Footwear Assembly Systems With 3D Printing

• US 20150246496A1
• Filed: 03/12/2015
• Published: 09/03/2015
• Est. Priority Date: 07/19/2012
• Status: Active Grant

• Current Assignee: Nike, Inc.
• Original Assignee: Nike, Inc.
• Inventors: Jones, David P., Larson, Ryan R.
• Granted Patent: US 9,914,274 B2
• Time in Patent Office: Days
• US Class Current: 1/1
• CPC Class Codes: A43B 1/04 braided, knotted, knitted or crocheted
• CPC Class Codes: A43B 13/14 characterised by the constructive form
• CPC Class Codes: A43B 23/0235 Different layers of different material
• CPC Class Codes: A43B 23/026 Laminated layers
• CPC Class Codes: A43B 3/0084 Arrangement of flocked decoration on shoes
• CPC Class Codes: A43D 11/00 Machines for preliminary treatment or assembling of upper-parts, counters, or insoles on their lasts preparatory to the pulling-over or lasting operations; Applying or removing protective coverings
• CPC Class Codes: A43D 2200/00 Machines or methods characterised by special features
• CPC Class Codes: A43D 2200/60 Computer aided manufacture of footwear, e.g. CAD or CAM
• CPC Class Codes: B29C 64/106 using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
• CPC Class Codes: B29C 64/112 using individual droplets, e.g. from jetting heads
• CPC Class Codes: B29C 64/245 Platforms or substrates support structures intended to be sacrificed after manufacture B29C64/40
• CPC Class Codes: B29C 64/264 Arrangements for irradiation
• CPC Class Codes: B29C 64/393 for controlling or regulating additive manufacturing processes
• CPC Class Codes: B29C 70/78 Moulding material on one side only of the preformed part
• CPC Class Codes: B29D 35/12 Producing parts thereof, e.g. soles, heels, uppers, by a moulding technique
• CPC Class Codes: B29K 2713/00 Use of textile products or fabrics for preformed parts, e.g. for inserts B29K2105/06 takes precedence
• CPC Class Codes: B29L 2031/50 Footwear, e.g. shoes or parts thereof
• CPC Class Codes: B33Y 10/00 Processes of additive manufacturing
• CPC Class Codes: B33Y 80/00 Products made by additive manufacturing

Abstract

Methods and systems are disclosed for apparel assembly using three-dimensional printing directly onto fabric apparel materials. Disclosed is a method and system for direct three-dimensional printing and assembly of an article of apparel, including designing a three-dimensional pattern for printing, positioning at least a portion of the article on a tray in a three-dimensional printing system, the portion being positioned substantially flat on the tray, printing a three-dimensional material directly onto the article using the designed pattern, curing the printed material, and removing the article from the three-dimensional printing system.

Claims

1. A system for three-dimensional printing directly onto multiple fabric portions of an article of footwear, comprising:

a first nontransitory computer-readable medium encoded with a first computer program product loadable into a first memory of a first computer and including first software code portions for storing a three-dimensional pattern for printing directly onto the multiple fabric portions of the article of footwear;

a print server;

a switching device;

a three-dimensional printer device;

wherein the print server is in direct communication with the three-dimensional printer device and the switching device;

wherein the switching device is in direct communication with the three-dimensional printer device and the print server;

wherein the first nontransitory computer-readable medium is in direct communication with the switching device;

wherein the print server comprises a second nontransitory computer-readable medium encoded with a second computer program product loadable into a second memory of a second computer and including second software code portions configured, when executed on the second computer, for instructing the three-dimensional printing device to print directly onto the multiple fabric portions of the article of footwear through a first sequence of printing steps and a second sequence of printing steps;

wherein a first fabric portion of the multiple fabric portions is at least a portion of a side of an upper of the article of footwear and a second fabric portion of the multiple fabric portions is at least a portion of a bottom of the upper of the article of footwear;

wherein the three-dimensional printer device comprises

a tray receiving, in the first sequence, the first fabric portion positioned substantially flat on the tray to provide a first fabric printing substrate and receiving, in the second sequence, the second fabric portion of the article of footwear positioned to provide a second fabric printing substrate for printing a sole of the article of footwear,

at least one printing head for printing three-dimensional material onto the first fabric portion in the first sequence and onto the second fabric portion in the second sequence, and

at least one ultraviolet light for curing three-dimensional material printed in the first and second sequences; and

wherein the three-dimensional printer device is configured to print the three-dimensional material onto at least one irregular surface portion of at least one of the first fabric portion and the second fabric portion.

2. The system according to claim 1, wherein the three-dimensional printer device is configured to compensate for irregularities in the at least one irregular surface portion by at least one of adjusting a distance between the at least one printing head and the at least one irregular surface portion and adjusting at least one of size, rate, and distribution of three-dimensional material ejected from the at least one printing head.

3. The system according to claim 1, wherein the at least one irregular surface portion comprises at least one of a knit and a weave of the at least one of the first fabric portion and the second fabric portion.

4. The system according to claim 1, wherein the second software code portions are configured, when executed on the second computer, to instruct the three-dimensional printing device to wait a predetermined amount of time after printing of the three-dimensional material prior to curing the three-dimensional material with the at least one ultraviolet light, to allow the three-dimensional material to at least partially absorb into the at least one irregular surface portion of the at least one of the first fabric portion and the second fabric portion, prior to curing the three-dimensional material.

5. The system according to claim 1, wherein the second software code portions are configured, when executed on the second computer, to instruct the three-dimensional printer device to:

print a first layer of three-dimensional material onto the at least one irregular surface portion of the at least one of the first fabric portion and the second fabric portion;

wait a predetermined amount of time after printing the first layer of three-dimensional material prior to curing the first layer of three-dimensional material with the at least one ultraviolet light, to allow the first layer of three-dimensional material to at least partially absorb into fabric of the at least one irregular surface portion of the at least one of the first fabric portion and the second fabric portion;

cure the first layer of three-dimensional material with the at least one ultraviolet light;

print at least one additional layer of three-dimensional material on the cured first layer; and

cure the at least one additional layer of three-dimensional material with the at least one ultraviolet light.

6. The system according to claim 5, wherein the first layer and the at least one additional layer differ in at least one of modulus of elasticity and color.

7. The system according to claim 1, wherein the at least one irregular surface portion of the at least one of the first fabric portion and the second fabric portion comprises at least one of a textile, a natural fabric, a synthetic fabric, a knit, a woven material, a nonwoven material, a mesh, a leather, a synthetic leather, a polymer, a rubber, and a foam.

8. The system according to claim 1, wherein the first fabric portion and the second fabric portion of the upper of the article of footwear prevent durable adhesion of the three-dimensional material to the tray.

9. The system according to claim 1, wherein the three-dimensional material comprises at least one of an ink, a resin, an acrylic, a polymer, a thermoplastic material, a thermosetting material, and a light-curable material.

10. The system according to claim 1, wherein the three-dimensional material further comprises a filler material.

11. The system according to claim 1, wherein the three-dimensional material is bonded to the first fabric portion of the article of footwear and to the second fabric portion of the upper.

12. A system for printing three-dimensional material onto a fabric upper of an article of footwear, comprising:

a three-dimensional printer device;

a computer in communication with the three-dimensional printer device, wherein the computer includes;

a first nontransitory computer-readable medium encoded with a first computer program product loadable into memory of the computer and including first software code portions for storing a first three-dimensional pattern for printing directly onto a side fabric portion of the fabric upper and a second three-dimensional pattern for printing a sole of the article of footwear;

a second nontransitory computer-readable medium encoded with a second computer program product loadable into memory of the computer and including second software code portions configured, when executed on the computer, for instructing the three-dimensional printing device to print directly onto the side fabric portion of the fabric upper through a first sequence of printing steps using the first three-dimensional pattern and to print directly onto a bottom fabric portion of the fabric upper through a second sequence of printing steps using the second three-dimensional pattern;

wherein the three-dimensional printer device comprises

a tray receiving, in the first sequence, the fabric upper positioned substantially flat on the tray to present the side fabric portion of the fabric upper as a first fabric printing substrate;

a holder receiving, in the second sequence, the fabric upper formed into a secondary shape, with the bottom fabric portion positioned on the holder to provide a second fabric printing substrate for printing the sole of the article of footwear,

at least one printing head for printing three-dimensional material onto the side fabric portion in the first sequence and onto the bottom fabric portion in the second sequence, and

at least one ultraviolet light for curing three-dimensional material printed in the first and second sequences; and

wherein the second software code portions are configured, when executed on the computer, to instruct the three-dimensional printer device to print the three-dimensional material onto an irregular surface of at least one of the side fabric portion and the bottom fabric portion of the fabric upper.

13. The system according to claim 12, wherein the tray is configured to support the holder for the second sequence.

14. The system according to claim 13, wherein the holder comprises a last;

and

wherein the last is shaped to correspond to the secondary shape of the fabric upper.

15. The system according to claim 14, wherein the holder is configured to hold the fabric upper with the bottom fabric portion in an x-y plane in which printing of the sole occurs.

16. The system according to claim 15, wherein the tray has a horizontal upper surface defining an opening;

and

wherein the tray and the holder are configured such that the holder is positioned within the opening of the tray with the bottom fabric portion substantially flush with the horizontal upper surface of the tray.

17. The system according to claim 12, wherein the second software code portions are configured, when executed, to instruct the three-dimensional printer device to compensate for irregularities in the irregular surface by at least one of adjusting a distance between the at least one printing head and the irregular surface and adjusting at least one of size, rate, and distribution of three-dimensional material ejected from the at least one printing head.

18. The system according to claim 12, wherein the second software code portions are configured, when executed, to instruct the three-dimensional printer device to compensate for an uneven surface of a knit or weave of the irregular surface.

19. The system according to claim 12, wherein the second software code portions are configured, when executed, to instruct the three-dimensional printer device to wait a predetermined amount of time after printing a layer of three-dimensional material prior to curing the layer of three-dimensional material with the at least one ultraviolet light, to allow the layer of three-dimensional material to at least partially absorb into fabric of the fabric upper.

20. The system according to claim 12, wherein the computer comprises a single computer, partial resources of a computer, or two or more computers communicating with each other.

21. A system for printing three-dimensional material onto a fabric upper of an article of footwear, comprising:

a three-dimensional printer device including

a tray for receiving the fabric upper laid substantially flat on the tray with a first fabric portion of the fabric upper presenting a first irregular surface, the first fabric portion being at least a portion of a side of the fabric upper,

a holder for receiving the fabric upper formed into a secondary shape with a second fabric portion of the fabric upper presenting a second irregular surface, the second fabric portion being at least a portion of a bottom of the fabric upper,

at least one printing head for printing three-dimensional material onto the first fabric portion and the second fabric portion, and

an ultraviolet light for curing the three-dimensional material printed onto the first fabric portion and the second fabric portion;

a computer in communication with the three-dimensional printer device;

wherein the computer provides the three-dimensional printer device with first instructions configured, when executed on the three-dimensional printer device, to cause the three-dimensional printer device to print directly onto the first fabric portion through a first sequence of printing steps corresponding to a first three-dimensional pattern;

wherein, based on the first instructions, the three-dimensional printer device prints the three-dimensional material onto the first fabric portion while compensating for irregularities in the first irregular surface of the first fabric portion;

wherein the computer provides the three-dimensional printer device with second instructions configured, when executed on the three-dimensional printer device, to cause the three-dimensional printer device to print directly onto the second fabric portion through a second sequence of printing steps corresponding to a second three-dimensional pattern providing a sole of the article of footwear; and

wherein, based on the second instructions, the three-dimensional printer device prints the three-dimensional material onto the second fabric portion while compensating for irregularities in the second irregular surface of the second fabric portion to form the sole of the article of footwear.

22. The system according to claim 21, wherein, based on the second instructions, the three-dimensional printer device compensates for irregularities in the second irregular surface by at least one of adjusting a distance between the at least one printing head and the second irregular surface and adjusting at least one of size, rate, and distribution of three-dimensional material ejected from the at least one printing head.