UNIBODY CONSTRUCTION FOOTWEAR AND METHOD FOR MAKING THE SAME

• US 20110277349A1
• Filed: 01/18/2011
• Published: 11/17/2011
• Est. Priority Date: 01/04/2010
• Status: Active Grant

• Current Assignee: Applied Ft Composite Solutions Inc.
• Original Assignee: Applied Ft Composite Solutions Inc.
• Inventors: KIM, Daniel
• Granted Patent: US 10,716,357 B2
• Time in Patent Office: Days
• US Class Current: 36/84
• CPC Class Codes: A43B 13/12 Soles with several layers of different materials
• CPC Class Codes: A43B 13/186 Differential cushioning region, e.g. cushioning located under the ball of the foot resilient heel not included in the sole A43B21/26; resilient supports for the heel of the foot A43B21/32
• CPC Class Codes: A43B 23/0215 Plastics or artificial leather
• CPC Class Codes: A43B 23/0235 Different layers of different material
• CPC Class Codes: A43B 23/028 Resilient uppers, e.g. shock absorbing
• 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 3/34 with electrical or electronic arrangements
• CPC Class Codes: A43B 7/1405 with pads or holes on one or more locations, or having an anatomical or curved form
• CPC Class Codes: A43B 9/00 Footwear characterised by the assembling of the individual parts
• CPC Class Codes: A43D 111/00 Shoe machines with conveyors for jacked shoes or for shoes or shoe parts
• CPC Class Codes: A43D 8/00 Machines for cutting, ornamenting, marking or otherwise working up shoe part blanks pulling-over or lasting A43D9/00 - A43D23/00; making or fastening soles, heels or welts A43D25/00 - A43D83/00
• CPC Class Codes: A43D 8/08 Combined stamping-out and bonding, e.g. high frequency electric current being applied between cutting edge and work support

Abstract

The present application discloses footwear comprising a body structure in which at least upper is made of one continuous folded composite material comprised of layered sheets of material.

Claims

1. Footwear comprising a body structure in which at least upper is made of one continuous folded composite material comprised of layered sheets of material.

2. The footwear of claim 1, wherein different materials are inserted into the sheet of material so as to create non-uniform body structure of the footwear.

3. The footwear of claim 1, wherein the composite material comprises cushioning pod elements.

4. The footwear of claim 1, wherein the composite material comprises pod fitting apertures.

5. The footwear of claim 1, wherein a cushioning pod element is joined with a pod fitting aperture.

6. The footwear of claim 1, wherein at least one layered sheet is made of foam or rubber or combination thereof.

7. The footwear of claim 1, wherein at least one layered sheet comprises locking pod elements and locking pod apertures.

8. The footwear of claim 1, wherein the layered sheets of material comprise a full layer or a partial layer or a combination thereof.

9. The footwear of claim 1, wherein at least one layered sheet comprises an electronic, mechanical or electro-mechanical device.

10. The footwear of claim 1, wherein at least one layered sheet comprises a tongue section.

11. The footwear of claim 1, wherein at least one layered sheet comprises a cushioning padding element.

12. The footwear of claim 1, wherein at least one layered sheet comprises folding lines.

13. The footwear of claim 1, wherein at least one layered sheet comprises a reinforcing structure.

14. The footwear of claim 1, wherein the upper is attached to a prefabricated outsole assembly.

15. The footwear of claim 14, wherein the outsole assembly comprises sole pod elements.

16. The footwear of claim 15, wherein the sole pod elements are exposed to inside of the footwear so as to be in contact with the wearer of the footwear.

17. The footwear of claim 14, wherein the outsole assembly comprises an outsole layer, which is in contact with the bottom of the upper.

18. The footwear of claim 17, wherein the outsole layer is extended so as to wrap around the sole pod elements.

19. The footwear of claim 14, wherein the outsole assembly comprises midsole.

20. The footwear of claim 1, wherein the body structure comprising the upper and outsole is composed of one continuous folded composite material comprising layered sheets of material.

21. The footwear of claim 1, wherein the composite material is joined in one seam on the body structure.

22. The footwear of claim 2, wherein the non-uniform body structure is in thickness, texture, stiffness, hardness, color, breathability, shock absorption, resistance to abrasion, or flexibility of regions of the footwear.

23. The footwear of claim 1, which is athletic shoes, casual shoes, sandals, or formal shoes.

24. A process for making a footwear according to claim 1, comprising:

(i) providing a composite material comprising at least one layer of sheet of material; and

(ii) folding the composite so that a body structure comprising one continuous folded composite footwear is made.

25. The process according to claim 24, wherein the composite layer of sheets is composed of at least one full layer and at least one partial layer of sheets.

26. The process according to claim 24, comprising pre-cutting or cutting the at least one sheet to the size and perimeter to construct the footwear body structure that is complete when folded.

27. The process according to claim 24, comprising pre-cutting or cutting the at least one sheet to produce cushioning pod elements or pod fitting apertures.

28. The process according to claim 24, comprising laminating the layers of sheet material together.

29. The process according to claim 24, comprising after folding the composite material, shaping ends of the material and holding in place by engaging locking pod elements and locking pod apertures.

30. The process according to claim 24, comprising joining the composite material in one seam.

31. The process according to claim 24, comprising inserting different materials from the sheet material into the sheet of material so as to create non-uniform body structure of the footwear.

32. Footwear comprising an upper and insole made of a single contiguous piece, which is folded.

33. Footwear according to claim 32, wherein the upper is made of a single contiguous piece but with different materials in different areas of the shoe, which is folded.

34. Footwear comprising an upper and midsole and outsole made of a single contiguous piece, which is folded.

35. Footwear according to claim 34, wherein the upper is made of a single contiguous piece but with different materials in different areas of the shoe, which is folded.