Article of Footwear of Nonwoven Material and Method of Manufacturing Same

• US 20090140470A1
• Filed: 02/11/2009
• Published: 06/04/2009
• Est. Priority Date: 06/02/2005
• Status: Abandoned Application

• Current Assignee: Nike, Inc.
• Original Assignee: Nike, Inc.
• Inventors: Dua, Bhupesh, Thomas, Edward N.
• Application Number:
  US12/369,156
• Publication Number:
  US 20090140470A1
• Time in Patent Office: Days
• US Class Current: 264/555
• CPC Class Codes: A43B 7/125 provided with a vapour permeable member, e.g. a membrane A43B23/022 takes precedence
• CPC Class Codes: B29D 35/0072 Last constructions; Mountings therefor
• CPC Class Codes: B29D 35/146 Uppers
• CPC Class Codes: D04H 1/56 in association with fibre formation, e.g. immediately following extrusion of staple fibres
• CPC Class Codes: Y10T 442/68 Melt-blown nonwoven fabric
• CPC Class Codes: Y10T 442/681 Spun-bonded nonwoven fabric

Abstract

A method of forming a portion of an article of footwear includes the steps of providing a last having an exterior surface, extruding a plurality of polymeric fibers, projecting a stream of the extruded polymeric fibers onto the last to form a mat having the shape of the exterior of the last, and subjecting the mat to heat and pressure in a mold.

Claims

21. A method of forming an article of footwear comprising the steps of:

providing a last having an exterior surface;

providing a vacuum at the exterior surface of the last;

extruding a plurality of polymeric fibers;

depositing at least some of the polymeric fibers onto the last to form a mat having the shape of the exterior of the last;

subjecting the mat to heat and pressure in a mold to form an upper; and

securing the upper to a sole assembly.

1. A method of forming a portion of an article of footwear comprising the steps of:

providing a last having an exterior surface;

extruding a plurality of polymeric fibers;

projecting a stream of the extruded polymeric fibers onto the last to form a mat having the shape of the exterior surface of the last; and

subjecting the mat to heat and pressure in a mold.

2. The method of claim 1, wherein the polymeric fibers are formed of polyurethane.

3. The method of claim 1, wherein the polymeric fibers are formed of a polyether block amide.

4. The method of claim 1, wherein the last comprises a frame covered by a mesh material.

5. The method of claim 4, wherein the frame and mesh material are formed of metal.

6. The method of claim 1, wherein the polymeric fibers are meltblown.

7. The method of claim 1, wherein the polymeric fibers are spunbond.

8. The method of claim 1, wherein the step of subjecting the mat to heat and pressure in the mold is performed with the mat on the last.

9. The method of claim 8, further comprising the step of removing the mat from the last.

10. The method of claim 1, wherein the mold includes at least one surface irregularity to form a mating surface irregularity on the mat.

11. The method of claim 1, wherein the mold includes a recess to form a mating projection on the mat.

12. The method of claim 1, wherein the mold includes a projection to form a mating recess on the mat.

13. The method of claim 1, further comprising the step of moving the last as the polymeric fibers are projected onto the last.

14. The method of claim 13, wherein the step of moving the last is performed with a robot.

15. The method of claim 1, further comprising the step of moving the stream of extruded polymeric fibers with respect to the last as the polymeric fibers are projected onto the last.

16. The method of claim 15, wherein the step of moving the stream of extruded polymeric fibers is performed with a robot.

17. The method of claim 1, further comprising the steps of moving the last and moving the stream of extruded polymeric fibers with respect to the last as the polymeric fibers are projected onto the last.

18. The method of claim 1, wherein the mat forms an upper for an article of footwear.

19. The method of claim 1, further comprising the step of providing a vacuum at the exterior surface of the last.

20. The method of claim 1, wherein the mat is water resistant.

22. The method of claim 21, wherein the polymeric fibers are formed of polyurethane.

23. The method of claim 21, wherein the polymeric fibers are formed of polyether block amide.

24. The method of claim 21, wherein the last comprises a frame covered by a mesh material.

25. The method of claim 21, wherein the polymeric fibers are meltblown.

26. The method of claim 21, wherein the polymeric fibers are spunbond.

27. The method of claim 21, further comprising the step of removing the upper from the last.

28. The method of claim 21, wherein the mold includes at least one surface irregularity to form a mating surface irregularity on the upper.

30. The method of claim 21, wherein the mold includes a projection to form a mating recess on the upper.

31. The method of claim 21, wherein the sole assembly includes a midsole and an outsole.

32. The method of claim 20, further comprising the step of moving the last as the polymeric fibers are deposited on the last.

33. The method of claim 21, further comprising the step of moving the stream of extruded polymeric fibers with respect to the last.

34. The method of claim 21, further comprising the steps of moving the last as the polymeric fibers are deposited on the last and moving the stream of extruded polymeric fibers with respect to the last.

35. The method of claim 21, wherein the upper is water resistant.

28-1. The method of claim 21, wherein the mold includes a recess to form a mating projection on the upper.

36-65. -65. (canceled)