Molded Footwear Upper And Method Of Making Same

• US 20140283410A1
• Filed: 03/22/2013
• Published: 09/25/2014
• Est. Priority Date: 03/22/2013
• Status: Active Grant

• Current Assignee: Reebok International Limited (Authentic Brands Group, LLC)
• Original Assignee: Reebok International Limited (Authentic Brands Group, LLC)
• Inventors: MARVIN, William, Leary, Kevin, Litchfield, Paul E., Piacentini, Thomas
• Granted Patent: US 10,499,706 B2
• Time in Patent Office: Days
• US Class Current: 36/45
• CPC Class Codes: A43B 1/00 Footwear characterised by the material
• 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 23/026 Laminated layers
• CPC Class Codes: A43B 23/028 Resilient uppers, e.g. shock absorbing
• CPC Class Codes: B29D 35/146 Uppers
• CPC Class Codes: B29D 35/148 Moulds or apparatus therefor

Abstract

A method for manufacturing an upper for an article of footwear includes: forming a foam layer; forming a preliminary upper by laminating an outer layer, an inner layer, and the foam layer intermediate to the outer layer and the inner layer; and molding the preliminary upper to a shape having: a contour to substantially fit at least a portion of a foot to provide at least a portion of an upper for an article of footwear.

Claims

1. A method for manufacturing an upper for an article of footwear, comprising:

forming a contoured foam layer;

forming a preliminary upper by laminating an outer layer, an inner layer, and the foam layer intermediate to the outer layer and the inner layer; and

molding the preliminary upper to a shape having a contour to substantially fit at least a portion of a foot to provide at least a portion of an upper for an article of footwear.

2. The method of claim 1, wherein the preliminary upper is molded to a shape having a contour to fit a heel portion of the foot.

3. The method of claim 1, wherein the preliminary upper is molded to a shape having a contour to fit a forefoot portion of the foot and a heel portion of the foot.

4. The method of claim 1, wherein the preliminary upper is molded to a shape having a contour to fit a forefoot portion of the foot, a heel portion of the foot, and an intermediate portion of the foot between the forefoot portion and the heel portion.

5. The method of claim 1, wherein the preliminary upper is molded to form a single piece upper having a medial portion, a lateral portion, and a footbed portion.

6. The method of claim 1, wherein the outer layer comprises an elastic material.

8. The method of claim 1, wherein the outer layer comprises elastane.

9. The method of claim 1, wherein the outer layer and the inner layer comprise an elastic material.

10. The method of claim 1, wherein the outer layer and the inner layer comprise the same material.

11. The method of claim 1, wherein the step of molding the preliminary upper includes applying heat and pressure to the preliminary upper.

12. The method of claim 1, wherein the foam layer is formed to a shape having a contour to fit a heel portion of a foot.

13. The method of claim 1, wherein the preliminary upper is substantially flat before molding.

14. The method of claim 1, wherein the foam layer has a variable thickness.

7. The method of clam 1, wherein outer layer comprises an elastic polyurethane fiber.

15. A method for manufacturing an upper for an article of footwear, comprising:

forming a foam layer;

forming a laminate having an outer layer, an inner layer, and the foam layer intermediate to the outer layer and the inner layer;

applying heat and pressure to the laminate to form a medial portion of an upper shaped to fit a medial portion of a foot and a lateral portion of an upper shaped to fit a lateral portion of the foot; and

attaching the medial portion to the lateral portion to form a single piece upper for an article of footwear.

16. The method of claim 15, wherein the outer layer and the inner layer comprise an elastic polyurethane fiber.

17. The method of claim 15, further comprising attaching the medial portion to the lateral portion along a seam extending along the length of the upper.

18. The method of claim 15, wherein the laminate is a single piece laminate and the medial portion and the lateral portion are integral portions of the single piece laminate,

19. The method of claim 15, wherein the laminate is substantially flat before applying heat and pressure during molding.

20. The method of claim 15, wherein the foam layer has a variable thickness.

21. The method of claim 15, wherein the step of applying heat and pressure includes heating the laminate and placing the heated laminate into a mold.

22. A method for manufacturing an article of footwear, comprising:

forming a single piece preliminary upper having an outer layer comprising an elastic polyurethane fiber, an inner layer, and a foam layer disposed between the outer layer and the inner layer;

molding the preliminary upper to form a medial portion of an upper shaped to fit a medial portion of a foot and a lateral portion of an upper shaped to fit a lateral portion of the foot;

attaching the lateral portion to the medial portion to form a single piece upper for an article of footwear; and

attaching a sole to the upper.

23. A method for manufacturing an article of footwear, comprising the steps of:

forming a contoured foam cushioning member;

forming a preliminary upper by enveloping the foam cushioning member between an outer layer and an inner layer; and

molding the preliminary upper to a shape having a contour to substantially fit at least a portion of a foot.

24. The method of claim 23 wherein the molding step includes placing the preliminary upper on a mold and applying heat and pressure, wherein a first region of the mold corresponds to a portion of a medial side of a foot and a second region of the mold corresponds to a portion of a lateral side of the foot.

25. The method of claim 23 wherein the molding step includes placing the preliminary Upper on a mold having a shape corresponding to a medial side of a foot and applying heat and pressure to the preliminary upper.

26. The method of claim 23 wherein the molding step includes placing the preliminary upper on a mold having a shape corresponding to a lateral side of a foot and applying heat and pressure to the preliminary upper.

27. The method of claim 23 wherein the foam cushioning member is formed by molding.

28. An upper for an article of footwear, comprising:

a single piece laminate including a contoured foam cushioning member, an inner layer, and an outer layer, wherein the foam cushioning member is enveloped between the inner layer and the outer layer,

wherein a first region of the single piece laminate corresponds to a portion of a lateral side of the foot and a second region of the single piece laminate corresponds to a portion of a medial side of the foot, and wherein the outer layer comprises an elastic material.

29. An article of footwear comprising:

a footwear upper formed of one or more pieces, each piece comprising one or more layers;

a footwear lower attached to the footwear upper to provide a sole supporting member to the article of footwear;

wherein the one or more pieces used to form the footwear upper are molded into a three dimensional configuration.

30. An article of footwear according to claim 29, wherein at least one of the pieces forming the footwear upper is multilayered.

31. An article of footwear according to claim 30, wherein the multilayered piece comprises;

an outer layer;

a middle layer; and

an inner layer.

32. An article of footwear according to claim 29, wherein the footwear upper comprises a single layer.

33. An article of footwear according to claim 29, wherein the one or more pieces forming the footwear upper are joined so as to provide a substantially seamless inner surface.

34. An article of footwear according to claim 29, wherein the footwear upper is formed from a single piece.

35. An article of footwear according to claim 34, wherein the footwear upper is formed from a single piece comprising an outer fabric layer, a middle foam layer and an inner fabric layer.

36. An article of footwear according to claim 30, wherein the footwear upper includes padding positioned at one or more anatomically determined positions to provide enhanced cushioning, reinforcement or support.

37. An article of footwear according to claim 29, wherein the footwear upper includes an upper opening to receive a wearer'"'"'s foot, the upper opening having an upper edge, and a lower opening having a lower edge to which the footwear lower is attached to provide a sole supporting member, wherein the upper edge is finished to provide a seamless edge.

38. An article of footwear according to claim 29, wherein one or more decorative and/or structural features are added to an outer surface of the footwear upper by use of a heat sealable film along at least an outer periphery of the decorative feature.

39. An article of footwear according to claim 38, wherein structural features in the form of eyes for receiving shoe laces are attached to the footwear upper using a heat sealable film.

40. An article of footwear according to claim 29, wherein the molding involves the application of heat and pressure.

41. A method for forming an article of footwear, the method comprising the following steps:

molding one or more pieces for forming a footwear upper into a suitable three dimensional configuration;

forming the footwear upper from the one or more pieces, each piece comprising one or more layers; and

attaching a footwear lower to the footwear upper to provide a sole supporting member to the article of footwear.

42. A method for forming an article of footwear according to claim 41, wherein the step of molding one or more pieces for forming a footwear upper into a suitable three dimensional configuration includes placing the piece into a heat press molding apparatus including complementary shaped first and second molding portions, wherein the first molding portion is configured to receive a complementary shaped second molding portion so that the piece is formed into a three dimensional configuration there between.

43. A method for forming an article of footwear according to claim 41, wherein the footwear upper is formed from more than one piece and each piece is joined to its adjacent piece by ultrasonic welding.

46. A method for forming an article of footwear according to claim 41, wherein the molding involves the application of heat and pressure.

47. A method for forming an article of footwear according to claim 41, wherein the molding of each of the one or more pieces for forming a footwear upper into a suitable three dimensional configuration comprises the steps of:

providing a first sheet of material which is to be an outer layer of the footwear upper,

providing a second sheet of material which is to be an inner layer of the footwear upper,

providing between the first and second sheets of material a sheet of foam which is to be a middle layer of the footwear upper, and

molding together the first and second sheets of material and the sheet of foam to laminate the sheets.

48. A method for forming an article of footwear according to claim 47, wherein the first and second sheets of material each comprises a layer of fabric.

44. (canceled)

45. (canceled)

49. A inner lining for an article of footwear, comprising:

a footwear liner formed of one or more pieces, each piece comprising one or more layers, the footwear liner configured to receive a wearer'"'"'s foot;

wherein the one or more pieces used to form the footwear liner are molded into a three dimensional configuration.

50. An inner lining for an article of footwear according to claim 49, wherein the inner lining is placed within and fastened to a footwear upper to form an article of footwear.

51. An inner lining for an article of footwear according to claim 50, wherein the inner lining is removably fastened to the footwear upper.

52. An inner lining for an article of footwear according to claim 49, wherein the footwear liner is formed from one piece, the one piece being molded into a three dimensional configuration using a heat press molding apparatus,

53. An inner lining for an article of footwear according to claim 52, wherein the heat press molding apparatus includes complementary shaped first and second molding portions, wherein the first molding portion is configured to receive a complementary shaped second molding portion so that the footwear liner is formed into a three dimensional configuration there between.

54. An inner lining for an article of footwear according to claim 49, wherein the footwear liner is formed from two pieces, each piece being molded into a three dimensional configuration using a heat press molding apparatus.

55. An inner lining for an article of footwear according to claim 54, wherein one of the two pieces is independently molded into a left side piece and the other one of the two pieces is independently molded into a right side piece, such that the molded left side piece and the molded right side piece can be joined together to form the footwear liner configured to receive a wearer'"'"'s foot.

56. An inner lining for an article of footwear according to claim 55, wherein the molded left side piece and the molded right side piece are joined together using non stitching means.

57. An inner lining for an article of footwear according to claim 55, wherein the molded left side piece and the molded right side piece are joined together by ultrasonic welding.

58. An article of footwear including an inner lining, comprising:

a footwear upper;

a footwear liner formed of one or more pieces, each piece comprising one or more layers, the footwear liner configured to receive a wearer'"'"'s foot; and

a footwear lower attached to the footwear upper to provide a sole supporting member to the article of footwear;

wherein the one or more pieces used to form the footwear liner are molded into a three dimensional configuration.

59. An article of footwear comprising:

a footwear upper formed of one or more pieces, each piece comprising one or more layers;

a footwear lower attached to the footwear upper to provide a sole supporting member to the article of footwear;

wherein the one or more pieces used to form the footwear upper are molded into a three dimensional configuration, each of the one or more pieces used to form the footwear upper having no seams away from the edges of the piece.

60. An inner lining for an article of footwear, comprising:

a footwear liner formed of one or more pieces, each piece comprising one or more layers, the footwear liner configured to receive a wearer'"'"'s foot;

wherein the one or more pieces used to form the footwear liner are molded into a three dimensional configuration, each of the one or more pieces used to form an upper part of the footwear liner having no seams away from the edges of the piece.

61. An article of footwear including an inner lining, comprising:

a footwear upper;

a footwear liner formed of one or more pieces, each piece comprising one or more layers, the footwear liner configured to receive a wearer'"'"'s foot; and

a footwear lower attached to the footwear upper to provide a sole supporting member to the article of footwear;

wherein the one or more pieces used to form the footwear liner are molded into a three dimensional configuration, the one or more pieces used to form the footwear liner including two pieces used to form an upper part of the footwear liner.