Article and method for laser-etching stratified materials

• US 7,065,820 B2
• Filed: 06/30/2003
• Issued: 06/27/2006
• Est. Priority Date: 06/30/2003
• Status: Active Grant

• Current Assignee: Nike, Inc.
• Original Assignee: Nike, Inc.
• Inventors: Meschter, James
• Primary Examiner(s): KAVANAUGH, JOHN T
• Application Number:
  US10/609,010
• Publication Number:
  US 20040261295A1
• Time in Patent Office: 1,093 Days
• Field of Search: 36/45, 121/46.C
• US Class Current: 12/146.00C
• CPC Class Codes: A43B 23/0235 Different layers of different material
• CPC Class Codes: A43B 23/027 with a part of the upper particularly flexible, e.g. permitting articulation or torsion
• CPC Class Codes: A43D 8/24 Embossing using heat, e.g. high frequency electric current
• CPC Class Codes: B23K 26/364 for making a groove or trench, e.g. for scribing a break initiation groove
• CPC Class Codes: B29D 35/146 Uppers
• CPC Class Codes: B44B 3/007 in layered material
• CPC Class Codes: B44B 3/009 using a computer control means
• CPC Class Codes: B44B 3/02 wherein plane surfaces are worked
• CPC Class Codes: B44C 1/228 by laser radiation

Abstract

A method for utilizing a laser to etch a stratified material is disclosed. The method includes providing a stratified material having at least two layers that are secured together, the layers including a first layer and a second layer. An incision is then formed in the stratified material with a laser, the incision extending through the first layer to expose the second layer. The stratified material may then be incorporated into an upper of the article of footwear, for example. By exposing portions of the second layer, properties of the second layer may be exposed in the area of the removed first layer.

Claims

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

providing a stratified material having a first layer and a second layer that are secured together;

forming an incision in the stratified material with a laser, the incision extending through the first layer to expose the second layer, and the incision segregating a first area of the first layer from a second area of the first layer;

removing the first area of the first layer by separating the first area of the first layer from the second layer; and

incorporating the stratified material into an upper of the article of footwear.

2. The method recited in claim 1, further including a step of selecting the first layer and the second layer to have different properties.

3. The method recited in claim 2, wherein the step of selecting the first layer and the second layer includes choosing the different properties to be abrasion-resistance.

4. The method recited in claim 2, wherein the step of selecting the first layer and the second layer includes choosing the different properties to be air-permeability.

5. The method recited in claim 2, wherein the step of selecting the first layer and the second layer includes choosing the different properties to be flexibility.

6. The method recited in claim 2, wherein the step of selecting the first layer and the second layer includes choosing the different properties to be stretch-resistance.

7. The method recited in claim 2, wherein the step of selecting the first layer and the second layer includes choosing the different properties to be characteristics of the first layer and the second layer not including color.

8. The method recited in claim 1, wherein the step of providing the stratified material includes selecting the stratified material to have a third layer, the second layer being positioned between the first layer and the third layer.

9. The method recited in claim 8, wherein the step of forming the incision includes extending the incision through the second layer to also expose the third layer.

10. The method recited in claim 8, further including a step of forming another incision that extends through each of the first layer and the second layer to expose an underlying portion of the third layer.

11. The method recited in claim 1, further including a step of applying heat and pressure to the stratified material to bond the layers together, the step of applying heat and pressure being performed following the step of removing the first area of the first layer.

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

providing a stratified material having a first layer and a second layer that are non-permanently secured together;

forming an incision in the stratified material with a laser, the incision extending through the first layer to expose the second layer, and the incision segregating a first area of the first layer from a second area of the first layer;

removing the first area of the first layer by separating the first area of the first layer from the second layer;

permanently securing the first layer and the second layer together following removal of the first area; and

incorporating the stratified material into an upper of the article of footwear.

13. The method recited in claim 12, wherein the step of permanently securing includes applying heat and pressure to the stratified material to bond the layers together.

14. The method recited in claim 12, wherein the step of providing the stratified material includes applying an adhesive to an area between the first layer and the second layer.

15. The method recited in claim 14, wherein the step of permanently securing includes curing the adhesive.

16. The method recited in claim 12, further including a step of selecting the first layer and the second layer to have different properties.

17. The method recited in claim 16, wherein the step of selecting the first layer and the second layer includes choosing the different properties to be at least one of abrasion-resistance, air-permeability, flexibility, and stretch-resistance.

18. The method recited in claim 16, wherein the step of selecting the first layer and the second layer includes choosing the different properties to be characteristics of the first layer and the second layer not including color.

19. The method recited in claim 12, wherein the step of providing the stratified material includes selecting the stratified material to have a third layer, the second layer being positioned between the first layer and the third layer.

20. The method recited in claim 19, wherein the step of forming the incision includes extending the incision through the second layer to also expose the third layer.

21. The method recited in claim 19, further including a step of forming another incision that extends through each of the first layer and the second layer to expose an underlying portion of the third layer.

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

providing a stratified material having a first layer, a second layer, and a third layer that are secured together, the second layer being positioned between the first layer and the second layer;

forming a first incision in one side of the stratified material with a laser, the first incision extending through the first layer to expose the second layer;

forming a second incision in an opposite side of the stratified material, the second incision extending through the third layer to expose the second layer; and

incorporating the stratified material into an upper of the article of footwear.

23. The method recited in claim 22, further including a stop of selecting the first layer and the third layer to have different properties than the second layer.

24. The method recited in claim 23, wherein the step of selecting includes choosing the different properties to be at least one of abrasion-resistance, air-permeability, flexibility, and stretch-resistance.

25. The method recited in claim 23, wherein the step of selecting includes choosing the different properties to be characteristics of the first layer and the second layer not including color.

26. The method recited in claim 22, further including a step of applying heat and pressure to the stratified material to bond the layers together, the step of applying heat and pressure being performed following the steps of forming the first incision and forming the second incision.

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

providing a stratified material having a first layer, a second layer, and a third layer that are secured together, the second layer being positioned between the first layer and the second layer;

forming a first incision in the stratified material with a laser, the first incision extending through the first layer to expose the second layer, and the first incision segregating an area of the first layer from a remainder of the first layer;

removing the area of the first layer by separating the area of the first layer from a portion of the second layer;

forming a second incision in the stratified material, the second incision extending through the portion of the second layer to expose the third layer, and the second incision segregating an area of the second layer from a remainder of the second layer;

removing the area of the second layer by separating the area of the second layer from a portion of the third layer; and

incorporating the stratified material into an upper of the article of footwear.

28. The method recited in claim 27, further including a step of selecting the first layer, the second layer, and the third layer to have different properties.

29. The method recited in claim 28, wherein the step of selecting includes choosing the different properties to be at least one of abrasion-resistance, air-permeability, flexibility, and stretch-resistance.

30. The method recited in claim 28, wherein the step of selecting includes choosing the different properties to be characteristics of the first layer and the second layer not including color.

31. The method recited in claim 27, wherein the step of providing the stratified material includes non-permanently securing the layers together.

32. The method recited in claim 31, further including a step of permanently securing the first layer and the second layer together following removal of the area of the second layer.

33. The method recited in claim 32, wherein the step of permanently securing includes applying heat and pressure to the stratified material to bond the layers together.

34. The method recited in claim 31, wherein the step of providing the stratified material includes applying an adhesive between the first layer and the second layer and between the second layer and the third layer.

35. The method recited in claim 34, wherein the step of permanently securing includes curing the adhesive.