U.S. patent application number 17/586253 was filed with the patent office on 2022-05-12 for footwear articles and methods for preparing a footwear article.
The applicant listed for this patent is VANS, INC.. Invention is credited to Safir Bellali, Henry Song, Longtao Wang.
Application Number | 20220142306 17/586253 |
Document ID | / |
Family ID | 1000006104347 |
Filed Date | 2022-05-12 |
United States Patent
Application |
20220142306 |
Kind Code |
A1 |
Bellali; Safir ; et
al. |
May 12, 2022 |
FOOTWEAR ARTICLES AND METHODS FOR PREPARING A FOOTWEAR ARTICLE
Abstract
Footwear articles are disclosed herein. Footwear articles may be
formed using a method comprising disposing uncured resin adjacent a
mold, disposing a lattice structure in at least a portion of the
uncured resin disposed adjacent the mold, closing the mold using a
lasted upper, and injecting foam into the closed mold such that the
foam operates to couple the lasted upper and the lattice structure
together.
Inventors: |
Bellali; Safir; (Pasadena,
CA) ; Wang; Longtao; (Alhambra, CA) ; Song;
Henry; (Glendale, CA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
VANS, INC. |
Costa Mesa |
CA |
US |
|
|
Family ID: |
1000006104347 |
Appl. No.: |
17/586253 |
Filed: |
January 27, 2022 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
17121447 |
Dec 14, 2020 |
|
|
|
17586253 |
|
|
|
|
62948508 |
Dec 16, 2019 |
|
|
|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B29K 2105/04 20130101;
B29K 2075/00 20130101; B29D 35/081 20130101; B33Y 80/00 20141201;
A43B 13/125 20130101; B29D 35/061 20130101; B29D 35/142 20130101;
A43D 86/00 20130101; A43B 1/0009 20130101 |
International
Class: |
A43D 86/00 20060101
A43D086/00; A43B 13/12 20060101 A43B013/12; B29D 35/14 20060101
B29D035/14; B29D 35/06 20060101 B29D035/06; B29D 35/08 20060101
B29D035/08; A43B 1/00 20060101 A43B001/00 |
Claims
1. A footwear article formed using a method comprising: disposing
uncured resin adjacent a mold; disposing a lattice structure in at
least a portion of the uncured resin disposed adjacent the mold;
closing the mold using a lasted upper; and injecting foam into the
closed mold such that the foam operates to couple the lasted upper
and the lattice structure together.
2. The footwear article of claim 1, wherein the lattice structure
is formed using additive manufacturing.
3. The footwear article of claim 1, wherein the upper comprises a
knit upper.
4. The footwear article of claim 1, wherein the closing the mold
using a lasted upper comprises using a mold component comprising an
integral upper.
5. The footwear article of claim 1, wherein the foam is injected
into the mold via an aperture formed in the mold.
6. The footwear article of claim 1, wherein the foam operates as a
base cushion layer in a footwear article.
7. The footwear article of claim 1, wherein the first resin
comprises a clear resin.
8. The footwear article of claim 1, wherein the lattice structure
is formed using additive manufacturing.
9. The footwear article of claim 1, wherein the lattice structure
is formed in the shape of the footwear article.
10. The footwear article of claim 1, wherein the lattice structure
comprises one or more struts interconnected to define a plurality
of apertures.
11. A footwear article comprising: A lasted upper; a midsole; and
an outsole, wherein at least one of the midsole or the outsole are
formed using a method comprising: disposing a first resin in a
female mold portion of a mold associated with footwear; closing the
mold using a male mold portion; disposing an uncured second resin
on at least a portion of the first resin in the female mold
portion; disposing a lattice structure in at least a portion of the
uncured second resin disposed on the first resin in the female mold
portion; injecting foam into the mold such that the foam operates
to couple the lasted upper and the lattice structure together; and
releasing the mold.
12. The footwear article of claim 11, wherein one or more of the
first resin or the second resin comprises a clear resin.
13. The footwear article of claim 11, wherein the foam is injected
into the mold via an aperture formed in the female mold
portion.
14. The footwear article of claim 11, wherein the foam operates as
a base cushion layer in a footwear article.
15. The footwear article of claim 11, wherein the first resin is
uncured.
16. The footwear article of claim 15, further comprising curing the
first resin to provide a cured first resin in the female mold
portion.
17. The footwear article of claim 11, wherein the male mold portion
comprises a lasted upper.
18. The footwear article of claim 11, wherein the lasted upper is
an integral upper.
19. The footwear article of claim 11, wherein rereleasing the mold
comprises forming at least portion of at least one of the outsole
or the midsole.
20. The footwear article of claim 11, wherein the lattice structure
comprises one or more struts interconnected to define a plurality
of apertures.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. Nonprovisional
application Ser. No. 17/121,447, filed Dec. 14, 2020, which is a
Nonprovisional of and claims the benefit of U.S. Provisional
Application No. 62/948,508 filed Dec. 16, 2019, each of which is
hereby incorporated by reference in its entirety.
BACKGROUND
[0002] Footwear components can be joined by any number of
well-known methods, including, but not limited to, stitching by
hand or machine, adhesives, vulcanization, and injection molding.
The method of joining can affect many aspects of the footwear,
including durability and cost of manufacture.
[0003] However, improvements are needed.
SUMMARY
[0004] Systems and/or methods for preparing a footwear article are
disclosed herein. An example method may comprise disposing a
material (e.g., uncured resin, cured resin, vulcanized rubber,
etc.) adjacent a mold, disposing a lattice structure in at least a
portion of the material (e.g., uncured resin, cured resin, rubber
outsole, etc.) disposed adjacent the mold, closing the mold using a
lasted upper, injecting foam into the closed mold such that the
foam operates to couple the lasted upper and the lattice structure
together. Other processes and systems may be used, for example,
including the absence of an outsole altogether. Steps need not be
performed.
[0005] Additive manufacturing methods like 3D printing have allowed
footwear manufacturers to create footwear components, like foot
beds and even midsoles that are customized to a person's anatomy
and activity. The challenge is that these custom components, if not
removable, still have to be glued to the footwear upper and easily
collect debris and small objects in the open lattice structure, and
offer limited durability and abrasion resistance. The present
disclosure may address one or more challenges in the prior art by
enclosing a component (e.g., customized component) in foam and
using the injected foam as a bonding agent between the upper and
the outsole. As a further example, this may allow automation of one
or more parts of a manufacturing process while offering customized
fit.
[0006] Systems and/or methods for preparing a footwear article are
disclosed herein. An example method may comprise disposing an first
resin (e.g., a cured or uncured resin) or vulcanized rubber in a
female mold associated with footwear. Such a first resin or rubber
may comprise a portion of an outsole of a footwear article.
However, the example method may not comprise using an outsole. The
example method may comprise closing the mold. If the first resin is
uncured, the example method may comprise curing the first resin to
provide a cured first resin in the mold. The example method may
comprise disposing a second resin (e.g., a cured or uncured resin)
on at least a portion of the cured first resin in the mold. The
example method may comprise disposing a lattice structure in at
least a portion of the second resin disposed on the cured first
resin in the mold. The example method may comprise closing the mold
using a lasted upper. The example method may comprise injecting
foam into the closed mold such that the foam operates to couple the
lasted upper and the lattice structure together. The example method
may comprise releasing the closed mold.
[0007] Systems and/or methods for preparing a footwear article are
disclosed herein. An example method may comprise disposing an
uncured first resin in a mold. Reference is made to an uncured
resin, but use of a cured resin, vulcanized rubber or other
materials may be used. Moreover, the inclusion of the first resin
or rubber component is not required. The example method may
comprise curing the first resin (if uncured) to provide a cured
first resin. The example method may comprise disposing a second
resin (e.g., a cured or uncured resin) on at least a portion of the
cured first resin in the mold. The example method may comprise
disposing a lattice structure in at least a portion of the second
resin disposed on the cured first resin in the mold. The example
method may comprise closing the mold using a lasted upper. The
example method may comprise injecting foam into the closed mold
such that the foam operates to couple the lasted upper and the
lattice structure together.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] The following drawings show generally, by way of example,
but not by way of limitation, various examples discussed in the
present disclosure. In the drawings:
[0009] FIG. 1 shows an example footwear article in accordance with
the present disclosure.
[0010] FIG. 2A illustrates an example mold in accordance with the
present disclosure.
[0011] FIG. 2B shows side views of the example mold of FIG. 2A
before it is closed in accordance with the present disclosure.
[0012] FIG. 2C shows a side view of the example mold of FIG. 2A
when closed in accordance with the present disclosure.
[0013] FIG. 2D shows a perspective view of the example mold of FIG.
2A when closed in accordance with the present disclosure.
[0014] FIG. 3A shows a perspective view of an example mold and
lattice in accordance with the present disclosure.
[0015] FIG. 3B shows a perspective view of the mold and lattice of
FIG. 3A with the lattice disposed within the mold in accordance
with the present disclosure.
[0016] FIG. 4A shows a perspective view of an example mold in
accordance with the present disclosure.
[0017] FIG. 4B shows a perspective view of the example mold of FIG.
4A when closed in accordance with the present disclosure.
[0018] FIG. 4C shows a side view of an example footwear article
formed from the example mold of FIG. 4A in accordance with the
present disclosure.
[0019] FIG. 5 is flowchart illustrating an example method of
preparing a footwear article in accordance with the present
disclosure.
DETAILED DESCRIPTION
[0020] Up until now, additive manufacturing methods like 3D
printing have allowed footwear manufacturers to create footwear
components, such as footbeds and midsoles, which are customized to
a person's anatomy and activity. The challenge is that these custom
components, if not removable, still have to be glued to the
footwear upper and easily collect debris and small objects in the
open lattice structure, and offer limited durability and abrasion
resistance. The articles and methods of the present disclosure may
address one, or both of these challenges at the same time, by
enclosing a customized component in a foam and using an injected
foam as a bonding agent between an upper and an outsole.
[0021] Systems and/or methods for preparing a footwear article are
disclosed herein. An example method may comprise disposing a first
resin (e.g., a cured or uncured resin) in a female mold associated
with footwear. The first resin may comprise a clear resin. The
example method may comprise closing the mold. The example method
may also comprise curing the first resin (if uncured) to provide a
cured first resin in the mold. A first cured resin may form at
least a portion of an outsole of a footwear article. Other
materials, such as rubber or vulcanized rubber, may be used in lieu
of the resin. Moreover, footwear articles may be formed without
including a resin or rubber material as an outsole component. The
example method may comprise disposing a second resin (e.g., a cured
or uncured resin) on at least a portion of the cured first resin in
the mold. The second resin may comprise a clear resin.
[0022] The example method may comprise disposing a lattice
structure in at least a portion of the second resin disposed on the
cured first resin in the mold. The lattice structure may be formed
using additive manufacturing. In certain aspects, the second resin
may be disposed in or adjacent the mold with or without the first
resin. As such, the term "second resin" as used herein is
illustrative in certain examples and is not intended to require
multiple resin layers.
[0023] The example method may comprise closing the mold using a
lasted upper. The closing the mold using a lasted upper may
comprise using a mold component comprising an integral upper. The
upper may comprise a knit upper.
[0024] The example method may comprise injecting foam into the
closed mold such that the foam operates to couple the lasted upper
and the lattice structure together. The foam may operate as a base
cushion layer in a footwear article. The example method may
comprise releasing the closed mold.
[0025] A footwear article may be formed using the example
method.
[0026] Systems and/or methods for preparing a footwear article are
disclosed herein.
[0027] Footwear articles formed using the example methods are
described herein. Footwear articles formed using the example
methods may comprise one or more portions (e.g., footwear
subcomponents). An example footwear article may comprise an upper,
a midsole, an outsole and other portions.
[0028] The upper may comprise the topmost external portion of the
footwear article which conforms to the wearer's foot. The upper may
comprise material such as knit material, fabric or leather suitable
for forming an external portion of the footwear article.
[0029] The midsole may be disposed within the footwear article
between the upper and the outsole. The midsole may comprise foam,
encapsulated air, gel or plastic suitable for cushioning the
wearer's foot and stabilizing the footwear article.
[0030] A footwear article may comprise one or more lattice
structures in one or more of its portions. The midsole may be or
comprise one or more lattice structures. The lattice structure may
comprise plastic or other materials. The lattice structure may be
defined by a plurality of interconnected struts. The lattice
structure may comprise a substantially planar three-dimensional
structure formed using additive manufacturing.
[0031] The outsole may comprise the bottom of the footwear article
which makes contact with the ground. The outsole may comprise
plastic or other durable materials which are suitable for forming
the bottom of the footwear article.
[0032] As illustrated in FIG. 1, a footwear article 100 may
comprise an upper 101, a midsole 102, and an outsole 103. The upper
101 may be a knitted upper or other material or configuration. The
midsole 102 may be defined by a region between the upper 101 and
the outsole 103. However, other configurations may be used. The
midsole 102 may be formed from a foamed material (e.g., rubber) or
other materials. The midsole 102 may provide functional cushioning
to the footwear article 100 to support the wearer, while providing
comfort. The outsole 103 may be disposed adjacent the midsole 102.
The outsole 103 may be configured to engage the ground. As an
example, the outsole 103 may be disposed to protect a portion of
the midsole 102. The footwear article 100 may comprise other layers
such as an insole or barrier layer.
[0033] Portions of the footwear article 100 such as the midsole 102
or the outsole 103 may be formed using injection molding, resin
casting, and other methods. Portions of the footwear article 100
may be formed using one or more molds. The mold may comprise two or
more portions. The mold may comprise a male portion and a female
portion. The male portion may be configured to be closed over the
female portion. Other configurations of molds may be used. The mold
may be flexible and may comprise rubber, silicone or other
materials suitable for casting resins. The mold may comprise a
shallow, hollow cavity. The mold may be integral, comprising
portions of the footwear article such as the upper or the outsole
or be integrated with a portion of the footwear article (e.g. a
mold with an integral upper). The mold may comprise a lasted upper,
a knit upper, or the outsole.
[0034] FIGS. 2A-2B illustrate an example mold 104 in accordance
with the present disclosure. As shown, the mold 104 may comprise a
female portion 105 and a male portion 106. One or more of the
portions 105, 106 may have a general shape of a human foot. Other
shapes may be used. The female portion 105 may be configured to
serve as the bottom unit and the male portion 106 is configured to
serve as the top unit configured to enclose a cavity in concert
with the bottom unit. The female portion 105 may comprise a cavity
105a that may be at least partially defined by one or more walls
105b. The one or more walls 105b may be disposed at least partially
circumferentially about a periphery of a bottom 105c. The bottom
105c may be generally planar, but may have other shapes and
contours. The bottom 105c may comprise a texture or pattern formed
therein. The female portion 105 may comprise an aperture 107 or
through-hole configured to allow material to pass through the wall
105b and into the cavity 105a. The male portion 106 may comprise a
cavity 106a that may be at least partially defined by one or more
walls 106b. The one or more walls 106b may be disposed at least
partially circumferentially about a periphery of a bottom 106c. The
bottom 106c may be generally planar, but may have other shapes and
contours. The bottom 105c may comprise a texture or pattern formed
therein. The shape of the male portion 106 may be configured to
mate with a shape of the female mold 105 (e.g., the cavity 105a) to
mold a part or piece. The mold 104 or components of the mold 104
may be formed from rubber or similar materials and correspond with
the shape of a footwear article. The male portion 106 may be closed
over the female portion 105 of the mold 104 as part of a process to
form at least portion of a footwear article, such as the footwear
article 100 (FIG. 1).
[0035] FIG. 2B illustrates a side vie w of the female portion 105
and the male portion 106 of the mold 104 of FIG. 2A before they are
closed. FIG. 2C illustrates a side view of the female and male
portions 105, 106 when closed. Although an example mold is shown in
the figures, other molds may be used. For example, various mold
materials and shapes may be used.
[0036] One or more resins may be disposed in one or more parts of
the mold to form portions of the footwear article. Resin may be a
viscous substance that converts into rigid polymers through a
curing process. The resins may be clear, substantially clear,
opaque, substantially opaque, and generally flexible. Types of
resins that may be used may include, but not be limited to clear or
opaque epoxy, silicone, or polyurethane resins. Other suitable
molding or casting resins are also contemplated. The resins may be
organic or synthetic. The resins may comprise additives such as
plasticizers, fibers, colorants and flame retardants to provide
additional properties in the portions of the footwear article.
Resins may be cured using any appropriate process (e.g., time,
heat, radiation, electron beams, additives, etc.). First or second
resins may be partially cured, such that an application of an
additional resin (e.g., second resin, third resin) will chemically
link with an adjacent layer of resin. Resins disposed in parts of
the mold may be given time to cast and solidify as part of the
preparation process. One or many different types of resins may be
utilized. A first resin may be disposed in a part of the mold and
cured and a second resin may be disposed on at least a portion of
the first cured resin. The second resin may also be disposed
elsewhere to achieve different functionalities. Additional resins
may be added and cured successively to achieve different properties
in the portions of the footwear article.
[0037] Referring to FIG. 2D, a first resin 108 (e.g., a cured or
uncured resin) may be disposed in the female portion 105 of the
mold 104. The first resin 108 may be clear and flexible. Other
resins may be used. Rubber such as vulcanized rubber may be used.
In certain examples, this first resin 108 is not included. Where a
first uncured resin is used, the first resin 108 may be cured to
provide a cured first resin 108 in the female portion 105 of the
mold 104. For example, the male portion 106 of the mold 104 may be
closed upon the female portion 105 to mold the resin into a desired
shape and texture. Then the mold may be released, leaving a cured,
molded resin in a particular form. This form may define at least a
portion of an outsole of an article of footwear (e.g., footwear
article 100 (FIG. 1)). A second resin 109 (e.g., a cured or uncured
resin) may be disposed on at least a portion of the cured first
resin 108, for example, in the mold 104. Although the term second
is used as an example, the second resin 109 may be disposed in or
adjacent the mold 104 with or without other resins. As a further
example, the second resin 109 may be disposed on the molded, cured
first resin 108 such that the second resin provides another layer.
If the second resin 109 is uncured, one or more components, such as
a lattice structure (lattice structure 307 (FIGS. 3A-3B) may be
disposed in the second resin 109.
[0038] FIG. 3A illustrates a lattice structure 307, which may form
at least a portion of a footwear article. The lattice structure 307
may have a shape of an article of footwear. The lattice structure
307 may have a shape based on the cavity 105a of the female portion
105 of the mold 104. The lattice structure 307 may comprise one or
more struts interconnected to define a plurality of apertures. The
lattice structure 307 may have varying thickness and may be
designed to provide a particular form of a portion of a footwear
article. FIG. 3B illustrates the lattice structure 307 when
disposed in the mold 104. The lattice structure 307 may have any
shape or features and may be customized for a particular wearer or
characteristic of a wearer.
[0039] As illustrated in FIG. 4A, a mold 404 may comprise one or
more portions of a footwear article integrated therewith. The mold
404 may comprise a male portion 406. The male portion 406 may be
configured to mate with a female portion, such as the female
portion 105. As shown, the male portion 406 may comprise a lasted
knitted upper 401 and the female portion 105 may comprise the first
and second resins 108, 109 and the lattice structure 307. As shown
in FIG. 4B, the mold 404 may be closed to couple the lattice
structure 307 to the other portions of the footwear article, such
as the lasted knit upper 401.
[0040] As illustrated in FIG. 4C, after the mold 404 is closed, a
material may be injected into at least a portion of the closed mold
404 such that the material operates to couple two or more portions
of the footwear article together. The material may be foam such as
foam rubber. The material may be injected via an aperture formed in
the mold 404 (e.g., aperture 107 (FIG. 2A-2B). The foam may
comprise polyurethane or other types of foam. The material may flow
into the cavity of the mold 404 and may flow through the apertures
of the lattice structure 307. The material may operate to couple
the upper 401 with the lattice structure 307, and thereby couple
the upper 401 to the cured resins (not shown). The mold 404 may
then be released to provide a footwear article such as footwear
article 100 (FIG. 1). The injected material may operate as a base
cushion layer of the footwear article 100.
[0041] FIG. 5 is a flowchart detailing an example method for
preparing a footwear article according to the present disclosure. A
mold comprising a female portion and a male portion is prepared. At
step 501, a first resin is disposed into the female portion of the
mold to form a first layer. Other materials such as vulcanized
rubber may be used. At step 502, the mold is closed. At step 503,
the male portion is released to open the mold. It should be
understood that the first layer is not required. The additional
steps may be implemented without inclusion of the first layer. At
step 504, a second resin is disposed into the female mold to form a
second layer of resin, wherein the first layer is cured and the
second layer is uncured. At step 505, a 3D lattice structure is
disposed on the second uncured layer of resin. At step 506, the
mold is closed with a lasted upper male portion of the mold. At
step 507, material (e.g., foam) is injected into the mold.
Thereafter, the mold may be released to provide the footwear
article.
* * * * *