrates a flowchart of a workflow for customizing
an upper for a running shoe in accordance with an embodiment of the
present invention;
[0013] FIG. 8 illustrates a flowchart of a workflow for assembling
an upper for a running shoe in accordance with an embodiment of the
present invention;
[0014] FIG. 9 illustrates a flowchart of a workflow for lasting and
quality control for a running shoe in accordance with an embodiment
of the present invention;
[0015] FIG. 10 illustrates a flowchart of an outsole manufacturing
workflow for a basketball shoe for the outsole/midsole module in
accordance with an embodiment of the present invention;
[0016] FIG. 11 illustrates a flowchart of a midsole manufacturing
workflow for a basketball shoe for the outsole/midsole module in
accordance with an embodiment of the present invention;
[0017] FIG. 12 illustrates a flowchart of a workflow for a
basketball shoe for the priming and adhesive module in accordance
with an embodiment of the present invention;
[0018] FIG. 13 illustrates a flowchart of a workflow for joining an
outsole and a midsole into a midsole-outsole on a basketball shoe
in accordance with an embodiment of the present invention;
[0019] FIG. 14 illustrates a flowchart of a workflow for
customizing an upper for a basketball shoe in accordance with an
embodiment of the present invention;
[0020] FIG. 15 illustrates a flowchart of a workflow for assembling
an upper for a basketball shoe in accordance with an embodiment of
the present invention;
[0021] FIG. 16 illustrates a flowchart of a workflow for lasting
and quality control for a basketball shoe in accordance with an
embodiment of the present invention;
[0022] FIG. 17 illustrates a flowchart of an outsole manufacturing
workflow for a skate shoe for the outsole/midsole module in
accordance with an embodiment of the present invention;
[0023] FIG. 18 illustrates a flowchart of a midsole manufacturing
workflow for a skate shoe for the outsole/midsole module in
accordance with an embodiment of the present invention;
[0024] FIG. 19 illustrates a flowchart of a workflow for a skate
shoe for the priming and adhesive module in accordance with an
embodiment of the present invention;
[0025] FIG. 20 illustrates a flowchart of a workflow for joining an
outsole and a midsole into a midsole-outsole on a skate shoe in
accordance with an embodiment of the present invention;
[0026] FIG. 21 illustrates a flowchart of a workflow for
customizing an upper for a skate shoe in accordance with an
embodiment of the present invention;
[0027] FIG. 22 illustrates a flowchart of a workflow for assembling
an upper for a skate shoe in accordance with an embodiment of the
present invention;
[0028] FIG. 23 illustrates a flowchart of a workflow for lasting
and quality control for a skate shoe in accordance with an
embodiment of the present invention;
[0029] FIG. 24 illustrates a work flow diagram of a shoe
component-manufacturing facility for the manufacture of custom shoe
components in accordance with an embodiment of the present
invention;
[0030] FIG. 25 illustrates a schematic of a module configuration
for use in shoe production in accordance with an embodiment of the
present invention;
[0031] FIG. 26 illustrates a system for producing and assembling
shoe components in accordance with an embodiment of the present
invention; and
[0032] FIG. 27 illustrates a flowchart of a workflow of a shoe
manufactured through a process in accordance with an embodiment of
the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0033] The subject matter of the present invention is described
with specificity herein to meet statutory requirements. However,
the description itself is not intended to limit the scope of this
patent. Rather, the inventors have contemplated that the claimed
subject matter might also be embodied in other ways, to include
different steps or combinations of steps similar to the ones
described in this document, in conjunction with other present or
future technologies. Moreover, although the term "step" may be used
herein to connote different components of methods employed, the
terms should not be interpreted as implying any particular order
among or between various steps herein disclosed unless and except
when the order of individual steps is explicitly described.
[0034] Embodiments of the invention may provide a method for
efficiently producing shoes that may meet the demands of a
geographic location. By way of example only and not limitation, a
production facility for efficient production of shoes may be
divided into particular modules, wherein a module may refer to an
area of distributive labor or of specificity relating to one or
more aspects of the shoemaking process, such as embroider or
production of midsoles. In one embodiment, one or more modules may
be designed to best benefit the working environment of individual
operators such that the interaction between the operator and the
machines in an operator's module are ergonomically designed to be
conducive to the worker's good health. Each module may be referred
to as a "module." As a shoe component moves through modules,
different processes and modifications may occur that comprise the
steps in the overall manufacture of a shoe.
[0035] A shoe article, wherein a shoe article may be a final shoe
or a partially final shoe or a component of a final shoe, may be
produced only after a customer order has been received. A customer
order may contain custom shoe parameters that pertain to one or
more shoes produced for a given consumer. Moreover, since each shoe
may be custom-made, each shoe may have a variety of characteristics
according to each customer's request (e.g., a left-foot men's size
9 in blue with medium-level hardness may be paired with a
right-foot men's size 9.5 with high-level hardness in red).
[0036] Once a customer has placed an order for one or more shoes,
the order may be tracked throughout the production system so as to
notify one or more operators of the unique characteristics of each
order. In one method, the customer order may be presented to one or
more operators on one or more sheets of paper. Each sheet of paper
may travel to an appropriate operator so as to indicate to the
operator what modifications to make to the shoe and/or shoe
component the operator is modifying. The operator may then select
the desired characteristics, such as a preferred color, from a
source of materials within the modularized production facility, or
the operator may select the desired design and/or markings from a
series of program choices on a computer system. In the latter
method, the operator may search through a pre-defined set of
designs available for printing and/or embroidering and/or etching
onto a material and may program the computer to print and/or
embroider and/or etch the design onto a material. In another
method, the operator may input a design or program supplied by the
customer as a customized design on one or more shoe components.
[0037] In another embodiment, an operator can access information
pertaining to a customer order throughout the shoe
component-manufacturing facility by having the customer information
stored on a database that is accessible to an operator in the shoe
component-manufacturing facility. An operator may access the
customer order information through a computer interface at or near
one or more modules in the shoe-components manufacturing facility.
An operator may also access information pertaining to the customer
through the use of one or more bar codes. In one method, a bar code
may access customer order info from a database that may contain all
of the necessary information for the production of a customer's
order of one or more shoes. A bar code may be used to access all
information related to one or more shoe components, or may be used
to access particular information related to one or more shoe
components.
[0038] For example, an operator may scan one bar code at each
software access point along the process. In another example, a bar
code may be associated with each characteristic aspect and/or
component of a shoe. For example, a bar code may be associated with
the color which is desired to have on the background of a shoe
component. In another example, a bar code may be associated with
the components and/or designs desired to be reflected on an upper.
In still another example, a bar code may be associated with to
selection of components from a marketplace. For instance, one bar
code may represent men's running shoes size 9, whereas another bar
code may represent women's basketball shoes size 7. In another
example, the use of bar codes may be associated with or supplanted
by the use of number codes to supply the characteristics of a
customer's order. For example, if a barcode is damaged or if a
barcode reader is simply not working, an operator may input a
number code to reflect the characteristic customer information
associated with an order of one or more shoes.
[0039] There may be three starting points from which one or more
shoe components are produced: the production of the outsole, the
production of the midsole, and the production of the upper. The
production of the outsole and/or midsole may begin before a
customer places an order. An outsole and/or midsole may also be
produced on an as-needed basis after a customer order is received
for the production of one or more shoes.
[0040] Referring to the drawings in general, and initially to FIG.
1 in particular, an exemplary operating environment suitable for
implementing embodiments of the present invention is shown and
designated generally as shoe component-manufacturing facility
100.
[0041] Shoe component-manufacturing facility 100 is but one example
of a suitable manufacturing environment and is not intended to
suggest any limitation as to the scope of use or functionality of
the invention. Neither should the shoe component-manufacturing
facility 100 be interpreted as having any dependency or requirement
relating to any one or combination of components illustrated.
[0042] FIG. 1 shows the floor layout of six shoe
component-manufacturing modules organized by the processes
performed by an operator associated with a module. The six modules
represented in FIG. 1 include: the Outsole and Midsole module; the
Midsole, Outsole, Upper Prime and Adhesive module; the Final
Assembly & Stockfit module; the Upper Customization module; the
Upper Forming and Stitching module; and the Lasting, De-Lasting,
Quality Control and Packing module. With reference to the diagram
of FIG. 1, the areas of each module in shoe component-manufacturing
facility 100 are described. The Outsole and Midsole module may
contain injection mold pre-forming machine 102 that may be used to
produce phylon biscuits. The Outsole and Midsole module may also
contain midsole marketplace 108 that may store phylon biscuits for
use in forming midsoles. The Outsole and Midsole module may also
contain press 106, that may specifically be a Kingstead Quick Open
Press, that may be used for characterizing phylon biscuits as being
right-oriented shoes, left-oriented shoes, or neutral-oriented
shoes may. The Outsole and Midsole module may also contain a
microwave heat source to pre-heat the phylon biscuit. The Outsole
and Midsole module may also contain stabilization oven 110 that may
be used to stabilize midsoles and may also decrease the volume of
midsoles. The Outsole and Midsole module may also contain a
wash/dry are 112. The Outsole and Midsole module may also contain a
midsole marketplace 104. The Outsole and Midsole module may also
contain injection mold rubber machine 116 that may be used to
produce outsoles. The Outsole and Midsole module may also contain a
wash/dry area 114 that may be used to wash outsoles with an
alkaline or acid wash. The Outsole and Midsole module may also
contain an outsole marketplace 118.
[0043] The Midsole, Outsole, Upper Prime and Adhesive module may
contain midsole marketplace 104 and outsole marketplace 118. The
Midsole, Outsole, Upper Prime and Adhesive module may also contain
primer and adhesive area 120. In another method, the primer area
and adhesive area may be two separate areas. The Midsole, Outsole,
Upper Prime and Adhesive module may also contain chemical storage
area 156 that may contain chemicals related to one or more
processes in the manufacturing of shoe components and/or shoe
articles in the shoe-components manufacturing facility 100. The
Midsole, Outsole, Upper Prime and Adhesive module may also contain
infrared (IR) oven 122. In another method, the Midsole, Outsole,
Upper Prime and Adhesive module may also contain a standard oven
wherein one or more shoe articles may undergo manufacturing
processes, such as having adhesive activated.
[0044] The Final Assembly & Stockfit module may contain IR oven
122. The Final Assembly & Stockfit module may also contain a
bladder press 124 that may be used to fit a midsole and outsole
together. The Final Assembly & Stockfit module may also contain
standard press 126. The Final Assembly & Stockfit module may
also contain chiller 128 that may be used to set the adhesive of a
midsole-outsole shoe article. The Final Assembly & Stockfit
module may also contain swing arm stage post 130.
[0045] The Upper Customization module may contain Eco-Solvent
Printer 132 and print desk 134 and dye sub printer 136. The Upper
Customization module may also contain custom clicker 138 that may
be used to modify material used in upper customization and a
tooling area 160 that may contain tools related to one or more
processes in the manufacturing of one or more shoe components
and/or one or more shoe articles in the shoe-components
manufacturing facility 100. The Upper Customization module may also
contain laser 140 that may be used to etch material used in upper
customization and a laser/embroidery desk 146. The Upper
Customization module may also contain dye sub press 142. The Upper
Customization module may also contain left embroidery machine 162
and may contain right embroidery machine 164. The Upper
Customization module may also contain tooling area 166 that may
contain tools related to one or more processes in the manufacturing
of one or more shoe components and/or one or more shoe articles in
the shoe-component manufacturing facility 100. The Upper
Customization module may also contain radio frequency (RF) Welder
148 wherein RF Welder 148 may include an RF staging area that may
be used to temporarily store shoe components in the process of
producing a shoe.
[0046] The Upper Forming and Stitching module may contain RF Welder
148 wherein RF Welder 148 may include an RF staging area that may
be used to temporarily store shoe components in the process of
producing or modifying a shoe article. The Upper Forming and
Stitching module may also contain marketplace 150 that may be used
to temporarily store and make easily available customizable parts
needed to complete production of a shoe or shoe article. The Upper
Forming and Stitching module may also contain material storage 168
that may contain materials and/or shoe components related to one or
more processes in the manufacturing of shoe components and/or shoe
articles in shoe-component manufacturing facility 100. The Upper
Forming and Stitching module may also contain final trim clicker
144 and wing arm staging area 130. The Upper Forming and Stitching
module may also contain market clicker 170, heat press 172, cooling
rack 174, cutting press 176, heel former 178, post stitch 180 and
strobel stitch 182.
[0047] The Lasting, De-Lasting, Quality Control and Packing module
may contain swing arm staging area 130. The Lasting, De-Lasting,
Quality Control and Packing module may also contain lasting area
152, final quality control 154, lacing and packing 156 and storage
material 184.
[0048] With reference to the diagram of FIG. 1, the production of
one shoe through the one or more modules of shoe
component-manufacturing facility 100 is described. It should be
understood that this and other arrangements described herein are
set forth only as examples. Other arrangements and elements (e.g.,
machines, processes, methods, etc.) can be used in addition to or
instead of those discussed, and some elements may be omitted
altogether. Further, many of the elements described herein are
functional entities that may be implemented as discrete or
distributed components or in conjunction with other components, and
in any suitable combination and location.
[0049] In one embodiment, the first step in the production of the
outsole may utilize injection rubber mold machine 102.
Different-sized and/or -shaped molds may be used to produce a range
of outsoles for a range of shoe sizes and styles. Various types
and/or colors of rubber may also be used to produce outsoles with
different functional and/or aesthetic properties. For example,
indicating marks (such as dotted lines) may be used to guide a
designer (e.g. someone who embroiders or adds mechanical lights or
who uses glue or another form of adhesive to add fabric and
accessories onto one or more shoe components) in the production of
the outsole. In another case, different colors of shoe components
may have a functional component, such as adding an easily seen
color, such as bright yellow, to one or more shoe components to
make a shoe-wearer more visible. Alternatively, different rubbers
with a higher slippage may be placed along a shoe component in
order to minimize the extent to which mud or other outside
components stick to the shoe-wearer's one or more shoes.
[0050] The operator of injection rubber mold machine 102 may
determine the number of each size, style, color, etc. of outsoles
to make initially based on an indicator of outsoles required in
outsole marketplace 118. For example, an indicator may include a
pre-set range of expected sales for that store. A number of
outsoles may also be created upon receipt of an indication of
depleting inventory of a particular size, style, color, etc. The
pre-set range of sales may be projected for a day or for another
period of time, such as a week or a month or a season. The operator
of injection rubber mold machine 102 alternatively or additionally
may determine which size of outsole to make based on the quantity
of outsoles of that size remaining in outsole marketplace 118.
Outsole marketplace 118 of may comprise a plurality of temporary
storage methods, with each temporary storage method corresponding
to a particular style, size, color, functional property, etc. For
example, a temporary storage method may comprise placing newly
formed outsoles for size 9 in a first-come-first-serve (i.e. FIFO)
queue. In another example, a temporary storage method may consist
of an operator placing each newly formed outsole into a bin
associated with one or more properties of that outsole (e.g.,
outsoles for men's size 9 are in one bin while outsoles for men's
size 5 are in another bin). In still another example, a temporary
storage method may comprise placing all newly formed outsoles into
a bin and then allowing the operator to remove the appropriately
sized outsole from the bin when needed, e.g. by choosing an outsole
based on sight variation between different sized outsoles or by
textured indications of different sized outsoles.
[0051] Upon determining that there is a low quantity of a certain
size of outsole remaining in outsole marketplace 118, such as by
visual inspection, the operator may then decide to manufacture
outsoles of that size. Outsoles may also be produced in direct
response to an order, and may be made having the style, size,
color, functional properties, etc. specified in an order.
[0052] Once the outsole is removed by the operator from injection
rubber mold machine 102 it may be placed into wash/dry area 114.
Wash/dry area 114 may comprise one or more cleaning steps to clean
the shoe and remove any residue from the rubber. For example,
rubber residue may be caused by the oils and stearic acid used
during a curing process. In another example, a curing process may
eliminate the use of stearic acid in the curing process and/or
reduce the amount of oil used in the curing process, thereby
reducing or eliminating the need for wash/dry area 114. This curing
process may reduce or eliminate the rubber residue produced during
the curing process and may reduce or eliminate the need for one or
more cleaning steps. As such, the outsole could be ready for
priming directly after it is formed in injection rubber mold
machine 116.
[0053] After washing, if any, the outsole may be dried. For
example, the outsole may be dried using wash/dry area 114. In
another example, the outsole may be dried by placing it in a
sufficient heated, sufficiently de-humidified area (e.g. place the
one or more shoes next to a window to dry). The operator may remove
the dried outsole from wash/dry 114 and place it into outsole
marketplace 118 to be available for use.
[0054] Outsole marketplace 118 and midsole marketplace 104 may be
comprised of one or more temporary storage methods wherein midsoles
may be stored in bins that are arranged according to size, style,
color, or other attributes of the components stored in the bins.
Outsole marketplace 118 and midsole marketplace 104 may store
outsoles and midsoles that have been produced upon receipt of an
indication of anticipation of customer orders. Outsole marketplace
118 and midsole marketplace 104 may also contain outsoles or
midsoles produced upon receiving a specific customer order. By way
of further example, outsoles and/or midsoles produced upon receipt
of a customer order may bypass outsole marketplace 118 and/or
midsole marketplace 104 and move directly onto further production
steps. Still more embodiments may be obvious to one of ordinary
skill in the art.
[0055] The production of the midsole may begin before a customer
places an order. A midsole may also be produced on an as-needed
basis upon the receipt of a customer order for one or more shoes.
Further, a midsole may be produced as a result of the receipt of an
indication that the quantity and character of midsoles remaining in
midsole marketplace 104 should be adjusted.
[0056] To begin midsole production, a pre-measured volume of raw,
unblown EVA pellets may be injected into a mold at injection mold
pre-form 102 that is heated to approximately 100.degree. Celsius.
The temperature of the mold may be hot enough to melt the EVA
pellets to conform to the shape of the mold, but not hot enough to
activate the EVA's blowing agent. The product is an injection
phylon biscuit, hereinafter referred to as a "biscuit," that may be
stored prior to activating the blowing agent to fabricate a
midsole. Different volumes of EVA pellets may be associated with
different shoe sizes, styles, densities and or hardnesses of
portions of a midsole. Furthermore, the base polymer that is used
in the injection phylon biscuit process may differ based on the
ultimate hardness characteristic that is desired in the midsole of
a shoe. Each set of shoes may contain one or more biscuits of
varying volumes and dimensions comprising the midsole of each shoe.
The hardness of one or more biscuits in a midsole may be customized
to vary laterally and/or vary lengthwise across the shoe. Such a
characteristic may, for example, prevent mild pronation in shoe
users, such as runners, or simply enhance comfort.
[0057] Once the biscuit is made, it may be removed and placed into
biscuit marketplace 108. From biscuit marketplace 108, the biscuits
may be taken out on an as-needed basis. When a customer orders one
or more shoes, for example, an operator may take one or more
biscuits that are in accordance with the customer's order. In
another method, operator may take the one or more biscuits from the
marketplace and place them in a machine that exposes the one or
more biscuits to a source of microwave radiation. For example, one
or more biscuits may be placed in a Magic Chef MCB780W 1.2 kilowatt
microwave and exposed to microwave radiation at high power for a
period of sixty-five seconds.
[0058] Next, an operator may place each biscuit into press 106
which may be designated for left shoes and right shoes or a
combination of both. The operator may load the left shoe
designation or right shoe designation of press 106, and may use
press 106 to configure each biscuit as "left" or "right." The
operator may then unload each biscuit from press 106. Press 106 may
not be limited to holding only one biscuit, but may hold a
plurality of biscuits at any given time. Moreover, the pressing of
the biscuits need not be in sync with respect to each biscuit in
press 106, but rather, may be designed to have multiple biscuits
loading and pressing and unloading at any given time. In still a
further example, an operator of a module may bypass the step of
using a press 106 to designate a shoe article as being oriented
"left" or "right", and may simply use a lathe or a pair of shears
or one or more blades to shape the biscuit by hand. An operator may
also use another type of machine to designate each biscuit as being
oriented "left" or "right" before placing each biscuit into a
neutral, un-oriented press 106. An operator may also keep the
biscuit as a neutral designation, such that each shoe part is
interchangeable as being used for a left shoe and/or a right
shoe.
[0059] Once press 106 contains the biscuit it may heat up to a
temperature of approximately 172.degree. Celsius that is sufficient
to melt the biscuit. The temperature is sufficient to activate a
blowing agent in the biscuit. This blowing agent may degrade the
polymer chains and start a foaming process which increases the
volume of the biscuit approximately 200% to conform to the shape of
the press. Simultaneously, the a curing agent within the biscuit
working at a slower reaction rate than the blowing agent may begin
to cross-link polymer chains to hold the form of the augment
biscuit.
[0060] After the augmented biscuit is formed, an operator may
unload the augmented midsole from press 106 and load the augmented
midsole into stabilization oven 110. Upon entering stabilization
oven 110, the augmented midsole may be approximately 75.degree.
Celsius. In another example, the augmented midsole may enter
stabilization oven 110 at a temperature that is higher or lower
than 75.degree. Celsius. In one example, the augmented midsole may
be as hot as the highest temperature achieved in the press 106 and
may be transferred at that same temperature into the stabilization
oven 110. The stabilization process in stabilization oven 110 may
be comprised of three or more cooling stages in which the
temperature may decrease from approximately 75.degree. Celsius to
approximately 45.degree. Celsius. In another example, the
stabilization process in stabilization oven 110 may be conducted
over a greater number of steps through the use of water and or air
as mediums of cooling. In still another example, additional media
and/or chemical solutions may be used to enhance the cooling
process in the stabilization process of stabilization oven 110. The
stabilizing process may decrease the volume of the augmented
midsole by approximately 20% such that the midsole resulting from
the stabilization process is approximately 160% of the original
biscuit volume. In another example, the stabilizing process may be
modified to increase or decrease the percentage change seen in the
volume of the augmented midsole. In another method, any form of
stabilization method may be used to stabilize one or more augmented
biscuits, including immersion into water or other liquid at a
desired temperature. In another example, augmented biscuits may be
stabilized through the use of an aerosol solution or exposure to
air at a desired temperature.
[0061] Another method of changing the volume of an augmented
midsole may be to modify the midsole by hand, e.g. by the use of a
lathe or the use of one or more cutting tools or the use of a
second mold from which the augmented midsole may be placed in to
decrease volume either by using pressure to shrink volume or using
pressure to press a desired form from the augmented midsole and
subsequently cutting and/or trimming off any undesired excess
material.
[0062] Next, an operator may unload the biscuit from stabilization
oven 110 and load the biscuit into wash/dry table 112 wherein a
sonic bath may be used to clean one or more midsoles. Wash/dry
table 112 may use one or more cleaning stages to clean a midsole.
In another embodiment, the stabilization of the augmented biscuit
may be combined with wash/dry table 112. In another embodiment, the
biscuit may be unloaded from stabilization oven 110 and loaded into
another type of cleaning machine and/or solvent and/or solution
wash. In another example, each biscuit unloaded from stabilization
oven 110 may be hand-polished by one or more operators.
[0063] Next, an operator unloads the biscuit from wash/dry table
112 and loads the biscuit into the drying oven. In another
embodiment, the biscuit may be unloaded from wash/dry table 112
exposed to a sufficiently high temperature to evaporate a desired
amount of water from the biscuit. The drying of the midsole may
occur by placing the midsoles out to air dry. Next, an operator may
unload the biscuit from drying oven and load the biscuit into
marketplace.
[0064] At this point in the current embodiment, midsole marketplace
104 and outsole marketplace 118 may be comprised of a series of
different classes of outsoles and the one or more midsoles
described above. When a customer orders one or more shoes, the
outsoles and the one or more midsoles associated with the
customer's order may be removed from outsole marketplace 118 and
midsole marketplace 104, respectively, if available. If one or more
midsoles or outsoles of a customer's order are not available in
midsole marketplace 104 or outsole marketplace 118, respectively,
the necessary component or components may be made on a per-order
basis.
[0065] After the outsole and one or more midsoles are removed from
outsole marketplace 118 or midsole marketplace 104, respectively,
they may be primed with an UV-activated primer at area 120. The
primer may be placed on the one or more midsoles within 24 hours of
its being activated. In an alternative embodiment, the primer can
be placed on each outsole and midsole prior to entering outsole
marketplace 118 or midsole marketplace 104, respectively.
[0066] After the outsole and the one or more midsoles are primed,
each component may be placed in infrared oven 122. Once in the
oven, the temperature may be increased to approximately 55.degree.
Celsius. At a sufficiently high temperature, the primer may be
activated. Each component may then be removed from the infrared
oven and an adhesive may be applied at prime and adhesive area 120.
Each component may then be loaded into infrared oven 122, where it
may be heated to approximately 55.degree. Celsius, at which point
the adhesive may be activated. Each component may then be removed
from infrared oven 122. In an alternative embodiment, each
component may have adhesive applied at prime and adhesive area 120
and then loaded into a standard oven to be heated. The standard
oven may be heated, at which point the adhesive may be activated.
The outsole and the one or more midsoles may be pressed together.
For example, the outsole and the one or more midsoles may be
hand-fit together through the use of bladder press 124 and standard
press 126. In another example, the outsoles and midsoles may be
loaded into a pressing alignment machine that works to fit the
outsole and one or more midsoles together.
[0067] Once an outsole is pressed together with its associate
midsole, the outsole-midsole is then placed in chiller 128. Chiller
128 may decrease the temperature of the outsole-midsole, to
approximately 0.degree. Celsius, allowing the adhesive to set. In
an alternative method, the outsole-midsole may be set out to cool
for a sufficient amount of time as is necessary to reduce the
temperature of the adhesive to a point that it sets the adhesive.
Next, the outsole-midsole may be sent to the staging area at swing
arm post 130.
[0068] In one embodiment, the production of the upper may begin
when the customer places an order for one or more shoes. After a
customer places an order for one or more shoes, an operator may
load a piece of synthetic material (e.g., synthetic leather,
polyester, or mesh, etc.) onto eco-solvent printer 132. The
synthetic material may be white, which may allow customer to
request synthetic material to be printed with one or more desired
aesthetic elements pertaining to the customer's order.
Alternatively, the synthetic material may be dyed to customize the
customer's order for one or more shoes. In another method, an
operator may load a natural material (e.g. cotton or natural
leather) onto eco-solvent printer 132. In another method, the
desired color of a material may be loaded into eco-solvent printer
132. Loading a desired color of a material may reduce or eliminate
steps for dyeing material.
[0069] The operator may then load eco-solvent printer 132 and dye
sub printer 136 with materials associated with imprinting and/or
dyeing and/or marking the parameters of customer's order onto
eco-solvent printer 132. Eco-solvent printer 132 may then print to
dye sub printer 136. Next, eco-solvent printer 132 may print. Next,
eco-solvent printer 132 may cut out a customized synthetic from an
original piece of synthetic material. In another method, the
customized synthetic may be cut with the use of shears or a blade
or the use of a press.
[0070] After the piece of customized synthetic has been cut, the
operator may load a piece of customized synthetic into laser 140.
The operator may then input the specifications given by the
customer and may start the laser etching job, if applicable.
[0071] Next, the operator may remove the piece of customized
synthetic and may load it into dye sub press 142. The dye sub press
142 may be used to imprint designs, such as a Nike swoosh, onto
material. The operator may remove the laser cut upper from the dye
sub press 142 and load the upper into embroidery machine 146. The
operator may then start embroidering machine 146, customizing the
upper by embroidering a desired set of designs using a desired set
of colors. The operator can then unload the customized upper from
embroidering machine 146 and deliver it to radio frequency welder
148.
[0072] At this point in the process, the upper and outsole-midsole
may be retrieved by an operator. The operator may also retrieve a
kit of the remaining shoe components from marketplace 150. In one
embodiment, the remaining shoe components are composed in a "kit"
wherein an operator can, for example, retrieve the remaining
components needed for a Men's size 9 running shoe. In another
method, one or more operators may retrieve one or more remaining
shoe components from a marketplace of kit components. After the
shoe components are gathered, the operator may utilize radio
frequency welder 148 to combine the components.
[0073] After the parts of the upper have been assembled, the
operator may make one or more final cuts with final trim clicker
144 to define the shape of an upper. In another example, the upper
may be cut by an operator using visual judgment and or expertise to
guide the operator in knowing where and/or at which angle and/or
how much to cut. Swing arm 130 may then stitch the upper to the
outsole-midsole. In another example, the upper may be stitched by
an operator using visual judgment and or expertise to guide the
operator in knowing where and/or at which angle and/or how much to
cut. This sub-assembly may then be sent to lasting area 152.
[0074] In FIG. 2, a method 200 for the efficient manufacturing of
multiple models of custom shoes at a single manufacturing facility,
such as the facility disclosed above, is illustrated. In accordance
with the present invention, a first customer may place an order for
a first model of shoe and one or more customization parameters
particular to that customer's order. A second customer may place an
order for a second model of shoe and one or more customization
parameters particular to that customer's order. By utilizing
systems and methods in accordance with the present invention, both
the first and second customers' shoes may be manufactured in the
same facility efficiently, at a reasonable cost and within a
reasonable amount of time. By utilizing the systems and methods in
accordance with the present invention, the physical footprint of a
manufacturing facility capable of producing multiple models of
shoes may also be reduced.
[0075] Again, it should be understood that this and other
arrangements and workflows described herein are set forth only as
examples. Other arrangements and elements (e.g., processes,
methods, etc.) can be used in addition to or instead of those shown
and discussed, and some elements may be omitted altogether.
[0076] In step 205, shoe model options may be presented to a
customer. Shoe model options presented in step 205 may include, for
example, a running shoe model, a basketball shoe model, and a skate
shoe model. Of course, other shoe models, both athletic and
non-athletic may be alternatively or additionally comprise
available shoe model options presented in step 205. Step 205 may
optionally comprise, for example, all available shoe model options
that are available to be made on-site at a connected or local shoe
manufacturing facility. Additionally, shoe model options may
comprise shoe models capable of being made on-site at a connected
or local shoe manufacturing facility along with shoe models not
capable of being made on-site at a connected or local shoe
manufacturing facility. An indication of whether a particular shoe
model may optionally be made on-site at a connected or local
manufacturing facility or not may also be optionally presented.
Step 205 may comprise, for example, presenting information
describing the available shoe model options, along with an
indication of local manufacturing availability for each particular
model, to a customer on a computer using a graphical user
interface.
[0077] In step 210, a customer's shoe model selection may be
received. For example, step 210 may comprise receiving a user
selection of a presented shoe model from within a graphical user
interface. A customer may select a checkbox associated with a
basketball shoe model, for instance, to indicate that he or she
would like to order a basketball shoe.
[0078] In step 215, functional options for the selected shoe model
may be presented to the customer. Similarly to step 205, step 215
may be performed, for example, within a graphical user interface
operating on a computer. Functional options may include parameters
such as shoe size. Other types of options that may be selected in
step 215 may include outsole hardness options, support options,
motion control options, outsole texture options, outsole material
options, and the like. It should be appreciated that step 215 need
not necessarily be presented after step 205 and step 210, but that
in many instances the functional options available may depend upon
the shoe model selected. For instance, functional options relating
to foot motion control may be relevant to a running shoe and
therefore made available for customer selection after a customer
has selected a running shoe model, while motion control options are
not relevant for a basketball shoe, and therefore need not be
available for basketball shoe models. Additionally, similarly to
step 205, site-manufacturing information specific to each
functional option may be indicated. For example, some functional
options may be available for shoes manufactured on-site at a
connected or local manufacturing facility, while others may only be
available at a non-local manufacturing facility. One or ordinary
skill in the art will readily appreciate any number of other types
of functional options that are relatively specific to one or more
particular model type of shoe.
[0079] In step 220, a customer's functional options selection may
be received. Similarly to step 210, step 220 may be performed, for
example, within a graphical user interface operating on a computer.
For example, step 220 may comprise receiving a user selection of a
specific functional option, such as midsole hardness, within a
graphical user interface. For example, a customer may select a
checkbox associated with an indication of midsole hardness to
indicate that he or she would like the midsoles on his or her shoes
to be of a specific hardness.
[0080] In step 225, aesthetic options for the selected shoe model
and/or functional options may be presented to the customer. Step
225 may occur using a graphical user interface on a computer,
similarly to step 205 and step 215. The aesthetic options presented
in step 225 may depend, at least in part, upon the model option
selected by a customer and/or the functional options selected by a
customer. However, it is also possible that aesthetic options may
exist entirely or partially independent of model and/or functional
options, in which case step 225 may occur prior to or in
conjunction with step 205 and/or step 215. For example, options
regarding shoe color may not depend upon shoe model or functional
options. On the other hand, options relating to the color of a
particular functional element, for example, will necessarily be
dependent upon whether that functional element has been selected,
either as part of a shoe model selection or as a functional option.
Also, similarly to step 205, site-manufacturing information
specific to each aesthetic option may be indicated. For example,
some aesthetic options may be available for shoes manufactured
on-site at a connected or local manufacturing facility, while
others may only be available at a non-local manufacturing
facility.
[0081] In step 230, the aesthetic option selections may be received
from the customer. Step 230 may be performed, for example, by
receiving customer selections using a pointing device in a
graphical user interface on a computer, for example, by clicking
checkboxes appropriate for each aesthetic option selected.
[0082] In step 235, a customer's site manufacturing options may be
presented.
[0083] Similarly to step 205, step 235 may be performed, for
example, within a graphical user interface operating on a computer.
Site manufacturing options presented in step 235 may comprise, for
instance, an option for on-site manufacture at a connected or local
manufacturing facility, the option for manufacture at a specific
local or non-local facility, or an option to indicate no
site-manufacturing preference. It may be appreciated that the
options presented in this step may be influenced by the customer's
selection of shoe model in step 210, the customer's selection of
functional shoe options in step 220, and/or the customer's
selection of aesthetic options in step 230. For example, if a
customer selects a shoe model in step 210 that cannot be
manufactured on-site at a connected or local manufacturing
facility, step 215 might not present such a manufacturing option to
the user. Also, as an example, if a customer selects a functional
option in step 220 or and aesthetic option in step 230 that cannot
be incorporated into a shoe at a specific manufacturing site, such
manufacturing site might not be included in the list of
manufacturing options in step 235. Step 235 may comprise, for
example, presenting to the user a list of options comprising all
sites where a particular model of shoe with the particular selected
functional and aesthetic options may be manufactured.
[0084] In step 240, a customer's site manufacturing selection may
be received. Similarly to step 210, step 240 may be performed, for
example, within a graphical user interface operating on a computer.
For example, step 240 may comprise receiving a user selection of a
presented manufacturing facility from within a graphical user
interface. For example, a customer may select a checkbox associated
with an local manufacturing facility to indicate that he or she
would like his or her shoes to be manufactured on-site at a
connected or local manufacturing facility.
[0085] In step 245, pickup options for the selected shoe model may
be presented to the customer. For example, step 245 may comprise
presenting a list of options to the user comprising the option of
picking up the shoes at the store where an order has been placed,
the option of picking up the shoes from a connected or local
manufacturing facility, the option of having the shoes delivered to
a different store location, and the option of having the shoes
delivered to the customer at his or her residence. It will be
appreciated by one of ordinary skill in the art that the options
presented in this step may be tailored to reflect the customer's
manufacturing site selection in step 240. For example, if in step
240 a user selects on-site manufacturing for his or her order, step
245 may present the user with the option of picking his or her
shoes up from the store or from a connected or nearby manufacturing
facility. On the other hand, if, for example, the customer in step
240 selects a shoe that cannot be manufactured on-site, the options
presented in step 245 might not comprise the option to pick up the
shoes at a nearby manufacturing facility.
[0086] In step 250, a customer's pickup selection may be received.
Similarly to step 210, step 250 may be performed, for example,
within a graphical user interface operating on a computer. Step 250
may comprise, for instance, receiving a user selection of a pickup
option from within a graphical user interface. For example, a
customer may select from a dropdown list to indicate that he or she
would like his or her shoes to be available for pickup at the store
in which the order was placed. Alternatively, step 250 may comprise
receiving an indication that the user would prefer to have his or
her order mailed to his or her residence. In another example, step
250 may comprise receiving an indication that the user would prefer
to have his or her order delivered to another store site for
pickup.
[0087] In step 255, a workflow may be initiated in a facility
designated by the user in step 240 to construct an outsole in
accordance with the shoe model option selected by the customer. The
workflow may also incorporate the functional options, and/or
aesthetic options selected by a customer. For example, if, in step
210, the customer selected a basketball shoe model, a basketball
shoe workflow may be initiated in the outsole manufacturing
compartment. It should be noted that the specific basketball shoe
workflow for any particular basketball shoe may vary to some degree
such that the customer's particular functional and/or aesthetic
selections be incorporated into the final basketball shoe yet the
workflow may still be considered a basketball shoe workflow (as
opposed to being a skate shoe workflow). Alternatively, had the
customer selected a running shoe model in step 210, for instance, a
running shoe workflow may be initiated to construct an outsole in
accordance with a running shoe model.
[0088] It should first be noted that step 255 need not necessarily
incorporate a different workflow for each shoe model, as some shoe
models may exhibit a certain amount of overlap in certain component
manufacturing compartments. For example, a workflow for a skate
shoe outsole may be similar enough to a workflow for a basketball
shoe outsole such that there need be only one outsole workflow for
the production of both basketball and skate shoe outsoles. This
does not necessarily mean, however, that each component for these
shoes can similarly share a workflow; while the workflow for a
basketball shoe outsole may converge with the workflow for a skate
shoe outsole such that a single outsole workflow common to both
shoe models may be utilized, for instance, the workflows for each
shoe may diverge significantly in the production of their
respective midsoles such that separate midsole workflows need be
maintained. Different shoe model workflows may thus be implemented
in various component manufacturing compartments with varying
degrees of overlap. These overlapping, diverging and converging
workflows allow for the efficient manufacture of multiple models of
shoes in a single manufacturing facility while at the same time
reducing physical footprint of said manufacturing facility.
[0089] It should finally be noted that step 255 need not be
necessarily initiated by a specific selection by a specific
customer. For example, a predetermined level of inventory of
outsoles having various characteristics may be maintained. Outsoles
in three different colors may be made in each available size for
each of three different models of shoes available at a facility,
for instance. Outsoles may then be used from the inventory based
upon customer orders. Whenever a given model, size, and color of
outsole begins to run low in inventory, an operator may then
initiate a workflow for that model to construct additional outsoles
meeting those parameters. In this way, step 255 may be performed in
a way that is responsive to the shoe model, functional options,
and/or aesthetic options selected by customers, while not being
directly initiated by those customer selections. Further, step 255
may be performed in different ways for different types of outsoles,
for example by using an inventory system to initiate workflows for
commonly used outsoles and initiating workflows that produce less
commonly used outsoles only in response to orders requiring
them.
[0090] In step 260, a workflow for the production of a midsole may
be initiated in accordance with the shoe model; functional and/or
aesthetic options may also be incorporated in accordance with the
customer's selected options. First, it should be noted that,
similarly to step 255, each shoe model may not necessarily have its
own specific workflow but rather may share a workflow with another
shoe model. Second, similarly to step 255, a workflow for a
particular shoe model may vary to some degree to allow for the
functional and/or aesthetic customizations selected by the user to
be incorporated into the shoe model. Third, also similarly to step
255, step 260 need not be initiated in response to any given shoe
order by a particular customer, but may instead optionally utilize
an inventory system to initiate workflows to produce midsoles
having the desired characteristics. Finally, similarly to step 255,
initiating workflows to produce midsoles may be performed in
different ways for different types of midsoles, for example by
using an inventory system to initiate workflows for commonly used
midsoles and initiating workflows to produce less commonly used
midsoles only in response to orders requiring them.
[0091] In step 265, a workflow may be initiated to ready the
outsole and midsole to be affixed together in accordance with the
selected shoe model; functional options and aesthetic options
desired by the customer may also be incorporated. Step 265 may
comprise, for example, removing from outsole marketplace one or
more outsoles appropriate to the customer's order, removing from
midsole marketplace one or more midsoles appropriate to customers
order, skiving the edges of the removed midsole(s) and outsole(s),
placing the removed midsole(s) and outsole(s) in infrared oven,
priming the removed midsole(s) and outsole(s), and again placing
the removed midsole(s) and outsole(s) in infrared oven. It should
be noted that similarly to steps 255 and 260, each shoe model may
not necessarily have its own specific workflow at step 265 but
rather may share workflows with other shoe models. Also similarly
to step 255 and 260, a workflow for a particular shoe model may
vary to some degree to allow for the functional and/or aesthetic
customizations selected by the user to be incorporated into the
shoe model.
[0092] It should also be noted that any and/or all workflows for
any and/or all compartments, including those utilized in steps 255
and 260, may advantageously take similar amounts of time to
complete, allowing for completed components to be complete at
similar times. For example, the workflows from steps 255 and 260
may produce components that arrive at similar times so that they
may be readied in step 265 without the need to delay initiating a
workflow in step 265 to wait for certain necessary components to
arrive.
[0093] As an example, if a customer selected a basketball shoe
model, step 255 may comprise initiating a basketball shoe workflow
that comprises the steps of (1) injection molding a rubber outsole
taking approximately 220 seconds of machine time and approximately
15 seconds of human time, (2) removing flash and staging the
outsole in a finished outsole marketplace taking approximately 5
seconds of human time, (3) removing the outsole from the finished
marketplace taking approximately 5 seconds of human time, (4)
alkaline washing the outsole taking approximately 50 seconds of
machine time, (5) acid washing the outsole taking approximately 50
seconds of machine time, (6) drying the outsole taking
approximately 90 seconds of machine time, (7) removing the outsole
from the drying oven taking approximately 2 seconds of human time,
and (8) staging the outsole in the outsole marketplace taking
approximately 3 seconds of human time. Thus, the workflow for
producing a basketball shoe outsole in this example may take
approximately 350 seconds.
[0094] This being the case in this example, it may be advantageous
for the workflow utilized in step 260 to similarly take
approximately 350 seconds so that the parts may arrive at similar
times so that step 265 may proceed without undue delay.
[0095] It should further be noted that any workflow may overlap not
only spatially but also temporally with another workflow. For
example, a workflow for the production of a basketball midsole in
step 260 may comprise (1) injection molding a biscuit taking
approximately 30 seconds of machine time, (2) placing the biscuit
in biscuit marketplace taking approximately 10 seconds of human
time, (3) heat pressing the biscuit taking approximately 420
seconds of machine time and approximately 20 seconds of human time,
(4) loading the biscuit into a stabilization oven taking
approximately 5 seconds of human time, (5) heating the biscuit to
produce a midsole taking approximately 3600 seconds of machine
time, (6) removing the biscuit from the stabilization oven taking
approximately 5 seconds of human time, (7) water washing the
midsole taking approximately 600 seconds of machine time, (8)
drying the midsole and staging it in midsole staging marketplace
taking approximately 300 seconds of machine time and approximately
5 seconds of human time, (9) removing the midsole from midsole
staging marketplace taking approximately 2 seconds of human time,
and (10) staging the midsole for assembly taking approximately 3
seconds of human time.
[0096] Utilizing this example workflow without temporal overlap
would thus produce a midsole approximately every 5000 seconds.
However, while step (5) for instance may in this example take
approximately 3600 seconds, the stabilization may be done by a load
stabilization oven that may comprise a unit that allows multiple
midsoles to be in the process of stabilization at once. So, for
instance, a first basketball midsole workflow may be initiated, and
steps (1), (2), (3) and (4) may be performed on a first biscuit. In
step (5), the first biscuit may need to remain in the stabilization
oven for approximately 3600 seconds to become a first midsole.
During this time, while this first biscuit is thus in the
stabilization oven, a second midsole workflow, basketball or
otherwise, may be initiated, starting with step (1) for that
particular workflow, and progressing up to the step in that
particular workflow wherein the second biscuit is loaded into the
stabilization oven, for example. At this point in the example, two
separate workflows are in progress, each having progressed up to
and being currently in the stabilization step; accordingly, two or
more different biscuits, associated with different models of shoe
or not, may be in the stabilization oven in different stages of
stabilization at any given time. Any number of workflows may thus
be initiated be in varying stages of progress and overlap in such a
manner. At the point in time when the stabilization of step (5) for
the first workflow is finished, the first midsole may be removed
from the stabilization oven and the first initiated basketball
midsole workflow may be resumed at step (6).
[0097] In another example of temporally overlapping workflows, and
again referring to the example basketball midsole workflow above,
after having loaded the first biscuit into the stabilization oven
at step (5), a second workflow may be initiated to produce a
basketball shoe outsole. This second workflow may be completed and
a third basketball outsole workflow may be initiated and completed.
As would be appreciated by one of ordinary skill in the art, any
number of workflows may be thus initiated while the first midsole
workflow from the above example remains in step (5). At any point
in time, the midsole workflow of the original example may be
resumed at step (6) to complete the first midsole.
[0098] It may be noted that these workflows may overlap in any
advantageous manner as would be obvious to one of ordinary skill in
the art. In this example, each workflow may be tailored to overlap
such that a new midsole will emerge in an amount of time similar to
the amount of time it takes to produce other shoe components in
this or other shoe component manufacturing compartments. This may
advantageously allow various components to arrive at similar times
to undergo a joining workflow for instance. In the current example,
for instance, through the use of temporally overlapping workflows,
a midsole may be produced approximately every 350 seconds to
coincide with the amount of time it takes to execute an outsole
workflow from the example used in step 255. These two workflows may
thus take a similar amount of time to produce two components to be
joined utilizing a joining workflow without undue delay. It should
also be noted that the use of temporally overlapping workflows can
be applied to any step utilizing workflows, such as, for example,
steps 255 and 260, as would be obvious to one of ordinary skill in
the art.
[0099] In step 270, one or more customization workflows for an
upper for a particular shoe model may be initiated in accordance
with the shoe model; again, functional options, and/or aesthetic
options selected by a customer may be incorporated. It should again
be noted that, similarly to step 255, 260, and 265, each shoe model
may not necessarily have its own specific workflow but rather may
share a workflow with another shoe model. Also similarly to step
255, 260, and 265, a workflow for a particular shoe model may vary
to some degree to allow for the functional and/or aesthetic
customizations selected by the user to be incorporated into the
shoe model. While step 270, similarly to step 255, 260, and 265,
may be performed without regard to any particular order by a
customer, in practice the customization attainable in a shoe upper
will likely result in step 270 being performed in response to a
specific customer order. For example, step 270 may initiate a
workflow to construct an upper for a running shoe having a red
color. Similarly, step 270 may initiate a workflow to construct
uppers for other types of shoe models, such as basketball shoes or
skate shoes; these workflows may further incorporate any of a
variety of functional characteristics, such as additional ankle
support, side ventilation, and other similar functional options,
with any of a variety of aesthetic options, such as particular
colors, stitching patterns, insignia, and the like.
[0100] As another example, step 270 may comprise initiating a
basketball shoe upper customization workflow comprising (1)
printing echo-solvent customization taking approximately 120
seconds of machine time and approximately 30 seconds of human time,
(2) cutting vamp liner and vamp qtr. taking approximately 30
seconds of human time, (3) laser customization taking approximately
120 seconds of machine time and approximately 30 seconds of human
time, (4) embroidery customization taking approximately 120 seconds
of machine time and approximately 30 seconds of human time, (5)
delivering parts to heat press taking approximately 5 seconds of
human time, and (6) checking the marketplace and cutting the parts
if needed, taking approximately 6 seconds of human time. Thus, the
basketball workflow in this example may take approximately 491
seconds. It should be noted that this process may, similarly to
steps 255, 260, and 265, use varying degrees of temporally
overlapping workflows such that an upper may be produced in a
shorter amount of time more similar to the amount of time it takes
to produce other components in this or other compartments utilizing
different workflows. For example, temporally overlapping workflows
may be utilized such that a customized upper, of any model type,
may be produced approximately every 350 seconds.
[0101] As another example, and to further illustrate how workflows
may overlap spatially, step 270 may comprise initiating a running
shoe upper customization workflow in response to having received
certain customer model selection input. This workflow might
comprise, for example, (1) printing echo-solvent customization
taking approximately 120 machine seconds and approximately 30 human
seconds, (2) cutting vamp liner and vamp qtr. taking approximately
30 human seconds, (3) print dye sublimation customization taking
approximately 120 machine seconds and approximately 20 human
seconds, (4) press dye sub.
[0102] customization taking approximately 12 machine seconds and
approximately 10 human seconds, (5) laser customization taking
approximately 120 machine seconds and approximately 30 human
seconds, (6) embroidery customization taking approximately 120
machine seconds and approximately 30 human seconds, (7) delivering
customized parts to radiofrequency welding marketplace taking
approximately 5 human seconds, and (8) checking radiofrequency
welding marketplace and cutting parts if needed, taking
approximately 6 human seconds. Thus, in this example, a customized
running shoe upper may be constructed in approximately 613 seconds.
It should be noted that this process may, similarly to previous
steps utilizing workflows, use varying degrees of temporally
overlapping workflows such that a running upper may be produced in
a shorter amount of time more similar to the amount of time it
takes to produce other components in this or other compartments
utilizing different workflows. For example, temporally overlapping
workflows may be utilized such that a customized running upper, of
any model type, may be produced approximately every 350 seconds. It
should be noted also that it will be obvious to one of ordinary
skill in the art how, in these examples, this running shoe upper
customization workflow overlaps similar machines, skills, and work
areas involved in the basketball shoe upper customization workflow
given as an example above.
[0103] In step 275, one or more workflows for further manufacturing
an upper for a particular shoe model may be initiated in accordance
with the shoe model; again, functional options, and/or aesthetic
options selected by a customer may be incorporated. It should again
be noted that, similarly to step 255, 260, 265, and 270 each shoe
model may not necessarily have its own specific workflow but rather
may share a workflow with another shoe model. Also similarly to
step 255, 260, 265, and 270, a workflow for a particular shoe model
may vary to some degree to allow for the functional and/or
aesthetic customizations selected by the user to be incorporated
into the shoe model. While step 275, similarly to step 255, 260,
265, and 270, may be performed without regard to any particular
order by a customer, in practice the customization attainable in a
shoe upper will likely result in step 275 being performed in
response to a specific customer order, or, more specifically, to
the upper piece produced in step 270. For example, step 275 may
initiate a workflow to stitch an upper for a running shoe according
to the user selections, said upper having been produced and
customized according the user selections in step 270.
[0104] As an example, step 275 may comprise initiating a basketball
upper forming and stitching workflow comprising (1) gathering parts
from marketplace taking approximately 15 seconds of human time, (2)
assembling the upper pieces taking approximately 20 seconds of
machine time and approximately 30 seconds of human time, (3)
activating heat press taking approximately 10 seconds of machine
time and approximately 2 seconds of human time, (4) loading the
parts into cooling rack taking approximately 60 seconds of machine
time and approximately 1 second of human time, (5) cutting final
trim taking approximately 15 seconds of human time, (6) heel
forming taking approximately 180 seconds of machine time and
approximately 20 seconds of human time, (7) post stitching taking
approximately 30 seconds of human time, (8) strobel stitching
taking approximately 40 seconds of human time, and (9) delivering
the upper to lasting station taking approximately 5 seconds of
human time. Thus, the basketball upper forming and stitching
workflow in this example may take approximately 428 seconds. It
should be noted that the process in the above example may,
similarly to steps 255, 260, 265, and 270, use varying degrees of
temporally overlapping workflows such that an upper may be produced
in a shorter amount of time more similar to the amount of time it
takes to produce other components in other compartments utilizing
different workflows. For example, in step (6), while waiting for a
machine to stitch the heel, the operator may initiate another
workflow for the same or another model of shoe. When the operator
reaches step (6) in this second workflow, for instance, the first
upper may be finished with step (6) and the operator may then
perform step (6) on the second upper and, while allowing the
machine to continue with step (6) on the second upper, may continue
with steps (7), (8), and (9) on the first upper. Any of these or
steps any other steps of a given workflow may be advantageously
overlapped as would be obvious to one of ordinary skill in the
art.
[0105] As another example, and to further illustrate how workflows
may overlap spatially, step 275 may comprise initiating a running
shoe upper radiofrequency welding and stitching workflow. This
workflow might comprise, for example, (1) gathering parts from
radiofrequency welding marketplace taking approximately 15 seconds
of human time, (2) assembling upper pieces taking approximately 30
seconds of human time, (3) activating the radiofrequency welding
cycle taking approximately 10 seconds of machine time and
approximately 10 seconds of human time, (4) cutting final trim
taking approximately 15 seconds of human time, (5) stitching upper
to sole taking approximately 60 seconds of human time, and (6)
delivering to final quality control area taking approximately 5
seconds of human time. This example workflow may thus take
approximately 145 seconds. It should be noted that this process
may, similarly to previous steps utilizing workflows, use varying
degrees of temporally overlapping workflows such that a running
shoe upper may be produced in a shorter amount of time more similar
to the amount of time it takes to produce other components in this
or other compartments utilizing different workflows. For example,
temporally overlapping workflows may be utilized such that a
customized running upper, of any model type, may be produced
approximately every 350 seconds. It should be noted also that it
will be obvious to one of ordinary skill in the art how, in these
examples, this running shoe upper radiofrequency welding and
stitching workflow overlaps similar machines, skills, and work
areas involved in the basketball upper forming and stitching
workflow given as an example above.
[0106] In step 280, a workflow may be initiated such that the
outsole, midsole, and upper may be affixed together to form the
selected shoe model in accordance with the selected shoe model;
functional options and aesthetic options desired by the customer
may also be incorporated. Step 280 may comprise, for example,
matching the appropriate outsole, the appropriate midsole, and a
specially customized upper to form a single shoe as ordered by a
customer. It should be noted that similarly to steps 255, 260, 265,
270, and 275, each shoe model may not necessarily have its own
specific workflow at step 280 but rather may share workflows with
other shoe models. Also similarly to step 255, 260, 265, 270, and
275, a workflow for a particular shoe model may vary to some degree
to allow for the functional and/or aesthetic customizations
selected by the user to be incorporated into the shoe model.
[0107] In another example, step 280 may comprise (1) applying
adhesive to the upper produced by step 275, the midsole produced by
step 260, and the outsole produced by step 255 taking approximately
75 human seconds, (2) placing the parts in oven taking
approximately 120 machine seconds, (3) hand fitting the parts
together taking approximately 75 human seconds, (4) pressing the
parts taking approximately 30 machine seconds and approximately 10
human seconds, (5) chilling the parts taking approximately 60
machine seconds and approximately 5 human seconds. Thus, the
workflow in this example may take approximately 460 seconds. It
should be noted that, like the other steps utilizing workflows in
this example, and number of workflows may be temporally overlapped
to lower the amount of time it takes to complete step 280 as would
be appreciated by one of ordinary skill in the art.
[0108] In step 285, a workflow may be initiated to quality control,
lace and last the customized combined shoe component; functional
options and aesthetic options desired by the customer may also be
incorporated. It should be noted that similarly to steps 255, 260,
265, 270, 275, and 280, each shoe model may not necessarily have
its own specific workflow at step 280 but rather may share
workflows with other shoe models. Also similarly to step 255, 260,
265, 270, 275, and 280, a workflow for a particular shoe model may
vary to some degree to allow for the functional and/or aesthetic
customizations selected by the user to be incorporated into the
shoe model.
[0109] In an example, step 285 may comprise (1) quality control
checking and lasting the combined shoe component taking
approximately 90 seconds of machine time and approximately 90
seconds of human time, (2) quality control checking and de-lasting
the combined shoe component taking approximately 30 seconds of
human time, (3) lacing the combined shoe component taking
approximately 60 seconds of human time, and (4) packing the shoe
taking essentially no time. Thus, the workflow in this example may
take approximately 270 seconds. It should be noted that, like the
other steps utilizing workflows in this example, and number of
workflows may be temporally overlapped to change the amount of time
it takes to complete step 285 as would be appreciated by one of
ordinary skill in the art.
[0110] In step 290, the customized shoe may be delivered to a
customer in accordance with the customer's selected pickup options
from step 245. Step 290 may further include inspection and approval
by a customer, payment, etc. It should be appreciated that while
step 290 may occur geographically distant from the location at
which all or parts of the other steps of method 200 are performed,
one desirable attribute of method 200 is that it permits the
localized manufacture of shoes to custom orders. Such localized
manufacturing can be more responsive to local needs and preferences
than remote manufacturing, and can provide reduced inventory and
shipping costs. Accordingly, step 290 may occur geographically
near, in fact in the same larger facility, as does the remainder of
steps of method 200.
[0111] Turning now to FIG. 3, an illustrative method for creating
an outsole for a running shoe is referenced generally by the
numeral 300. At a step 305, an injection rubber mold outsole is
created by way of an injection-mold process. In the illustrative
injection-mold-rubber process, rubber is injected into a mold that
forms an outsole. In another method, an outsole may be carved
and/or cut from a piece of rubber. At 310, an outsole is cured. In
another method, an outsole may be cured using stearic acid and
oils. This combination may cause blooming of the rubber, resulting
in rubber residue which may not be desired on an outsole.
[0112] At step 315, flash is removed from the outsole. One method
of removing flash from the outsole includes cutting and/or removing
and/or trimming undesired excess rubber. Another method of removing
flash may be to hand-wipe or hand-pick the flash off the rubber
outsole. At a step 320, the outsole is staged in an outsole
pre-wash marketplace. In one alternative, the number and character
(e.g., size, shape, color, etc.) of outsoles placed into a
marketplace are based on an expectation of demand. At a step 325,
an order is received. An illustrative method for receiving an order
includes receiving an order manually. In still another method, an
order may be received by uploading details of an order through a
web interface. In one alternative, steps 305-320 are not performed
until after an order is received. In that alternative, the outsole
is produced on an as-needed basis, not as a result of a projected
market demand. At step 330, the outsole is removed from the outsole
pre-wash marketplace.
[0113] At step 335 the outsole is washed. In one method, the
outsole is washed by way of an alkaline solution. In another
method, the outsole may go directly from step 315, where the flash
is removed from the outsole, to step 335, where the outsole is
washed. At step 340 the outsole is washed. In one method the
outsole is washed by way of an acid solution. The washing steps 335
and/or 340 may be a means of removing excess rubber residue created
by the curing process at step 310. In another method, a curing
process may be used wherein stearic acid is not used, thereby
reducing or minimizing the rubber residue produced. In this method,
the cleaning steps 335 and/or 340 would be reduced in time and/or
materials, or could be eliminated. At step 345 the outsole is dried
in an oven. In another way, an outsole may be dried in any way that
is capable of producing heat that dries the outsole to a desired
dryness within a desired period of time. At step 350 the outsole is
removed from the oven. In another method, the outsole may be
removed from another heating device that has been used to take away
moisture from the outsole mold. At step 355, the outsole is staged
in an outsole staging marketplace. In another method, where there
is little or no rubber excess produced from the curing process 315,
the outsole may go directly from the curing process 315 to being
staged in the outsole staging marketplace 355. In another method,
where there is minimal rubber residue, the outsole may go from the
curing process 315 to a cleaning step 335 wherein the outsole is
wiped with a material, such as a cloth, to remove the excess
rubber. In the former example, the outsole may either go directly
from the curing process 315 to a cleaning step 335, or may go from
the curing process 315 to an outsole marketplace 320 before being
removed from an outsole marketplace 330. The outsole would be able
to skip the time spent in an outsole marketplace 320-330 when an
order is received prior to the production of the outsole (e.g. when
the outsole is produced on an as-needed basis).
[0114] Referring to FIG. 4, an illustrative method for creating a
midsole for a running shoe is referenced generally by the numeral
400. At step 402, a pre-specified volume of EVA pellets are loaded
into an injection mold. In an alternative, the selection of the
type of polymer injected at step 402 may be correlated to the
desired hardness associated with the customer order of the
resulting midsole. The EVA pellets are processed in the same mold
at the same conditions, thus the introduction of EVA pellets with
longer polymer chains will result in an increased hardness compared
to EVA pellets that are introduced with shorter polymer chains,
because the longer polymer chains will not be able to break down to
the same extent as shorter polymer chains under the same reaction
conditions. At step 404, the injection mold is then heated to
100.degree. Celsius to form the volume of EVA pellets into a
biscuit. In another embodiment, the EVA pellets may be heated to a
temperature that may be hot enough to form the EVA pellets into the
form of a biscuit and yet may not be hot enough to activate the
foaming agent within the phylon. In still another embodiment, the
reaction conditions of the mold may be changed to influence the
extent that a given polymer is allowed to break down, thereby
resulting in a variety of different hardnesses. At step 406 the
biscuit is then removed from the injection mold. At step 410, the
biscuit is then staged into a biscuit marketplace. At step 415, an
order is received. An illustrative method for receiving an order
includes receiving an order manually. In still another method, an
order may be received by uploading details of an order through a
web interface.
[0115] At step 420, the biscuit is removed from the biscuit
marketplace. At step 430, biscuit is then loaded into a heat press.
In another method, such as when an order is received prior to the
biscuit being made, the biscuit may go directly from being removed
from an injection mold 406 to being loaded into a heat press 430.
In another method, there is a right heat press and a left heat
press for the right-shoe-biscuit and left-shoe-biscuit,
respectively. In still another method, the right heat press and the
left heat press may be operated concurrently. At step 434, the
biscuit is then heated to 172.degree. Celsius. In another
embodiment, the biscuit may be heated to a temperature that may be
hot enough to activate the foaming agent. At step 438, the biscuit
is removed from the heat press. In step 440, the biscuit is loaded
into a stabilization oven. In the stabilization oven, the biscuit
is cooled to a lower temperature that allows the biscuit to become
the desired size as a midsole. At step 444, the biscuit may be
placed into an air stabilization oven and the temperature may be
lowered to 75.degree. Celsius. The process by which air is passed
over a biscuit in a stabilization oven may be through the use of
one or more air knife centrifugal blowers. In steps 448-452, the
biscuit may have its temperature lowered over three stages. At step
448, the temperature of the biscuit may be lowered from 75.degree.
Celsius to 65.degree. Celsius. At step 452, the temperature of the
biscuit may be lowered from 65.degree. Celsius to 55.degree.
Celsius. At step 454, the temperature of the biscuit may be lowered
from 55.degree. Celsius to 45.degree. Celsius. In another method,
the cooling stages of 448-452 may be done in three or more stages.
In another alternative method, the step at 444 of lowering biscuit
temperature to 75.degree. Celsius may be adjusted to a higher or
lower temperature. In another method, one or more biscuits may be
stabilized using a series of baths of water that may range from
90.degree. Celsius to 45.degree. Celsius. The temperature of the
biscuit may decrease from 90.degree. Celsius to 75.degree. Celsius,
then 75.degree. Celsius to 45.degree. Celsius, wherein the time
within each bath may be spread evenly.
[0116] At step 458, the midsole is removed from the stabilization
oven. At step 460, the midsole is loaded into one or more sonic
baths. At step 464 in the sonic bath, the midsole is washed. In
another method, step 458 may be removed and the midsole may be
washed while it is still in a dual stabilization-oven-sonic-bath
device. At step 468 the midsole is removed from the sonic bath. At
step 470, the midsole is loaded into one or more drying ovens. At
step 474 the midsole is dried. At step 478, the midsole is removed
from the one or more drying ovens. At step 480, the midsole is
loaded into a midsole staging marketplace.
[0117] Turning now to FIG. 5, an illustrative method for applying
primer and adhesive on a running shoe is referenced generally by
the numeral 500. At step 504, a customer order is received. The
customer order contains specifications for the characteristics
associated with one or more desired running shoes, such as size or
style or color. At step 506, an outsole fitting the characteristics
defined in the customer order is removed from the outsole staging
marketplace. At step 508, a midsole fitting the characteristics
defined in the customer order may be removed from the midsole
staging marketplace. At step 510, a midsole and an outsole are
primed. At step 520, the primed midsole and the primed outsole may
be placed in an infrared (hereinafter "IR") oven. At step 530, the
midsole and outsole may be removed from the IR oven. At step 540,
adhesive may be applied to the midsole and the outsole. At step
550, the midsole and the outsole are placed in an IR oven.
[0118] Turning now to FIG. 6, an illustrative method for joining an
outsole and a midsole into a midsole-outsole on a running shoe is
referenced generally by the numeral 600. At step 610, the outsole
and the midsole are removed from the IR oven. At step 620, the
outsole and midsole are fit together to form a midsole-outsole. At
step 630, the midsole-outsole is loaded into a stockfit press. At
step 634, the midsole-outsole is heated. The heat may allow the
adhesive to more permanently bind the components of the
midsole-outsole. At step 638, the midsole-outsole is removed from
the stockfit press. At step 640, the midsole-outsole is loaded into
a chiller. The chiller is used to cool down the midsole-outsole to
approximately 0.degree. Celsius to allow the adhesive to set. In
another method, the midsole-outsole may be placed in a more
temperate area where the midsole-outsole may be left to cool over a
longer period of time. In another method, at step 644, the
temperature of the midsole-outsole is lowered. In another method,
the press may be turned off and the midsole-outsole may be left to
cool in the press until the heat dissipates. In still another
method, the press may be wired with both a heating component and a
cooling component such that a shoe article, such as a
midsole-outsole, may be heated and cooled in one location. In that
regard, having a dual heating and cooling press would both save
room and would also eliminate the risk of having components of a
shoe article become misaligned or fall apart during the period they
are moved between the heat press and the chiller. At step 648, the
midsole-outsole is removed from the chiller. At step 650, the
midsole-outsole is delivered to the swing arm post staging
area.
[0119] Referring to FIG. 7, an illustrative method for customizing
an upper for a running shoe is referenced generally by the numeral
700. At step 702, an order is received.
[0120] An illustrative method for receiving an order includes
receiving an order manually. In still another method, an order may
be received by uploading details of an order through a web
interface. At step 704, material associated with the order for the
upper (e.g. synthetic leather or mesh or polyester, etc.) is loaded
into an eco-solvent printer. At step 706, the eco-solvent printer
and dye sub printer are loaded with material, such as desired
colors, associated with an order. At step 708, the dye sub printer
is used to print desired designs and/or markings on the desired
material used for the upper. At step 710, the eco-solvent printer
is used to print desired designs and/or markings on the desired
material used for the upper. At step 715, a customized synthetic is
cut out from the desired material according to the specifications
characterizing an order. At step 720, the customized synthetic is
loaded into a laser. At step 724, the laser is loaded with the
specification of the design associated with the order. At step 728,
the laser etches a customized design onto the customized
synthetic.
[0121] At step 730, the dye sub press is loaded. At step 735, the
customized synthetic is removed from the laser. At step 740, the
right embroidery machine is loaded with the customized synthetic.
At step 742, the left embroidery machine is loaded with the
customized synthetic. At step 744, the embroidery machines are
loaded with design specifications associated with the order. At
step 746, left and right parts are embroidered using the left
embroidery machine and right embroidery machine, respectively. At
step 750, the left part and right part are removed from the
embroidery machines. At step 760, the customized parts are
delivered to the radio frequency (hereinafter "RF") welding staging
area.
[0122] Note that some of the decorative techniques disclosed above
may not be applicable to each shoe model and therefore some of the
steps disclosed above may be omitted. For instance, not all shoe
models may require embroidery or laser etching. Moreover, different
components of an upper may proceed through different steps, in
different orders, and at different times.
[0123] Referring to FIG. 8, an illustrative method for assembling
an upper for a running shoe is referenced generally by the numeral
800. At step 805, customized parts for the upper are retrieved from
the RF welding staging area. At step 810, a kit is retrieved from
the marketplace which contains necessary parts associated with the
customer order. At step 820, an upper is assembled from the
customized parts. At step 825, an RF welding cycle is activated,
binding together the assembled upper constructed of the customized
parts. At step 830, a final trim is cut on the upper to define the
final shape of the upper. At step 840, the midsole-outsole is
retrieved from the swing arm staging area. At step 850, the upper
is stitched to the midsole-outsole.
[0124] Referring to FIG. 9, an illustrative method for lasting and
quality control for a running shoe is referenced generally by the
numeral 900. At step 910, the shoe component is retrieved from the
swing arm area. At step 920, a quality control check is performed
and the upper is lasted. At step 930, a quality control check is
performed on the lasted upper and the upper is then de-lasted. At
step 940 a quality control check is performed and the upper is
laced. At step 950, a quality control check is performed and the
shoe is packed.
[0125] Turning now to FIG. 10, an illustrative method for creating
an outsole for a basketball shoe is referenced generally by the
numeral 1000. At a step 1005, an injection rubber mold outsole is
created by way of an injection-mold process. In the illustrative
injection-mold-rubber process, rubber is injected into a mold that
forms an outsole. In another method, an outsole may be carved
and/or cut from a piece of rubber. At 1010, an outsole is cured. In
one alternative, an outsole may be cured using stearic acid and
oils. This combination may cause blooming of the rubber, resulting
in rubber residue which may not be desired on an outsole.
[0126] At step 1015, flash is removed from the outsole. One method
of removing flash from the outsole includes cutting and/or removing
and/or trimming undesired excess rubber. Another method of removing
flash may be to hand-wipe or hand-pick the flash off the rubber
outsole. At a step 1020, the outsole is staged in an outsole
pre-wash marketplace.
[0127] In one alternative, the number and character (e.g., size,
shape, color, etc.) of outsoles placed into a marketplace are based
on an expectation of demand. At a step 1025, an order is received.
An illustrative method for receiving an order includes receiving an
order manually. In still another method, an order may be received
by uploading details of an order through a web interface. In one
alternative, steps 1005-1020 are not performed until after an order
is received. In that alternative, the outsole is produced on an
as-needed basis, not as a result of a projected market demand. At
step 1030, the outsole is removed from the outsole pre-wash
marketplace.
[0128] At step 1035 the outsole is washed. In one method, the
outsole is washed by way of an alkaline solution. In another
method, the outsole may go directly from step 1015, where the flash
is removed from the outsole, to step 1035, where the outsole is
washed. At step 1040 the outsole is washed. In one method the
outsole is washed by way of an acid solution. The washing steps
1035 and/or 1040 may be a means of removing excess rubber residue
created by the curing process at step 1010. In another method, a
curing process may be used wherein stearic acid is not used,
thereby reducing or minimizing the rubber residue produced. In this
method, the cleaning steps 1035 and/or 1040 would be reduced in
time and/or materials, or could be eliminated. At step 1045 the
outsole is dried in an oven. In another way, an outsole may be
dried in any way that is capable of producing heat that dries the
outsole to a desired dryness within a desired period of time. At
step 1050 the outsole is removed from the oven. In another method,
the outsole may be removed from another heating device that has
been used to take away moisture from the outsole mold. At step
1055, the outsole is staged in an outsole staging marketplace. In
another method, where there is little or no rubber excess produced
from the curing process 1015, the outsole may go directly from the
curing process 1015 to being staged in the outsole staging
marketplace 1055. In another method, where there is minimal rubber
residue, the outsole may go from the curing process 1015 to a
cleaning step 1035 wherein the outsole is wiped with a material,
such as a cloth, to remove the excess rubber. In the former
example, the outsole may either go directly from the curing process
1015 to a cleaning step 1035, or may go from the curing process
1015 to an outsole marketplace 1020 before being removed from an
outsole marketplace 1030. The outsole would be able to skip the
time spent in an outsole marketplace 1020-1030 when an order is
received prior to the production of the outsole (e.g. when the
outsole is produced on an as-needed basis).
[0129] Referring to FIG. 11, an illustrative method for creating a
midsole for a basketball shoe is referenced generally by the
numeral 1100. At step 1102, a pre-specified volume of EVA pellets
are loaded into an injection mold. In an alternative, the selection
of the type of polymer injected at step 1102 may be correlated to
the desired hardness associated with the customer order of the
resulting midsole. The EVA pellets are processed in the same mold
at the same conditions, thus the introduction of EVA pellets with
longer polymer chains will result in an increased hardness compared
to EVA pellets that are introduced with shorter polymer chains,
because the longer polymer chains will not be able to break down to
the same extent as shorter polymer chains under the same reaction
conditions. At step 1104, the injection mold is then heated to
100.degree. Celsius to form the volume of EVA pellets into an
biscuit. In another embodiment, the EVA pellets may be heated to a
temperature that may be hot enough to form the EVA pellets into the
form of a biscuit and yet may not be hot enough to activate the
foaming agent within the phylon. In still another embodiment, the
reaction conditions of the mold may be changed to influence the
extent that a given polymer is allowed to break down, thereby
resulting in a variety of different hardnesses. At step 1106 the
biscuit is then removed from the injection mold. At step 1110, the
biscuit is then staged into a biscuit marketplace. At step 1115, an
order is received. An illustrative method for receiving an order
includes receiving an order manually. In still another method, an
order may be received by uploading details of an order through a
web interface.
[0130] At step 1120, the biscuit is removed from the biscuit
marketplace. At step 1130, biscuit is then loaded into a heat
press. In another method, such as when an order is received prior
to the biscuit being made, the biscuit may go directly from being
removed from an injection mold 1106 to being loaded into a heat
press 1130. In another method, there is a right heat press and a
left heat press for the right-shoe-biscuit and left-shoe-biscuit,
respectively. In still another method, the right heat press and the
left heat press may be operated concurrently. At step 1134, the
biscuit is then heated to 172.degree. Celsius. In another
embodiment, the biscuit may be heated to a temperature that may be
hot enough to activate the foaming agent. At step 1138, the biscuit
is removed from the heat press. In step 1140, the biscuit is loaded
into a stabilization oven. In the stabilization oven, the biscuit
is cooled to a lower temperature that allows the biscuit to become
the desired size as a midsole. At step 1144, the biscuit is lowered
to a temperature 75.degree. Celsius. In steps 1148-1152, the
biscuit has its temperature lowered over three stages. At step
1148, the temperature of the biscuit is lowered from 75.degree.
Celsius to 65.degree. Celsius. At step 1152, the temperature of the
biscuit is lowered from 65.degree. Celsius to 55.degree. Celsius.
At step 1154, the temperature of the biscuit is lowered from
55.degree. Celsius to 45.degree. Celsius. In another method, the
cooling stages of 1148-1152 may be done in three or more stages. In
another method, the step at 1144 of lowering biscuit temperature to
75.degree. Celsius may be adjusted to a higher or lower
temperature.
[0131] At step 1158, the midsole is removed from the stabilization
oven. At step 1160, the midsole is loaded into one or more sonic
baths. At step 1164 in the sonic bath, the midsole is washed. In an
alternative method, step 1158 may be removed and the midsole may be
washed while it is still in a dual stabilization-oven-sonic-bath
device. At step 1168 the midsole is removed from the sonic bath. At
step 1170, the midsole is loaded into one or more drying ovens. At
step 1174 the midsole is dried. At step 1178, the midsole is
removed from the one or more drying ovens. At step 1180, the
midsole is loaded into a midsole staging marketplace.
[0132] Turning now to FIG. 12, an illustrative method for applying
primer and adhesive on a basketball shoe is referenced generally by
the numeral 1200. At step 1204, a customer order is received. The
customer order contains specifications for the characteristics
associated with one or more desired basketball shoes, such as size
or style or color. At step 1206, an outsole fitting the
characteristics defined in the customer order is removed from the
outsole staging marketplace. At step 1208, a midsole fitting the
characteristics defined in the customer order may be removed from
the midsole staging marketplace. At step 1210, a midsole and an
outsole are primed. At step 1220, the primed midsole and the primed
outsole may be placed in an IR oven. At step 1230, the midsole and
outsole are removed from the IR oven. At step 1240, adhesive may be
applied to the midsole and the outsole. At step 1250, the midsole
and the outsole are placed in an IR oven.
[0133] Turning now to FIG. 13, an illustrative method for joining
an outsole and a midsole into a midsole-outsole on a basketball
shoe is referenced generally by the numeral 1300. At step 1310, the
outsole and the midsole are removed from the IR oven. At step 1320,
the outsole and midsole are fit together to form a midsole-outsole.
At step 1330, the midsole-outsole is loaded into a stockfit press.
At step 1334, the midsole-outsole is heated. The heat may allow the
adhesive to more permanently bind the components of the
midsole-outsole. At step 1338, the midsole-outsole is removed from
the stockfit press. At step 1340, the midsole-outsole is loaded
into a chiller. The chiller is used to cool down the
midsole-outsole to approximately 0.degree. Celsius to allow the
adhesive to set. In another method, the midsole-outsole may be
placed in a more temperate area where the midsole-outsole may be
left to cool over a longer period of time. In another method, at
step 1344, the temperature of the midsole-outsole is lowered. In
another method, the press may be turned off and the midsole-outsole
may be left to cool in the press until the heat dissipates. In
still another method, the press may be wired with both a heating
component and a cooling component such that a shoe article, such as
a midsole-outsole, may be heated and cooled in one location. In
that regard, having a dual heating and cooling press would both
save room and would also eliminate the risk of having components of
a shoe article become misaligned or fall apart during the period
they are moved between the heat press and the chiller. At step
1348, the midsole-outsole is removed from the chiller. At step
1350, the midsole-outsole is delivered to the swing arm post
staging area.
[0134] Referring to FIG. 14, an illustrative method for customizing
an upper for a basketball shoe is referenced generally by the
numeral 1400. At step 1402, an order is received. An illustrative
method for receiving an order includes receiving an order
manually.
[0135] In still another method, an order may be received by
uploading details of an order through a web interface. At step
1404, material associated with the order for the upper (e.g.
synthetic leather or mesh or polyester, etc.) is loaded into an
eco-solvent printer. At step 1406, the eco-solvent printer and dye
sub printer are loaded with material, such as desired colors,
associated with an order. At step 1408, the dye sub printer is used
to print desired designs and/or markings on the desired material
used for the upper. At step 1410, the eco-solvent printer is used
to print desired designs and/or markings on the desired material
used for the upper. At step 1415, a customized synthetic is cut out
from the desired material according to the specifications
characterizing an order. At step 1420, the customized synthetic is
loaded into a laser. At step 1424, the laser is loaded with the
specification of the design associated with the order. At step
1428, the laser etches a customized design onto the customized
synthetic.
[0136] At step 1430, the dye sub press is loaded. At step 1435, the
customized synthetic is removed from the laser. At step 1440, the
right embroidery machine is loaded with the customized synthetic.
At step 1442, the left embroidery machine is loaded with the
customized synthetic. At step 1444, the embroidery machines are
loaded with design specifications associated with the order. At
step 1446, left and right parts are embroidered using the left
embroidery machine and right embroidery machine, respectively. At
step 1450, the left part and right part are removed from the
embroidery machines. At step 1460, the customized parts are
delivered to the heat press marketplace. At step 1470, uppers are
checked for excess material and cut when needed.
[0137] Note that some of the decorative techniques disclosed above
may not be applicable to each shoe model and therefore some of the
steps disclosed above may be omitted. For instance, not all shoe
models may require embroidery or laser etching. Moreover, different
components of an upper may proceed through different steps, in
different orders, and at different times.
[0138] Referring to FIG. 15, an illustrative method for forming and
stitching an upper for a basketball shoe is referenced generally by
the numeral 1500. At step 1505, customized parts for the upper are
retrieved from the heat press marketplace. At step 1510, a kit is
retrieved from the marketplace which contains necessary parts
associated with the customer order. At step 1520, an upper is
assembled from the customized parts. At step 1530, the assembled
upper parts are loaded into a heat press. At step 1534, the heat
press is activated and the assembled upper parts are heated. The
temperature reached is high enough that the adhesive used to bind
parts is activated. At step 1538, the parts are removed from the
heat press. At step 1540 the parts are placed on a cooling rack. At
step 1548, the parts are removed from the cooling rack. At step
1550, a heel is formed by stitching. In an alternative, the heel
may be formed by another binding method. At step 1560, the parts
are post-stitched. At step 1570, the parts are strobel stitched. At
step 1580, the parts are delivered to a lasting station.
[0139] Referring to FIG. 16, an illustrative method for lasting and
quality control for a basketball shoe is referenced generally by
the numeral 1600. At step 1610, the shoe component is retrieved
from the lasting station. At step 1620, a quality control check is
performed and the upper is lasted. At step 1630, a quality control
check is performed on the lasted upper and the upper is then
de-lasted. At step 1640 a quality control check is performed and
the upper is laced. At step 1650, a quality control check is
performed and the shoe is packed.
[0140] Turning now to FIG. 17, an illustrative method for creating
an outsole for a skate shoe is referenced generally by the numeral
1700. At a step 1705, an injection rubber mold outsole is created
by way of an injection-mold process. In the illustrative
injection-mold-rubber process, rubber is injected into a mold that
forms an outsole. In another method, an outsole may be carved
and/or cut from a piece of rubber. At 1710, an outsole is cured. In
one alternative, an outsole may be cured using stearic acid and
oils. This combination may cause blooming of the rubber, resulting
in rubber residue which may not be desired on an outsole.
[0141] At step 1715, flash is removed from the outsole. One method
of removing flash from the outsole includes cutting and/or removing
and/or trimming undesired excess rubber. Another method of removing
flash may be to hand-wipe or hand-pick the flash off the rubber
outsole. At a step 1720, the outsole is staged in an outsole
pre-wash marketplace. In one alternative, the number and character
(e.g., size, shape, color, etc.) of outsoles placed into a
marketplace are based on an expectation of demand. At a step 1725,
an order is received. An illustrative method for receiving an order
includes receiving an order manually. In still another method, an
order may be received by uploading details of an order through a
web interface. In one alternative, steps 1705-1720 are not
performed until after an order is received. In that alternative,
the outsole is produced on an as-needed basis, not as a result of a
projected market demand. At step 1730, the outsole is removed from
the outsole pre-wash marketplace.
[0142] At step 1735 the outsole is washed. In one method, the
outsole is washed by way of an alkaline solution. In another
method, the outsole may go directly from step 1715, where the flash
is removed from the outsole, to step 1735, where the outsole is
washed. At step 1740 the outsole is washed. In one method the
outsole is washed by way of an acid solution. The washing steps
1735 and/or 1740 may be a means of removing excess rubber residue
created by the curing process at step 1710. In another method, a
curing process may be used wherein stearic acid is not used,
thereby reducing or minimizing the rubber residue produced. In this
method, the cleaning steps 1735 and/or 1740 would be reduced in
time and/or materials, or could be eliminated. At step 1745 the
outsole is dried in an oven. In another way, an outsole may be
dried in any way that is capable of producing heat that dries the
outsole to a desired dryness within a desired period of time. At
step 1750 the outsole is removed from the oven. In another method,
the outsole may be removed from another heating device that has
been used to take away moisture from the outsole mold. At step
1755, the outsole is staged in an outsole staging marketplace. In
another method, where there is little or no rubber excess produced
from the curing process 1715, the outsole may go directly from the
curing process 1715 to being staged in the outsole staging
marketplace 1755. In another method, where there is minimal rubber
residue, the outsole may go from the curing process 1715 to a
cleaning step 1735 wherein the outsole is wiped with a material,
such as a cloth, to remove the excess rubber. In the former
example, the outsole may either go directly from the curing process
1715 to a cleaning step 1735, or may go from the curing process
1715 to an outsole marketplace 1720 before being removed from an
outsole marketplace 1730. The outsole would be able to skip the
time spent in an outsole marketplace 1720-1730 when an order is
received prior to the production of the outsole (e.g. when the
outsole is produced on an as-needed basis).
[0143] Referring to FIG. 18, an illustrative method for creating a
midsole for a skate shoe is referenced generally by the numeral
1800. At step 1802, a pre-specified volume of EVA pellets are
loaded into an injection mold. In an alternative, the selection of
the type of polymer injected at step 1802 may be correlated to the
desired hardness associated with the customer order of the
resulting midsole. The EVA pellets are processed in the same mold
at the same conditions, thus the introduction of EVA pellets with
longer polymer chains will result in an increased hardness compared
to EVA pellets that are introduced with shorter polymer chains,
because the longer polymer chains will not be able to break down to
the same extent as shorter polymer chains under the same reaction
conditions. At step 1804, the injection mold is then heated to
170.degree. Celsius to form the volume of EVA pellets into a
biscuit. In another embodiment, the EVA pellets may be heated to a
temperature that may be hot enough to form the EVA pellets into the
form of a biscuit and yet may not be hot enough to activate the
foaming agent within the phylon. In still another embodiment, the
reaction conditions of the mold may be changed to influence the
extent that a given polymer is allowed to break down, thereby
resulting in a variety of different hardnesses. At step 1806 the
biscuit is then removed from the injection mold. At step 1810, the
biscuit is then staged into a biscuit marketplace. At step 1815, an
order is received. An illustrative method for receiving an order
includes receiving an order manually. In still another method, an
order may be received by uploading details of an order through a
web interface.
[0144] At step 1820, the biscuit is removed from the biscuit
marketplace. At step 1830, biscuit is then loaded into a heat
press. In another method, such as when an order is received prior
to the biscuit being made, the biscuit may go directly from being
removed from an injection mold 1806 to being loaded into a heat
press 1830. In another method, there is a right heat press and a
left heat press for the right-shoe-biscuit and left-shoe-biscuit,
respectively. In still another method, the right heat press and the
left heat press may be operated concurrently. At step 1834, the
biscuit is then heated to 172.degree. Celsius. In another
embodiment, the biscuit may be heated to a temperature that may be
hot enough to activate the foaming agent. At step 1838, the biscuit
is removed from the heat press. In step 1840, the biscuit is loaded
into a stabilization oven. In the stabilization oven, the biscuit
is cooled to a lower temperature that allows the biscuit to become
the desired size as a midsole. At step 1844, the biscuit is lowered
to a temperature 75.degree. Celsius. In steps 1848-1852, the
biscuit has its temperature lowered over three stages. At step
1848, the temperature of the biscuit is lowered from 75.degree.
Celsius to 65.degree. Celsius. At step 1852, the temperature of the
biscuit is lowered from 65.degree. Celsius to 55.degree. Celsius.
At step 1854, the temperature of the biscuit is lowered from
55.degree. Celsius to 45.degree. Celsius. In another method, the
cooling stages of 1848-1852 may be done in three or more stages. In
another method, the step at 1844 of lowering biscuit temperature to
75.degree. Celsius may be adjusted to a higher or lower
temperature.
[0145] At step 1858, the midsole is removed from the stabilization
oven. At step 1860, the midsole is loaded into one or more sonic
baths. At step 1864 in the sonic bath, the midsole is washed. In an
alternative method, step 1858 may be removed and the midsole may be
washed while it is still in a dual stabilization-oven-sonic-bath
device. At step 1868 the midsole is removed from the sonic bath. At
step 1870, the midsole is loaded into one or more drying ovens. At
step 1874 the midsole is dried. At step 1878, the midsole is
removed from the one or more drying ovens. At step 1880, the
midsole is loaded into a midsole staging marketplace.
[0146] Turning now to FIG. 19, an illustrative method for applying
primer and adhesive on a skate shoe is referenced generally by the
numeral 1900. At step 1904, a customer order is received. The
customer order contains specifications for the characteristics
associated with one or more desired skate shoes, such as size or
style or color. At step 1906, an outsole fitting the
characteristics defined in the customer order is removed from the
outsole staging marketplace. At step 1908, a midsole fitting the
characteristics defined in the customer order may be removed from
the midsole staging marketplace. At step 1910, a midsole and an
outsole are primed. At step 1920, the primed midsole and the primed
outsole may be placed in an IR oven. At step 1930, the midsole and
outsole are removed from the IR oven. At step 1940, adhesive may be
applied to the midsole and the outsole. At step 1950, the midsole
and the outsole are placed in an IR oven.
[0147] Turning now to FIG. 20, an illustrative method for joining
an outsole and a midsole into a midsole-outsole on a skate shoe is
referenced generally by the numeral 2000. At step 2010, the outsole
and the midsole are removed from the IR oven. At step 2020, the
outsole and midsole are fit together to form a midsole-outsole. At
step 2030, the midsole-outsole is loaded into a stockfit press. At
step 2034, the midsole-outsole is heated. The heat may allow the
adhesive to more permanently bind the components of the
midsole-outsole. At step 2038, the midsole-outsole is removed from
the stockfit press. At step 2040, the midsole-outsole is loaded
into a chiller. The chiller is used to cool down the
midsole-outsole to approximately 0.degree. Celsius to allow the
adhesive to set. In another method, the midsole-outsole may be
placed in a more temperate area where the midsole-outsole may be
left to cool over a longer period of time. In another method, at
step 2044, the temperature of the midsole-outsole is lowered. In
another method, the press may be turned off and the midsole-outsole
may be left to cool in the press until the heat dissipates. In
still another method, the press may be wired with both a heating
component and a cooling component such that a shoe article, such as
a midsole-outsole, may be heated and cooled in one location. In
that regard, having a dual heating and cooling press would both
save room and would also eliminate the risk of having components of
a shoe article become misaligned or fall apart during the period
they are moved between the heat press and the chiller. At step
2048, the midsole-outsole is removed from the chiller. At step
2050, the midsole-outsole is delivered to the swing arm post
staging area.
[0148] Referring to FIG. 21, an illustrative method for customizing
an upper for a skate shoe is referenced generally by the numeral
2100. At step 2102, an order is received. An illustrative method
for receiving an order includes receiving an order manually. In
still another method, an order may be received by uploading details
of an order through a web interface. At step 2104, material
associated with the order for the upper (e.g. synthetic leather or
mesh or polyester, etc.) is loaded into an eco-solvent printer. At
step 2106, the eco-solvent printer and dye sub printer are loaded
with material, such as desired colors, associated with an order. At
step 2108, the dye sub printer is used to print desired designs
and/or markings on the desired material used for the upper. At step
2110, the eco-solvent printer is used to print desired designs
and/or markings on the desired material used for the upper. At step
2115, a customized synthetic is cut out from the desired material
according to the specifications characterizing an order. At step
2120, the customized synthetic is loaded into a laser. At step
2124, the laser is loaded with the specification of the design
associated with the order. At step 2128, the laser etches a
customized design onto the customized synthetic.
[0149] At step 2130, the dye sub press is loaded. At step 2135, the
customized synthetic is removed from the laser. At step 2140, the
right embroidery machine is loaded with the customized synthetic.
At step 2142, the left embroidery machine is loaded with the
customized synthetic. At step 2144, the embroidery machines are
loaded with design specifications associated with the order. At
step 2146, left and right parts are embroidered using the left
embroidery machine and right embroidery machine, respectively. At
step 2150, the left part and right part are removed from the
embroidery machines. At step 2160, the customized parts are
delivered to the heat press marketplace. At step 2170, uppers are
checked for excess material and cut when needed.
[0150] Note that some of the decorative techniques disclosed above
may not be applicable to each shoe model and therefore some of the
steps disclosed above may be omitted. For instance, not all shoe
models may require embroidery or laser etching. Moreover, different
components of an upper may proceed through different steps, in
different orders, and at different times.
[0151] Referring to FIG. 22, an illustrative method for forming and
stitching an upper for a skate shoe is referenced generally by the
numeral 2200. At step 2205, customized parts for the upper are
retrieved from the heat press marketplace. At step 2210, a kit is
retrieved from the marketplace which contains necessary parts
associated with the customer order. At step 2220, an upper is
assembled from the customized parts. At step 2230, the assembled
upper parts are loaded into a heat press. At step 2234, the heat
press is activated and the assembled upper parts are heated. The
temperature reached is high enough that the adhesive used to bind
parts is activated. At step 2238, the parts are removed from the
heat press. At step 2240 the parts are placed on a cooling rack. At
step 2244 the parts are cooled from. At step 2248, the parts are
removed from the cooling rack. At step 2250, a heel is formed by
stitching. In an alternative, the heel may be formed by another
binding method. At step 2260, the parts are post-stitched. At step
2270, the parts are strobel stitched. At step 2280, the parts are
delivered to a lasting station.
[0152] Referring to FIG. 23, an illustrative method for lasting and
quality control for a skate shoe is referenced generally by the
numeral 2300. At step 2310, the shoe component is retrieved from
the lasting station. At step 2320, a quality control check is
performed and the upper is lasted. At step 2330, a quality control
check is performed on the lasted upper and the upper is then
de-lasted. At step 2340 a quality control check is performed and
the upper is laced. At step 2350, a quality control check is
performed and the shoe is packed.
[0153] Referring now to FIG. 24, a work flow diagram 2400 of a shoe
component-manufacturing facility for the manufacture of custom shoe
components is illustrated in accordance with an embodiment of the
present invention. Work flow diagram 2400 may represent a physical
configuration of a factory floor, but may also be viewed as a
generalized work flow methodology. A plurality of modules may be
utilized in the efficient fabrication of shoes in accordance with
the present invention. Each module may be operated by at least one
operator 2401 at each module. These modules may vary, but may
comprise, as in the example of FIG. 24, cutting and kitting module
2402, customization module 2404, forming and stitching module 2406,
midsole and outsole fabrication module 2410, and stockfit and
assembly module 2408.
[0154] Cutting and kitting module 2402 may cut shoe upper
components from an inventory of raw upper materials. At least one
of the raw upper components may comprise a customizable gray good.
The cut shoe upper materials may then be assembled into kits. In
embodiments, the kits comprise all of the upper elements necessary
to form an entire shoe upper. The kits may then be temporarily
stored.
[0155] Initially, cutting and kitting module 2402 may cut out the
components required for the fabrication of a shoe upper and prepare
those assorted pieces into a kit that may be used in the
construction and customization of a shoe. Materials used in the
cutting and kitting module 2402 may be stored in a material storage
2413. The raw materials used to create the shoe components may be
supplied by vendors that may or may not apply a hot melt lamination
across to the raw materials. The lamination treatment may aid in
the construction of the shoe components, as the lamination may be
used to adhere the shoe components. As such, if materials for the
shoe components do not yet have a hot melt lamination as supplied
from the vendors, a hot melt lamination may be applied to the raw
material. In embodiments, raw materials retrieved from storage 2413
may have a hot melt lamination applied to the materials at hot melt
lamination press 2412. However, if materials supplied from vendors
already have a hot melt lamination applied, hot melt lamination
press 2412 may not be needed in diagram 2400.
[0156] After materials have been retrieved from material storage
2413, a component cutting machine 2414 may be used to modify the
materials into shoe components. Component cutting machine 2414 may
comprise an auto-cutting machine that may utilize blades, lasers,
and/or any other cutting methodology or tool to cut the fabrics
used to construct a shoe upper into one or more pieces for
fabrication. Fabric may be held in place using suction, clamps,
etc. when used by an auto-cutting machine such as one that may be
used by component cutting machine 2414. The material used in the
fabrication of a shoe upper may comprise gray goods that may be
readily customized through printing, dying, embroidering, etc. Cut
components may be stored in a component marketplace 2416. Once cut
components are stored in the marketplace, the cut components may be
assembled into kits. In embodiments, kits may comprise the upper
components required to assemble an upper for a single shoe or the
uppers for a pair of shoes. In embodiments, storage 2413 and
marketplace 2416 may comprise a vertical carousal. Depending upon
the shoe designs fabricated, a single kit of upper components may
be utilized to assemble a shoe of a single size or a shoe of any of
a plurality of sizes. For example, for some shoe designs, a single
kit might be able to be used to fabricate and assemble a shoe
having men's size 8, 9, or 10.
[0157] Upper kits may be provided from cut components stored in
marketplace 2416 on an as-needed basis as shoe orders are
processed. Cutting and kitting module 2402 may thereafter respond
to shortages for particular components of marketplace 2416 by
cutting and kitting the needed types of upper materials.
[0158] After a kit has been selected from component marketplace
2416, the kit may be customized in customization module 2404. In
alternative embodiments, customization module 2404 may retrieve
temporarily stored kits from cutting and kitting module 2402.
Customization module 2404 may then layer the shoe upper components
of the kit into a flat framed assembly with multiple layers.
Customization module 2404 may then customize at least a portion of
the shoe upper components by applying decoration to the shoe upper
components.
[0159] In embodiments, customization module 2404 may comprise a
plurality of discrete stations, but no single shoe upper need
necessarily be processed by every station in customization module
2404. For example, after a kit has been delivered to desk 2418, a
operator, such as operator 2401, may load up any print files
related to a customization order.
[0160] Print files may be related to order customization as input
by a customer at a customer input receiver 2422. In embodiments,
print files may be sent to an eco-solvent printer 2420 and/or a
digital printer dye sublimation stations. In embodiments,
eco-solvent printer 2420 may be used to print graphics for
application to a shoe upper from the kit. Further, digital printing
dye sublimation station 2422 may be used to sublimate designs
and/or graphics onto a shoe upper.
[0161] The upper customization may also utilize a lamination heat
press 2424 to laminate designs onto shoe upper components.
Similarly, dye sublimation patterns printed at 2422 may be applied
using dye sublimation heat press 2426. Additionally, customization
trim work may be performed at station 2428, where station 2428 may
comprise a first trim clicker. In embodiments, a first trim clicker
may be used to modify material used in upper customization.
Further, laser customization, such as customized cutting and/or
etching, may be performed at laser customization station 2430.
Additionally, a plurality of embroidery stations 2432 may be used
to apply embroidered customization to shoe uppers. In embodiments,
shoe components may be embroidered once they are loaded into an
embroidery machine. After the embroidery of the one or more shoe
components, the shoe components may be unloaded from the embroidery
machines. In embodiments, the number of embroidery stations may be
one or more, although the utilization of four embroidery stations
2432 as illustrated in FIG. 24 may prove desirable. Desk 2434 may
also be used in the customization of the shoe upper.
[0162] After customization of an upper, forming and stitching
module 2406 may form the upper. Forming and stitching module 2406
may receive the customized shoe upper components. The customized
shoe upper components may be placed on a flat frame to keep the
components in place. The frame may be loaded into a solid state
(SS) RF press 2436 to perform RF welding on the components of the
shoe upper. Additionally and/or alternatively, the flat frame may
be loaded into a heat press 2438. Heat press 2438 may be used to
form the upper from heat-activated components. Whether press 2436
and/or press 2438 are used, a press is used to join the components
of the shoe upper. Once the shoe components are joined together at
press 2436 and/or press 2438, the joined shoe components are cut
using shuttle cutter 2440. Shuttle cutter 2440 removes excess
material from the joined shoe components. After shuttle cutter 2440
has removed excess material, the joined shoe components are removed
from the flat frame. Further, stitching that is desired may be
performed to form an upper at stitching stations such as
flat-stitch station 2442, zigzag-stitch station 2444, post-stitch
station 2448, and gather-stitch station 2454, all of which may be
used to stitch shoe components in the form of a shoe upper.
Additionally, a hot melt sprayer 2446 may be used to affix shoe
components to other shoe components and/or a shoe upper in order to
hold components into place as the shoe upper is being formed.
[0163] Toe-forming component 2450 may be used in the formation of
the toe of an upper. Heel-former component 2452 may be used in the
formation of the heel of an upper. Strobel-stitch component 2456
may be used to affix a strobel to a shoe upper for lasting.
Toe-condition component 2458 may be used to condition the shoe
upper and/or shoe components as part of lasting. For instance, at
toe-condition component 2458, the shoe upper and/or shoe components
may be exposed to steam to soften the shoe components. Further,
lasting component 2460 may be used after the attachment of a
strobel to last a shoe upper prior to affixing a midsole and/or
outsole. As such, module 2406 may then form the customized shoe
upper components into a three-dimensional shoe upper. Further,
module 2406 may affix a strobel to the formed shoe upper.
Additionally, module 2406 may last the formed shoe upper and
strobel.
[0164] Midsole and outsole component 2410 may fabricate shoe
midsoles and shoe outsoles for use in conjunction with lasted
uppers for the assembly of shoes. The midsoles and outsoles may be
formed in a variety of fashions and from a variety of materials.
Midsoles may be formed from phylon materials, and outsoles may be
formed from latex rubber. Possible systems and processes for use in
midsole and outsole module 2410 are described elsewhere herein.
Midsoles and/or outsoles may be provided to stockfit and assembly
module 2408 using a marketplace system, or may be provided on an
order-by-order basis.
[0165] Stockfit and assembly module 2408 may receive the lasted and
formed shoe upper and strobel from the forming and stitching module
2406. Additionally, module 2408 may receive the shoe midsoles and
shoe outsoles from midsole and outsole module 2410. Module 2408 may
then assemble the shoe midsole, the shoe outsole, and the lasted
and formed shoe upper and strobel into a shoe.
[0166] In embodiments, midsoles, outsoles, and/or lasted shoe
uppers may be received at vented table 2462. At vented table 2462,
adhesive may be applied to the bottom of a midsole and to the top
of an outsole. The midsole-outsole combination may then be placed
into an IR oven such as IR oven 2462. The adhesive on the shoe
midsole and the shoe outsole may then be activated at IR oven 2462.
The shoe midsole and the shoe outsole may then be set at bladder
press station 2466, where the midsole and outsole are pressed
together to form a seal. In embodiments, a block press 2468 may be
used to press the midsole and outsole together to form a seal.
[0167] After the midsole and outsole have been pressed together,
the midsole-outsole may be delivered to bite mark machine 2470 to
be marked for adhesive. In particular, midsole-outsole may have a
shoe upper placed over midsole-outsole to determine the extent of
adhesive coverage needed. The midsole-outsole and the shoe upper
may then have adhesive applied at vented table 2472. After adhesive
has been applied to the shoe upper and to the midsole-outsole in
accordance with the bite line, the shoe upper and the
midsole-outsole may be placed in IR over 2474. At IR oven 2474, the
adhesive applied to the shoe upper and to the midsole-outsole may
be activated. The shoe upper and midsole-outsole may then be
pressed together at block press 2468. Once a shoe has been formed
by pressing together the shoe upper and midsole-outsole, the shoe
may be set at chiller 2476. Once the shoe has been set, the shoe
may be de-lasted at de-lasting station 2478. Further, the shoe may
be checked for quality control and packaged at table 2480.
[0168] Referring now to FIG. 25, a schematic 2500 of a module
configuration for use in shoe production in accordance with the
present invention is illustrated. As illustrated in the example of
FIG. 25, shoes may be manufactured using a single cutting and
kitting module 2530 and a single outsole and midsole module 2540 in
conjunction with two modules to perform customization, forming and
fitting, and stockfit and assembly. The operation of customization,
forming and fitting, and stockfit and assembly may be performed in
a first section 2510 and/or at a second section 2520. First section
2510 may include a first customization module 2512, a first forming
and fitting module 2514, and a first stockfit and assembly module
2516. The first customization module 2512 may receive completed
kits for shoe uppers from cutting and kitting module 2530. After
customization module 2512 performs required customization upon a
shoe upper, customization module 2512 may pass the customized shoe
upper to first forming and fitting module 2514. First forming and
fitting module 2514 may form the shoe upper and then pass the
formed shoe upper to first stockfit and assembly module 2516. First
stockfit and assembly module 2516 may receive formed shoe uppers
from first forming and fitting module 2514 and may receive outsoles
and midsoles from outsole and midsole module 2540. First stockfit
and assembly module 2516 may assemble and complete a shoe, and
thereafter pass the completed shoe to a completed product queue
2518.
[0169] Similarly, a second section 2520 may comprise a second
customization module 2522, a second forming and fitting module
2524, and a second stockfit and assembly module 2526. Second
customization module 2522 may receive kits for the fabrication of
shoe uppers from cutting and kitting module 2530. Second
customization module 2522 may then perform any required
customization for a shoe upper. Second customization module 2522
may thereafter pass a customized shoe upper to second forming and
fitting module 2524, which may then form the required shoe upper.
Second forming and fitting module 2524 may then pass a formed shoe
upper to second stockfit and assembly module 2526. Second stockfit
and assembly module 2526 may receive formed shoe uppers from second
forming and fitting module 2524 and may receive outsoles and
midsoles from outsole and midsole module 2540. Stockfit and
assembly module 2526 may pass completed shoes to complete product
queue 2528. Completed product queue 2518 and completed product
queue 2528 may be combined into a single completed product queue,
and may represent the point at which a customer receives a
customized shoe or pair of shoes. All of the modules illustrated in
FIG. 25 may be co-located at a single geographical location.
However, first section 2510 and first completed product queue 2518
may be located remote from second section 2520 and second completed
product queue 2528, from cutting and kitting module 2530, and/or
from outsole and midsole module 2540. Similarly, second section
2520 and second completed product queue 2528 may be located
remotely from first section 2510 and first completed product queue
2518, from cutting and kitting module 2530, and from outsole and
midsole module 2540. The use of a single cutting and kitting module
2530 and/or a single outsole and midsole module 2540 for two or
more modules for customization, forming and fitting, and stockfit
and assembly may be advantageous to maximize the production of
shoes for a set of modules.
[0170] FIG. 26 illustrates a system 2600 for producing and
assembling shoe components in accordance with an embodiment of the
present invention. System 2600 comprises a customer input receiver
2640. Receiver 2640 receives customer input related to, for
example, a customer's customization of shoes. For example, a
customer may input into receiver 2640 an order for red shoes.
System 2600 further comprises a marketplace 2610 that stores shoe
components. In embodiments, marketplace 2610 serves as a temporary
storage bin for a first shoe component. A first shoe component may
be produced at a first module 2620. First module 2620 may comprise
a first shoe component-manufacturing module that produces at least
a first shoe component upon receiving an indication 2612 from
marketplace 2610 to produce the first shoe component. Indication
2612 may be sent to first module 2620 from marketplace 2610 when a
threshold amount of the first shoe component stored in marketplace
2610 has fallen below a predefined threshold amount. In
embodiments, one or more first shoe components may comprise shoe
upper components, midsoles, and/or outsoles.
[0171] System 2600 may also comprise a second module 2630, where
second module 2630 produces one or more second shoe components in
response to receiving customer input 2642 from customer input
receiver 2640. In embodiments, customizable components may be
produced by second module 2630, where second shoe components may be
produced by modifying shoe components supplied from marketplace
2610 to second module 2630. The shoe components supplied from
marketplace 2610 to second module 2630 may comprise first shoe
components produced at first module 2620.
[0172] After one or more first components and one or more second
components are produced, the one or more first components and the
one or more second components may be assembled at third module
2650. The one or more first components may be delivered 2614 to
third module 2650 from marketplace 2610. Additionally and/or
alternatively, the one or more first components may be delivered
2624 to third module 2650 from first module 2620. Further, the one
or more second components may be delivered 2632 to third module
2650 from second module 2630. After the one or more first
components and the one or more second components are assembled at
third module 2650, one or more completed shoes may be delivered
2652 to completed product queue 2660.
[0173] FIG. 27 illustrates a flowchart 2700 of a workflow of a shoe
manufactured through a process. The process comprises steps
performed in shoe manufacturing modules, such as cutting and
kitting module 2710, customization module 2720, forming module
2730, outsole and midsole module 2740, and stockfit and assembly
module 2750. In cutting and kitting module 2710, a plurality of raw
materials required for a multilayered shoe upper are provided at
step 2712. Further, at step 2714 in module 2710, raw materials are
cut into the components of the multilayered shoe upper.
Additionally, at module 2710, the components necessary to make a
single multilayered shoe upper are placed in kits at step 2716.
[0174] In customization module 2720, a kit is received at step
2722. At step 2724, still at customization module 2720, the shoe
upper components are assembled into multiple layers. The multiple
layers are aligned on a flat frame. Further, at step 2426, the
multiplayer upper components are customized by applying decoration
to at least one layer of the multilayer shoe upper components. The
customization of step 2426, occurring at customization module 2420,
is performed while the multilayer shoe upper components are on a
flat frame.
[0175] In forming module 2730, the multilayer upper components are
joined to form one integral shoe upper at step 2732 while the
multilayer shoe upper components are on the frame. At step 2734,
the excess upper material is cut from the shoe upper. Further, at
step 2736, the joined shoe upper is removed from the frame. The
formed shoe upper is then formed into a three-dimensional shoe
upper at step 2738. Still in forming module 2730, a strobel is
stitched to the formed shoe upper at step 2739.
[0176] In outsole and midsole module 2740, a shoe midsole is formed
at step 2742. Further, a shoe outsole is formed at step 2744, still
in outsole and midsole module 2740. In stockfit and assembly module
2750, the shoe midsole is attached to the shoe upper at step 2752.
Still in stockfit and assembly module 2750, the shoe outsole is
attached to the shoe upper at step 2754.
[0177] The present invention has been described in relation to
particular embodiments, which are intended in all respects to be
illustrative rather than restrictive.
[0178] Alternative embodiments will become apparent to those of
ordinary skill in the art to which the present invention pertains
without departing from its scope. Different models of shoes, for
example, could utilize different specific processes, materials, or
modules and still fall within the scope of the claimed invention as
would be recognized by one of ordinary skill in the art.
[0179] From the foregoing, it will be seen that this invention is
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.
* * * * *