Shoe With A Flat Formed Shoe Upper
Shoes specifically designed to facilitate production via efficient shoe manufacturing methods and systems are described. In embodiments, the shoe upper is designed by way of a flat forming process, whereby the upper pattern is kept in a two-dimensional shape for most of the upper assembly and then stitched or otherwise affixed into a three-dimensional form in the final stage of upper assembly.
Latest Nike, Inc. Patents:
- INTELLIGENT ELECTRONIC FOOTWEAR AND LOGIC FOR NAVIGATION ASSISTANCE BY AUTOMATED TACTILE, AUDIO, AND VISUAL FEEDBACK
- INTELLIGENT ELECTRONIC FOOTWEAR AND CONTROL LOGIC FOR EXECUTING AUTOMATED FOOTWEAR FEATURES
- SOLE STRUCTURE FOR AN ARTICLE OF FOOTWEAR
- Adjustable foot support systems including fluid-filled bladder chambers
- Hybrid article of apparel
This application claims the benefit of U.S. Provisional Patent Application No. 61/194,403, filed Sep. 26, 2008, entitled “Shoe With a Flat Formed Shoe Upper.”
TECHNICAL FIELDThe present invention relates to athletic footwear. More particularly, the present invention relates to a shoe with a flat formed shoe upper.
BACKGROUND OF THE INVENTIONShoes, especially shoe uppers, have traditionally been assembled from a relatively large number of three-dimensional components. Both the large number and the three-dimensional nature of these components have required a great deal of labor to assemble a single shoe. Decreasing the labor required to manufacture a shoe by a meaningful amount is not possible with standard shoe designs.
SUMMARY OF THE INVENTIONThe present invention relates to a shoe specifically designed to facilitate production via efficient shoe manufacturing methods and systems. These shoe designs and/or manufacturing methods reduce the specialized individual labor required for shoe production, while avoiding high costs associated with highly automated manufacturing equipment. Shoes in accordance with the present invention may further permit a customer to select a particular model of shoe, select functional options for the shoe and/or select aesthetic options for the shoe.
Shoes, in accordance with the present invention, are designed to enable efficient manufacturing, and optionally, customization. Shoe model options in accordance with the present invention may include, for example, a running shoe model, a basketball shoe model, and a skate shoe model. In accordance with the present invention, upper forms of shoes may be manufactured by a flat forming construction process, whereby the upper pattern is kept in a two-dimensional shape for a substantial amount of the upper assembly and is then stitched or otherwise affixed into a three-dimensional form in the final stage of upper assembly. The flat forming process minimizes the amount of labor, such as labor intensive stitching traditionally needed to assemble a three-dimensional upper form. The upper forms are then coupled with midsole and/or outsole structures designed to permit efficient shoe production.
Referring now to
In step 100, internal foams 115, 117, and 119 of different shapes and sizes as illustrated in
Lining foam 120 may be layered over the internal foams 115, 117, and 119 in step 100. Lining foam 120 forms a barrier between lining layer 105 and external layer 110, and may enhance the comfort and three-dimensional form of the shoe. In alternative embodiments of the invention, lining foam 120 may be replaced by a forming foam or other reinforcement materials conventionally used in shoe upper manufacture.
In step 100, reinforcement pieces 125, 127, and 129 of different shapes and sizes as illustrated in
In step 100, hot-melt films (not shown) may be layered amongst the upper components between lining layer 105 and external layer 110. Upon heat pressing, these films act to adhesively bond the upper components between lining layer 105 and external layer 110. The hot-melt films may be composed of materials such as thermoplastic polyurethane (TPU) film. The TPU film(s) may be integral to one or more sides of the other layers, such as lining layer 105 and for external layer 110.
Referring now to
Referring now to
Referring now to
As
Referring now to
Heel-quarter element 405 may include a heel area 410 and quarter panels 415. To properly form heel area 410, heel-quarter element 405 may be subject to thermoform heel-forming processes. The thermoform heel-forming processes may involve heat pressing the heel counter upper component, as shown in
Similar to the formation of heel-quarter element 405, tongue-toe element 420 may be a single piece made from steps 100-300 of
Referring now to
Referring now to
Referring now to
Referring now to
Referring now to
Referring now to
The present invention has been described in relation to particular embodiments, which are intended in all respects to be illustrative rather than restrictive. Alternative embodiments will become apparent to those of ordinary skill in the art to which the present invention pertains without departing from its scope.
From the foregoing, it will be seen that this invention is one well adapted to attain all the ends and objects set forth above, together with other advantages which are obvious and inherent to the system and method. It will be understood that certain features and sub-combinations are of utility and may be employed without reference to other features and sub-combinations. This is contemplated by and is within the scope of the claims.
Claims
1. A shoe designed to facilitate a system for manufacturing shoes customized to an order placed by a customer, the shoe comprising: an upper, where the upper is manufactured by a flat forming construction process, the flat forming construction process comprising: layering a plurality of upper elements and hot-melt films in between a lining layer and an external layer; heat pressing the upper elements and the hot-melt films between the lining layer and the external layer to generate one or more basic laminated upper forms; and cutting out along pattern perimeters of the basic laminated upper forms.
2. The shoe of claim 1, wherein the hot-melt film is thermoplastic polyurethane (TPU).
3. The shoe of claim 1, wherein one or more of the upper elements are formed of polyurethane foam.
4. The shoe of claim 1, wherein the upper elements include one or more of internal foams, a lining foam, and reinforcement pieces.
5. The shoe of claim 4, wherein the internal foams are shaped consistent with various portions of the shoe, and include one or more of a collar, a vamp, a quarter, and a tongue of the shoe.
6. The shoe of claim 4, wherein the lining foam forms a barrier between the lining layer and the external layer to enhance comfort and provide a three-dimensional form of the shoe.
7. The shoe of claim 4, wherein the reinforcement pieces include one or more of a vamp reinforcement or an eyestay reinforcement.
8. The shoe of claim 1, wherein the external layer is made from one or more of synthetic leather or polyester mesh.
9. The shoe of claim 1, wherein the external layer forms an outer surface of the upper and allows for customization of an appearance of the upper in that various customization processes can be performed to the upper including one or more of dying, digital printing, embossing, or embroidering.
10. An upper portion of a shoe assembled using a flat forming construction process according to a method comprising: while maintaining a two-dimensional shape, layering a lining layer, one or more upper components, and an external layer to form the upper portion of the shoe, wherein a size and a shape of the upper components vary based on one or more of which portion of the shoe is being assembled, a type of shoe, and a size of shoe being assembled; adhering the lining layer, the upper components, and the external layer together by way of a heat press, wherein hot-melt films are also layered in between the lining layer and the external layer to bond the layers together; and cutting out the upper portion of the shoe along an upper perimeter.
11. The method of claim 10, wherein the upper components are in the shape of one or more of a collar, a vamp, a quarter or a tongue of the shoe.
12. The method of claim 10, wherein one or more reinforcement pieces are also layered in between the lining layer and the external layer to provide more support for the upper portion of the shoe.
13. The method of claim 10, further comprising forming a three-dimensional upper by affixing two or more upper portions of the shoe, wherein the two or more upper portions of the shoe include one or more of a heel-quarter element or a tongue-toe element.
14. The method of claim 13, further comprising inserting a last into the three-dimensional upper.
15. The method of claim 14, further comprising attaching the three-dimensional upper to a sole unit, wherein the sole unit includes a midsole and an outsole.
16. A shoe designed to facilitate a system for manufacturing customizable shoes, the shoe comprising: an upper whose components are manufactured by way of a flat forming process wherein the components of the upper maintain a two-dimensional shape throughout their formation, and wherein the upper comprises: a heel-quarter element that includes a heel area and multiple quarter panels; and a tongue-toe element that includes a tongue and a toe-box region, wherein the tongue-toe element is secured to the heel-quarter element to form a three-dimensional upper form.
17. The shoe of claim 16, wherein the tongue-toe element is secured to the heel-quarter element by way of one or more of stitching, gluing, RF welding, or ultrasonic welding.
18. The shoe of claim 16, wherein the heel-quarter element and the tongue-toe element are manufactured by a method comprising: layering a plurality of upper elements and hot-melt films in between a lining layer and an external layer; heat pressing the upper elements and the hot-melt films between the lining layer and the external layer to generate one or more basic laminated upper forms; and cutting out along pattern perimeters of the basic laminated upper forms.
19. The shoe of claim 18, wherein the external layer may be customized using a customization process that includes one or more of dying, digital printing, embossing, or embroidering.
20. The shoe of claim 18, wherein the upper elements include internal foams, a lining foam, and reinforcement pieces.
Type: Application
Filed: Sep 28, 2009
Publication Date: Sep 22, 2011
Applicant: Nike, Inc. (Beaverton, OR)
Inventors: Anthony Dean (Newberg, OR), Ciro Fusco (Portland, OR), Thomas Berend (Beaverton, OR)
Application Number: 13/122,702
International Classification: A43B 3/00 (20060101); A43B 23/00 (20060101);