Shoe with composite upper and foam element and method of making same

• US 9,572,404 B2
• Filed: 09/25/2013
• Issued: 02/21/2017
• Est. Priority Date: 10/21/2009
• Status: Active Grant

• Current Assignee: Nike, Inc.
• Original Assignee: Nike, Inc.
• Inventors: Dojan, Frederick J., Johnson, Daniel A., Kohatsu, Shane S., Huang, Chin-Chen
• Primary Examiner(s): BAYS, MARIE D
• Application Number:
  US14/036,381
• Publication Number:
  US 20140020193A1
• Time in Patent Office: 1,245 Days
• Field of Search: 121/42.R, 121/46.C, 36/45, 36/3.A
• US Class Current: 1/1
• CPC Class Codes: A43B 1/00 Footwear characterised by the material
• CPC Class Codes: A43B 23/022 with waterproof breathable membranes
• CPC Class Codes: A43B 23/0225 Composite materials, e.g. material with a matrix
• 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 23/0295 Pieced uppers
• CPC Class Codes: A43B 7/06 ventilated
• CPC Class Codes: A43B 7/085 in the upper
• CPC Class Codes: A43D 3/02 Lasts for making or repairing shoes making of wooden lasts B27M3/20
• CPC Class Codes: A43D 5/02 Stands for making footwear stands for cleaning shoes A47L23/16
• CPC Class Codes: B29D 35/146 Uppers
• CPC Class Codes: B29D 35/148 Moulds or apparatus therefor
• CPC Class Codes: H05K 999/99 dummy group

Abstract

A bonded mesh composite panel can be used to form a three-dimensional upper shell that includes extensions used for double-lasting and/or to otherwise provide a shelf to support foam padding. The foam padding may be, e.g., a foam midsole. The extensions of the upper shell may be located in a lower portion of the shell and may be bonded to the foam midsole in a heel, midfoot and/or forefoot regions.

Claims

1. A method of fabricating an article of footwear, comprising:

positioning a plurality of panels into an assembly, wherein the assembly includes

a substrate material panel having a first side and a second side,

a mesh material panel having a first side facing away from the substrate material panel and a second side facing the substrate material panel, at least a portion of the mesh material panel overlapping the substrate material panel in a mesh/substrate overlap area, and

a skin material panel having a first side facing away from the substrate material panel and a second side facing the substrate material panel, at least a portion of the skin material panel overlapping both the substrate material panel and the mesh material panel in a skin/mesh/substrate overlap area;

creating a bonded mesh composite panel by

compressing the assembly at a first temperature in a first pressing operation during which the first sides of the substrate material, mesh material and skin material panels face a compressible surface conforming to the assembly, and

compressing the assembly at a second temperature in a second pressing operation during which the first sides of the substrate material, mesh material and skin material panels face a compressible surface conforming to the assembly, wherein the second pressing operation is performed after the first pressing operation and the second temperature is lower than the first temperature;

subsequent to the second pressing operation, forming a three-dimensional upper shell from the composite panel; and

bonding portions of the three-dimensional upper shell to a bottom surface of a foam midsole.

2. The method of claim 1, wherein bonding portions of the three-dimensional upper shell comprises bonding portions of the upper shell to surfaces of a heel region of the foam midsole so as to form a double lasted heel cup.

3. The method of claim 1, wherein bonding portions of the three-dimensional upper shell comprises bonding portions of the upper shell to surfaces of the foam midsole so as to form a shelf, wherein the shelf is located in heel and midfoot regions.

4. The method of claim 3, wherein the shelf is located in heel, midfoot and forefoot regions.

5. The method of claim 1, wherein the assembly includes at least one reinforcement panel located on the first side of the substrate layer.

6. The method claim 5, wherein the reinforcement panel and the substrate layer are formed from artificial leather.

7. The method of claim 1, wherein the substrate material panel comprises a contiguous piece of substrate material having portions located in lateral forefoot, lateral midfoot, top forefoot, medial forefoot, medial midfoot and hindfoot regions at the conclusion of the forming of the three-dimensional upper shell.