Method of manufacturing an upper for an article of footwear

• US 20060112594A1
• Filed: 12/01/2004
• Published: 06/01/2006
• Est. Priority Date: 12/01/2004
• Status: Abandoned Application

• Current Assignee: Nike, Inc.
• Original Assignee: Nike, Inc.
• Inventors: Kilgore, Bruce J.
• Application Number:
  US11/001,289
• Publication Number:
  US 20060112594A1
• Time in Patent Office: Days
• US Class Current: 36/45
• CPC Class Codes: A43B 23/0235 Different layers of different material
• CPC Class Codes: A43B 23/042 Uppers made of one piece one piece slippers A43B3/106; one piece sandals A43B3/124
• CPC Class Codes: A43D 111/00 Shoe machines with conveyors for jacked shoes or for shoes or shoe parts
• CPC Class Codes: B29D 35/146 Uppers
• CPC Class Codes: Y10T 156/1052 with cutting, punching, tearing or severing
• CPC Class Codes: Y10T 428/15 Sheet, web, or layer weakened to permit separation through thickness

Abstract

A method of forming an upper for an article of footwear includes the steps of providing an exterior layer of an upper of an article of footwear having a layer of adhesive secured to an interior surface thereof, positioning an interior layer of the upper in contact with the interior surface of the exterior layer, applying heat and pressure to laminate the interior layer and exterior layer together, and cutting the laminated interior layer and exterior layer to a desired final form.

Claims

1. A method of forming a portion of an upper for an article of footwear comprising the following steps, in combination:

providing an exterior layer of an upper of an article of footwear having a layer of adhesive secured to an interior surface thereof;

positioning an interior layer of the upper in contact with the interior surface of the exterior layer;

applying heat and pressure to laminate the interior layer and exterior layer together; and

cutting the laminated interior layer and exterior layer to a desired final form.

2. The method of claim 1, further comprising the step of removing material from selected areas of the exterior layer prior to positioning the interior layer in contact with the interior surface.

3. The method of claim 2, wherein material is removed from a forefoot portion of the exterior layer.

4. The method of claim 2, wherein material is removed from a lateral side of the exterior layer.

5. The method of claim 2, wherein material is removed from a medial side of the exterior layer.

6. The method of claim 1, further comprising the step of placing a selected quantity of reinforcing elements on the interior surface prior to positioning the interior layer in contact with the interior surface, the reinforcing elements being positioned between the interior layer and the exterior layer.

7. The method of claim 6, wherein reinforcing elements are placed in an area of the exterior layer where eyelets are positioned.

8. The method of claim 6, wherein reinforcing elements are placed in a toe portion of the exterior layer.

9. The method of claim 1, further comprising the step of placing a selected quantity of cushioning elements on the interior surface prior to positioning the interior layer in contact with the interior surface, the cushioning elements being positioned between the interior layer and the exterior layer.

10. The method of claim 9, wherein cushioning elements are placed in an area of the exterior layer that will form an ankle opening.

12. The method of claim 1, wherein the step of cutting the laminated interior layer and exterior layer includes cutting eyelets.

13. The method of claim 1, wherein the step of cutting the laminated interior layer and exterior layer includes cutting an ankle opening.

14. The method of claim 1, wherein the step of cutting the laminated interior layer and exterior layer includes cutting an opening for a tongue.

15. The method of claim 1, wherein the adhesive is a hot-melt adhesive.

16. The method of claim 1, wherein the step of cutting is performed with a laser.

17. The method of claim 1, wherein the step of cutting is performed by die-cutting.

18. The method of claim 1, wherein the step of cutting is performed with a water jet.

19. The method of claim 1, further comprising the step of stitching selected portions of the exterior layer to the interior layer.

20. The method of claim 1, wherein the layer of adhesive comprises a plurality of microdots of adhesive.

21. A method of forming a portion of an upper for an article of footwear comprising the following steps, in combination:

providing an exterior layer of an upper of an article of footwear having a layer of adhesive secured to an interior surface thereof in a substantially flat configuration;

positioning an interior layer of the upper of an article of footwear in contact with the interior surface of the exterior layer;

applying heat and pressure to laminate the interior layer and exterior layer together; and

cutting the laminated interior layer and exterior layer to a desired final form.

22. The method of claim 21, further comprising the step of removing material from selected areas of the exterior layer prior to positioning the interior layer in contact with the interior surface.

23. The method of claim 21, further comprising the step of placing a selected quantity of reinforcing elements on the interior surface prior to positioning the interior layer in contact with the interior surface, the reinforcing elements being positioned between the interior layer and the exterior layer.

24. The method of claim 21, further comprising the step of placing a selected quantity of cushioning elements on the interior surface prior to positioning the interior layer in contact with the interior surface, the cushioning elements being positioned between the interior layer and the exterior layer.

25. The method of claim 21, wherein the step of cutting the laminated interior layer and exterior layer includes cutting eyelets.

26. The method of claim 21, wherein the step of cutting the laminated interior layer and exterior layer includes cutting an ankle opening.

27. The method of claim 21, wherein the step of cutting the laminated interior layer and exterior layer includes cutting an opening for a tongue.

28. The method of claim 21, further comprising the step of stitching selected portions of the exterior layer to the interior layer.

29. The method of claim 21, wherein the layer of adhesive comprises a plurality of microdots of adhesive.

30. A method of forming a portion of an upper for an article of footwear comprising the following steps, in combination:

providing a roll of material having an adhesive laminated to an inner surface thereof;

cutting a piece of material from the roll of material to form an exterior layer of an upper, the adhesive disposed on an interior surface of the exterior layer;

cutting at least one aperture in a selected area of the exterior layer;

placing a selected quantity of reinforcing elements on the interior surface of the exterior layer;

placing a selected quantity of cushioning elements on the interior surface of the exterior layer;

positioning an interior layer of the upper in contact with the interior surface of the exterior layer such that the reinforcing elements and cushioning elements are positioned between the interior layer and the exterior layer;

applying heat and pressure to laminate the interior layer and the exterior layer together; and

cutting the laminated interior layer and exterior layer to a desired final form.

31. A method of forming a portion of an upper for an article of footwear comprising the following steps, in combination:

providing an exterior layer of an upper of an article of footwear;

positioning an interior layer of the upper in contact with a interior surface of the exterior layer;

welding the interior layer and exterior layer together; and

cutting the laminated interior layer and exterior layer to a desired final form.

32. The method of claim 31, wherein the step of welding is performed by laser welding.

33. The method of claim 31, wherein the step of welding is performed by sonic welding.

34. The method of claim 31, wherein the step of welding is performed by ultrasonic welding.

35. The method of claim 31, wherein the step of welding is performed by RF welding.

36. The method of claim 31, further comprising the step of removing material from selected areas of the exterior layer prior to positioning the interior layer in contact with the interior surface.

37. The method of claim 31, further comprising the step of placing a selected quantity of reinforcing elements on the interior surface prior to positioning the interior layer in contact with the interior surface, the reinforcing elements being positioned between the interior layer and the exterior layer.

38. The method of claim 31, further comprising the step of placing a selected quantity of cushioning elements on the interior surface prior to positioning the interior layer in contact with the interior surface, the cushioning elements being positioned between the interior layer and the exterior layer.

39. A method of forming a portion of an upper for an article of footwear comprising the following steps, in combination:

cutting a piece of material from a roll of material to form an exterior layer of an upper;

removing a portion of material from a selected area of the exterior layer;

placing a selected quantity of reinforcing elements on the interior surface of the exterior layer;

placing a selected quantity of cushioning elements on the interior surface of the exterior layer;

positioning an interior layer of the upper in contact with the interior surface of the exterior layer such that the reinforcing elements and cushioning elements are positioned between the interior layer and the exterior layer;

welding the interior layer to the exterior layer; and

cutting the laminated interior layer and exterior layer to a desired final form.

40. The method of claim 39, wherein the step of welding is performed by laser welding.

41. The method of claim 39, wherein the step of welding is performed by sonic welding.

42. The method of claim 39, wherein the step of welding is performed by ultrasonic welding.

43. The method of claim 39, wherein the step of welding is performed by RF welding.

44. A method of forming a portion of an upper for an article of footwear comprising the following steps, in combination:

providing an exterior layer of an upper of an article of footwear;

providing an interior layer of an upper of an article of footwear;

placing a selected quantity of reinforcing elements between an interior surface of the exterior layer and an interior surface of the interior layer;

placing a selected quantity of cushioning elements between the interior surface of the exterior layer and the interior surface of the interior layer;

bonding the interior layer and the exterior layer together; and

cutting the bonded interior layer and exterior layer to a desired final form.

45. The method of claim 44, wherein the step of bonding is performed by positioning an adhesive layer between the interior layer and the exterior layer and applying heat and pressure to laminate the interior layer and exterior layer together.

46. The method of claim 44, wherein the step of bonding is performed by welding.

47. The method of claim 44, wherein the step of welding is performed by laser welding.

48. The method of claim 44, wherein the step of welding is performed by sonic welding.

49. The method of claim 44, wherein the step of welding is performed by ultrasonic welding.

50. The method of claim 44, wherein the step of welding is performed by RF welding.

51. An upper of an article of footwear comprising, in combination:

an exterior layer having an interior surface;

a layer of adhesive secured to the interior surface of the exterior layer; and

an interior layer positioned in contact with layer of adhesive on the interior surface of the exterior layer and laminated to the exterior layer with the application of heat and pressure;

wherein the laminated interior layer and exterior layer are cut to a desired final form.

52. The upper of claim 51, further comprising at least one aperture in the exterior layer formed by removing material from a selected area of the exterior layer prior to positioning the interior layer in contact with layer of adhesive on the interior surface of the exterior layer.

53. The upper of claim 51, further comprising at least one reinforcing element positioned between the interior layer and the exterior layer.

54. The upper of claim 51, further comprising at least one cushioning element positioned between the interior layer and the exterior layer.

55. The upper of claim 51, further comprising a plurality of eyelets formed by cutting through the exterior layer and the interior layer.

56. The upper of claim 51, further comprising stitching securing a portion of the exterior layer to the interior layer.

57. The upper of claim 51, wherein the cutting of the interior layer and exterior layer is performed by one of a laser, die-cutting, and a water jet.

58. The upper of claim 51, wherein the layer of adhesive comprises a plurality of microdots of adhesive.

59. An upper of an article of footwear comprising, in combination:

an exterior layer having an interior surface; and

an interior layer positioned in contact with the interior surface of the exterior layer and welded to the exterior layer;

wherein the welded interior layer and exterior layer are cut to a desired final form.

60. The upper of claim 59, wherein the welding of the interior layer to the exterior layer is performed by one of laser welding, sonic welding, ultrasonic welding, and RF welding.

61. The upper of claim 59, further comprising at least one aperture in the exterior layer formed by removing material from a selected area of the exterior layer prior to positioning the interior layer in contact with the interior surface of the exterior layer.

62. The upper of claim 59, further comprising at least one reinforcing element positioned between the interior layer and the exterior layer.

63. The upper of claim 59, further comprising at least one cushioning element positioned between the interior layer and the exterior layer.

64. The upper of claim 59, further comprising a plurality of eyelets formed by cutting through the exterior layer and the interior layer.

65. The upper of claim 59, further comprising stitching securing a portion of the exterior layer to the interior layer.

66. An upper of an article of footwear comprising, in combination:

an exterior layer having an interior surface;

a layer of adhesive on the interior surface of the exterior layer; and

an interior layer secured to the exterior layer with the layer of adhesive.

11. The upper of claim 66, wherein the layer of adhesive comprises a plurality of microdots of adhesive.

67. The upper of claim 66, further comprising at least one aperture formed in the exterior layer.

68. The upper of claim 66, further comprising at least one reinforcing element positioned between the interior layer and the exterior layer.

69. The upper of claim 66, further comprising at least one cushioning element positioned between the interior layer and the exterior layer.

70. The upper of claim 66, further comprising a plurality of eyelets extending through the exterior layer and the interior layer.

71. The upper of claim 66, further comprising stitching securing a portion of the interior layer to a portion of the exterior layer.

72. (canceled)