CN111372484A

CN111372484A - Conformal films for shoe making

Info

Publication number: CN111372484A
Application number: CN201880075475.3A
Authority: CN
Inventors: 麦可·科尔伯; 朗尼·巴拉德; 约瑟夫·强森; 彼得·金; 金荣三
Original assignee: Nike Inc
Current assignee: Nike Inc; Nike Innovate CV USA
Priority date: 2017-11-22
Filing date: 2018-11-16
Publication date: 2020-07-03
Anticipated expiration: 2038-11-16
Also published as: WO2019103938A1; KR102359757B1; TWI800467B; KR20200067209A; KR20220018097A; CN111372484B; TW202220574A; CN114451638A; TWI757711B; EP3713440A1; TW202029902A; KR102421294B1; KR20220106847A; TWI692323B; TW201924556A; TW202306511A; US20190150572A1; KR102567119B1; TWI783861B

Abstract

A low-pressure operation conformal film (200) for making an article of footwear includes a peripheral portion (214) having a thickness (216, 226, 248) in a range of 1-15 millimeters and forming an outer periphery (222) of the conformal film (200). The conformal film (200) also includes a transition (224) having a thickness (216, 226, 248) in a range of 1-4 millimeters between the first surface (202, 204, 218, 220, 228, 230, 235, 237) and the second surface (202, 204, 218, 220, 228, 230, 235, 237), wherein the transition (224) extends inward of the outer perimeter (222). The conformal film (200) also includes a conformal portion, the conformal portion (234) extending from the transition portion (224) in a direction (236) of the second surface (202, 204, 218, 220, 228, 230, 235, 237) and forming a receiving cavity (238), the conformal portion (234) having a thickness (216, 226, 248) in a range of 1 mm to 4 mm. The peripheral portion (214), the transition portion (224), and the conformal portion (234) are unitary constructions comprising a common material composition.

Description

Conformal films for shoe making

Technical Field

The present invention relates to a press film (press membrane) for joining two articles.

Background

Traditionally, an article of footwear may be manufactured by bonding a sole portion with a lasting upper portion (1 elevated upper portion). The pressure, temperature, and/or time are adjusted to achieve a bond between the sole and the lasting. The application of pressure may be achieved by a press (press) that is effective to assist in supplying a compressive force between the sole and the lasting when an adhesive or other bonding material bonds the sole to the lasting.

Disclosure of Invention

Embodiments herein contemplate a conformal film for assisting in joining a first article with a second article. The conformal film includes a peripheral portion having a thickness in a range of 1 to 15 millimeters ("mm") and forming an outer perimeter of the conformal film. The conformal film also includes a transition having a thickness in a range of 1-4 millimeters between the first surface and the second surface. The transition portion extends inwardly of the outer periphery formed by the peripheral portion. The conformal film also includes a conformal portion extending upward from the transition portion in a direction of the second surface and forming a receiving cavity. The conformal portion has a thickness in a range of 1 millimeter to 4 millimeters. The peripheral portion, the transition portion, and the conformal portion are unitary constructions comprising a common material composition.

This summary is provided to teach and not to limit the scope of the methods and systems provided in full detail below.

Drawings

The invention is described in detail herein with reference to the accompanying drawings, wherein:

fig. 1 illustrates a press with a conformal membrane according to embodiments herein.

Fig. 2 illustrates the press shown in fig. 1 in a closed and secured configuration according to embodiments herein.

FIG. 3 illustrates a cross-sectional view of a press taken along cut line 3-3 of FIG. 2, according to embodiments herein.

Fig. 4 illustrates a perspective view of a conformal film according to embodiments herein.

Fig. 5 illustrates a side view of the conformal film illustrated in fig. 4, according to embodiments herein.

Fig. 6 illustrates a front view of the conformal film illustrated in fig. 4, according to embodiments herein.

Fig. 7 illustrates a plan view of the conformal film illustrated in fig. 4, according to embodiments herein.

Fig. 8 illustrates a cross-sectional view of a conformal film taken along cut line 8-8 of fig. 4, according to embodiments herein.

Fig. 9 illustrates a flow chart illustrating an exemplary method of manufacturing an article of footwear with a conformal film, according to embodiments herein.

Detailed Description

The manufacture of shoes, such as sports shoes, is traditionally carried out by joining different parts. For example, an upper is a portion of an article of footwear that extends around a foot of a wearer to secure the article of footwear to the wearer. The upper may be formed from a variety of materials, such as leather, film, textiles, printed materials, and the like. In some examples, the upper is part of a shoe that includes a securing structure (e.g., lacing holes for laces), an ankle opening that allows a wearer's foot to be donned and doffed, and other structures. The shape of the upper is determined in part when engaged with other portions. In some manufacturing situations, a cobbler last (also referred to as a "last") is embedded in the upper (or the upper is formed around the last) so that the upper takes the shape of the last. When the upper is placed on or otherwise formed around a last, this combination is often referred to as a "lasted upper. A lasting is an upper having a last that is used to provide support and size guidance to the upper during the manufacturing process. As the additional portions/components engage the lasting, the shape of the upper becomes more stable such that once the last is removed, the dimensional shape of the upper is maintained or at least affected by the last.

Another common component of an article of footwear is a sole. In some examples, the sole may be referred to as a "bottom unit. The sole may be a collection of multiple components (e.g., an outsole, a midsole, and/or an insole). Additional components may also be incorporated, such as cushioning elements (e.g., springs), stabilizing elements (e.g., torsion bars), etc., that combine to form the sole. Traditionally, a sole is the portion that extends between an upper and an underlying ground surface and over which a wearer of the shoe moves.

The sole may be formed from a variety of materials. For example, the sole may be formed from leather, felt, textile, and/or polymer-based materials (e.g., natural or synthetic). Different portions of the sole may be formed of different materials. For example, the outsole (e.g., ground-contacting portion) may be formed of rubber (e.g., synthetic or natural), and the midsole may be formed of a foamed polymer (e.g., Ethylene Vinyl Acetate (EVA), Polyurethane (PU)). As will be discussed below, the conformal film may be adapted to assist in joining the upper with a sole constructed of a foamed material (e.g., EVA or PU). Other foamed materials include, but are not limited to, low density polyethylene, polyimide foam, polypropylene foam, polystyrene foam, polyvinyl chloride foam, silicone foam, and the like.

The upper is conventionally joined to the sole. In some examples, the upper and the sole are joined via a sewing operation. In another example, the upper and the sole are joined via a bonding process. The bonding process may be accomplished using welding, melting, and/or adhesive bonding. In an exemplary embodiment, an adhesive material (e.g., a liquid, a paste, a film) is applied to at least one of the sole-contacting surface of the upper and/or the upper-contacting surface of the sole. The adhesive may be reactive or activated to facilitate bonding (e.g., mechanical bonding and/or chemical bonding) between the upper and the sole. The engagement may be enhanced by applying pressure (e.g., applying a force through the upper to the sole and/or applying a force through the sole to the upper). In addition to pressure, it is contemplated that thermal energy (e.g., heat) may also be applied to the upper and/or the sole to assist in joining the upper and the sole. Furthermore, it is contemplated that providing a prescribed period of time for application of thermal energy and/or pressure to the upper and/or sole will assist in achieving engagement between the upper and sole. As will be discussed below, the conformal film is effective to provide sufficient pressure at a desired location to assist in joining the upper and the sole, such as through the use of an adhesive or other bonding material.

However, in some conventional joining techniques, when used to join a compressible sole element (e.g., EVA, PU, or other foamed polymer based material) to a lasting, the application of pressure during the joining process can cause permanent, unintended deformation of the compressible sole and thus deformation of the compressible sole in an unintended shape when joined to an upper. In other words, the lack of a conformable film provided herein in a conventional press may result in deformation of the shoe bottom, wherein the deformation is at least partially maintained after the upper is engaged with the deformed shoe sole. As previously noted, the construction of the article of footwear may rely on the successive layering and joining of multiple materials and portions to maintain the shape of the upper defined by the last once the last is removed after joining occurs. However, if the lasted upper is engaged with a sole deformed by a conventional press, the sole may return (completely or partially) to its original undeformed shape once the last is removed after the sole and upper are engaged. Such return of the sole to the pre-deformed shape after engagement with the upper may result in deformation of the upper relative to the shape of the upper defined by the last. Thus, conventional presses that apply pressure to the sole to assist in joining the sole and the upper may introduce deformations of the sole during the pressing operation that result in unintended deformations of the sole and/or the upper after the pressing operation.

It is understood that different sole materials may be more susceptible to unintended permanent deformation. Thus, conventional presses may produce acceptable results for some shoe material combinations. However, as materials have advanced and the use of greater amounts of materials (e.g., foamed polymers) have been used in forming components of footwear, advances in presses have enabled integration of these materials into footwear. For example, when a conventional press is used to join a sole to a lasting upper, soles formed from certain materials result in an unsatisfactory bond (e.g., a bond gap). When the squeeze from a conventional press applies the squeeze over the last for a specified time (e.g., 30 seconds, 25 seconds), the material may deform and result in an inadequate bond. In addition, a reduced force may be applied to compensate for the non-conformal nature of conventional presses. However, the reduction in force (or time) may result in inadequate engagement (e.g., incomplete bonding). In addition, conventional presses may cause one or more portions (e.g., a foamed sole portion) to deform in appearance due to the linear application of force through the press, as opposed to the wrap-around manner achieved by the embodiments of the conformal films provided herein.

Accordingly, embodiments provided herein relate to a conformal film for assisting in bonding a first article and a second article. The conformal film is a film that conforms to the lasting and the sole to encapsulate the lasting and the sole with compressive forces normal to a plurality of surfaces (e.g., sole ground-contacting surface, sole sidewalls, upper medial side, upper lateral side, upper heel end, upper, cuff). The multidirectional compressive force provided by the conformal film secures the sole and the lasting upper for the bonding/joining process without deforming the foam material (e.g., the sole portion). This is in contrast to conventional presses, which do not conform adequately around the lasting upper and sole and/or rely on higher pressures to promote conformity of the press. In contrast to the multidirectional compressive forces provided by conformal membranes, conventional presses concentrate pressure in a more linear manner across the sole. Furthermore, conventional presses that may have "conformal" films may only "conform" at pressures significantly higher than those provided in connection with embodiments herein.

The conformal film includes a peripheral portion having a thickness in a range of 1 to 15 millimeters ("mm") and forming an outer perimeter of the conformal film. In some embodiments, the peripheral portion has a thickness in a range of 5 millimeters to 15 millimeters, 8 millimeters to 12 millimeters, or about 10 millimeters in another example. The conformal film also includes a transition having a thickness in a range of 1-4 millimeters between the first surface and the second surface. The transition portion extends inwardly of the outer periphery formed by the peripheral portion. The conformal film also includes a conformal portion extending from the transition portion in a direction of the second surface and forming a receiving cavity. The conformal portion has a thickness in a range of 1 millimeter to 4 millimeters. The peripheral portion, the conformal portion, and the transition portion may have the same thickness or different thicknesses. The conformal portion and the transition portion may have the same thickness or different thicknesses. The peripheral portion, the transition portion, and the conformal portion are unitary constructions comprising a common material composition.

Furthermore, it is contemplated to implement the conformal film in the manufacture of an article of footwear such that a method of manufacturing an article of footwear utilizing the conformal film for joining a shoe bottom and an upper includes positioning the upper on a securing element (e.g., a crush support). The method includes covering the conformal film over the upper and the shoe bottom on the retaining element. In this example, the first surface of the conformal film contacts the shoe bottom and the shoe upper. The conformal film may be the conformal film set forth in the preceding paragraph or any derivative provided herein. The method continues with the steps of: the pressure differential is reduced after a predetermined time period (e.g., greater than 25 seconds, greater than 30 seconds, greater than 35 seconds). In an exemplary embodiment, the pressure differential may be in the range of 0.5 bar to 3.9 bar (i.e., 50 kpa to 390 kpa).

The conformable membrane and contemplated method of use provide a tool to engage an upper with a sole in a manner that is less deformable with respect to conventional presses (e.g., membrane presses). In some examples, the properties of the conformal film (e.g., thickness and material composition) enable the film to conform around the shoe bottom and the shoe upper to apply pressure (and in some examples heat) across multiple surfaces (e.g., toe cap, heel counter, inner side of upper, outer side of upper, transition across sole to upper (e.g., bite line), sidewall of sole) during lower pressure joining of the shoe upper and shoe bottom. This is in contrast to conventional squeeze films of thicker or different material compositions that apply a more linear force at higher pressures (e.g., 4 bar or greater than 4 bar) that extends linearly across the sole and/or upper (as opposed to wrapping around from multiple directions), thereby causing deformation of the sole and/or upper during the squeezing operation.

Referring generally to the drawings and in particular to fig. 1, fig. 1 illustrates a press 100 for securing a lasting upper 252 and a sole 250 to a stationary member 102 according to embodiments herein. Note that the press 100 is adapted to maintain the relative positions of the upper and the sole while the upper and the sole are engaged. For example, the adhesive can be applied (e.g., sprayed, brushed, rolled, coated, printed) to the sole, the upper, or a combination of the sole and the upper. Further, it is contemplated that upper 252 and/or sole 250 may be formed from one or more materials (e.g., hot melt adhesives, meltable polymers) that are engageable with other components under pressure and/or heat. The sole 250 and upper 252 then have pressure applied by the conformal membrane 200 received in the membrane container 116 (e.g., lid). Because the film container 116 is positioned over the sole 250 and the upper 252, the combination of components is at least partially received in the receiving cavity 238 of the conformal film 200. The receiving cavity is intentionally deformed (e.g., molded or otherwise formed) from the planar configuration of the conformal film 200 such that multiple surfaces of the shoe to be formed (e.g., toe cap at medial, lateral, toe end 254, heel support shelf at heel end 256, bite line) are contacted by the conformal film 200 during the pressing operation. The film container 116 may be secured to the press 100 in a closed, operative arrangement by a film fastener 114 (e.g., a releasable latch mechanism). The film retainer 114 is effective to retain the film container 116 and associated conformal film 200 in position relative to the article of footwear to which pressure is to be applied.

With respect to pressure, it is contemplated that pressure may be applied to the sole 250 and the upper 252 by the press 100 in one or more ways. For example, the fixation element 102 may effectively apply a linear force, such as by a pneumatic cylinder, linear actuator, or the like. This linear force is transferred to the upper 252 and the sole 250 via the last 120 (as best seen in fig. 3), where the conformal film 200 contacting the upper 252 and/or the sole 250 encounters resistance to the linear force. Additionally or alternatively, it is contemplated that the securing element 102 is effective to adjust the position of the upper 252 and the sole 250 in the receiving cavity 238. For example, the securing element 102 may raise or lower (with reference to the illustrated vertical position of the press 100 of fig. 1) the shoe assembly based on the desired pressure, assembly size, assembly shape, and the like. The fixed element 102 may be stationary and immovable in some embodiments.

Pressure may alternatively or additionally be generated by the press 100 by pressurization of the conformal film 200. In the exemplary embodiment also shown in fig. 3, a positive pressure relative to ambient pressure may be introduced into the volume enclosed by the film container 116 and the conformal film 200. The increased pressure creates a pressure differential across the opposing surfaces of the conformal film 200. As the conformal film 200 deforms under the pressure differential, the pressure differential causes the conformal film 200 to conform around the upper 252 and the sole 250. It is this deformation that causes the conformal film 200 to wrap around portions of the upper 252 and the sole 250, thereby creating a compressive force that holds the upper 252 and the sole 250 in a fixed relative position during the joining operation. Depending on the pressure differential, sufficient pressure may be applied to the upper 252 and the sole 250 to assist in joining (e.g., via adhesive cure bonding) the components. Exemplary pressure differentials include from 0.5 bar up to 3.9 bar relative to ambient pressure. Above 3.9 bar, in exemplary embodiments, the conformal film may mechanically fail after a certain number of extrusion cycles or the extruded article may deform unexpectedly and permanently during the extrusion operation. While pressure differentials above 0.5 bar and below 3.9 bar are contemplated, embodiments herein implement pressure differentials within the provided ranges to reduce unintended deformation of the extruded article. The low degree of conformability of conventional presses can operate with pressure differentials of 4 bar or greater to conform to and conform to the article being pressed. This increased pressure may cause a conventional squeeze film to conform, but it may damage or otherwise cause unintended deformation of the extruded article (e.g., a portion of an article of footwear). Thus, the implementations of the conformal films provided herein operate at lower pressure differentials than conventional squeeze films to achieve film-to-film conformality to the extruded article. In additional embodiments, the pressure differential is in the range of 1 to 3 bar, 1 to 2 bar, 1 to 1.5 bar, 1 to 1.3 bar, 1 to 1.2 bar, 1.1 to 1.4 bar, and/or 1.25 to 1.35 bar, expressed as atmospheric pressure. Flexibility is provided by selecting various pressure differential conditions based on the materials to be bonded, extrusion times, film conformality, and the like. Accordingly, based on factors contemplated herein, various pressure differential ranges may be applied to achieve bonding of the footwear components while minimizing unintended permanent deformation of the footwear components.

Fig. 2 illustrates the press 100 with the film container 116 in a closed and fixed arrangement, according to embodiments herein. The closed arrangement is a configuration that enables the press 100 to effectively apply pressure to the shoe assembly during the joining operation. The input mechanism of the press 100 is also shown. Time control 110, pressure control 112, and temperature control 118 are shown. The input mechanism enables the user to adjust the same name parameters (e.g., time, temperature, pressure). However, it is contemplated that one or more of the input mechanisms may be omitted or altered in exemplary embodiments. For example, computer instructions may be transmitted to the press from a controller that controls the time, pressure, and/or time applied to a particular (or general) component. Further, it is contemplated that in some examples one or more of time, temperature, or pressure may not be adjusted.

FIG. 3 illustrates a cross-sectional view taken along cut line 3-3 of FIG. 2, according to embodiments herein. A toe-to-heel (toe-to-heel) perspective view is provided to illustrate the securing element 102 holding the last 120 in a position that enables the upper 252 and the upper 250 to be contacted by the conformal membrane 200. Fig. 3 shows the conformal film 200 during a pressure differential that causes the conformal film 200 to conform to the lasting upper 252 and the sole 250. Pressure source 106 provides an exemplary pressure source to create a pressure differential. The pressure source may provide compressible or incompressible materials (e.g., gases or liquids) into the membrane chamber 104 from an external source (e.g., tanks, pumps, and compressors). The film chamber 104 is surrounded and formed by the film container 116 and the conformal film 200. The film chamber 104 is effective to receive a pressurized material (e.g., a pressurized gas) and provide a volume for the pressurized material to surround and exert a force on portions of the conformal film 200 from within the conformal film 200. The pressure may be controlled using one or more mechanisms (e.g., regulators, etc.). Unlike conventional squeeze films operating at 4 bar and above 4 bar, embodiments herein contemplate operation at lower pressures (e.g., 0.5 bar to 3.9 bar), so conventional macro-level control of pressure can result in unintended permanent deformation of the extruded article due to the large tolerances of macro-level control (e.g., analog regulators with 1 bar or greater than 1 bar tolerances) operating on pressure. This large tolerance will result in a greater pressure differential at the conformal films provided herein, resulting in an unintended permanent deformation of the extruded article. Thus, in exemplary embodiments, such macro-level control of pressures with pressure differentials of 4 bar or greater than 4 bar may not be effective in controlling pressure differentials having a range of 0.5 bar to 3.9 bar. Furthermore, in exemplary embodiments, such macro-level control of pressures with pressure differentials of 4 bar or greater than 4 bar may not be effective in controlling pressure differentials having a range of 1 bar to 2 bar. Thus, embodiments herein contemplate upgrading the pressure control mechanism to a micro-scale control (e.g., a digital regulator with a tolerance of 0.9 bar or less than 0.9 bar) that is capable of maintaining pressure differentials within tighter tolerances than the pressure mechanisms of conventional presses. Control to increase pressure tolerance may provide better durability (e.g., a reduction in pressurization potential) of the conformal film and allow more consistent operation at the lower pressures provided herein. In other words, in the exemplary embodiments herein, since the embodiments herein contemplate operating at lower pressure differentials than standard presses, greater control over the pressure differentials may gain results from conformal film presses.

An optional heating source 108 is also shown in fig. 3. The heating source 108 may be a resistive heating element, an infrared heating element, an inductive heating element, or the like. Alternatively, in some embodiments, it is contemplated that the pressurized material may be heated outside of the membrane chamber 104 and introduced at a higher (or lower) temperature relative to ambient conditions. Heat may be used to activate, melt, or cure one or more materials (e.g., a bonding material). For example, a low melting point adhesive having a deformation temperature (e.g., melting temperature) lower than that of the film, the upper, and the sole can be disposed between the upper and the sole. Heat can be generated or applied to activate the low melt adhesive before or after conforming the conformable film 200 around portions of the sole and upper. The thermal energy can then be reduced while maintaining pressure from the conformal film 200 until the low melt adhesive (or any bonding material) has sufficient bonding between the components. It is contemplated that heating source 108 is optional and may be omitted in embodiments contemplated herein.

Fig. 3 illustrates three regions of a conformal film 200. The peripheral portion 214, the transition portion 224, and the conformal portion 234 will be discussed in more detail in fig. 4-8 below. As shown in fig. 3, the conformal film 200 surrounds and encircles the upper 252 and portions of the sole 250 from multiple directions on multiple surfaces. It is this conformity with the various surfaces and components that enables the conformal film 200 to effectively bond the upper 252 to the sole 250.

As previously provided, the low degree of conforming (or non-conforming) membrane of the conventional press, in contrast, permanently deforms the sole 250 (e.g., compresses the foam material) during the pressing operation because it does not sufficiently conform and thus applies a more concentrated and unidirectional pressure to the sole. Permanent deformation resulting in unacceptable pressed portions may also result from a conventional lamination operating at higher pressures (e.g., 4 bar and above 4 bar) to achieve some degree of conformance of the conventional lamination to the pressed component. Higher pressure differentials are used on conventional presses to compensate for low levels of conformal film material, which translates into potentially damaging forces being applied to the extruded article. This unintended deformation may be further exaggerated if thermal energy is applied to the process to activate or cure the bonding material. This increased thermal energy may cause the material forming the sole (e.g., PU, EVA) to become more compliant and thus more prone to undesirable deformation under certain pressures from the press. Thus, by the compliant membrane surrounding the various surfaces of the components to be joined from multiple directions, the pressure of the press is applied over a greater surface area in more directional angles, enabling the same material that may deform unexpectedly under a conventional membrane to effectively engage with the conformal membrane 200.

Fig. 4 illustrates a perspective view of a conformal film 200 according to embodiments herein. For reference purposes, the longitudinal direction 206 is shown generally as well as the transverse direction 210. As envisioned, a conformal film is used in conjunction with an article of footwear, the conformal film having a receiving cavity formed in a shape similar to the portion intended to receive the article of footwear. This common and expected deformation is placed under a certain pressure differential, limiting creases or other membrane deviations to form a compliant conformation with the underlying shoe component. In other words, in some examples, the receiving cavity has a similar shape to the article it is expected to conform to under a certain pressure differential. This coordination between the receiving chamber shape and the article of footwear allows the membrane to conform more consistently to the components to be joined under certain pressure differentials.

The peripheral portion 214, the transition portion 224, and the conformal portion 234 of the conformal film 200 are shown in fig. 4. In addition, the outer perimeter 222 is shown as forming the outermost portion of the conformal film 200. Conformal film second surface 204 is also shown. Conformal film second surface 204 is opposite conformal film first surface 202, as best seen in fig. 8.

Fig. 5 illustrates a side view of a conformal film 200 according to embodiments herein. The z direction 236 is shown. The z-direction 236 is the direction in which the conformal portion 234 extends from the transition portion 224. Fig. 6 illustrates a front view of a conformal film 200, according to embodiments herein.

Fig. 7 illustrates a plan view of the conformal film 200 illustrated in fig. 4-6, according to embodiments herein. Several exemplary positional elements are shown in fig. 7. For example, a receiving cavity first half-section 240 and a receiving cavity second half-section 244 are shown along the longitudinal direction 206. In addition, a series of arrow indicators 232 are shown to illustrate the "inside" direction relative to the outer perimeter 222 in the plan view plane of the conformal film 200.

The conformal portion 234 includes a receiving cavity 238. The receiving cavity first half 240 has a maximum width 242 and the receiving cavity second half 244 has an exemplary width 246. The width of the receiving cavity portion is measured in the transverse direction 210. In this example, the maximum width 242 of the receiving cavity first half 240 is greater than any width (e.g., width 246) of the receiving cavity second half 244, as the receiving cavity is shaped to conform to the article of footwear. It is contemplated that the receiving cavity may have any shape depending on the article to be compressed by the conformal film.

The conformal film 200 has a length 208 measured from an outer perimeter 222 in the longitudinal direction 206. The conformal film 200 has a width 212 measured in the lateral direction 210 from an outer perimeter 222. In an exemplary embodiment, it is contemplated that the length 208 is in a range of 400 millimeters to 500 millimeters. In an exemplary embodiment, it is contemplated that length 208 is in a range of 425 millimeters to 475 millimeters. In an exemplary embodiment, it is contemplated that the length 208 is in a range of 450 millimeters to 465 millimeters. In an exemplary embodiment, it is contemplated that the width 212 is in a range of 200 millimeters to 300 millimeters. In an exemplary embodiment, it is contemplated that the width 212 is in a range of 210 millimeters to 250 millimeters. In an exemplary embodiment, it is contemplated that the width 212 is in a range of 220 millimeters to 240 millimeters. In view of the exemplary ranges provided, it is contemplated that outer perimeter 222 may define a planar surface area of 0.08 square meters to 0.15 square meters. This area enables sufficient conformal film material to conform to the components to be compressed while minimizing the material and weight associated with the conformal film 200. The length and width may depend on the style, size, or type of article to be compressed by the conformal film 200.

In addition, the conformal portion 234 has a maximum length 209. In an exemplary embodiment, it is contemplated that length 209 is in a range of 350 millimeters to 450 millimeters. In an exemplary embodiment, it is contemplated that the length 209 is in a range of 375 millimeters to 425 millimeters. In an exemplary embodiment, it is contemplated that length 209 is in a range of 395 millimeters to 415 millimeters. In an exemplary embodiment, it is contemplated that the maximum width 242 is in the range of 150 millimeters to 250 millimeters. In an exemplary embodiment, it is contemplated that the maximum width 242 is in the range of 175 millimeters to 225 millimeters. In an exemplary embodiment, it is contemplated that the maximum width 242 is in the range of 190 millimeters to 210 millimeters. The length 209 and width 242 of the receiving cavity are selected in the exemplary embodiment to provide a receiving cavity of sufficient size for the component to be received therein while limiting excess conformal film material. For example, the length and width of the receiving cavity 238 may be 1% to 10% greater than similar measurements of the component to be received therein to achieve easy insertion and removal without introducing unintended deformation when the film conforms to the underlying component.

Fig. 8 illustrates a cross-section along cut line 8-8 of the conformal film 200 of fig. 4, according to embodiments herein. The peripheral portion 214 has a peripheral portion first surface 218 and a peripheral portion second surface 220 defining a thickness 216 therebetween. The transition 224 has a transition first surface 228 and a transition second surface 230 with a thickness 226 defined therebetween. The conformal portion 234 has a conformal portion first surface 235 and a conformal portion second surface 237, with a thickness 248 defined therebetween.

The thicknesses of the conformal portion 234, the transition portion 224, and the peripheral portion 214 affect the ability of the conformal film 200 to conform to an article under a certain pressure differential. The historical film in the historical press may have a greater thickness in various sections. Greater thicknesses may have traditionally been implemented to enable the materials forming conventional films to have longer lifetimes during industrial applications. However, the conformal film 200 may operate under different conditions (e.g., temperature, pressure, time) to bond and/or form more compliant features from different materials, and thus may have a thinner (e.g., smaller) thickness than conventional films. In some examples, as the thickness of a portion of the conformal film decreases, the conformal film may become more compliant and able to conform to the underlying article. However, if the thickness is reduced too much, the conformal film may experience fatigue and failure in practical industrial applications. Thus, in exemplary embodiments, various ranges of thicknesses are contemplated to provide sufficient compliance to the conformal film 200 while achieving sufficient service life.

According to embodiments herein, it is contemplated that the peripheral portion thickness 216 is in a range of 1 millimeter to 15 millimeters. According to embodiments herein, it is contemplated that the peripheral portion thickness 216 is in a range of 5 millimeters to 15 millimeters. According to embodiments herein, it is contemplated that the peripheral portion thickness 216 is in a range of 8 millimeters to 12 millimeters. According to embodiments herein, it is contemplated that the peripheral portion thickness 216 is about 10 millimeters. According to embodiments herein, it is contemplated that the transition thickness 226 is in the range of 1 millimeter to 4 millimeters. According to embodiments herein, it is contemplated that the transition thickness 226 is about 2 millimeters. In accordance with embodiments herein, it is contemplated that the conformal portion thickness 248 is in a range of 1 millimeter to 4 millimeters. In accordance with embodiments herein, it is contemplated that the conformal portion thickness 248 is about 2 millimeters. In an exemplary embodiment, the peripheral portion thickness 216, the transition portion thickness 226, and the conformal portion thickness 248 may be the same. In an exemplary embodiment, the peripheral portion thickness 216, the transition portion thickness 226, and/or the conformal portion thickness 248 may be different.

In the exemplary embodiment, it is contemplated that conformal portion 234 and transition portion 224 have similar thicknesses. This common thickness may cause the transition 224 to similarly follow the conformal portion 234 during exposure to a pressure differential, thereby preventing areas of greater elongation in the conformal portion 234. In some examples, the transition 224 completely borders or surrounds the conformal portion 234. In other words, the transition 224 provides a functional transition extending in the z-direction between the peripheral portion 214 and the contoured portion 234. By surrounding the conformer 234, the transition 224 enables the conformer 234 to conform to the received article even at the outermost portion of the conformer 234.

In an exemplary embodiment, the peripheral portion thickness 216 may be greater than the transition thickness 226 to increase the life, service life, and concentration of compression energy around the received article. Because the thickness of the conformal film affects the functional properties (e.g., elongation), the conformal film 200 is more susceptible to deformation from pressure differences at locations with a smaller thickness (i.e., thinner regions). Thus, by reducing the thickness of the conformal film 200 at the receiving cavity 238 and near the article to be received, the conformal film 200 conforms more around the received article than at the peripheral portion 214 having a greater thickness. In an exemplary embodiment, the peripheral portion 214 is less susceptible to fatigue failure from repeated conformations during pressure differential cycles because the peripheral portion 214 has a greater thickness resulting in less conformability.

Fig. 8 illustrates the extended height 258 of the conformal portion 234 from the transition portion 224. According to embodiments herein, the height 258 is in a range of 70 millimeters to 110 millimeters. According to embodiments herein, the height 258 is in a range of 80 millimeters to 100 millimeters. According to embodiments herein, the height 258 is about 90 millimeters (e.g., within 10%). The conventional film may have a height that is significantly less than the conformal film 200. In such examples, the smaller height-inhibiting film surrounds multiple surfaces of the article, and thus materials that are susceptible to deformation under directional compression of conventional films (e.g., foamed polymers of shoe soles) may deform. The conformable film 200 having a greater height than conventional films is instead allowed to wrap around the shoe bottom and at least a portion of the upper, thereby enclosing the article with a unified pressure rather than a directional pressure (e.g., linearly from the film toward the securing element).

In the exemplary embodiment, peripheral portion first surface 218 and peripheral portion second surface 220 are positioned above transition portion second surface 230. Further, because the conformal portion 234 extends (e.g., upwardly in fig. 8), it is contemplated in the exemplary embodiment that the peripheral portion first surface 218 and the peripheral portion second surface 220 are positioned on the same side of the transition portion second surface 230. This offset between the peripheral portion 214 and the transition portion 224 allows for greater conformality of the conformal film 200 around the received article in an inner direction relative to the outer periphery 222. In other words, in the exemplary embodiment, the offset in the vertical placement of peripheral portion 214 and transition portion 224 enables the transfer of vertical placement for horizontal conformality as the pressure differential is applied.

The conformal film 200 is formed of a conformal material. In one embodiment, the conformal film is formed from a material composition that includes rubber (e.g., natural rubber), silicon dioxide (i.e., silica), and calcium carbide. Additional materials may be included in the composition. In an exemplary embodiment, the material composition of the conformal film 200 is comprised of 75% to 85% by weight rubber and 5% to 15% by weight silica. In an exemplary embodiment, the material composition of the conformal film 200 is composed of 5% to 15% by weight of calcium carbide and 5% to 15% by weight of silicon dioxide. In an exemplary embodiment, the material composition of the conformal film 200 is comprised of 8% to 12% by weight of dispersible silica. In an exemplary embodiment, the material composition of the conformal film 200 is composed of 75% to 85% rubber by volume and 5% to 15% silica by volume. In an exemplary embodiment, the material composition of the conformal film 200 is composed of 5% to 15% calcium carbide by volume and 5% to 15% silicon dioxide by volume. In an exemplary embodiment, the material composition of the conformal film 200 is comprised of 8% to 12% by volume of the dispersible silica. In an exemplary embodiment, the percentage of composition is determined prior to combining.

Conformal films are contemplated as a unitary material extending between two or more portions. For example, it is contemplated that the conformal portion 234 and the transition portion 224 are formed of the same material such that the composition of the material forming the portion is homogenous. Similarly, it is contemplated that the peripheral portion 214, the transition portion 224, and the conformal portion 234 are unitary and are formed of a common material. A unified structure is a single entity with a uniform material composition. For example, two or more portions of the conformal film may be generated simultaneously. In an example, a molding operation that combines to form two or more parts may be performed. In an alternative fabrication process, it is contemplated to reduce (e.g., polish) the common material to form a conformal film. In this example, the portions formed by the subtraction are unified in that they all start from a common source material without subsequent bonding.

The functional characteristics of the conformal film 200 can be quantified to provide a range of conformal films suitable for the exemplary embodiments herein. For example, according to embodiments herein, the conformal film 200 at least in the conformal portion 234 may have a hardness of 60 to 61 Askel (ASKER) C as measured on an ASKER type C durometer. According to embodiments herein, the conformal film 200 at least in the conformal portion 234 may have a thickness at 84 kilograms per cubic centimeter (kg/cm)³) To a maximum tensile strength in the range of 90 kg/cc. The maximum tensile strength may be tested using a testing protocol such as ASTM D638-14. According to embodiments herein, the conformal film 200 at least in the conformal portion 234 may have a maximum elongation of at least 540% until damaged. The maximum elongation may be measured using a test such as the ASTM D-638 test protocol.

In an exemplary embodiment, the material composition and resulting functional properties of the conformal film 200 provide suitable materials as a film to join two or more shoe portions without deforming the foamed polymer component (e.g., EVA or PU midsole element) or damaging the material composition provided herein for the conformal film 200 may save labor, cost, and/or material. For example, operating at lower pressures than conventional film presses to achieve film conformability to the underlying extruded article may reduce subsequent intervention to correct for unintended deformation of the extruded material. In addition, energy savings are achieved by using lower pressure requirements through the use of conformal membranes operating at lower pressures. Additionally, in exemplary embodiments, operating a conformal film at a lower pressure with contemplated material compositions enables thinner films to be achieved that reduce the materials used to form the film, which in turn reduces material costs.

Turning to fig. 9, fig. 9 illustrates a method 900 of making an article of footwear utilizing a conformal film to join a shoe bottom and an upper, according to embodiments herein. At block 902, an upper is positioned on a securing element. The upper may be a lasted upper, wherein the last is secured to the fixing element. At block 904, a conformal film (e.g., conformal film 200 provided herein) is draped over the upper and shoe bottom. In this example, the upper and the sole are positioned in the desired relative positions. An adhesive or other bonding material may be applied prior to joining the two components.

At block 906, a pressure differential is created between opposing surfaces of the conformal film. For example, a pressurized fluid (e.g., a gas or liquid) may be injected into the film cavity, wherein the conformal film is more compliant than other materials forming the film cavity. Thus, the cavity deforms and conforms around the lasting and the sole, thereby creating a compressive force to secure the sole to the lasting. Compressive forces are applied to both the upper and the sole at a plurality of surfaces including the interface between the sole and the upper. This enveloping compression holds the sole in a defined position relative to the upper during the joining operation.

At block 908, after a predetermined period of time, the pressure differential is reduced. This time period may be 20 seconds, 25 seconds, 30 seconds, or any time suitable to allow engagement of the sole with the upper.

Other steps contemplated but not shown in fig. 9 include, but are not limited to, applying thermal energy, extracting thermal energy (e.g., cooling), and adjusting time, pressure, and/or temperature.

The following is a non-limiting exemplary list of components provided in the figures.

-press-100

-a fixing element-102

Membrane chamber-104

-pressure source-106

Temperature source-108

Time control-110

-pressure control-112

-film fastener-114

-membrane container-116

Conformal film-200

Conformal film first surface-202

-conformal film second surface-204

-longitudinal direction-206

-longitudinal length-208

Receiving chamber length-209

-transverse direction-210

-transverse width-212

Peripheral portion-214

Peripheral thickness-216

Peripheral first surface-218

-a peripheral second surface-220

-outer periphery-222

-transition-224

Transition thickness-226

-transition first surface-228

-transition second surface-230

-interior direction-232

Conformal portion-234

Conformal first surface-235

-Z direction-236

Conformal second surface-237

Receiving chamber-238

First half-section of receiving chamber-240

Width of the first half-section of the receiving chamber-242

Receiving chamber second half-section-244

Width of receiver second half-segment-246

-conformal thickness-248

Sole-250

-shoe upper-252

-toe end-254

Heel end-256

Many different arrangements of the various components shown, as well as components not shown, may be made without departing from the spirit and scope of the present disclosure. The embodiments of the present disclosure have been set forth for purposes of illustration and not limitation. Alternative embodiments will become apparent to those skilled in the art that do not depart from the scope of the present disclosure. Those skilled in the art may develop alternative means of implementing the above improvements without departing from the scope of the present disclosure.

It will be understood that certain features and sub-combinations are of utility and may be employed without reference to other features and sub-combinations and are contemplated to be within the scope of the claims. Not all steps listed in the various figures need be performed in the particular order described.

The term "any of the clauses" or similar variations of the term as used herein in connection with the clauses listed below is intended to be construed so that the features of the clauses may be combined in any combination. For example, exemplary clause 4 may indicate a method/apparatus as described in any of clauses 1-3, which is intended to be construed such that the features of clauses 1 and 4 may be combined, the elements of clauses 2 and 4 may be combined, the elements of clauses 3 and 4 may be combined, the elements of clauses 1, 2 and 4 may be combined, the elements of clauses 2, 3 and 4 may be combined, the elements of clauses 1, 2, 3 and 4 may be combined, and/or other variations. Further, the term "any of the clauses" or similar variations of the term are intended to include "any of the clauses" or other variations of this term as indicated by some of the examples provided above. Furthermore, it is contemplated that the terms may be drafted into the embodiments claimed herein.

Exemplary clauses

1. A conformable film for aiding in bonding a first article to a second article, comprising: a peripheral portion having a thickness in a range of 1 millimeter to 15 millimeters forming an outer perimeter of the conformal film; a transition portion having a thickness in a range of 1 to 4 millimeters between a first surface and a second surface, wherein the transition portion extends inward of the outer perimeter formed by the peripheral portion; and a conformal portion extending from the transition portion in a direction of the second surface and forming a receiving cavity, the conformal portion having a thickness in a range of 1-4 millimeters, wherein the peripheral portion, the transition portion, and the conformal portion are unitary constructions comprising a common material composition.

2. The conformable film of clause 1, wherein the first article is a foamed polymer-based article.

3. The conformal film of clause 2, wherein the first article is a midsole and the second article is an upper.

4. The conformal film of any one of clauses 1-3, wherein the peripheral portion further comprises a first surface and a second surface, both the peripheral portion first surface and the peripheral portion second surface being positioned on the same side of the transition second surface as the conformal portion.

5. The conformal film of any one of clauses 1-4, wherein the peripheral portion has a thickness in a range of 8-12 millimeters.

6. The conformal film of any one of clauses 1-5, wherein the outer perimeter defines a planar area of 0.08 square meters to 0.15 square meters.

7. The conformal film of any one of clauses 1-6, wherein the outer perimeter has a longitudinal length in a range of 400-500 millimeters and a lateral length in a range of 200-300 millimeters.

8. The conformal film of any one of clauses 1-7, wherein the transition portion completely interfaces with the conformal portion and joins the conformal portion and the peripheral portion.

9. The conformal film of any one of clauses 1-8, wherein the conformal portion has a durometer hardness in the range of 60 to 61 askel (Asker) C.

10. The conformable film of any of clauses 1-9, wherein the conformable portion has a tensile strength in the range of 84 to 90 kilograms per cubic centimeter.

11. The conformal film of any one of clauses 1-10, wherein prior to failure of the conformal portion, the conformal portion has a percent elongation of at least 540% elongation.

12. The conformal film of any one of clauses 1-11, wherein the transition and the conformal portion have the same durometer hardness, tensile strength, or elongation.

13. The conformal film of any one of clauses 1-12, wherein the conformal portion extends from the transition second surface in a range of 70 millimeters to 110 millimeters.

14. The conformal film of any one of clauses 1-13, wherein the conformal portion extends within a range of 80-100 millimeters from the transition second surface.

15. The conformal film of any one of clauses 1-14, wherein the receiving cavity has a width in the lateral direction at a first half in the longitudinal direction that is greater than a width in the lateral direction at a second half in the longitudinal direction.

16. The conformal film of any one of clauses 1-15, wherein the conformal portion has a thickness of 2 millimeters.

17. The conformal film of any one of clauses 1-16, wherein the material composition comprises natural rubber, silica, and calcium carbide.

18. The conformal film of any one of clauses 1-17, wherein the material composition is comprised of 75-85% rubber and 5-15% silica by weight.

19. The conformal film of any one of clauses 1-18, wherein the material composition comprises 5% to 15% silicon dioxide and 5% to 15% calcium carbide by weight.

20. The conformal film of any one of clauses 1-19, wherein the material composition comprises dispersible silica in a range of 8% to 12% by weight of the material composition.

21. A press having a conformable film for assisting in joining a first article to a second article, the press comprising: a conformal film, comprising: (1)

a peripheral portion having a thickness in a range of 1 millimeter to 15 millimeters forming an outer perimeter of the conformal film; (2) a transition portion having a thickness in a range of 1 to 4 millimeters between a first surface and a second surface, wherein the transition portion extends inward of the outer perimeter formed by the peripheral portion; and (3) a conformal portion extending from the transition portion in a direction of the second surface and forming a receiving cavity, the conformal portion having a thickness in a range of 1-4 millimeters, wherein the peripheral portion, the transition portion, and the conformal portion are unitary constructions comprising a common material composition; and a pressure source fluidly coupled to the press to control a pressure differential between the transition first surface and the transition second surface to be 0.5 bar to 3.9 bar.

22. A method of making an article of footwear with a conformal film for joining a shoe bottom and an upper, the method comprising: positioning the upper on a fixing element; covering the conformal film over the upper and the shoe bottom on the securing element, wherein a first surface of the conformal film contacts the shoe bottom and the upper, the conformal film comprising: (1) a peripheral portion having a thickness in a range of 5 millimeters to 15 millimeters forming an outer perimeter of the conformal film; (2) a transition having a thickness in a range of 1 to 4 millimeters between a first surface and a second surface, wherein the transition extends inward of the outer perimeter formed by the peripheral portion; and (3) a conformal portion extending from the transition portion in a direction of the second surface and forming a receiving cavity, the conformal portion having a thickness in a range of 1-4 millimeters, wherein the peripheral portion, the transition portion, and the conformal portion are unitary constructions comprising a common material composition; and generating a pressure differential experienced across the first surface of the conformal film and an opposing second surface of the conformal film, wherein a pressure at the second surface of the conformal film is a greater pressure than a pressure at the first surface; and reducing the pressure difference after a predetermined period of time.

23. The method of clause 22, wherein the pressure differential is in the range of 0.5 bar to 3.9 bar.

24. The method of any of clauses 22-23, wherein the predetermined period of time is at least 25 seconds.

Claims

1. A conformable film for aiding in bonding a first article to a second article, comprising:

a peripheral portion having a thickness in a range of 1 millimeter to 15 millimeters forming an outer perimeter of the conformal film;

a transition portion having a thickness in a range of 1 to 4 millimeters between a first surface and a second surface, wherein the transition portion extends inward of the outer perimeter formed by the peripheral portion; and

a conformal portion extending from the transition portion in a direction of the second surface and forming a receiving cavity, the conformal portion having a thickness in a range of 1-4 millimeters, wherein the peripheral portion, the transition portion, and the conformal portion are a unitary construction comprising a common material composition.

2. The conformal film of claim 1, wherein said first article is a foamed polymer-based article.

3. The conformal film according to claim 2, wherein said first article is a midsole and said second article is an upper.

4. The conformal film of claim 1, wherein the peripheral portion further comprises a first surface and a second surface, both the peripheral portion first surface and the peripheral portion second surface being positioned on a same side of the transition second surface as the conformal portion.

5. The conformal film of claim 1, wherein the peripheral portion has a thickness in a range of 8-12 millimeters.

6. The conformal film of claim 1, wherein said outer perimeter defines a planar area of 0.08 square meters to 0.15 square meters.

7. The conformal film of claim 1, wherein said outer periphery has a longitudinal length in the range of 400-500 millimeters and a lateral length in the range of 200-300 millimeters.

8. The conformal film of claim 1, wherein said transition portion completely interfaces with said conformal portion and engages said conformal portion with said peripheral portion.

9. The conformal film of claim 1, wherein the conformal portion has a durometer hardness in the range of 60 a-61 Asker C.

10. The conformal film of claim 1, wherein the conformal portion has a tensile strength in a range of 84 kilograms per cubic centimeter to 90 kilograms per cubic centimeter.

11. The conformal film of claim 1, wherein prior to failure of the conformal portion, the conformal portion has a percent elongation of at least 540% elongation.

12. The conformal film of claim 1, wherein the transition portion and the conformal portion have the same durometer hardness, tensile strength, or elongation.

13. The conformal film according to claim 1, wherein said conformal portion extends from said transition second surface in a range of 70 millimeters to 110 millimeters.

14. The conformal film according to claim 1, wherein said conformal portion extends from said transition second surface in a range of 80 millimeters to 100 millimeters.

15. The conformal film of claim 1, wherein a first half of the receiving cavity in a longitudinal direction has a width in a lateral direction that is greater than a width in the lateral direction of a second half of the receiving cavity in the longitudinal direction.

16. The conformal film of claim 1, wherein said conformal portion has a thickness of 2 millimeters.

17. The conformal film according to claim 1, wherein said material composition comprises natural rubber, silica, and calcium carbide.

18. The conformal film of claim 1, wherein said material composition comprises 75% to 85% rubber and 5% to 15% silica by weight.

19. The conformal film according to claim 1, wherein said material composition comprises 5% to 15% silicon dioxide and 5% to 15% calcium carbide by weight.

20. The conformal film of claim 1, wherein said material composition comprises dispersible silica in a range of 8% to 12% by weight of said material composition.

21. A press having a conformable film for assisting in joining a first article to a second article, the press comprising:

a conformal film, comprising:

(1) a peripheral portion having a thickness in a range of 1 millimeter to 15 millimeters forming an outer perimeter of the conformal film;

(2) a transition portion having a thickness in a range of 1 to 4 millimeters between a first surface and a second surface, wherein the transition portion extends inward of the outer perimeter formed by the peripheral portion; and

(3) a conformal portion extending from the transition portion in a direction of the second surface and forming a receiving cavity, the conformal portion having a thickness in a range of 1-4 millimeters, wherein the peripheral portion, the transition portion, and the conformal portion are unitary constructions comprising a common material composition; and

a pressure source fluidly coupled with the press to control a pressure differential between the transition first surface and the transition second surface to be 0.5 bar to 3.9 bar.

22. A method of making an article of footwear with a conformal film for joining a shoe bottom and an upper, the method comprising:

positioning the upper on a fixing element;

covering the conformal film over the upper and the shoe bottom on the securing element, wherein a first surface of the conformal film contacts the shoe bottom and the upper, the conformal film comprising:

(1) a peripheral portion having a thickness in a range of 5 millimeters to 15 millimeters forming an outer perimeter of the conformal film;

creating a pressure differential experienced across the first surface of the conformal film and an opposing second surface of the conformal film, wherein a pressure at the second surface of the conformal film is a greater pressure than a pressure at the first surface; and

after a predetermined period of time, the pressure differential is reduced.

23. The method of claim 22, wherein the pressure differential is in a range of 0.5 bar to 3.9 bar.

24. The method of claim 22, wherein the predetermined period of time is at least 25 seconds.