U.S. patent application number 13/192244 was filed with the patent office on 2013-01-31 for upper with zonal contouring and fabrication of same.
This patent application is currently assigned to NIKE, INC.. The applicant listed for this patent is Michael A. Calvano, Thienchai Chaisumrej, Gjermund Haugbro, N. Scot Hull, Tee L. Wan. Invention is credited to Michael A. Calvano, Thienchai Chaisumrej, Gjermund Haugbro, N. Scot Hull, Tee L. Wan.
Application Number | 20130025157 13/192244 |
Document ID | / |
Family ID | 46548800 |
Filed Date | 2013-01-31 |
United States Patent
Application |
20130025157 |
Kind Code |
A1 |
Wan; Tee L. ; et
al. |
January 31, 2013 |
Upper with Zonal Contouring and Fabrication of Same
Abstract
A composite panel portion of an upper may include a contouring
element located between a backing and an outer panel. The outer
panel conforms to the contouring element and the backing so as to
form a raised contour.
Inventors: |
Wan; Tee L.; (Portland,
OR) ; Calvano; Michael A.; (Tualatin, OR) ;
Hull; N. Scot; (Vancouver, WA) ; Haugbro;
Gjermund; (Beaverton, OR) ; Chaisumrej;
Thienchai; (Hochiminh City, OR) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Wan; Tee L.
Calvano; Michael A.
Hull; N. Scot
Haugbro; Gjermund
Chaisumrej; Thienchai |
Portland
Tualatin
Vancouver
Beaverton
Hochiminh City |
OR
OR
WA
OR
OR |
US
US
US
US
US |
|
|
Assignee: |
NIKE, INC.
Beaverton
OR
|
Family ID: |
46548800 |
Appl. No.: |
13/192244 |
Filed: |
July 27, 2011 |
Current U.S.
Class: |
36/45 |
Current CPC
Class: |
A43B 23/026 20130101;
A43B 23/0255 20130101; A43B 23/042 20130101; A43B 7/06 20130101;
A43B 7/085 20130101; A43B 5/025 20130101; A43B 23/0235
20130101 |
Class at
Publication: |
36/45 |
International
Class: |
A43B 23/00 20060101
A43B023/00 |
Claims
1. A portion of an upper, comprising: a backing; a contouring
element; and a porous outer panel, wherein the backing and the
outer panel each has an interior side configured to face toward an
interior space of an article of footwear, and an exterior side
configured to face away from the interior space, when the upper is
incorporated into the article of footwear, the contouring element
is located between the exterior side of the backing and the
interior side of the outer panel, and the backing, the contouring
element and the outer panel form a bonded composite panel in which
the outer panel conforms to the contouring element and the backing
so as to form a raised contour.
2. The upper portion of claim 1, wherein the outer panel has a
thickness less than a thickness of the contouring element, and
wherein regions of the outer panel interior side not contacting the
contouring element are bonded to regions of the backing exterior
side not contacting the contouring element.
3. The upper portion of claim 1, wherein regions of the outer panel
overlaying the contouring element are under tension and deform the
contouring element.
4. The upper portion of claim 1, wherein the outer panel comprises
a mesh.
5. The upper portion of claim 4, wherein the backing includes at
least one opening defining a ventilation window, and wherein a
portion of the mesh spans the ventilation window and is bonded to
regions of the backing exterior side at an edge of the ventilation
window.
6. The upper portion of claim 4, wherein the backing includes
openings defining a plurality of ventilation windows, each of the
ventilation windows is spanned by a corresponding portion of the
mesh, and each of the window spanning mesh portions is bonded to
regions of the backing exterior side at edges of the corresponding
ventilation window.
7. The upper portion of claim 4, further comprising a second
contouring element located between the exterior side of backing and
the interior side of the mesh, wherein the second contouring
element is surrounded by adjacent regions of the backing exterior
side not contacting the second contouring element, and the adjacent
backing regions surrounding the second contouring element are
bonded to the interior side of the mesh.
8. The upper portion of claim 1, wherein the contouring element is
surrounded by adjacent regions of the backing exterior side not
contacting the contouring element, and wherein the surrounding
adjacent regions are bonded to the interior side of the outer
panel.
9. The upper portion of claim 1, wherein the contouring element has
a thickness greater than the combined thicknesses of the outer
panel and of the backing.
10. The upper of claim 9, wherein the backing includes at least one
ventilation window, and wherein a portion of the flexible porous
fabric spans the ventilation window and is bonded to regions of the
backing exterior side at an edge of the ventilation window.
11. The upper portion of claim 9, wherein the contouring element is
surrounded by adjacent regions of the backing exterior side not
contacting the contouring element, and wherein the surrounding
adjacent regions are bonded to the interior side of the outer
panel.
12. The upper portion of claim 11, wherein the outer panel
comprises a mesh.
13. The upper portion of claim 12, wherein regions of the outer
panel overlaying the contouring element are under tension and
deform the contouring element.
14. A portion of an upper for an article of footwear, comprising: a
backing; a contouring element; and a porous outer panel, wherein
the backing and the outer panel each has an interior side
configured to face toward an interior space of an article of
footwear, and an exterior side configured to face away from the
interior space, when the upper is incorporated into the article of
footwear, the contouring element is located between the exterior
side of the backing and the interior side of the outer panel, and
the outer panel is bonded to portions of the backing exterior side
and is conformed to the contouring element along multiple interface
edges of the backing and the contouring element.
15. The upper portion of claim 14, wherein the porous outer panel
comprises a mesh.
16. The upper portion of claim 14, wherein the backing includes at
least one opening defining a ventilation window, and wherein a
portion of the outer panel spans the ventilation window and is
bonded to regions of the backing exterior side at an edge of the
ventilation window.
17. The upper portion of claim 14, wherein the backing includes a
plurality of openings defining ventilation windows, each of the
ventilation windows is spanned by a corresponding portion of the
outer panel, each of the window spanning outer panel portions is
bonded to regions of the backing exterior side at edges of the
corresponding ventilation window, the upper portion includes a
second contouring element located between the exterior side of
backing and the interior side of the outer panel, the second
contouring element is surrounded by adjacent regions of the backing
exterior side not contacting the second contouring element, and the
adjacent backing regions surrounding the second contouring element
are bonded to the interior side of the outer panel.
18. A method comprising: assembling a stack of components
comprising a backing, a bonding agent, at least one contouring
element and a porous outer panel, wherein the contouring element is
located between the backing and the porous outer panel; and heating
and compressing the assembled stack so as to bond the backing,
contouring element and outer panel and form a composite panel
having a contour corresponding to the contouring element.
19. The method of claim 18, wherein the stack of components
comprises a contouring element having a thickness greater than a
thickness of the porous outer panel.
Description
BACKGROUND
[0001] It is sometimes desirable to include contoured regions in a
footwear upper. In some cases, such contouring may be for aesthetic
reasons. For example, a shoe designer might wish to include raised
portions on a shoe upper to enhance certain lines, to create a
certain look, to emulate a product logo, or for any of various
reasons. In other cases, contouring is added for functional
reasons. Raised regions might be added to increase padding in
certain areas, to stiffen certain areas, to provide increased foot
support, or for other purposes. In still other cases, contours may
be added for both functional and ornamental purposes.
[0002] Adding contours to a shoe upper can present challenges,
particularly when those contours are created by attaching extra
elements to the outside of an upper. Such elements may tend to
separate from the upper. Although the attachment of such an element
can be reinforced with stitching, this can increase manufacturing
cost and/or detract from the shoe appearance. Including contours in
an athletic shoe upper can be especially challenging, particularly
when an upper is to be formed from relatively thin, lightweight
material.
SUMMARY
[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 invention.
[0004] In at least some embodiments, a composite panel portion of
an upper includes a contouring element located between a backing
and an outer panel. The outer panel conforms to the contouring
element and the backing so as to form a raised contour. The outer
panel can be, e.g., a mesh or other flexible porous material and
can be bonded to portions of the backing adjacent to the contouring
element. The composite panel can include multiple contouring
elements and/or may include one or more ventilation windows defined
in the backing and spanned by the outer panel.
[0005] In some embodiments, a composite panel may be formed by
assembling a stack comprising a backing, a bonding agent, one or
more contouring elements and an outer panel. The assembled stack
may then be heated and compressed so as to form a composite panel
having a contour corresponding to the contouring element.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] Some embodiments are illustrated by way of example, and not
by way of limitation, in the figures of the accompanying drawings
and in which like reference numerals refer to similar elements.
[0007] FIGS. 1A through 1C are lateral, medial and top views,
respectively, of a shoe according to some embodiments.
[0008] FIG. 2 is an enlarged, partially schematic area
cross-sectional view from the location indicated in FIG. 1A.
[0009] FIGS. 3A1-3G show various steps in a process for fabricating
a composite panel for the upper of the shoe shown in FIGS.
1A-1C.
DETAILED DESCRIPTION
[0010] FIG. 1A is a lateral side view of a shoe 10 according to one
exemplary embodiment. FIG. 1B is a medial side view of shoe 10.
FIG. 1C is a top view of shoe 10. Additional embodiments include
the upper 11 of shoe 10 and/or portions of upper 11, as well as
processes for fabricating upper 11 or portions thereof. Shoe 10 is
a running shoe, but other embodiments include shoes intended for
wear by participants in other sporting and non-sporting activities,
as well as uppers for such shoes and processes for fabrication of
such uppers. Although various aspects of shoe 10 are discussed in
detail below, the shapes, sizes and locations of various elements
of shoe 10, as well as other features of shoe 10, merely represent
one embodiment. Other embodiments include uppers with different
features and/or different combinations, sizes and arrangements of
features, portions of such uppers, shoes incorporating such uppers,
and processes for fabricating such uppers.
[0011] To assist and clarify subsequent description of various
embodiments, various terms are defined herein. Unless otherwise
indicated, the following definitions apply throughout this
specification (including the claims). The "interior" of a shoe
refers to space that is occupied by a wearer's foot when the shoe
is worn. The "interior side" (or surface) of a panel or other shoe
element refers to the face of that panel or element that is (or
will be) oriented toward the shoe interior in a completed shoe. An
"exterior side" (or surface) of an element refers to the face of
that element that is (or will be) oriented away from the shoe
interior in the completed shoe. In some cases, the interior side of
an element may have other elements between that interior side and
the interior in the completed shoe. Similarly, an exterior side of
an element may have other elements between that exterior side and
the space external to the completed shoe.
[0012] Certain regions of a shoe upper can be defined by reference
to the anatomical structures of a human foot wearing that shoe, and
by assuming that shoe is properly sized for that wearing foot. One
or more of the below-defined regions may overlap. The "forefoot"
region of an upper is the portion of the upper that will generally
cover the metatarsal and phalangeal bones of the wearer's foot, and
which will extend beyond the wearer's toes to the front most
portion of the upper. The "midfoot" region of an upper is the
portion of the upper that will generally cover the cuboid,
navicular, medial cuneiform, intermediate cuneiform and lateral
cuneiform bones of the wearer's foot. The "hindfoot" region of an
upper extends from the midfoot region to the rearmost portion of
the upper and covers the wearer heel. The hindfoot region covers
the sides of the calcaneus bone of a wearer and may, depending on a
particular shoe configuration, cover some or all of the wearer's
talus bone (ankle).
[0013] The top forefoot and top midfoot regions of an upper will
generally cover the upper surfaces of a wearer's forefoot and
midfoot bones described above. The toe of the upper is the portion
that will generally cover the tops and fronts of the toes and that
extends from the top forefoot region to the lowest edge of the
upper in the direction of the sole. The lateral forefoot region
extends between the top forefoot and the lowest edge of the upper
in the direction of the sole and between the toe and lateral
midfoot regions. The lateral midfoot region extends between the top
midfoot region and the lowest edge of the upper in the direction of
the sole and between the lateral forefoot and hindfoot regions. In
a similar manner, the medial forefoot region extends between the
top forefoot region and the lowest edge of the upper in the
direction of the sole and between the toe and medial midfoot
regions. The medial midfoot region extends between the top midfoot
region and the lowest edge of the upper in the direction of the
sole and between the medial forefoot and hindfoot regions. The
topfoot region includes the top forefoot and top midfoot regions.
The lateral side region includes the lateral forefoot and lateral
midfoot regions. The medial side region includes the medial
forefoot and medial midfoot regions.
[0014] Returning to FIGS. 1A-1C, shoe 10 includes an upper 11 that
is attached to a sole structure 12. Embodiments include shoes
having sole structures of numerous widely varying types. A sole
structure in some embodiments may be, e.g., a single piece molded
from synthetic rubber or other material. In other embodiments, a
sole structure may include multiple components that have been
sequentially molded or otherwise bonded together. For example, a
sole structure may include a midsole formed from a first material
(e.g., foamed ethylene vinyl acetate) bonded to an outsole formed
from different materials (e.g., synthetic rubber). A sole structure
could also include one or more fluid-filled cushions, a stiffening
plate or other support element(s), traction elements (e.g.,
cleats), etc. For convenience, and because of differing internal
details of sole structures according to various embodiments, sole
structure 12 is treated as a single unitary component in FIGS.
1A-1C.
[0015] Upper 11 includes a zonally-contoured composite panel 15,
portions of which are exposed in the fore- and midfoot regions, and
a foxing panel 16 in the hindfoot region. Foxing panel 16 includes
an ankle collar 17. The hindfoot portion of upper 11 further
includes a heel counter (not shown), as well as padding and an
inner lining.
[0016] Composite panel 15 includes a mesh outer panel 19 that wraps
around the sides and front of a foot of a shoe 10 wearer W. So as
to avoid obscuring the drawings, outer panel 19 is represented
throughout the drawings as a relatively coarse diagonal grid. In
practice, however, the material of outer panel 19 can have a much
finer weave (or other pattern) than is represented in the drawings
and/or have openings of other shapes. As but one example, the
openings in outer panel 19 could be approximately 1 to 2
millimeters in size.
[0017] As seen in FIG. 1A, composite panel 15 covers the lateral
sides of the midfoot and forefoot. In particular, composite panel
15 extends from below the top edge 20 of sole structure 12 on the
lateral side, over the mid- and forefoot side regions, and under
the lateral side of an eyelet reinforcing strip 21. The rear
lateral side of composite panel 15 extends under the forward
lateral edge 22 of foxing panel 16. As shown in FIG. 1B, composite
panel 15 also covers the medial sides of the wearer forefoot and
midfoot. Similar to the lateral side, the medial side of composite
panel 15 extends from below the top edge 20 of sole structure 12,
over the mid- and forefoot side regions, and under reinforcing
strip 21. The rear medial side of composite panel 15 extends under
the forward medial edge 26 of foxing panel 16. As seen in FIG. 1C,
another portion of composite panel 15 covers the tops of the toes.
Composite panel 15 extends under toe cap 25 and under the front of
reinforcing strip 21.
[0018] In addition to outer panel 19, composite panel 15 includes a
backing 29 and contouring elements 31, 32, 33 and 34. As explained
in more detail below, composite panel 15 is formed by bonding outer
panel 19 and contouring elements 31-34 to backing 29. Contouring
elements 31-34 are positioned between outer panel 19 and backing 29
in composite panel 15. As seen in FIGS. 1A-1C, backing 29 only
extends over limited regions of composite panel 15. Openings in
backing 29 are spanned by portions of outer panel 19 and define
numerous ventilation windows in upper 11. Toe vent window 36
generally corresponds to the tops of the 2nd through 5th proximal
and middle phalanges, to at least a portion of the top of the 1st
proximal phalange, to tops of the distal ends of the 1st through
5th metatarsals, to the medial side of the 1st proximal phalange
and first metatarsal distal end, and to the lateral sides of the
5th metatarsal distal end and 5th proximal phalange. Three vent
windows 37-39 are located on the medial side (FIG. 1B) and three
more vent windows 40-42 are located on the lateral side.
[0019] Backing 29 further includes an inner border that surrounds a
tongue opening 47 and that has an area generally coinciding with
the area of eyelet reinforcing strip 21. The inner border of
backing 29 is not visible in FIGS. 1A-1C but is shown in FIG. 3A1.
Numerous bands bridge the inner border of backing 29 and the bottom
regions of composite panel 15, below edges 20 of sole structure 12,
joined to a lasting sock (not shown). On the medial side, and as
seen in FIG. 1B, bands 51, 52, 53 and 54 form an "M" shape.
Similarly, and as seen in FIG. 1A, bands 55, 56, 57 and 58 form
another "M" shape on the lateral side. In the embodiment of shoe
10, bands 51-54 and 55-58 provide additional reinforcement in side
portions of upper 11 adjacent the shoe laces and limit the stretch
of upper 11 in those side portions.
[0020] In the embodiment of shoe 10, each of contouring elements
31-34 has an inverted "V" shape. As shown in FIG. 1B, contouring
element 31 is located between the exterior sides of backing element
29 bands 51 and 52 and the interior side of outer panel 19.
Contouring element 32 is located between the exterior sides of
backing element 29 bands 53 and 54 and the interior side of outer
panel 19. As seen in FIG. 1A, contouring element 33 is located
between the exterior sides of backing element 29 bands 55 and 56
and the inner side of outer panel 19. Contouring element 34 is
located between the exterior sides of backing element 29 bands 57
and 58 and the interior side of outer panel 19.
[0021] In the embodiment of shoe 10, upper 11 does not include a
"bootie" or other liner in the region of composite panel 15. Thus,
there is nothing separating a socked foot of wearer W and the
interior sides of the portions of outer panel 19 spanning windows
36-42. In this manner, greater ventilation can be achieved. In
other embodiments, a bootie or other type of liner can be
included.
[0022] FIG. 2 is an enlarged, partially schematic area
cross-sectional view taken from the location indicated in FIG. 1A
and showing the structure of composite panel 15. Backing 29 is
located on the interior side of upper 11. Contouring element 33 and
outer panel 19 are bonded to the exterior side of backing 29. Outer
panel 19 may also be bonded to the exterior surface of contouring
element 33 and to exterior surfaces of contouring elements 31, 32
and 34. Alternatively, the interface between outer panel 19 and the
exterior surfaces of contouring elements 31-34 may lack glue or
other bonding agent.
[0023] Outer panel 19 tightly conforms to contouring element 33.
Tension in outer panel 19 causes outer panel 19 to exert inward
pressure on contouring element 33. This causes a slight compression
of contouring element 33 and a rounding of the contouring element
outer edges (e.g., edges e1). Outer panel 19 is bonded to the
portions of backing 29 band 55 surrounding contouring element 33,
with the bond between panel 19 and band 55 extending to inner edges
e2 where contouring element 33 meets band 55. Outer panel 19 is
similarly bonded to the portions of band 56 surrounding contouring
element 33 and to the portions of the other bands surrounding the
other contouring elements. Thus, outer panel 19 tightly conforms to
the other portions of contouring element 33 and to contouring
elements 31, 32 and 34 in a manner similar to that shown in FIG.
2.
[0024] In the embodiment of shoe 10, contouring elements 31-34 are
substantially thicker than backing 29 and outer panel 19. In some
embodiments, the thickness TC of contouring elements 31-34 is equal
to or greater than the thickness TB of backing 29 and equal to or
greater that the thickness TO of outer panel 19. In certain
embodiments, the contouring element thickness is equal to or
greater than the combined thicknesses of the backing and outer
panel (i.e., TC.gtoreq.TB+TO).
[0025] Although panel 19 of composite panel 15 is referred to as an
"outer panel," panel 19 need not be the outermost panel of
composite panel 15. In the embodiment of shoe 10, some portions of
the outer panel 19 exterior surface are covered by toe cap 25 and
by reinforcing strip 21. Other portions are covered by foxing panel
16. Other components could also be attached over other portions of
the outer panel 19 exterior surface. Similarly, backing 19 need not
be the innermost component of composite panel 15. Moreover,
contouring element 33 need not be directly bonded to backing 29. In
some embodiments, for example, another panel, a stiffener or some
other element could be interposed between the interior face of a
contouring element and the exterior face of a backing.
[0026] The construction shown in FIG. 2 offers several advantages.
It is often desirable to include raised ridges or other types of
surface contours in a footwear upper. Such contours may have
aesthetic and/or functional purposes. For example, zones of
increased thickness may provide additional support and/or
additional cushioning in certain regions. Adding surface contours
presents certain challenges when using meshes and other types of
lightweight materials, however. Stitching a contouring element to a
mesh material can be difficult, particularly with meshes having
more open weave patterns. Moreover, stitching operations can be
time consuming and expensive, and thus it is often desirable to
minimize the amount of stitching needed.
[0027] Bonding or stitching a contour element to the outside of a
mesh or other lightweight upper material can also present problems.
A contour element that is attached in such a fashion may be prone
to separation. If an interface between a contour element and an
exterior face of an upper is exposed, that interface might be
snagged as a wearer foot brushes against external objects. As a
result, the contour element might begin to separate from the upper.
With the construction shown in FIG. 2, however, the interface
between the contouring element and backing 29 (e.g., edges e2) is
protected by outer panel 29. By locating the contouring elements on
the interior side of a lightweight material and tightly conforming
that material to those contouring elements, there is less potential
for separation. As a result, contouring elements are attached in a
more secure manner.
[0028] Simply attaching a contour element to the outer surface of a
mesh panel might also have other disadvantages. Such an attachment
might be aesthetically unpleasing and result in an upper with an
unfinished and/or ragged look. Conforming a mesh or other
lightweight panel to a contouring element permits creation of an
upper with a more finished overall appearance. For example, a mesh
pattern that extends across much of an upper can be overlaid onto
the contour element. This helps blend the contour elements with
other portions of the upper. Moreover, the tension of the mesh
material on the surface of a contour element can help soften the
edges of the contour element and give it a more rounded
appearance.
[0029] FIGS. 3A1 through 3G show a process, according to at least
some embodiments, to fabricate composite panel 15 of upper 11. In a
first step shown in FIG. 3A1, backing 29 is placed onto an assembly
jig 60. Jig 60 includes a flat surface 61 having multiple pins 62
that extend perpendicularly from surface 61. In the top plan view
of FIG. 3A1, pins 62 extend out of the plane of the drawing. So as
to distinguish pins 62 from unlabeled eyelet holes shown in backing
29, the tops of pins 62 are represented as filled-in black
circles.
[0030] Each of pins 62 is pushed through corresponding holes in one
or more components of composite panel 15 as those components are
added to a stack of components being assembled on surface 61. This
allows proper positioning of those components relative to one
another. In FIG. 3A1, backing 29 has been placed by pushing backing
29 onto surface 61 so that pins 62 are pushed through corresponding
locating holes in backing 29. FIG. 3A2 is a side view of jig 60 and
backing 29 from the location indicated in FIG. 3A1. Backing 29 has
been placed onto surface 61 and pins 62 extend upward from surface
61 through backing 29.
[0031] As previously indicated, backing 29 includes an inner border
65 that surrounds tongue opening 47. Also seen in FIG. 3A1 are
lateral side bands 55-58 and medial side bands 51-54. Vent windows
36-42 are also visible in FIG. 3A1. Surface 66 of backing 29 will
be the exterior surface of backing 29 in the completed upper.
[0032] Numerous types of materials can be used for backing 29. In
the embodiment of shoe 10, backing 29 is a polyester knit material
having a layer of unactivated hot melt bonding agent pre-applied to
surface 66. In other embodiments, a backing material may not
include a pre-applied hot melt agent layer. Instead, a separate
layer of hot melt bonding agent material having the same shape as
backing 29 could be placed over surface 66 after backing 29 has
been placed on jig 60. In some embodiments, a backing may have a
thickness (TB from FIG. 2) of approximately 0.5 millimeters.
[0033] In a next step, and as shown in FIG. 3B, pre-cut contouring
elements 31, 32, 33 and 34 are put into place on portions of
backing 29 surface 66. In particular, each of contouring elements
31-34 has been placed by pushing the contouring element onto
surface 66 so that appropriate ones of pins 62 are pushed through
corresponding locating holes in the contouring element. In the
embodiment of shoe 10, each of contouring elements 31-34 is formed
from a synthetic leather and has a thickness (TC from FIG. 2) of
between approximately 1 millimeter and approximately 3 millimeters.
In some embodiments, the exterior surfaces of contouring elements
31-34 may have a pre-applied layer of unactivated hot-melt bonding
agent. In other embodiments, separate pieces of hot-melt bonding
agent material having the same shape as the contouring elements may
be placed onto the exterior surfaces of the contouring elements. In
still other embodiments, there is no hot-melting bonding agent
between the exterior surface of the contouring elements and
portions of the outer panel 19 interior surface that contact those
contouring element exterior surfaces.
[0034] In a subsequent step, and as shown in FIG. 3C, outer panel
19 is put into place by pushing outer panel 19 onto jig 60 so that
pins 62 are pushed through corresponding holes in outer panel 19.
In the embodiment of shoe 10, outer panel 19 is a relatively fine
mesh (e.g., having openings of approximately 1 mm or smaller)
formed from a woven synthetic material. Other embodiments utilize
other types of flexible porous fabrics for outer panel 19. Such
other types of flexible porous fabrics can include, e.g., woven and
non-woven meshes formed from synthetic and/or nonsynthetic
materials and/or having finer or coarser mesh patterns, various
types of textile materials, and other porous materials.
[0035] At the conclusion of the step shown in FIG. 3C, backing 29,
contouring elements 31-34 and outer panel 19 have been assembled
into a stack 70 onto jig 60. At this stage, the individual
components of stack 70 are not yet bonded to one another. If stack
70 were to be removed from jig 60 in this unbonded condition, great
care would be needed to keep the components in their desired
relative positions. In a subsequent step, and as shown in FIG. 3D1,
jig 60 is placed under a heated press platen 72 as part of a first
pressing operation. As shown in FIG. 3D2, sufficient heat and
pressure are applied by platen 72 so as to at least partially
activate the hot-melt bonding agent on backing 29. This results in
a partial bonding of backing 29, contouring elements 31-34 and
outer panel 29 that temporarily allows these components to remain
in an assembled configuration when stack 70 is removed from jig 60.
Although not shown in FIG. 3D1 or 3D2, platen 72 may include holes
or recesses corresponding to and accommodating pins 61.
[0036] The temperature, pressure and press time for the first
pressing operation of FIG. 3D1 will vary based on the type of
materials used. In some embodiments utilizing the example materials
identified above, the assembled components stack is pressed at
150.degree. C. and 100 kg/cm.sup.2 for approximately for 15
seconds. For different types of materials, appropriate pressing
parameters to achieve a partial component bonding is readily
determinable by persons of ordinary skill in the art. As but one
example, samples of components to be used could be assembled and
subjected to the press parameters described above. If insufficient
partial bonding results, additional sample assemblies can be
prepared and pressed at increasingly higher temperatures (e.g., in
5.degree. C. incremental increases) and or pressures (e.g., in 2
kg/cm.sup.2 incremental increases) until the desired result
(partial bonding sufficient to retain component arrangement prior
to second pressing) is achieved.
[0037] In a subsequent step shown in FIG. 3E1, the partially bonded
stack 70 is removed from jig 60 and placed onto a heat-transferring
silicone pad 73 on a heated lower platen 74 of a second press.
Another heat-transferring silicone pad 75 is attached to a heated
upper platen 76 of that press. Sheets of release paper (not shown)
could be placed between partially bonded stack 70 and pads 73 and
75. The partially bonded stack 70 is then pressed between platens
74 and 76 (FIG. 3E2). Heat from platens 74 and 76 is transferred to
stack 70 through pads 73 and 75. Because pads 73 and 75 are
partially compressible, however, outer panel 19 can be pressed into
close conformance to backing element 29 and contouring elements
31-34 (e.g., as shown in FIG. 2).
[0038] The temperature, pressure and press time for the second
pressing operation of FIG. 3E2 will also vary based on the type of
materials used. In some embodiments utilizing the example backing,
contouring element and outer panel materials identified above,
partially-bonded stack 70 is pressed at 150.degree. C. and 35 to 40
kg/cm.sup.2 for approximately for 30 seconds. For different types
of materials, appropriate pressing parameters to achieve a complete
component bonding (as shown in FIG. 2) is readily determinable by
persons of ordinary skill in the art. As but one example, after
determining process parameters for a first pressing as described
above, a sample of partially bonded components could be created and
subjected to the second pressing parameters described above (e.g.,
150.degree. C., 35-40 kg/cm.sup.2, approximately 30 seconds). If
insufficient bonding or insufficient conformance of the mesh to the
backing and contouring elements occurs, additional samples of the
partially-bonded components can be prepared and pressed at
increasingly higher temperatures (e.g., in 5.degree. C. incremental
increases) and/or pressures (e.g., in 2 kg/cm.sup.2 incremental
increases) and/or for increased time periods (e.g., in 5 second
incremental increases) until the desired result (complete conformal
bonding of mesh to backing and contouring elements) is
achieved.
[0039] At the conclusion of the second pressing operation, stack 70
has been transformed into composite panel 15. Outer panel 19 is
bonded to backing 29 and tightly conforms to contouring elements
31-34. FIG. 3F shows composite panel 15 after removal from the
press of FIGS. 3E1 and 3E2. Although not visible in the view of
FIG. 3F, composite panel 15 has contours corresponding to
contouring elements 31-34. Specifically, outer panel 19 is bonded
to backing 29 and conforms to the exterior surfaces of each of
contouring elements 31-34 in a manner similar to that shown in FIG.
2, thereby creating raised elements that will be located on the
exterior surface of a completed upper.
[0040] Subsequently, and as shown in FIG. 3G, toe cap 25 and
reinforcing panel 21 are attached to composite panel 15. In some
embodiments, toe cap 25 and reinforcing panel 21 are stitched in
place. Eyelet holes in panel 21 align with corresponding eyelet
holes in backing 29. Portions of mesh 19 covering eyelet holes in
backing 29 can be cleared in a punching operation (not shown). In
some embodiments, panel 21 and toe cap 25 could be glued or
otherwise bonded to composite panel 15. For example, panel 21 and
toe cap 25 could include a layer of unactivated hot-melt adhesive
material on their interior surfaces and be bonded to composite
panel 15 in a heated press. In still other embodiments, panel 21
and/or toe cap 25 could be assembled with the components of
composite panel 15 (e.g., in a step between the steps shown in
FIGS. 3C and 3D1) and then bonded in the first and second pressing
steps. In the embodiment of shoe 10, panel 21 and toe cap 25 are
formed from synthetic leather. In at some embodiments, panel 21
and/or toe cap 25 could be formed of one or more other materials
(e.g., natural leather, polyurethane (PU), thermoplastic
polyurethane (TPU), a mesh material, etc.).
[0041] After attachment of reinforcing panel 21 and toe cap 25,
rear edge 75 of composite panel 15 is joined (e.g., by stitching)
to rear edge 76 so as to form a shell of upper 11. Foxing panel 16
(with attached collar 17), padding and a heel counter are then
joined to the shell by stitching and/or bonding. Foxing panel 16
can be formed in a separate operation in a manner known in the art.
Tongue 13 is then attached to the shell and the shell placed on a
last. A lasting sock (or Strobel) can then be attached to the
lasted shell to complete upper 11, and sole structure 12
attached.
[0042] As can be appreciated from the foregoing, techniques
described herein permit simple fabrication of an upper (or portion
of an upper) with zonally-specific contours. The resulting upper
(or upper portion) can include one or more contouring elements that
are securely located on the interior side of a lightweight panel
and that lack exposed interfaces that promote separation of the
contouring element.
[0043] Shoe 10 and the fabrication operations described above are
merely examples of products and processes according to some
embodiments. Other embodiments include numerous other materials and
material combinations. For example, a backing could be formed from
synthetic leather or from some other material different from
polyester knit material. Instead of synthetic leather, strips of
EVA (ethylene vinyl acetate) foam, TPU foam, other types of foam,
non-foamed materials, natural leather, or other materials could be
used for contouring elements. As indicated above, various types of
meshes and other porous fabrics could be employed. A single upper
might also include combinations of multiple backing materials,
combinations of multiple contouring element materials and/or
combinations of multiple mesh (or other porous fabric) materials.
Additional layers and/or components could also be added. For
example additional PU or TPU coated panels similar to toe cap 25
and/or reinforcing panel 21 could be attached to an upper in other
locations.
[0044] Other embodiments may also include different shapes and/or
arrangements of various components. Ventilation windows could be
larger or smaller, fewer or more numerous, have different shapes
and locations, etc. Contouring elements could also have different
shapes, thicknesses, locations, etc. Other embodiments may have a
foxing panel with a different shape and/or having different
internal padding. In some embodiments, a separate foxing panel
might be omitted.
[0045] Additional fabrication techniques can also be employed. In
some embodiments, only a single pressing operation is performed. As
one example thereof, a first pressing operation to temporarily bond
components is omitted. Instead, a dual pan assembly jig such as is
described in commonly-owned U.S. patent application Ser. No.
12/603,494 (incorporated by reference herein) is employed.
[0046] The foregoing description of embodiments has been presented
for purposes of illustration and description. The foregoing
description is not intended to be exhaustive or to limit
embodiments of the present invention to the precise form disclosed,
and modifications and variations are possible in light of the above
teachings or may be acquired from practice of various embodiments.
As but one example, techniques such as are described herein can be
used to fabricate articles other than footwear uppers. The
embodiments discussed herein were chosen and described in order to
explain the principles and the nature of various embodiments and
their practical application to enable one skilled in the art to
utilize the present invention in various embodiments and with
various modifications as are suited to the particular use
contemplated. Any and all combinations, subcombinations and
permutations of features from above-described embodiments are the
within the scope of the invention.
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