Compression molded footwear and methods of manufacture

• US 20070199210A1
• Filed: 02/24/2006
• Published: 08/30/2007
• Est. Priority Date: 02/24/2006
• Status: Abandoned Application

• Current Assignee: The Timberland Company (V.F. Corporation)
• Original Assignee: The Timberland Company (V.F. Corporation)
• Inventors: Dillon, Peter, Vattes, David
• Application Number:
  US11/362,248
• Publication Number:
  US 20070199210A1
• Time in Patent Office: Days
• US Class Current: 36/45
• CPC Class Codes: A43B 13/12 Soles with several layers of different materials
• CPC Class Codes: A43B 23/022 with waterproof breathable membranes
• CPC Class Codes: A43B 23/0235 Different layers of different material
• CPC Class Codes: A43B 23/0255 assembled by gluing or thermo bonding
• CPC Class Codes: A43B 23/042 Uppers made of one piece one piece slippers A43B3/106; one piece sandals A43B3/124
• CPC Class Codes: A43B 7/085 in the upper
• CPC Class Codes: B29D 35/142 Soles
• CPC Class Codes: B29D 35/146 Uppers
• CPC Class Codes: B32B 1/00 Layered products having a non-planar shape
• CPC Class Codes: B32B 2255/102 synthetic resin or rubber layer being a foamed layer
• CPC Class Codes: B32B 2266/0207 Materials belonging to B32B25/00
• CPC Class Codes: B32B 2266/0214 Materials belonging to B32B27/00
• CPC Class Codes: B32B 2266/0221 Vinyl resin
• CPC Class Codes: B32B 2266/0264 Polyester
• CPC Class Codes: B32B 2266/06 Open cell foam
• CPC Class Codes: B32B 2307/54 Yield strength; Tensile strength
• CPC Class Codes: B32B 2307/724 Permeability to gases, adsorption
• CPC Class Codes: B32B 2307/738 Thermoformability
• CPC Class Codes: B32B 2437/02 Gloves, shoes
• CPC Class Codes: B32B 25/00 Layered products comprising a layer of natural or synthetic rubber fibrous or filamentary layer made of a natural or synthetic rubber B32B5/02; particulate layer made of a natural or synthetic rubber B32B5/16; foamed layer made of a natural or synthetic rubber B32B5/18
• CPC Class Codes: B32B 25/045 : of foam
• CPC Class Codes: B32B 5/18 : characterised by features of a layer of foamed material
• CPC Class Codes: B32B 5/245 : another layer next to it being a foam layer
• CPC Class Codes: B32B 5/32 : at least two layers being foamed and next to each other
• CPC Class Codes: B32B 7/12 : using interposed adhesives or interposed materials with bonding properties

Abstract

An article of footwear having an upper, which includes a first foam layer having a first surface and a second surface remote from the first surface, a second foam layer having a first surface and a second surface remote from the first surface, and a middle layer having a first surface and a second surface remote from the first surface. The first surface of the middle layer is affixed to the second surface of the first foam layer, and the second surface of the middle layer is affixed to the first surface of the second foam layer. The upper defines at least a portion of a foot receiving cavity for the article of footwear.

Claims

1. An article of footwear, comprising an upper including:

a first foam layer having a first surface and a second surface remote from said first surface thereof;

a second foam layer having a first surface and a second surface remote from said first surface thereof; and

a middle layer having a first surface and a second surface remote from said first surface thereof;

wherein said first surface of said middle layer is affixed to said second surface of said first foam layer and said second surface of said middle layer is affixed to said first surface of said second foam layer, and said upper defines at least a portion of a foot receiving cavity for the article of footwear.

2. The upper of claim 1, wherein at least one of said first and second foam layers comprises an open-cell foam.

3. The upper of claim 1, wherein at least one of said first and second foam layers comprises a thermoformable foam.

4. The upper of claim 3, wherein at least one of said first and second foam layers comprises a thermoset foam.

5. The upper of claim 3, wherein at least one of said first and second foam layers comprises a thermoplastic foam.

6. The upper of claim 5, wherein said thermoplastic foam is an EVA foam.

7. The upper of claim 1, wherein said first foam layer further includes a feature affixed to said first surface thereof.

8. The upper of claim 7, wherein said feature is a protective feature and is located in a toe region of said upper.

9. The upper of claim 7, wherein said feature is a supportive feature and is located in an ankle region of said upper.

10. The upper of claim 9, wherein said feature is integrally formed with said first foam layer.

11. The upper of claim 8, wherein said feature comprises a coating applied to at least a portion of said first surface of said first foam layer.

12. The upper of claim 11, wherein said coating comprises a latex paint.

13. The upper of claim 11, wherein said coating comprises a lacquer.

14. The upper of claim 1, wherein:

said first foam layer, said second foam layer, and said middle layer form a unitary piece of layered material having a first seam and a second seam;

said unitary piece of layered material defines a first substantially seamless portion on a medial side of said upper between said first seam and said second seam; and

wherein said upper defines a second substantially seamless portion on a lateral side of said upper between said first seam and said second seam.

15. The upper of claim 14, wherein said first seam is positioned at a heal section of said upper, and wherein said second seam is positioned at a toe section of said upper.

16. An article of footwear comprising:

a sole; and

a unitary upper affixed to said sole and formed of a layered material having;

a first foam layer;

a second foam layer; and

a middle layer interposed between said first and second foam layers, said upper defining at least a portion of a foot-receiving cavity of said article of footwear.

17. The article of claim 16, wherein said middle layer is adhesively affixed between said first and second foam layers.

18. The article of claim 16, wherein said middle layer is a mesh textile material.

19. The article of claim 16, wherein said first and second foam layers each comprise a thermoformable foam.

20. The article of claim 19, wherein said thermoformable foam is a thermoplastic foam.

21. The article of claim 20, wherein said thermoplastic foam is an EVA foam.

22. The article of claim 21, wherein said EVA foam comprises an open-cell foam.

23. The article of claim 19, wherein said thermoformable foam comprises a polyester foam.

24. The article of claim 19, wherein said thermoformable foam comprises a polyether foam.

25. The article of claim 19, wherein said thermoformable foam comprises a latex foam.

26. A method for making an article of footwear, comprising:

providing a first foam layer, a second foam layer and a middle layer and integrally forming said first foam layer, said second foam layer and said middle layer by interposing said middle layer between said first foam layer and said second foam layer to form a blank defining a profile having first and second mating portions; and

forming an upper defining a portion of a foot receiving cavity from said blank by aligning said first and second mating portions.

27. The method of claim 26, wherein integrally forming said first foam layer, second foam layer and middle layer includes compression molding said first and second foam layers and said middle layer together.

28. The method of claim 27, wherein said compression molding includes the use of a mold, said mold being used to form a sole for said article of footwear concurrently with said integrally forming said first foam layer, second foam layer and middle layer.

29. The method of claim 27, wherein integrally forming said first foam layer, second foam layer and middle layer further includes adhesively affixing said middle layer between said first foam layer and said second foam layer.

30. The method of claim 26, wherein said integrally forming said first foam layer, second foam layer and middle layer includes cold molding of the first and second foam layers and the middle layer.

31. The method of claim 30, wherein said cold molding includes using rollers.

32. The method of claim 31, wherein said cold molding includes using plates, said plates being substantially flat.

33. The method of claim 26, further including trimming said layered material to form a blank.

34. The method of claim 26, further including applying a coating to said first surface of said first foam layer after said step of compression molding.

35. The method of claim 26 further including forming a first seam from said first mating portion, and forming a second seam from said second mating portion.

36. The method of claim 26 further including:

affixing an insole to said upper at an outside edge thereof so as to define a foot receiving cavity therebetween;

inserting a last into said foot receiving cavity;

heating said upper so as to form said upper to a shape of said last;

allowing said upper to cool; and

removing said last from said foot receiving cavity.

37. An article of footwear having a unitary upper formed from a layered material, and a sole, said upper forming at least a portion of a foot receiving cavity of said article of footwear, and said sole being affixed to said upper, said article of footwear being formed by the process of:

providing a first foam layer, a second foam layer and a middle layer and integrally forming said first foam layer, said second foam layer and said middle layer by interposing said middle layer between said first foam layer and said second foam layer to form a blank defining a profile having first and second mating portions; and

forming said upper from said blank by forming first and second seams from said first and second mating portions; and

affixing said sole to said upper.

38. The article of claim 37, wherein integrally forming said first foam layer, second foam layer and middle layer includes compression molding of the first and second foam layers and the middle layer.

39. The article of claim 38, wherein said middle layer is formed of a textile material defining a plurality of open portions such that said process step of compression molding forces said first foam layer and said second foam layer into mutual contact within said open portions so as provide tensile strength to said layered material.

40. The article of claim 39, wherein said process step of integrally forming said first foam layer, second foam layer and middle layer includes adhesively affixing said middle layer between said first foam layer and said second foam layer.

41. The article of claim 40, wherein said process step of adhesively affixing includes applying a heat-activated adhesive to a surface of said middle layer and applying heat thereto.

42. An article of footwear comprising:

a sole; and

a unitary upper affixed to said sole so as to define a foot receiving cavity therein, said unitary upper being formed of a layered material consisting essentially of;

a first layer of a thermoformable foam and having a first surface and a second surface remote from said first surface thereof; and

a second layer having a first surface and a second surface remote from said first surface thereof;

wherein said second surface of said first layer is affixed to said first surface of said second layer, said upper defining at least a portion of a foot-receiving cavity.

43. The article of claim 42, wherein said second layer is a textile material.

44. The article of claim 43, wherein said first surface of said first layer is disposed toward said foot receiving cavity such that said second surface of said second layer is spaced apart from said foot receiving cavity.

45. The article of claim 42 wherein said first layer further includes a feature affixed to said first surface thereof.

46. The upper of claim 45, wherein said feature is integrally formed with said first foam layer.

47. An article of footwear comprising:

an upper; and

a bottom affixed to said upper;

wherein said upper and said bottom are formed from a unitary piece of layered material including;

a first layer of thermoformable foam having a first surface and a second surface remote from said first surface thereof; and

a second layer having a first surface and a second surface remote from said first surface thereof;

said second surface of said first layer being affixed to said first surface of said second layer.

48. The article of claim 47, wherein said second layer includes a first region and a second region, said first region comprising a first material and said second region comprising a second material.

49. The article of claim 48, wherein said first material is a rubber and said second material is a textile.