Apparatus and method for manufacturing a shoe upper

• US 6,533,885 B2
• Filed: 08/03/2001
• Issued: 03/18/2003
• Est. Priority Date: 12/22/1998
• Status: Expired due to Term

• Current Assignee: Reebok International Limited (Authentic Brands Group, LLC)
• Original Assignee: Reebok International Limited (Authentic Brands Group, LLC)
• Inventors: Beaulieu, Paul N., Tripp, Jon E. Sr., Davis, Paul M.
• Primary Examiner(s): SELLS, JAMES D
• Application Number:
  US09/920,649
• Publication Number:
  US 20010055684A1
• Time in Patent Office: 592 Days
• Field of Search: 156/196, 156/209, 156/219, 156/242, 156/272.2, 156/277, 156/379.6, 156/284, 156/287, 156/500, 156/553, 156/580, 156/581, 156/583.1
• US Class Current: 156/219
• 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 23/045 Uppers with inserted gussets
• CPC Class Codes: A43D 8/24 Embossing using heat, e.g. high frequency electric current
• CPC Class Codes: B29C 33/306 Exchangeable mould parts, e.g. cassette moulds, mould inserts moulds with exchangeable mould parts for injection moulding B29C45/2673; mounting of exchangeable mould inserts for injection moulding B29C45/2675
• CPC Class Codes: B29C 33/42 characterised by the shape of the moulding surface, e.g. ribs or grooves
• CPC Class Codes: B29C 59/02 by mechanical means, e.g. pressing B29C59/007 takes precedence; embossing expanded porous articles B29C44/5627
• CPC Class Codes: B29D 35/148 Moulds or apparatus therefor
• CPC Class Codes: Y10T 156/1039 Surface deformation only of sandwich or lamina [e.g., embossed panels]
• CPC Class Codes: Y10T 156/1737 Discontinuous, spaced area, and/or patterned pressing
• CPC Class Codes: Y10T 428/24 Structurally defined web or sheet [e.g., overall dimension, etc.]
• CPC Class Codes: Y10T 428/294 including metal or compound thereof [excluding glass, ceramic and asbestos]

Abstract

The present invention is directed to an article of footwear and method for making the same, where the article of footwear has a minimal number of upper pieces. The method of the present invention is directed to a process for manufacturing an article of footwear having a single or multiple layer upper. Each layer of the upper according to the present invention is constructed of a one-piece upper material. At least the outer layer of the upper is molded utilizing an embossing tool according to the present invention, such that the desired appearance of the upper is embossed on the outer layer. Additionally, the improved shoe manufacturing process of the present invention may further comprise the step of decorating at least the outer layer of the upper, by screen printing, sublimation, large format ink jet printing, cold and hot peel transfers, fabric dyeing and/or multi-layered digital printing, allowing for multiple or different colorways to be created using a single base color upper material. The tool and process according to the present invention exhibit great flexibility with respect to aesthetics, construction and cost values, allowing for the creation of an unlimited variety of upper appearances with minimal retooling time and costs.

Claims

1. A tool for manufacturing an upper for a shoe comprising:

an embossing mold; and

a plurality of removable texture inserts disposed in said embossing mold, wherein said texture inserts serve as embossing aids.

2. A tool according to claim 1, wherein said tool is for manufacturing a one-piece upper.

3. A tool according to claim 1, wherein said tool is for manufacturing an upper component.

4. A tool according to claim 1, wherein said embossing mold is made of aluminum.

5. A tool according to claim 1, wherein said removable texture inserts are made of aluminum.

6. A tool according to claim 1, wherein said removable texture inserts are formed having textured surfaces and are interchangeable such that the molded appearance of said upper can be varied.

7. A tool according to claim 1, further comprising a plurality of location pins disposed on said embossing mold for aligning an upper material to said embossing mold.

8. A tool according to claim 1, wherein said tool can be used to emboss a screen printed upper material.

9. A tool according to claim 1, further comprising:

an upper half mold removably disposed on top of said embossing mold;

wherein said upper material can be disposed between said upper half mold and said embossing mold.

10. A method for manufacture of a shoe upper comprising:

molding material with a tool comprising an embossing mold and a plurality of removable texture inserts, such that the desired appearance of said shoe upper is embossed on said material;

joining the ends of said material to form said shoe upper.

11. A method according to claim 10, further comprising the step of screen printing color onto said material.

12. A method according to claim 11, wherein said screen printing step is performed prior to said molding step.

13. A method according to claim 10, wherein said molding step comprises heat emboss/compression molding.

14. A method according to claim 10, wherein said molding step comprises RF welding.