Last system for articles with braided components

• US 9,668,544 B2
• Filed: 12/10/2014
• Issued: 06/06/2017
• Est. Priority Date: 12/10/2014
• Status: Active Grant

• Current Assignee: Nike, Inc.
• Original Assignee: Nike, Inc.
• Inventors: Bruce, Robert M., Sills, Craig K., Lee, Eun Kyung
• Primary Examiner(s): BAYS, MARIE D
• Application Number:
  US14/565,568
• Publication Number:
  US 20160166010A1
• Time in Patent Office: 909 Days
• Field of Search: 12133 R, 12133 B, 12133 M, 12145
• CPC Class Codes: A43B 1/04 braided, knotted, knitted or crocheted
• CPC Class Codes: A43B 23/0205 characterised by the material material of the lining A43B23/07, material of toe stiffeners or heel stiffeners A43B23/08
• CPC Class Codes: A43B 23/0215 Plastics or artificial leather
• 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 23/042 Uppers made of one piece one piece slippers A43B3/106; one piece sandals A43B3/124
• CPC Class Codes: A43D 3/02 Lasts for making or repairing shoes making of wooden lasts B27M3/20
• CPC Class Codes: A43D 3/022 comprising means, e.g. hooks, for holding, fixing or centering shoe parts on the last
• CPC Class Codes: B29D 35/146 Uppers
• CPC Class Codes: B33Y 10/00 Processes of additive manufacturing
• CPC Class Codes: B33Y 80/00 Products made by additive manufacturing
• CPC Class Codes: D04C 1/06 Braid or lace serving particular purposes
• CPC Class Codes: D04C 3/48 Auxiliary devices
• CPC Class Codes: D10B 2501/043 Footwear

Abstract

A last system and a method of making the last system are disclosed. The last system includes a last member and an exterior layer. The exterior layer becomes deformable when heated above a characteristic temperature. The method can include forming a braided footwear component on the last system. The exterior layer may be joined with the braided footwear component by heating the last system above the characteristic temperature.

Claims

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

providing a last member, the last member having an outer surface;

forming an exterior layer of a heat deformable material onto the outer surface of the last member;

forming a braided footwear component onto the exterior layer;

heating the exterior layer so that the exterior layer is joined with the braided footwear component to form a composite structure; and

removing the last member from the composite structure.

2. The method according to claim 1, wherein the last member is more rigid than the exterior layer.

3. The method according to claim 1, wherein heating the exterior layer includes heating the exterior layer above a characteristic temperature, wherein the exterior layer is deformable above the characteristic temperature.

4. The method according to claim 3, wherein the characteristic temperature is a glass transition temperature of the material comprising the exterior layer.

5. The method according to claim 3, wherein the characteristic temperature is a melting temperature of the material comprising the exterior layer.

6. The method according to claim 1, wherein forming the braided footwear component onto the exterior layer comprises inserting the last member with the exterior layer through a braiding device.

7. A method of making an upper for an article of footwear, comprising:

providing a last member, the last member having an outer surface;

forming a first region of an exterior layer onto the outer surface of the last member, wherein the first region has a first thickness and wherein the exterior layer is comprised of a heat deformable material;

forming a second region of the exterior layer onto the outer surface of the last member, wherein the second region has a second thickness that is different from the first thickness;

forming a braided footwear component onto the exterior layer;

heating the exterior layer so that the exterior layer is joined with the braided footwear component to form a composite structure; and

removing the last member from the composite structure.

8. The method according to claim 7, wherein the first region of the exterior layer is associated with a first composite region of the composite structure, wherein the second region of the exterior layer is associated with a second composite region of the composite structure, wherein the first composite region has a first thickness, and wherein the second composite region has a second thickness that is different than the first thickness.

9. The method according to claim 8, wherein the first composite region is thicker than the second composite region.

10. The method according to claim 9, wherein the first composite region is more rigid than the second composite region.

11. The method according to claim 7, wherein forming the first region of the exterior layer includes printing the heat deformable material onto the last member using an additive manufacturing process.

12. The method according to claim 11, wherein forming the second region of the exterior layer includes printing the heat deformable material onto the last member using the additive manufacturing process.

13. The method according to claim 7, wherein forming the braided footwear component onto the exterior layer includes inserting the last member with the exterior layer through a braiding device.