U.S. patent application number 16/196137 was filed with the patent office on 2019-05-23 for conforming membrane for manufacturing footwear.
The applicant listed for this patent is NIKE, Inc.. Invention is credited to Lonnie Ballard, Joseph Johnson, Peter Kim, YoungSam Kim, Michael Kolb.
Application Number | 20190150572 16/196137 |
Document ID | / |
Family ID | 65036885 |
Filed Date | 2019-05-23 |
United States Patent
Application |
20190150572 |
Kind Code |
A1 |
Kolb; Michael ; et
al. |
May 23, 2019 |
CONFORMING MEMBRANE FOR MANUFACTURING FOOTWEAR
Abstract
A low-pressure operation conforming membrane for manufacturing
an article of footwear includes a perimeter portion having a
thickness in a range of 1 to 15 millimeters forming an outer
perimeter of the conforming membrane. The conforming membrane also
includes a transition portion having a thickness in a range of 1 to
4 millimeters between a first surface and a second surface with the
transition portion extending interior to the outer perimeter. The
conforming membrane also includes a conforming portion extending
from the transition portion in a direction of the second surface
and forming a receiving cavity, the conforming portion having a
thickness in a range of 1 to 4 millimeters. The perimeter portion,
the transition portion, and the conforming portion are a unitary
construction comprising a common material composition.
Inventors: |
Kolb; Michael; (Portland,
OR) ; Ballard; Lonnie; (Austin, TX) ; Johnson;
Joseph; (Austin, TX) ; Kim; Peter; (Saha-gu,
KR) ; Kim; YoungSam; (Saha-gu, KR) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
NIKE, Inc. |
Beaverton |
OR |
US |
|
|
Family ID: |
65036885 |
Appl. No.: |
16/196137 |
Filed: |
November 20, 2018 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
62589936 |
Nov 22, 2017 |
|
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|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
A43B 9/12 20130101; A43B
13/04 20130101; A43B 5/00 20130101; A43D 2200/50 20130101; A43B
9/00 20130101; A43D 25/10 20130101; B29D 35/0054 20130101; A43D
25/20 20130101; B29D 35/10 20130101 |
International
Class: |
A43D 25/10 20060101
A43D025/10; A43B 5/00 20060101 A43B005/00; A43B 13/04 20060101
A43B013/04; A43B 9/12 20060101 A43B009/12; A43D 25/20 20060101
A43D025/20 |
Claims
1. A conforming membrane for aiding in the joining of a first
article and a second article, the conforming membrane comprising: a
perimeter portion having a thickness in a range of 1 to 15
millimeters forming an outer perimeter of the conforming membrane;
a transition portion having a thickness in a range of 1 to 4
millimeters between a first surface and a second surface, wherein
the transition portion extends interior to the outer perimeter
formed by the perimeter portion; and a conforming portion extending
from the transition portion in a direction of the second surface
and forming a receiving cavity, the conforming portion having a
thickness in a range of 1 to 4 millimeters, wherein the perimeter
portion, the transition portion, and the conforming portion are a
unitary construction comprising a common material composition.
2. The conforming membrane of claim 1, wherein the first article is
a foamed polymer-based article.
3. The conforming membrane of claim 2, wherein the first article is
a footwear midsole and the second article is a footwear upper.
4. The conforming membrane of claim 1, wherein the perimeter
portion further comprises a first surface and a second surface,
both of the perimeter portion first surface and the perimeter
portion second surface are positioned on a common side of the
transition second surface as the conforming portion.
5. The conforming membrane of claim 1, wherein the perimeter
portion has a thickness in a range of 8 to 12 millimeters.
6. The conforming membrane of claim 1, wherein the outer perimeter
defines a planar area of 0.08 to 0.15 square meters.
7. The conforming membrane of claim 1, wherein the outer perimeter
has a longitudinal length in a range of 400 to 500 millimeters and
a transverse length in a range of 200 to 300 millimeters.
8. The conforming membrane of claim 1, wherein the transition
portion completely borders the conforming portion and joins the
conforming portion and the perimeter portion.
9. The conforming membrane of claim 1, wherein the conforming
portion has a durometer in a range of 60 to 61 Asker C.
10. The conforming membrane of claim 1, wherein the conforming
portion has a tensile strength in a range of 84 to 90
kg/cm.sup.3.
11. The conforming membrane of claim 1, wherein the conforming
portion has an elongation percentage of at least 540 percent
elongation prior to failure of the conforming portion.
12. The conforming membrane of claim 1, wherein the transition
portion and the conforming portion have a same durometer, tensile
strength, or elongation.
13. The conforming membrane of claim 1, wherein the conforming
portion extends in a range of 70 to 110 millimeters from the
transition portion second surface.
14. The conforming membrane of claim 1, wherein the conforming
portion extends in a range of 80 to 100 millimeters from the
transition portion second surface.
15. The conforming membrane of claim 1, wherein the receiving
cavity has a greater width in a transverse direction at a first
half in a longitudinal direction than a width in the transverse
direction at a second half in the longitudinal direction.
16. The conforming membrane of claim 1, wherein the conforming
portion has a thickness of 2 millimeters.
17. The conforming membrane of claim 1, wherein the material
composition comprises natural rubber, silicon dioxide, and calcium
carbonate.
18. The conforming membrane of claim 1, wherein the material
composition is comprised of 75% to 85% by weight rubber and 5% to
15% silicon dioxide.
19. The conforming membrane of claim 1, wherein the material
composition is comprised of 5% to 15% by weight silicon dioxide and
5% to 15% calcium carbonate.
20. The conforming membrane of claim 1, wherein the material
composition is comprised of a dispersible silica in a range of 8%
to 12% by weight of the material composition.
21. A press having a conforming membrane for aiding in the joining
of a first article and a second article, the press comprising: the
conforming membrane comprising: (1) a perimeter portion having a
thickness in a range of 1 to 15 millimeters forming an outer
perimeter of the conforming membrane; (2) a transition portion
having a thickness in a range of 1 to 4 millimeters between a first
surface and a second surface, wherein the transition portion
extends interior to the outer perimeter formed by the perimeter
portion; and (3) a conforming portion extending from the transition
portion in a direction of the second surface and forming a
receiving cavity, the conforming portion having a thickness in a
range of 1 to 4 millimeters, wherein the perimeter portion, the
transition portion, and the conforming portion are a unitary
construction comprising a common material composition; and a
pressure source fluidly coupled with the press to control a
pressure differential between the transition first surface and the
transition second surface of 0.5 to 3.9 bar.
22. A method of manufacturing an article of footwear using a
conforming membrane for joining a footwear sole portion and a
footwear upper, the method comprising: positioning the footwear
upper on a securing element; closing the conforming membrane over
the footwear upper on the securing element and the footwear sole
portion, with a first surface of the conforming membrane contacting
the footwear sole portion and the footwear upper, the conforming
membrane comprising: (1) a perimeter portion having a thickness in
a range of 5 to 15 millimeters forming an outer perimeter of the
conforming membrane; (2) a transition portion having a thickness in
a range of 1 to 4 millimeters between a first surface and a second
surface, wherein the transition portion extends interior to the
outer perimeter formed by the perimeter portion; and (3) a
conforming portion extending from the transition portion in a
direction of the second surface and forming a receiving cavity, the
conforming portion having a thickness in a range of 1 to 4
millimeters, wherein the perimeter portion, the transition portion,
and the conforming portion are a unitary construction comprising a
common material composition; generating a pressure differential
experienced on the first surface of the conforming membrane and an
opposite second surface of the conforming membrane, wherein a
pressure at the second surface of the conforming membrane is a
greater pressure than a pressure at the first surface; and after a
predefined time period, reducing the pressure differential.
23. The method of claim 22, wherein the pressure differential is in
a range of 0.5 bar to 3.9 bar.
24. The method of claim 22, wherein the predefined time period is
at least 25 seconds.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional
Application No. 62/589,936 entitled "Conforming Membrane for
Manufacturing Footwear," and filed Nov. 22, 2017. The entirety of
the aforementioned application is incorporated by reference
herein.
TECHNICAL FIELD
[0002] Directed to a press membrane used in the joining of two
articles.
BACKGROUND
[0003] Traditionally an article of footwear may be manufactured by
adhering a sole portion with a lasted upper portion. Pressure,
temperature, and/or time are adjusted to achieve a bond between the
sole and the lasted upper. The application of pressure may be
accomplished with a press effective to aid in supplying a
compressive force between the sole and the lasted upper as an
adhesive or other joining material bonds the sole and the lasted
upper.
BRIEF SUMMARY
[0004] Aspects hereof contemplate a conforming membrane for aiding
in the joining of a first article and a second article. The
conforming membrane includes a perimeter portion having a thickness
in a range of 1 to 15 millimeters ("mm") forming an outer perimeter
of the conforming membrane. The conforming membrane also includes a
transition portion having a thickness in a range of 1 to 4 mm
between a first surface and a second surface. The transition
portion extends interior to the outer perimeter formed by the
perimeter portion. The conforming membrane also includes a
conforming portion extending upwardly from the transition portion
in a direction of the second surface and forming a receiving
cavity. The conforming portion has a thickness in a range of 1 to 4
mm. The perimeter portion, the transition portion, and the
conforming portion are a unitary construction comprising a common
material composition.
[0005] This summary is provided to enlighten and not limit the
scope of methods and systems provided hereafter in complete
detail.
DESCRIPTION OF THE DRAWINGS
[0006] The present invention is described in detail herein with
reference to the attached drawing figures, wherein:
[0007] FIG. 1 depicts a press having a conforming membrane, in
accordance with aspects hereof;
[0008] FIG. 2 depicts the press of FIG. 1 in a closed and secured
configuration, in accordance with aspects hereof;
[0009] FIG. 3 depicts a cross sectional view of the press along
cutline 3-3 of FIG. 2, in accordance with aspects hereof;
[0010] FIG. 4 depicts a perspective view of a conforming membrane,
in accordance with aspects hereof;
[0011] FIG. 5 depicts a side view of the conforming membrane of
FIG. 4, in accordance with aspects hereof;
[0012] FIG. 6 depicts a front view of the conforming membrane of
FIG. 4, in accordance with aspects hereof;
[0013] FIG. 7 depicts a plan view of the conforming membrane of
FIG. 4, in accordance with aspects hereof;
[0014] FIG. 8 depicts a cross-sectional view of the conforming
membrane along cutline 8-8 of FIG. 4, in accordance with aspects
hereof; and
[0015] FIG. 9 depicts a flow chart illustrating an exemplary method
of manufacturing an article of footwear with a conforming membrane,
in accordance with aspects hereof.
DETAILED DESCRIPTION
[0016] Manufacturing of footwear, such as athletic shoes, is
traditionally performed by joining different portions. For example,
a footwear upper is a portion of an article of footwear that
extends around a wearer's foot to secure the article of footwear to
the wearer. The upper may be formed from a variety of materials,
such as leather, films, textiles, printed materials, and the like.
The upper, in some examples, is a portion of the footwear the
includes a securing structure, such as lacing apertures for a lace,
an ankle opening for allowing the donning and doffing of a wearer's
foot, and other structures. The shape of the upper is determined,
in part, at the time it is joined with other portions. In some
manufacturing scenarios, a cobblers last, also referred to as a
"last" is inserted into the upper (or the upper is formed about the
last) causing the upper to acquire a shape of the last. When an
upper is placed on a last or otherwise formed around a last, the
combination is commonly referred to as a "lasted upper." A lasted
upper is an upper having a last providing support and dimensional
guidance to the upper during a manufacturing process. As additional
portions/components are joined with the lasted upper, the shape of
the upper becomes more solidified such that dimensional shape is
maintained or at least influenced by the last once the last is
removed.
[0017] Another common component of an article of footwear is a
sole. A sole may be referred to as a "bottom unit" in some
examples. A sole may be a collection of multiple components, such
as an outsole, a midsole, and/or an insole. Additional components
may also be incorporated, such a cushioning element (e.g.,
springs), stability elements (e.g., torsion bars), and the like
that in combination form a sole. The sole is traditionally a
portion that extends between the upper and an underlying ground on
to which a wearer of the footwear moves.
[0018] A sole may be formed from a variety of materials. For
example, a sole may be formed from leather, felt, textile, and/or
polymer-based materials (e.g., natural or synthetic). Different
portions of the sole may be formed from different materials. For
example, an outsole (e.g., ground contacting portion) may be formed
from a rubber (e.g., synthetic or natural) and a midsole portion
may be formed from a foamed polymer (e.g., ethylene-vinyl acetate
(EVA), polyurethane (PU)). As will be discussed hereinafter, the
conforming membrane may be adapted to aid in joining an upper with
a sole comprised of a foamed material, such as EVA or PU. Other
foamed materials include, but are not limited to low-density
polyethylene, polyimide foam, polypropylene foam, polystyrene foam,
polyvinyl chloride foam, silicone foam, and the like.
[0019] The upper is traditionally joined with the sole. In some
examples the upper and the sole are joined through a stitching
operation. In another example, the upper is joined with the sole
through a bonding process. The bonding process may be accomplished
with welding, fusing, and/or adhesive joining. In an exemplary
aspect, an adhesive material (e.g., liquid, paste, film) is applied
to at least one of a sole-contacting surface of the upper and/or
the upper-contacting surface of the sole. The adhesive may be
active or activated to cause a joining (e.g., mechanical bond
and/or chemical bond) between the upper and the sole. The joining
may be enhanced through an application of pressure, such as
applying a force through the upper to the sole and/or applying a
force through the sole to the upper. In addition to pressure, it is
contemplated that thermal energy (e.g., heat) may be applied to the
upper and/or the sole to aid in the joining of the upper and the
sole. Further yet, it is contemplated that providing a prescribed
time period in which thermal energy and/or pressure is applied to
the upper and/or the sole aids in achieving a joining between the
upper and the sole. As will be discussed hereinafter, the
conforming membrane is effective to provide a sufficient pressure
at intended locations to aid in a joining of an upper and a sole,
such as through use of an adhesive or other bonding material.
[0020] However, in some traditional joining techniques when applied
to joining a compressible sole element (e.g., EVA, PU, or other
foamed polymer-based materials) with a lasted upper, the
application of pressure causes a permanent, unintended deformation
to the compressible sole during the joining processes and therefore
deforms the compressible sole in an unintended shape as it is
joined to the upper. Stated differently, traditional presses
lacking a conformable membrane as provided herein may cause a
deformation of a sole portion, wherein the deformation is
maintained, at least in part, subsequent to the joining of the
upper and the deformed sole. As indicated previously, the
construction of an article of footwear may use rely on a successive
layering and joining of materials and portions to maintain a shape
of the upper as defined by a last once the last is removed after
the joining occurs. However, if the lasted upper is joined with a
sole that is deformed by a traditional press, once the last is
removed after the joining of the sole and the upper, the sole may
return toward (completely or partially) the original, non-deformed
shape of the sole. This return of the sole to a pre-deformed shape
after being joined with the upper may cause a deformation of the
upper relative to the shape of the upper as defined by the last.
Therefore, a traditional press that applies pressure to a sole to
aid in a joining of the sole and an upper may introduce deformation
of the sole during the press operation that results in an
unintended deformation of the sole and/or the upper subsequent to
the press operation.
[0021] It is appreciated that different sole materials may be more
susceptible to unintended, permanent deformation. As a result, a
traditional press may produce acceptable results for some footwear
material combinations. However, as materials advance and
application of a greater number of materials (e.g., foamed
polymers) are utilized in the components forming the article of
footwear, advancement in the press allows for integration of those
materials into an article of footwear. For example, soles formed
from certain materials produced unsatisfactory bonding (e.g.,
bonding gaps) when a traditional press is used to join the sole and
a lasted upper. When press application from a traditional press
lasts over a prescribed time (e.g., 30 seconds, 25 second), the
material deforms and causes insufficient bonding. Additionally, a
reduced force may be applied to compensate for the non-conforming
nature of a traditional press. However, a reduction in force (or
time) may result in an insufficient joining (e.g., incomplete
bond). Further yet, a traditional press may cosmetically deform one
or more portions (e.g., foamed sole portions) as force is applied
linearly through the press as opposed in a surrounding manner
accomplished by aspects of the conforming membrane provided
herein.
[0022] As such, aspects provided herein are directed to a
conforming membrane for aiding in the joining of a first article
and a second article. A conforming membrane is a membrane that
conforms to the lasted upper and the sole to envelope the lasted
upper and sole in a compressive force that is normal to a variety
of surfaces (e.g., sole ground contacting surface, sole sidewalls,
upper medial side, upper, lateral side, upper heel end, upper, toe
box). This multi-directional compressive force provided by a
conforming membrane secures the sole and lasted upper for a
bonding/joining process without deforming a foamed material, such
as a sole portion. This is contrary to a traditional press that
fails to sufficiently conform around the lasted upper and the sole
and/or that relies on a higher pressure to cause the conformance of
the press material. A traditional press instead concentrates
pressure through the sole in a more linear manner as opposed to the
multi-directional compressive force provided by a conforming
membrane. Additionally, a traditional press that may have a
"conforming" membrane may only be "conforming" when under
significantly higher pressure than that provided in connection with
aspects hereof.
[0023] The conforming membrane includes a perimeter portion having
a thickness in a range of 1 to 15 millimeters ("mm") forming an
outer perimeter of the conforming membrane. In some aspects, the
perimeter portion has a thickness in a range of 5 to 15 mm, 8 to 12
mm, or about 10 mm in another example. The conforming membrane also
includes a transition portion having a thickness in a range of 1 to
4 mm between a first surface and a second surface. The transition
portion extends interior to the outer perimeter formed by the
perimeter portion. The conforming membrane also includes a
conforming portion extending from the transition portion in a
direction of the second surface and forming a receiving cavity. The
conforming portion has a thickness in a range of 1 to 4 mm. The
perimeter portion, conforming portion and the transition portion
may have a same thickness, or a different thickness. The conforming
portion and the transition portion may have a same thickness, or a
different thickness. The perimeter portion, the transition portion,
and the conforming portion are a unitary construction comprising a
common material composition.
[0024] Further, aspects contemplate implementing a conforming
membrane with a manufacturing of an article of footwear such that a
method of manufacturing an article of footwear using a conforming
membrane for joining a footwear sole portion and a footwear upper
includes positioning the footwear upper on a securing element
(e.g., a press support). The method includes closing the conforming
membrane over the footwear upper on the securing element and the
footwear sole portion. In this example a first surface of the
conforming membrane contacts the footwear sole portion and the
footwear upper. The conforming membrane may be the conforming
membrane in the preceding paragraph or any derivation provided
herein. The method continues with reducing the pressure
differential after a predefined period of time (e.g., greater than
25 seconds, greater than 30 seconds, greater than 35 seconds). The
pressure differential may be in a range of 0.5 to 3.9 bar (i.e., 50
kilopascals to 390 kilopascals), in an exemplary aspect.
[0025] The conforming membrane and contemplated method of use
provides a tool to join an upper and a sole with reduced
deformation of the upper and/or sole relative to a traditional
press (e.g., membrane press). In some examples, characteristics of
the conforming membrane, such as thickness and material composition
allow the membrane to conform around a sole portion and an upper
portion to apply pressure (and heat in some examples) across
multiple surfaces (e.g., toebox, heel counter, upper medial side,
upper lateral side, across the sole-to-upper transition (e.g.,
biteline), sidewalls of the sole) during a joining of the upper
portion and the sole portion at lower pressure. This is in contrast
to a thicker or different material composition of a traditional
press membrane that applies a more linear force that extends
linearly through the sole and/or upper (as opposed to around from
multiple directions) at higher pressures (e.g., 4 bar or greater)
causing a deformation of the sole and/or upper during a press
operation.
[0026] Turing to the figures in general and FIG. 1 specifically,
which depicts a press 100 having a lasted upper 252 and sole 250
secured to a securing element 102, in accordance with aspects
hereof. At a high level, the press 100 is adapted to maintain an
upper and sole in a relative position to each other while being
joined. For example, an adhesive may be applied (e.g., sprayed,
painted, rolled, laid, printed) to the sole, the upper, or a
combination of the sole and upper. Additionally, it is contemplated
that the upper 252 and/or the sole 250 may be formed from one or
more materials that join under pressure and/or heat to the other
component (e.g., hot-melt adhesive, meltable polymer). The sole 250
and the upper 252 then have a pressure applied by a conforming
membrane 200 that is housed in a membrane vessel 116 (e.g., a lid).
As the membrane vessel 116 is positioned over the sole 250 and the
upper 252, the combination of components are at least partially
received in a receiving cavity 238 of the conforming membrane 200.
The receiving cavity is an intentional deformation (e.g., molded or
otherwise formed) from a planar configuration of the conforming
membrane 200 to allow for multiple surfaces (e.g., medial side,
lateral side, toe box at a toe end 254, a heel counter at a heel
end 256, biteline) of the to-be-formed footwear to be contacted by
the conforming membrane 200 during a press operation. The membrane
vessel 116 may be secured in a closed, operational configuration to
the press 100 by a membrane securement 114, such as a releasable
latching mechanism. The membrane securement 114 is effective to
maintain the membrane vessel 116 and associated conforming membrane
200 in a position relative to the article of footwear to which
pressure will be applied.
[0027] With respect to pressure, it is contemplated that pressure
may be applied to the sole 250 and the upper 252 in one or more
ways by the press 100. For example, the securing element 102 may be
effective to apply a linear force, such as through a pneumatic
cylinder, a linear actuator, and the like. This linear force is
transferred through a last 120 (as best seen in FIG. 3) to the
upper 252 and the sole 250 where resistance to the linear force is
met by the conforming membrane 200 contacting the upper 252 and/or
the sole 250. Additionally or alternatively, it is contemplated
that the securing element 102 is effective to adjust a position of
the upper 252 and the sole 250 within the receiving cavity 238. For
example, the securing element 102 may raise or lower (with
reference to the vertical position the press 100 of FIG. 1 as
depicted) the footwear components based on a intended pressure,
component size, component shape, and the like. The securing element
102, in some aspects may be static and un-moveable.
[0028] Pressure may alternatively or additionally be generated by
the press 100 through pressurization of the conforming membrane
200. In an exemplary aspect also depicted in FIG. 3, a positive
pressure relative to ambient pressure may be introduced to a volume
enclosed by the membrane vessel 116 and the conforming membrane
200. The increased pressure forms a pressure differential on
opposing surfaces of the conforming membrane 200. The pressure
differential cause the conforming membrane 200 to conform around
the upper 252 and the sole 250 as the conforming membrane 200
deforms under the pressure differential. It is this deformation
that causes the conforming membrane 200 to wrap around portions of
the upper 252 and the sole 250 generating a pressure that maintains
the upper 252 and the sole 250 in fixed relative positions during a
joining operation. Depending on the differential in pressure, a
sufficient pressure may be exerted on the upper 252 and the sole
250 to aid in joining (e.g., bonding through adhesive curing) of
those components. Exemplary pressure differentials include 0.5 bar
up to 3.9 bar relative to ambient pressures. Above 3.9 bar, in an
exemplary aspect, the conforming membrane may mechanically fail
after a number of press cycles or the article being pressed may
unintentionally, permanently deform during the press operation.
While pressure differentials above and below 0.5 bar to 3.9 bar are
contemplated, aspects herein implement pressure differentials in
the provided range to reduce unintentional deformation of the
pressed article. Less conforming membranes of traditional presses
may operate with a pressure differential at or above 4 bar in order
to conform and comply with the pressed article. This increased
pressure may allow a tradition press membrane to conform, but it
can damage or otherwise insert unintended deformations into a
pressed article, such as a portion of an article of footwear.
Therefore, implementations of the conforming membrane provided
herein operate at a lower pressure differential to achieve a
conformance of the membrane to the pressed article than that of a
traditional press membrane. In additional aspect, the pressure
differential expressed in bar pressure is in a range of 1 to 3, 1
to 2, 1 to 1.5, 1 to 1.3, 1 to 1.2, 1.1 to 1.4, and/or 1.25 to 1.35
bar. The various pressure differential windows provide flexibility
based on materials to be bonded, press times, degree of conformance
of the membrane, and the like. Therefore, based on the factors
contemplated herein, various pressure differential ranges may be
applied to achieve a bonding of footwear component while minimizing
unintentional, permanent deformation of the footwear
components.
[0029] FIG. 2 depicts the press 100 having the membrane vessel 116
in a closed and secured configuration, in accordance with aspects
hereof. The closed configuration is a configuration that allows the
press 100 to effectively apply pressure to footwear components
during a joining operation. Also depicted are input mechanisms for
the press 100. A time control 110, a pressure control 112, and a
temperature control 118 are depicted. The input mechanisms allow a
user to adjust the namesake parameters (e.g., time, temperature,
pressure). However, it is contemplated that one or more of the
input mechanisms are omitted or altered in exemplary aspects. For
example, computer instructions may be communicated to the press
from a controller that controls the time, pressure, and/or time
applied to a specific (or general) component. Further, it is
contemplated that one or more of time, temperature, or pressure may
not be adjusted in some examples.
[0030] FIG. 3 depicts a cross-sectional view along cutline 3-3 of
FIG. 2, in accordance with aspects hereof. A toe-to-heel
perspective is provided illustrating the securing element 102
maintaining the last 120 in a position that allows the upper 252
and the upper 250 to be contacted by the conforming membrane 200.
FIG. 3 depicts the conforming membrane 200 during a pressure
differential causing the conforming membrane 200 to conform to the
lasted upper 252 and sole 250. A pressure source 106 provides an
exemplary source of the pressure to form the pressure difference.
The pressure source may provide a compressible or non-compressible
material (e.g., gas or liquid) into a membrane chamber 104 from an
exterior source (e.g., tank, pump, and compressor). The membrane
chamber 104 is enclosed and formed by the membrane vessel 116 and
the conforming membrane 200. The membrane chamber 104 is effective
to receive a pressurizing material (e.g., pressurized air) and
provide a volume for the pressurizing material to surround and
exert force on portions of the conforming membrane 200 from within
the membrane chamber 104. Pressure may be controlled with one or
mechanisms, such as a regulator and the like. Unlike a traditional
press membrane that operates at 4 bar and above, aspects herein
contemplate operating at lower pressures (e.g., 0.5 to 3.9 bar),
therefore a traditional macro-level control of pressure may result
in unintentional permanent deformation of a pressed article as the
macro-level control (e.g., analog regulator with 1 bar or greater
tolerances) has a large operating tolerance for pressure. This
large tolerance could result in a greater pressure differential at
the conforming membrane provided herein causing an unintended,
permanent deformation of the pressed article. As such, this
macro-level control of pressure for a pressure differential at or
above 4 bar is ineffective to control a pressure differential
having a range of 0.5 to 3.9 bar, in exemplary aspect. Further to
this, a macro-level control of pressure for a pressure differential
at or above 4 bar is ineffective to control a pressure differential
having a range of 1 to 2 bar, in exemplary aspect. Therefore,
aspects hereof contemplate upgrading the pressure control mechanism
to a micro-level control (e.g., a digital regulator with 0.9 bar or
less tolerance) that is able to maintain a pressure differential
within a tighter tolerance range than that of a pressure mechanism
of a traditional press. Increase pressure tolerance control may
provide greater durability of the conforming membrane (e.g.,
reduces over pressurization potential) and allows for more
consistent operation at lower pressures provided herein. Stated
differently, as aspects herein contemplate operating at a lower
pressure differential than a standard press, greater control of the
pressure differential increases results from the conforming
membrane press, in exemplary aspects hereof.
[0031] Also depicted in FIG. 3 is an optional heating source 108.
The heating source 108 may be a resistive heating element, an
infrared heating element, an induction heating element, and the
like. Alternatively, it is contemplated that the pressurized
material may be heated externally to the membrane chamber 104 and
introduced at an elevated (or reduced) temperature relative to
ambient conditions, in some aspects. Heat may be used to activate,
melt, or cure one or more materials, such as a bonding material.
For example, a low-melt adhesive that has a deformation temperature
(e.g., melting temperature) that is lower than the membrane, the
upper, and the sole may be positioned between the upper and the
sole. Prior to conforming or subsequent to conforming the
conforming membrane 200 around portions of the sole and the upper,
heat may be generated or applied to activate the low-melt adhesive.
The thermal energy may then be reduced while maintaining pressure
from the conforming membrane 200 until the low-melt adhesive (or
any bonding material) has a sufficient bond between the components.
It is contemplated that the heating source 108 is optional and may
be omitted altogether in aspects contemplated herein.
[0032] FIG. 3 introduces three regions of the conforming membrane
200. A perimeter portion 214, a transition portion 224, and a
conforming portion 234 that will be discussed in greater detail in
FIGS. 4-8 hereinafter. As depicted in FIG. 3, the conforming
membrane 200 wraps around and surrounds portions of the upper 252
and the sole 250 from multiple directions on multiple surfaces. It
is this conformance to multiple surfaces and components that allows
the conforming membrane 200 to effectively join the upper 252 and
the sole 250.
[0033] As previously provided, a less-conforming (or
non-conforming) membrane of a traditional press could instead
permanently deform the sole 250, such as compressing a foam
material, during a pressing operation as it fails to sufficient
conform and therefore applies a more focused and unidirectional
pressure to the sole. The permanent deformation that result in an
unacceptable pressed part may also result from operating a
traditional press membrane at a higher pressure (e.g., 4 bar and
higher) to achieve a level of conformance of the traditional press
membrane to the pressed component. The higher pressure differential
used on a traditional press compensates for a less conforming
membrane material, which translates to a potentially damaging force
being applied to the pressed article. This unintentional
deformation may be further exaggerated if thermal energy is applied
to the process to activate or cure a bonding material. The
increased thermal energy may cause the material forming the sole
(e.g., PU, EVA) to become more compliant and therefore more
susceptible to unintentional deformation under a pressure from a
press. As such, having a compliant membrane that surround from
multiple directions the various surfaces of the components to be
joined, the pressure of the press is applied across a greater
surface area in a greater number of degrees of direction allowing
the same materials that may unintentionally deform under a
traditional membrane to be effectively joined with the conforming
membrane 200.
[0034] FIG. 4 depicts a perspective view of the conforming membrane
200, in accordance with aspects hereof. A longitudinal direction
206 and a transverse direction 210 are generally illustrated for
reference purposes. As it is contemplated that the conforming
membrane is used in connection with articles of footwear, the
conforming membrane has a receiving cavity that is formed in a
general shape of an article of footwear portion intended to be
received. This general and intentional deformation limits creases
or other membrane deviations when place under a pressure
differential to form a smooth conformance to the underlying
footwear components. Stated differently, in some examples the
receiving cavity has a shape similar to the article to which it is
intended to conform under a pressure differential. This
coordination between the receiving cavity shape and the footwear
article allows for a more uniform conformance by the membrane to
the to-be-joined components under a pressure differential.
[0035] The perimeter portion 214, the transition portion 224, and
the conforming portion 234 of the conforming membrane 200 are
depicted in FIG. 4. Additionally, an outer perimeter 222 is
depicted as forming an outermost portion of the conforming membrane
200. A conforming membrane second surface 204 is also depicted. The
conforming membrane second surface 204 is opposite a conforming
membrane first surface 202, as best seen in FIG. 8.
[0036] FIG. 5 depicts a side view of the conforming membrane 200,
in accordance with aspects hereof. A z-direction 236 is
illustrated. The z-direction 236 is a direction in which the
conforming portion 234 extends from the transition portion 224.
FIG. 6 depicts a front view of the conforming membrane 200, in
accordance with aspects hereof.
[0037] FIG. 7 depicts a plan view of the conforming membrane 200 of
FIGS. 4-6, in accordance with aspects hereof. Several exemplary
positional elements are depicted in FIG. 7. For example, a
receiving cavity first half 240 and a receiving cavity second half
244 are depicted along the longitudinal direction 206. Additionally
a series of arrow indicators 232 are depicted to illustrate an
"internal" direction in the plan view plane of the conforming
membrane 200 relative to the outer perimeter 222.
[0038] The conforming portion 234 includes the receiving cavity
238. The receiving cavity first half 240 has a maximum width 242
and the receiving cavity second half 244 has an exemplary width
246. The width of the receiving cavity portions are measured in the
transverse direction 210. As the receiving cavity is shaped to
conform to an article of footwear, the maximum width 242 of the
receiving cavity first half 240 is greater than any width of the
receiving cavity second half 244 (e.g., width 246), in this
example. It is contemplated that the receiving cavity may have any
shape depending on the article to be compressed by the conforming
membrane.
[0039] The conforming membrane 200 has a length 208 in the
longitudinal direction 206 measured from the outer perimeter 222.
The conforming membrane 200 has a width 212 in the transverse
direction 210 measured from the outer perimeter 222. The length 208
is contemplated to be in a range of 400 to 500 mm, in an exemplary
aspect. The length 208 is contemplated to be in a range of 425 to
475 mm, in an exemplary aspect. The length 208 is contemplated to
be in a range of 450 to 465 mm, in an exemplary aspect. The width
212 is contemplated to be in a range of 200 to 300 mm, in an
exemplary aspect. The width 212 is contemplated to be in a range of
210 to 250 mm, in an exemplary aspect. The width 212 is
contemplated to be in a range of 220 to 240 mm, in an exemplary
aspect. In view of the provided exemplary ranges, it is
contemplated that the outer perimeter 222 may define a planar
surface area of 0.08 to 0.15 square meters. This area allows for
sufficient conforming membrane material to conform to the
components to be compressed while minimizing material and weight
associated with the conforming membrane 200. The length and width
may depend on a style, size, or type of article to be compressed by
the conforming membrane 200.
[0040] Additionally, the conforming portion 234 has a maximum
length 209. The length 209 is contemplated to be in a range of 350
to 450 mm, in an exemplary aspect. The length 209 is contemplated
to be in a range of 375 to 425 mm, in an exemplary aspect. The
length 209 is contemplated to be in a range of 395 to 415 mm, in an
exemplary aspect. The maximum width 242 is contemplated to be in a
range of 150 to 250 mm, in an exemplary aspect. The maximum width
242 is contemplated to be in a range of 175 to 225 mm, in an
exemplary aspect. The maximum width 242 is contemplated to be in a
range of 190 to 210 mm, in an exemplary aspect. The receiving
cavity length 209 and width 242 are selected, in an exemplary
aspect to provide a sufficiently sized receiving cavity for the
components to be received while limiting excess conforming membrane
material. For example, the length and width of the receiving cavity
238 may be 1 to 10% greater than similar measurements of the
components to be received therein to achieve easy insertion and
extraction without introducing unintentional deformations as the
membrane conforms to the underlying components.
[0041] FIG. 8 depicts a cross section along cutline 8-8 of the
conforming membrane 200 from FIG. 4, in accordance with aspects
hereof. The perimeter portion 214 has a perimeter portion first
surface 218 and a perimeter portion second surface 220 with a
thickness 216 defined there between. The transition portion 224 has
a transition portion first surface 228 and a transition portion
second surface 230 and a thickness 226 defined there between. The
conforming portion 234 has a conforming portion first surface 235
and a conforming portion second surface 237 and a thickness 248
there between.
[0042] Thickness of the conforming portion 234, the transition
portion 224, and the perimeter portion 214 affect the ability of
the conforming membrane 200 to conform to an article under a
pressure differential. Historical membranes in a historical press
may have a greater thickness in the various portions. The greater
thickness traditionally may have been implemented to allow
materials forming the traditional membranes to have a greater
longevity during industrial application. However, the conforming
membrane 200 may be operated at different conditions (e.g.,
temperature, pressure, time) as a result of the more compliant
parts to be joined and/or formed from different materials and
therefore can deviate to a thinner (e.g., less) thickness) than a
traditional membrane. In some examples, as a thickness in a portion
of the conforming membrane reduces, the conforming membrane may
become more compliant and able to conform to the underlying
article. However, if the thickness is reduced too much, the
conforming membrane may suffer from fatigue and failure for
practical industrial application. As such, in an exemplary aspect
ranges of various thicknesses are contemplated to provide a
sufficient compliance to the conforming membrane 200 while
achieving sufficient service life.
[0043] The perimeter portion thickness 216 is contemplated to be in
a range of 1 to 15 mm, in accordance with aspects hereof. The
perimeter portion thickness 216 is contemplated to be in a range of
5 to 15 mm, in accordance with aspects hereof. The perimeter
portion thickness 216 is contemplated to be in a range of 8 to 12
mm, in accordance with aspects hereof. The perimeter portion
thickness 216 is contemplated to be about 10 mm, in accordance with
aspects hereof. The transition portion thickness 226 is
contemplated to be in a range of 1 to 4 mm, in accordance with
aspects hereof. The transition portion thickness 226 is
contemplated to be about 2 mm, in accordance with aspects hereof.
The conforming portion thickness 248 is contemplated to be in a
range of 1 to 4 mm, in accordance with aspects hereof. The
conforming portion thickness 248 is contemplated to be about 2 mm,
in accordance with aspects hereof. The perimeter portion thickness
216, the transition portion thickness 226, and the conforming
portion thickness 248 may be the same in exemplary aspects. The
perimeter portion thickness 216, the transition portion thickness
226, and/or the conforming portion thickness 248 may be different
in exemplary aspects.
[0044] In an exemplary aspect, the conforming portion 234 and the
transition portion 224 are contemplated to have a similar
thickness. This common thickness may allow the transition portion
224 to similarly comply as the conforming portion 234 during a
pressure differential preventing areas of greater elongation in the
conforming portion 234. In some examples, the transition portion
224 completely borders or encircles the conforming portion 234.
Stated differently, the transition portion 224 provides functional
transition between the perimeter portion 214 and the conforming
portion 234 that extends in a z-direction. By surrounding the
conforming portion 234, the transition portion 224 allows the
conforming portion 234 to conform to a received article even at an
outermost portion of the conforming portion 234.
[0045] The perimeter portion thickness 216 may be greater than the
transition thickness 226, in an exemplary aspect, to increase
longevity, service life, and concentration of compressive energy
around a received article. As thickness of the conforming membrane
affects functional characteristics (e.g., elongation), the
conforming membrane 200 is more susceptible to deformation with a
pressure differential at locations having a smaller thickness
(i.e., thinner regions). Therefore, by reducing the thickness of
the conforming membrane 200 at the receiving cavity 238 and
proximate the article to be received, the conforming membrane 200
conforms more around the received article than at the perimeter
portion 214 having a greater thickness. As the perimeter portion
214 has a greater thickness resulting in fewer conformances, the
perimeter portion 214 may be less susceptible to fatigue failure
from repeated conformance during pressure differential cycles, in
an exemplary aspect.
[0046] FIG. 8 depicts an extension height 258 of the conforming
portion 234 from the transition portion 224. The height 258 is in a
range of 70 to 110 mm, in accordance with aspects hereof. The
height 258 is in a range of 80 to 100 mm, in accordance with
aspects hereof. The height 258 is about (e.g., within 10%) of 90
mm, in accordance with aspects hereof. A traditional membrane may
have a height that is significantly less than those of the
conforming membrane 200. In those examples, the lesser height
prohibits the membrane from surrounding multiple surfaces of the
article and therefore a deformation-susceptible material (e.g.,
foamed polymer of a sole) may deform under a directional
compression of a traditional membrane. The conforming membrane 200
having a greater height than a traditional membrane is allowed to
instead surround a sole portion and at least part of an upper to
envelope the article in a unitary pressure rather than a
directional pressure (e.g., linearly from the membrane toward a
securing element).
[0047] In an exemplary aspect, the perimeter portion first surface
218 and the perimeter portion second surface 220 are positioned
above the transition portion second surface 230. Further, it is
contemplated in an exemplary aspect that the perimeter portion
first surface 218 and the perimeter portion second surface 220 are
positioned on a common side of the transition portion second
surface 230 as the conforming portion 234 extends (e.g., upwardly
in FIG. 8). This offsetting between the perimeter portion 214 and
the transition portion 224 allows for greater conformance of the
conforming membrane 200 about the received article in an inner
direction relative to the outer perimeter 222. Stated differently,
the offsetting in vertical placement of the perimeter portion 214
and the transition portion 224 allows for a transfer of vertical
displacement for horizontal conformance as a pressure differential
is applied, in an exemplary aspect.
[0048] The conforming membrane 200 is formed from a conforming
material. In one aspect, the conforming membrane is formed from
material composition comprising a rubber (e.g., natural rubber),
silicon dioxide (i.e., silica), and calcium carbonate. Additional
materials may be included in the composition. In an exemplary
aspect, the material composition of the conforming membrane 200 is
comprised of 75% to 85% by weight rubber and 5% to 15% by weight
silicon dioxide. In an exemplary aspect, the material composition
of the conforming membrane 200 is comprised of 5% to 15% by weight
calcium carbonate and 5% to 15% by weight silicon dioxide. In an
exemplary aspect, the material composition of the conforming
membrane 200 is comprised of 8% to 12% by weight of a dispersible
silica. In an exemplary aspect, the material composition of the
conforming membrane 200 is comprised of 75% to 85% by volume rubber
and 5% to 15% by volume silicon dioxide. In an exemplary aspect,
the material composition of the conforming membrane 200 is
comprised of 5% to 15% by volume calcium carbonate and 5% to 15% by
volume silicon dioxide. In an exemplary aspect, the material
composition of the conforming membrane 200 is comprised of 8% to
12% by volume of a dispersible silica. Percentage of composition is
determined prior to combination, in exemplary aspects.
[0049] It is contemplated that the conforming membrane is a unitary
material extending between two or more portions. For example, it is
contemplated that the conforming portion 234 and the transition
portion 224 are formed from a common material such that the
composition of material forming the portions is homogenous.
Similarly, it is contemplated that the perimeter portion 214, the
transition portion 224, and the conforming portion 234 are unitary
and formed from a common material. A unitary construction is a
single entity having a uniform material composition. For example,
two or more portions of the conforming membrane may be produced
simultaneously. In an example, a molding operation may be performed
that forms the two or more portions in combination. In an
alternative manufacturing process, it is contemplated that a common
material is subtractively formed (e.g., milled) to form the
conforming membrane. In this example, the portions formed from the
subtractive method are unitary as they all begin with a common
source material without subsequent joining.
[0050] Functional characteristics of the conforming membrane 200
may be quantified to provide a range of a conforming membrane
suitable for exemplary aspects hereof. For example, the conforming
membrane 200, at least in the conforming portion 234, may have a
hardness of 60-61 Asker C as measured on an ASKER Type C Durometer,
in accordance with aspects hereof. The conforming membrane 200, at
least in the conforming portion 234, may have a maximum tensile
strength in a range of 84 to 90 kg/cm.sup.3 range, in accordance
with aspects hereof. The maximum tensile strength may be tested
using a test such as the ASTM D638-14 testing protocol. The
conforming membrane 200, at least in the conforming portion 234,
may have a maximum elongation until destruction of at least 540%,
in accordance with aspects hereof. The maximum elongation may be
tested using a test such as the ASTM D-638 testing protocol.
[0051] The material composition and resulting functional
characteristics of the conforming membrane 200 provide a suitable
material for use as a membrane to join two or more footwear
portions without deforming or damaging a foamed polymer component,
such as an EVA or PU midsole element, in an exemplary aspect. The
material composition provided herein for the conforming membrane
200 is contemplated to save in labor, cost, and/or material. For
example, operating at a lower pressure than a traditional membrane
press to achieve conformance of the membrane to the underlying
pressed article reduces subsequent interventions to correct
unintentional deformations of the pressed materials. Additionally,
with a conforming membrane that operates at a lower pressure,
energy savings are achieved by the use of lower pressure needs.
Additionally, operating a conforming membrane at a lower pressure
with the contemplated material composition allows for a thinner
membrane that reduces material use for forming the membrane, which
reduces material costs, in an exemplary aspect.
[0052] Turning to FIG. 9 illustrating a method 900 of manufacturing
an article of footwear using a conforming membrane for joining a
footwear sole portion and a footwear upper, in accordance with
aspects hereof. At a block 902 a footwear upper is positioned on a
securing element. The footwear upper may be a lasted upper where
the last is secured to the securing element. At a block 904, the
conforming membrane, such as the conforming membrane 200 provided
herein, is closed on the footwear upper and a footwear sole
portion. In this example, the footwear upper and the footwear sole
are positioned in an intended relative position to each other. An
adhesive or other bonding material may be applied prior to joining
the two components.
[0053] At a block 906, a pressure differential is generated between
opposing surfaces of the conforming membrane. For example, a
pressurized fluid (e.g., gas or liquid) may be inserted into a
membrane cavity where the conforming membrane is more compliant
than the other materials forming the membrane cavity. As a result,
the membrane cavity deforms and conforms around the lasted upper
and sole creating a compressive force to secure the sole with the
lasted upper. The compressive force is applied to both the upper
and the sole at multiple surfaces inclusive of a junction between
the sole and the upper. This enveloping compression maintains the
sole in a defined location relative to the upper during a joining
operation.
[0054] At a block 908, the pressure differential is reduced after a
predefined period of time. This tie period may be 20 seconds, 25
seconds, 30 seconds, or any time appropriate to allow for the
joining of the sole with the upper.
[0055] Other steps contemplated, but not illustrated in FIG. 9
include, but are not limited to, application of thermal energy,
extraction of thermal energy (e.g., cooling), and adjusting a time,
pressure, and/or temperature.
[0056] The following is a non-limiting exemplary listing of parts
provided in the figures. [0057] Press--100 [0058] Securing
element--102 [0059] Membrane chamber--104 [0060] Pressure
source--106 [0061] Heating source--108 [0062] Time control--110
[0063] Pressure control--112 [0064] Membrane securement--114 [0065]
Membrane vessel--116 [0066] Temperature control--118 [0067]
Conforming membrane--200 [0068] Conforming membrane first
surface--202 [0069] Conforming membrane second surface--204 [0070]
Longitudinal direction--206 [0071] Longitudinal length--208 [0072]
Receiving cavity length 209 [0073] Transverse direction--210 [0074]
Transverse width--212 [0075] Perimeter portion--214 [0076]
Perimeter portion thickness--216 [0077] Perimeter portion first
surface--218 [0078] Perimeter portion second surface--220 [0079]
Outer perimeter--222 [0080] Transition portion--224 [0081]
Transition portion thickness--226 [0082] Transition portion first
surface--228 [0083] Transition portion second surface--230 [0084]
Arrow indicators of an interior direction--232 [0085] Conforming
portion--234 [0086] Conforming portion first surface--235 [0087]
Z-direction--236 [0088] Conforming portion second surface--237
[0089] Receiving cavity--238 [0090] Receiving cavity first
half--240 [0091] Receiving cavity first half maximum width--242
[0092] Receiving cavity second half--244 [0093] Receiving cavity
second half width--246 [0094] Conforming portion thickness--248
[0095] Sole--250 [0096] Upper--252 [0097] Toe end--254 [0098] Heel
end--256
[0099] Many different arrangements of the various components
depicted, as well as components not shown, are possible without
departing from the spirit and scope of the present disclosure.
Embodiments of the present disclosure have been described with the
intent to be illustrative rather than restrictive. Alternative
embodiments will become apparent to those skilled in the art that
do not depart from its scope. A skilled artisan may develop
alternative means of implementing the aforementioned improvements
without departing from the scope of the present disclosure.
[0100] It will be understood that certain features and
subcombinations are of utility and may be employed without
reference to other features and subcombinations and are
contemplated within the scope of the claims. Not all steps listed
in the various figures need be carried out in the specific order
described.
* * * * *