GB2610416A - Support apparatus for a shoe - Google Patents

Abstract

A pulp fibre shoe support assembly 1 comprises an inner support including an upper part 2 and lower part 4 shaped to be received within a shoe. The upper part is formed from a single piece of moulded fibre and has a continuous outer support surface including a longitudinally extending central zone and side walls extending downwardly from the central zone. The lower part is also formed from a single piece of molded fiber and corresponds in shape to and nests within the hollow interior of the upper part. The lower part comprises an inner support surface located beneath and arranged to support the outer support surface of the upper part and has a longitudinally extending central zone, with side walls extending downwardly from the central zone to a lower edge. The lower part has a hollow interior and comprises a plurality of integrally moulded upright supports extending downwardly from the inner support surface. Preferably, at least part of the inner support surface is bonded to the outer support surface. The support may also comprise a heel support having hollow moulded inner and outer parts. Also claimed is a method of printing onto a shoe.

Description

SUPPORT APPARATUS FOR A SHOE

FIELD OF INVENTION

[001] The present invention relates to a support apparatus for a shoe, and in particular to a support apparatus for maintaining the form of a shoe during a HDMF printing operation.

BACKGROUND

[002] High Definition Micro Fusion (HDMF) is a process for printing on to a 3-dimensional article. The process uses a specialized polymer film and a multi-layer coating that is designed to accept water-based dyes and release them when subjected to a certain wavelength of energy under a vacuum. A digital image is printed onto a coated film as a pattern of pixel dots of thermally diffusible dye. The film functions as a carrier membrane for the dye. The membrane is then mounted in a heating chamber. The 3D article to be decorated is placed in a receiving chamber on a support plate beneath the film. The film is softened using infrared heat and the support plate is moved relative to the membrane to bring the article into contact with the softened film. This is done either by lifting the support plate or lowering the membrane. The movement and placement of the 3D object is coordinated to bring the article into precise registration with the image printed on the membrane. A vacuum is then applied to wrap the softened film holding it tight against the surface of the 3D object.

[003] Infra-red radiation is applied to the article and the membrane that heats the membrane and the underlying surface of the 3D article. The temperature and wavelength are strictly controlled using Passive Infrared Sensors. This process causes the molecular surface of the 3D object to open and the dyes in the film to be diffused into the surface of the 3D object surface. As a result, the printed image is transferred to the surface of the 3D object. The original digital image is generated taking into account the distortion of the membrane during the wrapping process to ensure that the image is correctly presented when wrapped about the article. This process is described in GB2547183.

[4] HDMF is a very efficient and environmentally friendly technology that allows manufactures to cater to the challenges of customisation and personalisation in a highly responsive manner as well as enabling the rapid execution of samples. For example, a company may ship products as universal 'blank' products without customisation, and the products may be customised at the point of sale using HMDF printing. This avoids the need to ship multiple different versions of the same product and avoids waste that arises when certain product variants fail to sell as well as others by printing the products in response to demand.

[5] It is desirable to be able to use the above process for applying printed indicia to shoes. One of the challenges of printing onto shoes is the flexible nature of the fabric construction. The HDMF process requires a large vacuum pressure to be applied to the membrane to cause the printed dye to diffuse from the membrane to the shoe. Such high vacuums compress and distort the flexible material of the shoe, causing the shoe to collapse. As a result, it is difficult to maintain accurate registration between the surface of the shoe and the printed image.

[6] It is known to provide shoe lasts for supporting shoes. Such shoe lasts are commonly formed from rubber or a similar material. This material is relatively expensive and heavy, and as a solid object is also space consuming. Such shoe lasts are therefore costly to transport. Hence, this material is not suitable if it is required to ship large volumes to enable printing of the shoes at the point of retail, or at onward warehouses or distribution centres.

[7] It is also essential when printing to a shoe, for example a sports shoe or 'trainer' that the ink is only applied to the desired fabric sections of the shoe. Therefore, some means of masking the shoe to prevent printing to areas such as the sole is required. As the shape and size of shoes varies greatly, any means of masking the shoe must be readily and economically adaptable for a wide range of shoes.

[008] It is therefore desirable to provide an improved support for a shoe and method of printing to a shoe which addresses the above-described problems and/or which offers improvements generally.

SUMMARY

[009] According to the present invention there is provided a pulp fibre shoe support, and a method of printing onto a shoe as described in the accompanying claims.

[0010] In an embodiment of the invention there is provided a pulp fibre shoe support assembly comprising an inner support including a single piece, moulded fibre upper part shaped to be received within a shoe, the upper part comprising a continuous outer support surface including a longitudinally extending central zone and side walls extending downwardly from the central zone, the upper part having a hollow interior; and a single piece, moulded fibre lower part corresponding in shape to and nested within the hollow interior of the upper part, the lower part comprising an inner support surface located beneath and arranged to support the outer support surface of the upper part, the inner support surface including a longitudinally extending central zone at least partially located beneath the central zone of the upper part, and side walls extending downwardly from the central zone to a lower edge. The lower part has a hollow interior and comprises a plurality of integrally moulded upright supports extending downwardly from the inner support surface.

[0011] The pulp fibre shoe inner support is light weight and cheap to manufacture. The inner support may be inserted into the shoe prior to shipping without adding any significant weight to the product, thereby limiting any additional shipping costs. The ability to insert the inner support prior to shipping allows the inner support to be inserted in a controlled environment by trained staff, rather than relying on personnel at the retail store to inert the inner support. Correct insertion and alignment of the support within the shoe ensures proper registration of the shoe and avoids defects during printing. In addition, the pulp fibre inner support is recyclable and may therefore be utilised as a single use commodity. The is beneficial as it avoids the risk of any ink applied to the inner support during printing being transferred to another shoe during secondary use.

[0012] The use of pulp fibre, and the associated advantages, are permitted by the two-layer construction. The continuous upper part provides support to the shoe upper and the absence of voids in the upper part ensures continues support and prevents the collapse of sections of the upper, which would result in misalignment during printing. The underlying lower part is formed having rigid uprights that support the continuous upper part.

[0013] The pulp fibre inner support is additionally beneficial due to the thermally insulating properties of pulp fibre. HDMF printing operates most effectively when the shoe can be heated rapidly. The use of a shoe last material such as wood, metal or polymer creates a heat sink beneath the shoe upper that increases the time the upper takes to reach the required temperature. As well as impairing printing this increases cycle time. Pulp fibre does not readily absorb heat, ensuring a quick cycle time and optimised printing.

[0014] The upright supports of the lower part preferably extend downwardly to a height level with the lower edge of the lower part. That is to say, the uprights extend to the base of the lower part. As such, the uprights directly bear the applied forces with minimal force being transferred through the side walls.

[0015] The central zone of the lower part preferably has a continuous surface. This provides continuous support to the overlying region of the shoe upper most prone to collapse under vacuum pressure.

[0016] The plurality of integrally moulded upright supports preferably comprises a first series of longitudinally spaced upright supports arranged at a first side of the central zone of the lower part and a second series of longitudinally spaced upright supports arranged at a second side of the central zone of the lower part. This provides balanced support along the inner support while ensuring that no recesses are located at the central zone of the lower part.

[0017] The upright supports preferably comprise integrally moulded recesses formed in the lower support surface and extending into the hollow interior of the lower part. The recesses, or cavities form protruding ridges within the interior, providing a reinforced structure while also maintaining a constant wall thickness.

[0018] Each upright support may include a pair of longitudinally facing side walls, a transversely facing side wall and a base that is coplanar with the lower edge of the lower part. One side wall faces forwardly while the other faces rearwardly, the walls extending in a lateral direction into the interior. The lateral facing wall extends in a longitudinal and vertical plane.

[0019] The upper part and lower part preferably each include an upstanding rear wall that provides vertical support at the rear end of the inner support.

[0020] Preferably at least part of the inner support surface is bonded to the outer support surface forming a unitary construction and increasing rigidity of the component.

[0021] The pulp fibre shoe support may further include a heel support comprising a single piece, moulded fibre outer part comprising a continuous outer support surface, the outer part having a hollow interior; and a single piece, moulded fibre inner part corresponding in shape to and nested within the hollow interior of the outer part, the lower part comprising an inner support surface located beneath and arranged to support the outer support surface of the outer part, the inner support surface including a plurality of integrally moulded support elements that in use are longitudinally extending relative to the length of the shoe. The inner support is configured to be received in the front part of the shoe and the heel support is configured to be received behind the inner support in the heel section of the shoe, in longitudinal abutment with the inner support. Together, the inner support and heel support substantially fill the and support the shoe over its s entire inner surface.

[0022] The outer support surface of the heel support preferably forms a curved rear wall and has a front edge. The inner support has a forwardly angled rear wall, and the front edge of the heel support is forwardly angled and configured to seat against the rear wall of the inner support. The front edge is thereby able to engage the rear edge of the inner support to longitudinally brace the shoe.

[0023] In another aspect of the invention there is provided a pulp fibre base support for a shoe comprising a moulded fibre base support including a base; and an upstanding side wall extending from the base, the base and the side wall defining a recess for receiving the sole of a shoe. The side wall is configured to abut and restrain the sole of the shoe and has an upper edge having profile shaped to correspond to the upper edge of a masking region on shoe, such that the side wall masks said masking region when in engagement with the shoe.

[0024] Preferably the side wall is a single thickness wall.

[0025] Preferably and at least part of the side wall is able to flex inwardly from a receiving position in which the upper edge is spaced from the shoe to a masking position in which the upper edge is in engagement with the shoe to mask the masking region. A rigid wall would require a high tolerance to ensure a close fit between the shoe and the side wall. By forming the side wall such that it is inwardly flexible, the shoe is able to be readily inserted into the base, and the side wall is then pulled inwardly by the flexible membrane into close masking engagement with the shoe.

[0026] The side wall preferably includes a rear section that receives the heel of the shoe, the rear section having an inner surface and an integrally moulded support element located at the inner surface. In use a gap is defined between at least part of the inner surface of the rear section, which may be an upper part, and the rear part of the shoe.

The base support further includes a removable masking insert configured to bridge said gap. The masking insert comprising an outer wall that abuts a region of the inner surface of the rear section of the side wall, an inner wall that in use abuts the rear part of the shoe to mask said rear part, and a base that is arranged to seat on the support element of the rear section, the inner wall being shaped to mask a rear masking region of the shoe when seated on the support element.

[0027] The rear section of the side wall preferably includes a lower part and an upper part that is stepped outwardly from the lower part, said step defining the support element. Preferably the outward step between the lower and upper part defines a horizontal support shelf on which the masking insert is seated in use. The inwardly stepped lower part is engaged by a portion of the heel of the shoe.

[0028] The inner wall and outer wall of the masking insert are spaced from each other along their lengths and connected by the base, and the masking element includes integrally moulded reinforcement members spanning the gap between the spaced inner wall and outer wall.

[0029] The base of the base support includes one or more locating features to locate the base section on a printing apparatus. The one or more locating features may comprise one or more apertures or recesses formed in the base to receive corresponding locating features of a printing apparatus. This enables the base to be accurately registered within eth heating chamber.

[0030] In another aspect of the invention there is provided a pulp fibre support assembly for supporting a shoe during a vacuum printing process. The support apparatus comprises an inner support as described above configured to be received within a shoe to maintain the shape of the shoe during printing; and a base support as described above configured to receive and support a shoe and mask a masking region of the shoe during printing. The inner support and base cooperate to ensure the shoe in internally and externally supported and registered, and the base also advantageously performs a masking function.

[0031] In another aspect of the invention there is provided a method of printing onto a shoe. The method comprises printing an image onto a first surface of a flexible carrier membrane; mounting the flexible carrier membrane within a heating chamber; placing the shoe within a base support, said base support including a base and at least one upstanding side wall extending from the base; locating the base on a support surface within the heating chamber; heating the carrier membrane; moving the shoe relative to the carrier membrane to bring the shoe into contact with the first surface of the carrier membrane such that the shoe is in registration with the printed image; applying a vacuum to draw the carrier membrane into a wrapped contact with the shoe and the support base; and applying infra-red radiation to the carrier membrane and the shoe when the membrane is wrapped around the shoe to heat the membrane and underlying surface of the shoe over to cause the printed image to diffuse into the surface of the shoe. The carrier membrane urges the upstanding wall into contact with the shoe and at least a portion of said upstanding defines a masking element that masks an underlying masking region of the shoe to prevent the transfer of the printed image to the masking region.

[0032] The inner support preferably includes a front support section and a heel support section and the method includes inserting the front support section into a front section of the shoe and then inserting the heel support section into the heel section of the shoe.

[0033] The base support preferably includes one or more first locating features and the support surface of the heating chamber includes one or more corresponding second locating elements configured to mate with the locating features of the base support, and the step of the locating the base support on the support surface comprises mating the first and second locating elements to register the base support on the support surface.

[0034] The method preferably comprises inserting a moulded fibre inner support within a shoe as described above.

s [0035] The base support is a base support formed from moulded pulp fibre as described above.

BRIEF DESCRIPTION OF THE DRAWINGS

[0036] The present invention will now be described by way of example only with reference to the following illustrative figures in which: Figure 1 shows a show support assembly according to an embodiment of the invention; Figure 2 is an exploded view of an inner shoe support according to an embodiment of the invention; Figure 3 is a side wireframe view of the inner shoe support of Figure 2; Figure 4 is an exploded view of a heel support according to an embodiment of the invention; Figure 5 is an illustrative view of a shoe with a masking region; Figure 6 shows the shoe of Figure 5 received within a base support according to an embodiment of the invention; Figure 7 shows a base support and masking insert according to an embodiment of the invention; Figure 8 is a view from above of the base support and masking insert of Figure 7; and Figure 9 shows a base support according to an embodiment of the invention retaining a shoe received and including a masking insert at the rear of the shoe.

DESCRIPTION OF EMBODIMENTS

[0037] The following description presents exemplary embodiments and, together with the drawings, serves to explain principles of the invention. The scope of the invention is not intended to be limited to the precise details of the embodiments or exact adherence with all method steps. Variations will be apparent to a skilled person and are deemed also to be covered by the description. Terms for features used herein should be given a broad interpretation that also encompasses equivalent functions and features. In some cases, several alternative terms (synonyms) for structural features have been provided but such terms are not intended to be exhaustive.

[0038] Descriptive terms should also be given the broadest possible interpretation; e.g. the term "comprising" as used in this specification means "consisting at least in part of" such that interpreting each statement in this specification that includes the term "comprising", features other than that or those prefaced by the term may also be present. Related terms such as "comprise" and "comprises" are to be interpreted in the same manner. Directional terms such as "vertical", "horizontal", "up", "down", "upper", "lower", "longitudinal" and "transverse" are relative terms that may be used for convenience of explanation usually with reference to the illustrations and are not intended to be ultimately limiting if an equivalent function can be achieved with an alternative dimension and/or direction.

[0039] The description herein refers to embodiments with particular combinations of configuration steps or features. However, it is envisaged that further combinations and cross-combinations of compatible steps or features between embodiments will be possible. The description of multiple features in relation to any specific embodiment is not an indication that such features are inextricably linked, and isolated features may function independently as an invention from other features and not necessarily require implementation as a complete combination.

[0040] Referring to Figure 1, a shoe support 1 comprises an inner support 2 and a base section 4 formed of moulded pulp fibre. The inner support 2 is sized and shaped to be inserted within a shoe to support the shoe during vacuum printing. The inner support 2 includes a front section 6 and a rear section 8. The base section 4 is an external support configured to receive and support the shoe. The base section 4 is also configured to mask sections of the shoe during printing, as will be described in further detail.

[0041] The front section 6 of the inner support 2 comprises an upper part 10 and a lower part 12 formed of moulded pulp fibre, which are shown in an exploded view in Figure 2. The upper part 10 and lower part 12 are bonded together to form the front section 6. The upper part 10 has solid upper support surface 14 that has a curved, contoured shape that conforms to the internal shape of the front part of the shoe upper.

The upper support surface 14 has upper wall section 16 and side wall sections 18. The upper part 10 further includes an upstanding rear wall 20. The upper part 10 is formed as a single-walled, hollow object with an inner surface 22, an open base section 44 and a lower peripheral edge 26.

[0042] The lower part 12 of the front section 6 of the inner support 2 comprises an upper support surface 28 that has a curved, contoured shape that conforms to the inner surface of upper part 10 such that the lower part 12 nests in a close tolerance fit within the upper part 10. The upper support surface 28 has an upper wall section 29 and side wall sections 30. The lower part 12 further includes an upstanding rear wall 32. The lower part 12 is formed as a substantially hollow object with an open base 34 and a lower peripheral edge 36. The upper wall section 29 is solid and extends longitudinally along the length of the uppermost part of the upper support surface 26.

[0043] The lower part 12 includes a plurality of upright supports 38 formed along each side wall section 30. The upright supports 38 are formed by a plurality of moulded recesses or channels 40 extending inwardly into the lower part 12 defining internal ridges or pillars. Each recess 40 has first and second longitudinally spaced side walls 42 facing forwardly and rearwardly in the longitudinal direction respectively. Each recess further includes a transversely facing inner side wall 44 interconnecting the forward and rearward side walls 42, and a base 46. The base 46 is co-planar with the lower peripheral edge 36. The side walls 42,44 extend from the base 46 to the upper support surface 28. The inner wall 44 is substantially vertically oriented.

[0044] As shown in Figure 3, the longitudinal side walls 42 are angled outwardly away from the base 46. The base 46 is relatively narrow, and the side walls 42 are angled outwardly away from each other in the direction of the upper support surface 28. The side walls 42 are angled outwardly and extend to an opening 48 that is wider than the base. The rear wall 32 is angled forwardly in the longitudinal direction, with an angle between the rear wall 32 and the lower edge 36 of less than 90 degrees. Similarly, the side walls 42 are formed such that they are angled at less than 90 degrees to the base plane defined by the lower edge 36 at all points along their curved surface. This creates a negative draft during the moulding process, ensuring easy removal of the lower part from the mould.

[0045] The upright supports 38 are spaced at substantially regular intervals along the side walls 30 in the longitudinal direction. The upright supports of the first side wall 30 are longitudinally offset from the upright supports of the second side wall 30. The side walls 42,44 of the upright supports 38 extend to the height of the upper wall section 29. The inner side walls 44 of the first and second sides 30 are transversely spaced at either side of the upper support wall 29. Locating the upright supports 38 to the side of the upper support wall 29 ensures that the upper support wall 29 of the upper support surface 28 is continuous, with no recesses or channels, enabling it to provide a continuous support to the upper support surface 14 of the upper part 10.

[0046] The upper part 10 and lower part 12 are moulded as separate components. Each is moulded with a flange portion extending from the lower peripheral edge 26,36.

Following moulding, the dried pulp parts 10,12 are assembled by applying a adhesive to the upper support surface 28 of the lower part and/or the inner surface 22 of the upper part 10. The lower part 12 is inserted into the upper part 10 and the two parts 10,12 are pressed together. The flanges sections of the upper and lower parts 10,12 are then removed in a trimming operation.

[0047] The continuous solid upper support surface 14 of the upper part in use supports the entire inner surface area of section of the fabric upper of the show within which it received. However, the single skin pulp upper part 10 would not have sufficient strength to support the shoe when the vacuum is applied during printing. The lower part 12 supports the upper part 10 and prevents compaction and deformation of the upper part 10 when it is compressed by the membrane under vacuum. The side walls 42,44 of the upright supports 38 provide vertical bracing to withstand downward compression applied through the top of the shoe. In addition, the base 46 of each upright support 38 provides lateral reinforcement and withstands compression applied to the sides of the shoe. The region of the shoe that experiences the greatest compression force and is most liable to be compressed is the uppermost surface of the shoe. The solid surface of the upper support surface 28 of the lower part 12 provides continuous support to the upper part 10 along this region. The recesses 40 formed by the upright supports 38 are spaced to the side of this region. Ensuring that no voids are located between the uppermost region of the shoe mitigates the risk of the upper part of the show compressing and caving inwards. At the same time, the upright support members 38 provide rigid, non-compressible support in the vertical direction to the outer parts of the upper surface of the shoe, extending to the curved sides.

[0048] The inner support 2 is formed as a two-piece component, having a front section 6 and a rear section 8 to enable the inner support to be easily inserted into a shoe. For other applications, for example open backed shoes, the inner support may be formed as a single-piece component. The front section 6 is inserted into the front part of the shoe from the rear, leaving a void at the rear heel section of the shoe once inserted. The rear section 8 is configured to fill the void at the heel section when the front section is in position. The rear section 8, as shown in Figure 4, has an open front face SO that is forwardly angled at an angled corresponding to the angle of the rear wall 32 of the front section 6. The closed rear wall 52 of the rear section 8 has a curved configuration Lo corresponding to the curved inner surface of the shoe.

[0049] The rear section 8 is formed of an inner part 54 and an outer part 56. As with the upper and lower parts 10,12 of the front section 6, the inner and outer parts 54,56 are configured to nest with a closely toleranced fit. The inner part 54 comprises a series of longitudinal recesses 58 formed in the rear wall extending rearwardly from the front face towards the rear end. The recesses 58 form internal reinforcement ridges that longitudinally brace and support the rear section 8 to resist forwardly directed compression from the rear of the shoe in the longitudinal direction. The outer part 56 of the rear section 8 is substantially the same shape as the inner part 54 but with a continuous outer surface and no support ridges. The inner and outer parts 54,56 and separately moulded and subsequently bonded together using a suitable adhesive and trimmed to finish.

[0050] Referring to Figure 5, a shoe 60 includes a sole 62 and a fabric upper 64. The region A is the area of the fabric upper that is to receive the printed ink. The region B is the area of sole that is not to be printed to. Line 66 represents the upper edge of the sole 62 and the lower boundary of the printed region A. During printing the ink is not to be transferred to the shoe 60 below the upper edge 66 of the sole 62. The base section 4, as shown in Figure 6, supports the shoe 60 during the printing process and also performs a masking function to mask the sole 62. The base section 4 is a moulded pulp object comprising a base 68 and an upstanding side wall 70 extending from the base 68. The side wall 70 has an upper edge 72. The shape and height of the side wall 70 conforms to the shape and height of the upper edge 66 of the sole such that the upper edge 72 of the side wall 70 aligns with the upper edge 66 of the sole 62. At the rear end 71 of the base section 4 the side wall 70 includes an upper part 73 and a lower part 75. The upper part 73 is stepped outwardly of the lower part 75, defining a horizontally extending support shelf 77.

[0051] The side wall 70 is a single wall that is configured to flex inwardly into contact with the shoe 60 under pressure from the flexible membrane when the vacuum is applied to the membrane during printing. The shoe 60 is positioned within the base section 4 such that the side wall 70 contacts the sole 62 with the upper edge 72 of the side wall in exact registration with the upper edge 66 of the sole 62 to mask the sole 62 during printing. To ensure a highly toleranced finish along the upper edge 66 of the sole 62 masking tape may be applied along the upper edge 66 of the sole 62 to ensure a clean and exact masking line along the upper edge 66. The remaining area of the sole is masked by the side wall 70 of the base section 4.

[0052] The sole 62 has a rearmost edge 74 and the upper edge 66 of the sole 62 has a rearmost edge 76. The side wall 70 has a rear end 78 with an inner surface 80. The rear end 78 of the side wall 70 is upstanding and angled outwardly to ensure a negative draft.

The rearmost edge 74 of the sole 62 projects rearwardly of the rearmost edge 76 of the upper edge 66 and abuts the inner surface 80 of the rear end 78 of the side wall 70. As a result, a gap 82 is defined between the rearmost edge 76 of the upper edge 66 of the sole 62 and the inner surface 80 of the rear end 78 of the side wall 70. Therefore, at the rear of the shoe 60 the upper edge 66 of the sole 62 is not in contact with and is therefore not masked by the side wall 70. It is not possible to form the rear end 78 of the side wall 70 to extend forwardly to bridge the gap 82 as this would create a positive draft and prevent the base section 4 from being removed from the mould.

[0053] As shown in Figure 7 a masking insert 84 is provided that is configured to fill the gap 82 and mask the sole 62 at the rear part of the shoe 60. The masking insert 84 has an arcuate shape when viewed from above. The masking insert 84 includes an inner wall 86, an outer wall 88 that is spaced rearwardly of the inner wall 86, an upper edge 90 and a lower edge 92. The arcuate shape of the outer wall 88 corresponds to the shape of the inner surface of the inner surface of the rear end 78 of the side wall 70. The arcuate shape of the inner wall 68 corresponds to the shape of the rear part of the shoe 60.

[0054] Referring to Figure 8, the base section 4 includes a plurality of locating apertures 94 located in the base 68. The locating apertures 94 include an elongate central slot 96 extending longitudinally along the base 68, a pair of circular apertures 98 located at opposing ends of the central slot 94 and transversely extending elongate slots 100 io located elongationally outwardly of the circular apertures 98 at respective ends. The locating apertures 94 correspond in shape and relative location to locating bosses arranged on the surface of the support plate of the printing device. The locating apertures 94 are arranged to receive the locating bosses to precisely locate and register the base 2 relative to the support surface. This enables the shoe 60 to be precisely registered is relative to the flexible membrane.

[0055] In use the inner support 2 is inserted into the shoe 60 by first inserting the front section 8 into the front part of the shoe 60, followed by the rear part 8. The shoe 60 is box and shipped with the inner support 2 within the shoe 60. The upper edge 66 of the sole 62 is also masked prior to boxing and shipping. The shoe 60 may be inserted into the base 4 prior to shipping, or the base 4 may be shipped with the shoe 60 for assembly and use at the printing location.

[0056] At the printing location, which may for example be a warehouse, distribution centre or retail outlet, the shoe 60 is inserted into the base section 4 as shown in Figure 9, with the sole 60 contacting the side wall 70 about its periphery to register the shoe 60 within the base. Pre-insertion the inner support 2 within the shoe 60 obviates the requirement for the operative to do so at the printing location. Correct insertion of the inner support 2 within the shoe 60 is important to ensure that the shoe is properly supported during printing. Failure to insert the inner support 2 correctly can result in compression and misregistration of the shoe 60 beneath the membrane during printing. The use of a hollow pulp inner support 2 advantageously reduces the weight and cost of the inner support 2, making it economically viable to ship an inner support 2 with every shoe 2. It also enables the inner support 2 to be dispose of and recycled following use, rather than having to be laboriously cleaned to remove ink deposits before the subsequent printing cycle. Similarly, the use of a pulp material for the base 4 enables a base 4 to be shipped with each shoe 60 and to be disposed of following use in an economical manner.

[0057] When the shoe 60 is located within the base section 4 the masking insert 84 is inserted into the gap 82. The inner wall 86 and outer wall 8 taper away from each other in an upward direction such that the masking insert 84 has a wedge configuration. The spacing between the inner and outer wall also tapers inwardly from the rear to the front of the masking insert 84, corresponding to the narrowing of the gap 82 between the shoe 60 and the side wall 70. As the masking insert 84 is pushed into the gap 82 the wedge configuration causes the inner wall to compress rearwardly, ensuring it is biased against the rear part of the shoe 60. The lower edge 92 of the masking insert 84 seats on the support shelf 77 at the rear of the base section 4.

[0058] The base 4 containing the shoe 60 is located onto a support plate or jig of the printing device by arranging the locating apertures 94 onto the corresponding locating bosses. The shoe, supported within the base 4, is located beneath the ink coated film.

Infrared heat is applied to soften the film. The support plate carrying the shoe 60 is then moved relative to the membrane to bring the shoe into contact with the softened film, either by raising the support plate or lowering the membrane.

[0059] A vacuum is applied that draws the film down against the shoe 60. The softened film wraps the shoe 60 and the sides of the base 4. The film, under the action of the vacuum, pulls the side wall 70 into engagement with the sole 62 holding it tight against the surface of the shoe 60. The front section 6 of the inner support 2 supports and retains the shape of the shoe upper as the shoe 60 is compressed vertically and laterally the film.

The continuous surface of the upper part 10 avoid depressions forming in the shoe upper.

This is assisted by the continuous upper support surface 28 at the central zone of the lower part 12, which reinforces the central zone of the upper part across its entire surface. Further and more robust support is provided by the underlying support uprights 38 that vertically and laterally brace the front section 6 of the inner support 2. The heel support 8 fills the heel section and prevents compression of the heel in the longitudinal S and lateral directions.

[0060] The ink from the heated film transfers to the areas of the shoe 60 in contact with the film. The side wall 70 masks and the masking insert 84 mask the masking region of the shoe 60, which is typically the sole 62, preventing the transfer of ink to the underlying masking region. Following use, the shoe 60 is removed from the base 4, the inner support 2 is then removed, and both the inner support 2 and base 4 are disposed of.

Claims (22)

1. CLAIMS1. A pulp fibre shoe support assembly comprising: an inner support including: a single piece, moulded fibre upper part shaped to be received within a shoe, the upper part comprising a continuous outer support surface including a longitudinally extending central zone and side walls extending downwardly from the central zone, the upper part having a hollow interior; a single piece, moulded fibre lower part corresponding in shape to and nested within the hollow interior of the upper part, the lower part comprising an inner support surface located beneath and arranged to support the outer support surface of the upper part, the inner support surface including a longitudinally extending central zone at least partially located beneath the central zone of the upper part, and side walls extending downwardly from the central zone to a lower edge; wherein the lower part has a hollow interior and comprises a plurality of integrally moulded upright supports extending downwardly from the inner support surface.
2. 2. A pulp fibre shoe support according to claim 1 wherein the upright supports extend downwardly to a height level with the lower edge of the lower part
3. 3. A pulp fibre shoe support according to claim 1 or 2 wherein the central zone of the lower part has a continuous surface.
4. 4. A pulp fibre shoe support according to any preceding claim wherein the plurality of integrally moulded upright supports comprises a first series of longitudinally spaced upright supports arranged at a first side of the central zone of the lower part and a second series of longitudinally spaced upright supports arranged at a second side of the central zone of the lower part.
5. 5. A pulp fibre shoe support according to claim 4 wherein the upright supports comprise integrally moulded recesses formed in the lower support surface and extending into the hollow interior of the lower part.
6. 6. A pulp fibre shoe support according to claim 5 wherein each upright support includes a pair of longitudinally facing side walls, a transversely facing side wall and a base that is coplanar with the lower edge of the lower part.
7. 7. A pulp fibre shoe support according to any preceding claim wherein the upper part and lower part each include an upstanding rear wall.
8. 8. A pulp fibre shoe support according to any preceding claim wherein at least part of the inner support surface is bonded to the outer support surface.
9. 9. A pulp fibre shoe support according to any preceding claim further comprising a heel support including: a single piece, moulded fibre outer part comprising a continuous outer support surface, the outer part having a hollow interior; a single piece, moulded fibre inner part corresponding in shape to and nested within the hollow interior of the outer part, the lower part comprising an inner support surface located beneath and arranged to support the outer support surface of the outer part, the inner support surface including a plurality of integrally moulded support elements that in use are longitudinally extending relative to the length of the shoe; wherein the inner support is configured to be received in the front part of the shoe and the heel support is configured to be received behind the inner support in the heel section of the shoe.
10. 10. A pulp fibre shoe support according to claim 9 wherein the outer support surface forms a curved rear wall having a front edge, and wherein the inner support has a forwardly angled rear wall, and the front edge of the heel support is forwardly angled and configured to seat against the rear wall of the inner support.
11. 11. A pulp fibre base support for a shoe comprising a moulded fibre base support including: a base; an upstanding side wall extending from the base, the base and the side wall defining a recess for receiving the sole of a shoe; wherein the side wall is configured to abut and laterally restrain the sole of the shoe and has an upper edge having profile shaped to correspond to the upper edge of a masking region on shoe, such that the side wall masks said masking region when in engagement with the shoe.
12. 12. A pulp fibre shoe support according to claim 11 wherein at least part of the side wall is able to flex inwardly from a receiving position in which the upper edge is spaced from the shoe and a masking position in which the upper edge is in engagement with the shoe to mask the masking region.
13. 13. A pulp fibre shoe support according to claim 12 wherein the side wall includes a rear section that receives the heel of the shoe, the rear section having an inner surface and an integrally moulded support element located at the inner surface, and wherein in use a gap is defined between the inner surface of the rear section and the rear part of the shoe and the base support further includes a removable masking insert for bridging said gap, the masking insert comprising an outer wall that abuts the inner surface of the rear section of the side wall, an inner wall that in use abuts the rear part of the shoe, and a base that is arranged to seat on the support element, the inner wall being shaped to mask a rear masking region of the shoe.
14. 14. A pulp fibre shoe support according to claim 13 wherein the rear section of the side wall includes a lower part and an upper part that is stepped outwardly from the lower part, said step defining the support element.
15. 15. A pulp fibre shoe support according to claim 14 wherein the inner wall and outer wall of the masking insert are spaced from each other along their lengths and connected by the base, and the masking element includes integrally moulded reinforcement members spanning the gap between the spaced inner wall and outer wall.
16. 16. A pulp fibre shoe support according to any one of claims 11 to 15 wherein the base of the base support includes one or more locating features to locate the base section on a printing apparatus.
17. 17. A pulp fibre shoe support according to claim 16 wherein the one or more locating features comprises one or more apertures formed in the base to receive corresponding locating features of a printing apparatus.
18. 18. A pulp fibre support assembly for supporting a shoe during a vacuum printing process, the support apparatus comprising: an inner support as defined in any one of claims 1 to 10 configured to be received within a shoe to maintain the shape of the shoe during printing; and a base support as defined in any one of claims 11 to 17 configured to receive and support a shoe and mask a masking region of the shoe during printing.
19. 19. A method of printing onto a shoe, the method comprising: printing an image onto a first surface of a flexible carrier membrane; mounting the flexible carrier membrane within a heating chamber; placing the shoe within a base support, said base support including a base and at least one upstanding side wall extending from the base; locating the base on a support surface within the heating chamber; heating the carrier membrane; moving the shoe relative to the carrier membrane to bring the shoe into contact with the first surface of the carrier membrane such that the shoe is in registration with the printed image; applying a vacuum to draw the carrier membrane into a wrapped contact with the shoe and the support base; and applying infra-red radiation to the carrier membrane and the shoe when the membrane is wrapped around the shoe to heat the membrane and underlying surface of the shoe over to cause the printed image to diffuse into the surface of the shoe; wherein the carrier membrane urges the upstanding wall into contact with the shoe and at least a portion of said upstanding defines a masking element that masks an underlying masking region of the shoe to prevent the transfer of the printed image to the masking region.
20. 20. The method of claim 19 wherein the inner support includes a front support section and a heel support section and the method includes inserting the front support section into a front section of the shoe and then inserting the heel support section into the heel section of the shoe.21. The method of claim 19 or 20 wherein the base support includes one or more first locating features and the support surface of the heating chamber includes one or more corresponding second locating elements configured to mate with the locating features of the base support, and the step of the locating the base support on the support surface comprises mating the first and second locating elements to register the base support on the support surface.
21. 21. The method of any one of claims 18 to 21 further comprising inserting a moulded fibre inner support within a shoe as defined in any one of claims 1 to 10.
22. 22. The method of claim 22 wherein the base support is a base support formed from moulded pulp fibre as defined in any one of claims 11 to 17.