KR102421294B1 - Conforming membrane for manufacturing footwear - Google Patents

Abstract

A low pressure actuation compliant membrane 200 for making an article of footwear includes a perimeter 214 having a thickness 216 , 226 , 248 between 1 and 15 mm defining an outer perimeter 222 of the compliant membrane 200 . . The compliant membrane 200 is also interposed between a first surface 202, 204, 218, 220, 228, 230, 235, 237 and a second surface 202, 204, 218, 220, 228, 230, 235, 237. has a thickness 216 , 226 , 248 of 1 to 4 mm and includes a transition portion 224 extending inside the periphery 222 . The compliant membrane 200 also extends from the transition portion 224 in a direction 236 of the second surface 202 , 204 , 218 , 220 , 228 , 230 , 235 , 237 and includes a receiving cavity 238 . and includes a compliant portion 234 having a thickness 216 , 226 , 248 of 1 to 4 mm. The perimeter 214 , the transition portion 224 and the compliant portion 234 are of a single construction comprising a common material composition.

Description

CONFORMING MEMBRANE FOR MANUFACTURING FOOTWEAR

It relates to a press membrane used for bonding two articles.

Conventionally, articles of footwear may be manufactured by gluing a sole portion and a lasted upper portion. Pressure, temperature and/or time are adjusted to achieve bonding between the sole and the lasted upper. When an adhesive or other bonding material joins the sole and the lasted upper, the application of pressure may be accomplished using a press effective to assist in supplying a compressive force between the sole and the lasted upper.

Aspects herein are contemplated for a compliant membrane for assisting in bonding of a first article to a second article. The compliant membrane includes a perimeter having a thickness of 1 to 15 mm forming an outer perimeter of the compliant membrane. The compliant membrane also includes a transition portion having a thickness of 1 to 4 mm between the first and second surfaces. The transition portion extends within the perimeter defined by the perimeter. The compliant membrane also includes a compliant portion extending upwardly from the transition portion in the direction of the second surface and defining a receiving cavity. The compliant portion has a thickness of 1 to 4 mm. The perimeter, the transition, and the compliant portion are of a single construction comprising a common material composition.

This summary is provided to provide an understanding of the scope of the methods and systems given in detail hereinafter, but not to limit them.

The present invention will be described in detail with reference to the accompanying drawings.
1 depicts a press with a compliant membrane, in accordance with an aspect of the present invention.
2 depicts the press of FIG. 1 in a closed and fixed configuration, in accordance with aspects of the present invention.
3 is a cross-sectional view of the press taken along line 3-3 of FIG. 2, in accordance with an aspect of the present invention;
4 is a perspective view of a compliant membrane in accordance with an aspect of the present invention.
5 is a side view of the compliant membrane of FIG. 4 in accordance with aspects of the present invention;
6 is a front view of the compliant membrane of FIG. 4 in accordance with an aspect of the present invention.
7 is a top view of the compliant membrane of FIG. 4 in accordance with an aspect of the present invention.
8 is a cross-sectional view of the compliant membrane taken along line 8-8 of FIG. 4, in accordance with an aspect of the present invention.
9 is a flow diagram illustrating an exemplary method of making an article of footwear with a compliant membrane, in accordance with aspects of the present invention.

Usually, the manufacture of footwear such as athletic shoes is performed by joining different parts. For example, an upper of footwear is a portion of an article of footwear that extends around a wearer's foot to secure the article of footwear to the wearer. The upper may be formed of a variety of materials such as leather, film, fabric, printed matter, and the like. In some examples, the upper is a portion of footwear that includes a securing structure, such as a lacing opening for a lace, an ankle opening to allow removal of a wearer's foot, and other structures. The shape of the upper is determined in part when the upper is coupled to another portion. In some manufacturing scenarios, cobblers last, referred to as “lasts,” are inserted into the upper (or the upper is formed around the last) so that the upper takes on the shape of the last. When the upper is disposed on or otherwise formed around the last, the combination is commonly referred to as a "lasted upper." A lasted upper is an upper with a last that provides support and dimensional guidance for the upper during the manufacturing process. As additional parts/components are joined with the lasted upper, the shape of the upper becomes more solid, such that, once the last is removed, its dimensional shape is maintained or at least influenced by the last.

Another common component of articles of footwear is the sole. The sole may be referred to as a “floor unit” in some examples. The sole may be a set of a plurality of components, such as an outsole, a midsole, and/or an insole. Additional components may be incorporated, such as cushioning elements (eg, springs), stabilizing elements (eg, torsion bars), etc. that combine to form the sole. The sole is the portion that extends between the upper and the ground below which the footwear wearer typically travels.

The sole may be formed from a variety of materials. For example, the sole may be formed of leather, felt, fabric, and/or a polymer-based material (eg, natural or synthetic). Different portions of the sole may be formed of different materials. For example, the outsole (eg, the ground contacting portion) may be formed of rubber (eg, synthetic or natural) and the midsole may be formed of a foamed polymer (eg, ethylene-vinyl acetate (EVA), polyurethane (PU)). can As will be discussed below, the compliant membrane may be adapted to assist in bonding the upper and the sole comprised of a foam material such as EVA or PU. Other foams 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 usually associated with the sole. In some examples, the upper and the sole are joined through a stitching operation. In another example, the upper is coupled to the sole through a bonding process. The bonding process may be accomplished by welding, fusing and/or adhesive bonding. In an exemplary aspect, an adhesive material (eg, liquid, paste, 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 activated or active to cause bonding (eg, mechanical bonding and/or chemical bonding) between the upper and the sole. The engagement may be improved through application of pressure, such as applying a force to the sole through the upper and/or applying a force to the upper through the sole. In addition to pressure, it is contemplated that thermal energy (eg, heat) may be applied to the upper and/or the sole to assist in engagement of the upper and the sole. It is also contemplated that providing a predetermined amount of time to apply thermal energy and/or pressure to the upper and/or sole helps achieve engagement between the upper and the sole. As discussed below, the compliant membrane is effective to provide sufficient pressure in the intended location to assist in bonding the upper to the sole, such as through the use of an adhesive or other bonding material.

However, in some conventional bonding techniques, when applied to bonding a lasted upper with a compressible sole element (eg, EVA, PU, or other foamed polymer-based material), the application of pressure during the bonding process causes the compressible sole It causes permanent and unintended deformation of the sole and thus deforms the compressible sole into an unintended shape when engaged with the upper. In other words, a conventional press without a compliant membrane as provided herein may cause deformation of the sole portion, which deformation is maintained, at least in part, after engagement of the modified sole with the upper. As noted above, the construction of an article of footwear may rely on the continuous lamination and bonding of materials and parts to maintain the shape of the upper as defined by the last once the last is removed after bonding has occurred. However, when the lasted upper is joined with a deformed sole by a conventional press, once the last is removed after joining the sole and the upper, the sole returns to its original undeformed form (completely or partially) can be returned. As the sole returns to its pre-deformation shape after engagement with the upper, deformation of the upper with respect to the shape of the upper as determined by the last may be caused. Thus, conventional presses that apply pressure to the sole to assist in bonding of the sole and the upper may cause deformation of the sole during the press operation, resulting in unintentional deformation of the sole and/or upper after the pressing operation. Deformation may occur.

It is understood that different sole materials may be more susceptible to unintentional permanent deformation. As a result, conventional presses may produce acceptable results for some footwear material combinations. However, as materials advance and a greater number of materials (eg, foamed polymers) are utilized in the components forming the article of footwear, advancements in the press allow for the incorporation of these materials into articles of footwear. For example, when joining a sole and a lasted upper using a conventional press, the sole formed from certain materials creates an unsatisfactory bond (eg, bond gap). If the application of pressure from a conventional press lasts a predetermined time (eg, 30 seconds, 25 seconds), the material deforms and causes insufficient bonding. In addition, a reduced force can be applied to compensate for the non-conforming nature of conventional presses. However, a decrease in force (or time) may lead to insufficient bonding (eg, incomplete bonding). In addition, conventional presses apparently deform one or more portions (eg, foam soles) when a force is applied linearly through the press, as opposed to the enveloping manner achieved by aspects of the compliant membrane provided herein. can do it

As such, aspects provided herein relate to a compliant membrane for assisting in bonding a first article to a second article. The compliant membrane is formed to enclose the lasted upper and the sole with a compressive force perpendicular to various surfaces (eg, sole ground contact surface, sole sidewall, upper inner portion, upper outer portion, upper heel end, upper toe box), and the lasted upper to enclose the sole. and a membrane that conforms to the sole. This multidirectional compressive force provided by the compliant membrane secures the sole and the lasted upper during the bonding/bonding process without deforming the foam material such as the sole. This is in contrast to conventional presses, which do not sufficiently conform around the lasted upper and the sole and/or rely on higher pressures to cause conformability of the press material. Instead, conventional presses concentrate pressure through the sole in a more linear manner, as opposed to the multidirectional compressive force provided by a compliant membrane. Additionally, conventional presses that may have a “compliant” membrane may only be “compliant” when under significantly higher pressures than those provided in connection with aspects herein.

The compliant membrane includes a perimeter having a thickness of 1 to 15 mm defining its periphery. In some embodiments, the perimeter has a thickness of 5 to 15 mm, 8 to 12 mm, or in other instances about 10 mm. The compliant membrane also includes a transition having a thickness of 1 to 4 mm between the first surface and the second surface. The transition portion extends within the perimeter defined by the perimeter. The compliant membrane also includes a compliant portion extending from the transition portion in the direction of the second surface and defining a receiving cavity. The compliant portion has a thickness of 1 to 4 mm. The perimeter, the compliant portion and the transition portion may have the same thickness or different thicknesses. The compliant portion and the transition portion may have the same thickness or different thicknesses. The perimeter, transition and compliant portions are of a single construction comprising a common material composition.

Aspects also provide for the manufacture of an article of footwear such that a method of making an article of footwear using a compliant membrane for joining a footwear sole and a footwear upper comprises positioning the footwear upper on a securing element (eg, a press support). Consider implementing a compliant membrane on The method includes closing the compliant membrane over the footwear upper and the footwear sole on the securing element. In this example, a first surface of the compliant membrane contacts the footwear sole and the footwear upper. The compliant membrane may be the compliant membrane of the preceding paragraph or any derivative provided herein. The method continues to reduce the pressure differential after a predetermined period of time (eg, greater than 25 seconds, greater than 30 seconds, greater than 35 seconds). In an exemplary embodiment, the pressure difference may be 0.5 to 3.9 bar (ie, 50 kilopascals to 390 kilopascals).

The compliant membrane and contemplated method of use provide a tool for engaging the upper and sole with reduced deformation of the upper and/or sole compared to a conventional press (eg, a membrane press). In some examples, properties of the compliant membrane, such as thickness and material composition, can affect multiple surfaces (eg, toe box, heel counter, inner upper, upper outer, sole) while joining the upper and the sole at lower pressures. to apply pressure (and in some instances heat) across the transition from the to the upper (eg, the biteline), the sidewall of the sole], allowing the membrane to conform around the sole and upper skin . This results in a more linear extension linearly through the sole and/or upper (as opposed to ambient from multiple directions) at higher pressures (eg, 4 bar or higher) causing deformation of the sole and/or upper during the press operation. This is contrary to the thick or different material composition of conventional press membranes that apply force.

Referring generally to the drawings and specifically to FIG. 1 , there is shown a press 100 having a sole 250 and a lasted upper 252 secured to a fastening element 102 as a press 100 according to this aspect. . At a high level, the press 100 is adapted to hold the upper and sole in relative positions relative to each other while engaged. For example, an adhesive may be applied (eg, sprayed, coated, rolled, laminated, printed) to the sole, upper, or combination of sole and upper. It is also contemplated that upper 252 and/or sole 250 may be formed from one or more materials (eg, hot-melt adhesives, meltable polymers) that bond to other components under pressure and/or heating. The sole 250 and upper 252 then have pressure applied by the compliant membrane 200 received within the membrane container 116 (eg, lid). As the membrane container 116 is positioned over the sole 250 and upper 252 , the combination of components is at least partially received within the receiving cavity 238 of the compliant membrane 200 . The receiving cavity is such that, during a press operation, the various surfaces of the footwear formed (eg, inner, outer, toe box at toe end 254, heel counter at heel end 256, bite line) are formed by the compliant membrane 200 . is an intentional deformation (eg, molded or otherwise formed) from the planar configuration of the compliant membrane 200 to allow it to be contacted by The membrane vessel 116 may be secured to the press 100 in a closed operating configuration by a membrane retainer 114 , such as a releasable latching mechanism. Membrane retainer 114 is effective to retain membrane container 116 and associated compliant membrane 200 in position relative to the article of footwear to which pressure is applied.

With respect to pressure, it is contemplated that pressure may be applied by press 100 to sole 250 and upper 252 in one or more ways. For example, the stationary element 102 may be effective in applying a linear force via a pneumatic cylinder, linear actuator, or the like. This linear force is transmitted through the last 120 (best shown in FIG. 3 ) to the upper 252 and the sole 250 , where the resistance to the linear force is the upper 252 and/or the sole 250 . ) is met by a compliant membrane 200 in contact with Additionally or alternatively, it is contemplated that the securing element 102 is effective in adjusting the position of the upper 252 and the sole 250 within the receiving cavity 238 . For example, the securing element 102 may raise or lower the footwear component based on an intended pressure, component size, component shape, etc. (relative to the vertical position of the press 100 of FIG. 1 as shown). have. In some aspects, the fixation element 102 may be static and immovable.

Pressure may alternatively or additionally be generated by press 100 through pressurization of compliant membrane 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 membrane vessel 116 and the compliant membrane 200 . The increased pressure creates a pressure differential on both surfaces of the compliant membrane 200 . The pressure differential causes the compliant membrane 200 to conform around the upper 252 and the sole 250 as the compliant membrane 200 deforms under the pressure differential. This deformation causes the compliant membrane 200 to wrap around a portion of the upper 252 and the sole 250, creating pressure to hold the upper 252 and the sole 250 in a fixed relative position during the mating operation. Depending on the pressure difference, sufficient pressure may be applied to upper 252 and sole 250 to assist bonding of these components (eg, bonding through adhesive curing). Exemplary pressure differentials include from 0.5 bar to 3.9 bar relative to ambient pressure. Above 3.9 bar, in exemplary embodiments, the compliant membrane may mechanically break after numerous press cycles, or the article being pressed may inadvertently permanently deform during the press operation. While pressure differentials from 0.5 bar to less than or greater than 3.9 bar are contemplated, aspects herein implement pressure differentials within the ranges set forth above to reduce unintended deformation of the pressed article. The less compliant membranes of conventional presses can operate at pressure differentials of 4 bar or greater in order to conform and conform to the pressed article. This increased pressure may allow a conventional press membrane to conform, but may damage or otherwise insert unintended deformations into the pressed article, such as a portion of an article of footwear. Accordingly, embodiments of the compliant membrane provided herein operate at a lower pressure differential than conventional press membranes to achieve compliance of the membrane to the pressed article. In a further embodiment, the pressure differential expressed in bar pressure is from 1 to 3, from 1 to 2, from 1 to 1.5, from 1 to 1.3, from 1 to 1.2, from 1.1 to 1.4 and/or from 1.25 to 1.35 bar. The various pressure differential windows provide flexibility based on the material being joined, the press time, the degree of conformability of the membrane, and the like. Thus, based on the factors considered herein, various pressure differential ranges can be applied to achieve bonding of footwear components while minimizing unintended permanent deformation of the footwear components.

2 shows a press 100 with a membrane vessel 116 in a closed, fixed configuration, in accordance with aspects herein. The closed configuration is a configuration that allows the press 100 to effectively apply pressure to the footwear component during the joining operation. Also shown is an input mechanism for press 100 . A time control 110 , a pressure control 112 , and a temperature control 118 are shown. The input mechanism allows the user to adjust parameters of the same name (eg time, temperature, pressure). However, in exemplary aspects, omission or alteration of one or more of the above input mechanisms is contemplated. For example, computer commands may be communicated to the press from a controller that controls the time, pressure and/or time applied to a particular (or general) component. It is also contemplated that, in some instances, one or more of time, temperature, or pressure may not be adjusted.

3 is a cross-sectional view taken along line 3-3 of FIG. 2 in accordance with aspects of the present disclosure; A toe-to-heel perspective view showing the securing element 102 holding the last 120 in a position that allows the upper 252 and the sole 250 to be contacted by the compliant membrane 200 . is provided 3 shows the compliant membrane 200 during a pressure differential acclimating the compliant membrane 200 to the lasted upper 252 and the sole 250 . The pressure source 106 provides an exemplary source of the pressure that forms the pressure differential. The pressure source may provide a compressible or incompressible material (eg, gas or liquid) into the membrane chamber 104 from an external source (eg, tank, pump, and compressor). The membrane chamber 104 is closed by a membrane vessel 116 and a compliant membrane 200 . The membrane chamber 104 is effective to receive a pressurizing material (eg, compressed air) and provide a volume for the pressurizing material to enclose and apply a force from within the membrane chamber 200 to a portion of the compliant membrane 200 . . The pressure may be controlled by one or more mechanisms, such as a regulator or the like. Unlike conventional press membranes operating above 4 bar, aspects herein contemplate operating at lower pressures (eg 0.5 to 3.9 bar), and thus conventional macro-level control of pressures Level controls (eg analog regulators with tolerances of 1 bar or greater) have large operating tolerances for pressure, which can cause unintentional permanent deformation of the pressed article. Such large tolerances may result in greater pressure differentials in the compliant membrane provided herein, which may cause unintentional permanent deformation of the pressed article. As such, this macro level control of pressure for a pressure differential of 4 bar or greater is not effective to control a pressure differential of 0.5 to 3.9 bar in an exemplary embodiment. In addition, macro level control of pressure for a pressure difference of 4 bar or more is not effective to control a pressure difference of 1 to 2 bar in an exemplary embodiment. Accordingly, an aspect of the present disclosure is to upgrade the pressure control mechanism to a micro-level control (eg, a digital regulator with a tolerance of 0.9 bar or less) capable of maintaining a pressure differential within a tighter tolerance range than that of a conventional press. consider that Increased pressure tolerance control can increase the durability of the compliant membrane (eg, reduce the likelihood of overpressurization) and allow for more consistent operation at the lower pressures provided herein. In other words, as aspects herein contemplate operating at lower pressure differentials than standard presses, in exemplary embodiments herein, increased control of the pressure differential increase results from the compliant membrane press.

Also shown in FIG. 3 is an optional heat source 108 . The heating source 108 may be a resistive heating element, an infrared heating element, an induction heating element, or the like. Alternatively, in some embodiments, it is contemplated for the pressurized material to be heated outside the membrane chamber 104 and introduced at an elevated (or lowered) temperature relative to ambient conditions. Heat may be used to activate, melt, or cure one or more materials, such as a bonding material. For example, a low-melt adhesive having a lower deformation temperature (eg, melt temperature) than the membrane, upper, and sole may be disposed between the upper and the sole. Heat may be generated or applied to activate the low-melt adhesive prior to or after conforming the compliant membrane 200 around the sole and portions of the upper. The low-melt adhesive (or any bonding material) may then reduce thermal energy while maintaining pressure from the compliant membrane 200 until sufficient bonding is achieved between the components. In aspects contemplated herein, it is contemplated that the heat source 108 is optional and may be omitted entirely.

3 introduces three regions of a compliant membrane 200 . Peripheral portion 214 , transition portion 224 , and compliant portion 234 are described in greater detail below in FIGS. 4-8 . As shown in FIG. 3 , the compliant membrane 200 wraps around and surrounds portions of the upper 252 and sole 250 from a plurality of directions on a plurality of surfaces. This conformance to a plurality of surfaces and components allows the compliant membrane 200 to effectively couple the upper 252 and the sole 250 .

Instead, as indicated above, the less compliant (or non-compliant) membranes of conventional presses do not conform well enough and thus apply a more intensive, one-way pressure to the sole, thereby displacing the foam material during the press operation. As with compression, the sole 250 may be permanently deformed. This permanent deformation resulting in unacceptable pressed parts also causes the conventional press membranes to be subjected to higher pressures (eg 4 bar) to achieve a certain level of compliance with the pressed components. It can come from working. The higher pressure differential used in conventional presses compensates for a less compliant membrane material, leading to potential damaging forces applied to the pressed article. This unintentional deformation can be greater if thermal energy is applied to the process of activating or curing the bonding material. The increased thermal energy may make the material forming the sole (eg PU, EVA) more flexible and thus more susceptible to unintentional deformation under pressure from the press. As such, having a flexible membrane that surrounds the multiple surfaces of the components to be joined from multiple directions allows the pressure of the press to be applied at multiple directional angles over a larger surface area, which can inadvertently deform under conventional membranes. Allow the same material to be effectively bonded by the compliant membrane 200 .

4 is a perspective view of a compliant membrane 200 in accordance with this aspect. For reference, a longitudinal direction 206 and a transverse direction 210 are shown generally. When a compliant membrane is contemplated for use in connection with an article of footwear, the compliant membrane has a receiving cavity formed in the overall shape of the portion of the article of footwear it is intended to receive. These general and intentional deformations limit wrinkling or other membrane anomalies when placed under pressure differentials that create smooth conformability to lower footwear components. In other words, in some instances, the receiving cavity has a shape similar to an article intended to conform under pressure differential. This adjustment between the receiving cavity shape and the article of footwear allows for a more uniform conformance by the membrane to the mating components under pressure differentials.

A perimeter 214 , a transition 224 , and a compliant portion 234 of the compliant membrane 200 are shown in FIG. 4 . Also shown is an outer perimeter 222 forming the outermost portion of the compliant membrane 200 . A second surface 204 of the compliant membrane is also shown. The compliant membrane second surface 204 is opposite the compliant membrane first surface 202 , as best shown in FIG. 8 .

5 is a side view of a compliant membrane 200 in accordance with aspects herein. The z-direction 236 is shown. The z-direction 236 is the direction in which the compliant portion 234 extends from the transition portion 224 . 6 is a front view of a compliant membrane 200 in accordance with aspects herein.

7 is a top view of the compliant membrane 200 of FIGS. 4-6 in accordance with aspects herein. Some exemplary location elements are shown in FIG. 7 . For example, a receiving cavity first half 240 and a receiving cavity second half 244 are shown along the longitudinal direction 206 . Additionally, a series of arrows 232 are shown to indicate an “inside” direction in a plan view plane of the compliant membrane 200 with respect to the perimeter 222 .

The compliant 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 portions is measured in the transverse direction 210 . Because the receiving cavity is configured to conform to an article of footwear, in this example, the maximum width 242 of the receiving cavity first half 240 is any width (eg, width 246]. It is contemplated that the receiving cavity may have any shape depending on the article being compressed by the compliant membrane.

The compliant membrane 200 has a length 208 in the longitudinal direction 206 measured from the perimeter 222 . The compliant membrane 200 has a width 212 in the transverse direction 210 measured from the perimeter 222 . Length 208 is contemplated in an exemplary aspect between 400 and 500 mm. Length 208 is contemplated as being between 425 and 475 mm in an exemplary aspect. The length 208 is contemplated as being between 450 and 465 mm in an exemplary aspect. Width 212 is contemplated in an exemplary aspect between 200 and 300 mm. Width 212 is contemplated as being between 210 and 250 mm in an exemplary aspect. Width 212 is considered 220-240 mm in an exemplary aspect. In view of the exemplary ranges presented above, it is contemplated that the perimeter 222 may define a planar surface area of 0.08 to 0.15 m 2 . This area allows sufficient compliant membrane material to conform to the component being compressed while minimizing the weight and material associated with the compliant membrane 200 . The length and width may depend on the style, size or type of article being compressed by the compliant membrane 200 .

Also, the compliant portion 234 has a maximum length 209 . The length 209 is contemplated as being between 350 and 450 mm in an exemplary aspect. The length 209 is contemplated as being between 375 and 425 mm in an exemplary aspect. Length 209 is considered 395-415 mm in an exemplary aspect. The maximum width 242 is contemplated in an exemplary aspect between 150 and 250 mm. The maximum width 242 is contemplated in an exemplary aspect between 175 and 225 mm. The maximum width 242 is contemplated as being between 190 and 210 mm in an exemplary aspect. The receiving cavity length 209 and width 242 are selected to provide a receiving cavity dimensioned sufficient for the component being received, while limiting excess compliant membrane material, in an exemplary aspect. For example, the length and width of the receiving cavity 238 are similar dimensions of the receiving component to achieve easy insertion and extraction without causing unintentional deformation when the membrane conforms to the subcomponent. It may be 1 to 10% larger than

8 is a cross-sectional view taken along line 8-8 of the compliant membrane 200 of FIG. 4 , in accordance with aspects herein. The perimeter 214 has a perimeter first surface 218 and a perimeter second surface 220 with a thickness 216 defined between these surfaces. The transition 224 has a transition first surface 228 and a transition second surface 230 and a thickness 226 defined therebetween. The compliant portion 234 has a compliant first surface 235 and a compliant second surface 237 with a thickness 248 defined therebetween.

The thickness of the compliant portion 234 , the transition 224 , and the perimeter 214 affects the ability of the compliant membrane 200 to conform to an article under a pressure differential. A traditional membrane in a traditional press may have a greater thickness in the various parts above. The greater thickness could conventionally be implemented to allow the material forming the conventional membrane to have a greater lifetime during industrial applications. However, the compliant membrane 200 can be operated under different conditions (eg, temperature, pressure, time) as a result of more flexible parts formed and/or bonded from different materials, and thus is thinner (eg, thinner) than a conventional membrane. , less) thickness. In some instances as the thickness in a portion of the compliant membrane decreases, the compliant membrane may become more flexible and conform to the underlying article. However, if the thickness is reduced too much, the compliant membrane may suffer fatigue and failure during practical industrial applications. As such, in exemplary embodiments, various thickness ranges are contemplated to provide sufficient conformability to the compliant membrane 200 while achieving a sufficient shelf life.

Perimeter thickness 216 is considered between 1 and 15 mm, according to an exemplary aspect. Perimeter thickness 216 is considered between 5 and 15 mm, according to an exemplary aspect. The perimeter thickness 216 is considered between 8 and 12 mm, according to an exemplary aspect. Perimeter thickness 216 is considered to be about 10 mm, according to an exemplary aspect. Transition thickness 226 is considered between 1 and 4 mm, according to an exemplary embodiment. Transition thickness 226 is considered to be about 2 mm, according to an exemplary aspect. The compliant thickness 248 is considered between 1 and 4 mm, according to an exemplary aspect. The compliant thickness 248 is considered to be about 2 mm, according to an exemplary aspect. Perimeter thickness 216 , transition thickness 226 , and compliant thickness 248 may be the same in an exemplary aspect. Perimeter thickness 216 , transition thickness 226 , and/or compliant thickness 248 may be different from each other in exemplary aspects.

In an exemplary aspect, compliant portion 234 and transition portion 224 are considered to have similar thicknesses. This common thickness allows the transition 224 to follow similarly to the compliant portion 234 between pressure differential areas of greater elongation in the compliant portion 234 . In some examples, transition portion 224 completely borders or surrounds compliant portion 234 . In other words, transition portion 224 provides a functional transition extending in the z-direction between perimeter portion 214 and compliant portion 234 . By enclosing the compliant portion 234 , the transition 224 allows the compliant portion 234 to conform to the contained article even in the outermost portion of the compliant portion 234 .

In an exemplary aspect, the perimeter thickness 216 may be greater than the transition thickness 226 to increase the service life, service life, and concentration of compressive energy around the contained article. As the thickness of the compliant membrane affects its functional properties (eg, elongation), the compliant membrane 200 is more susceptible to deformation due to pressure differentials at locations of smaller thickness (eg, thinner regions). . Thus, by reducing the thickness of the compliant membrane 200 in the receiving cavity 238 and near the item being received, the compliant membrane 200 is made more compliant around the contained item than at the perimeter 214 having a greater thickness. do. Because the perimeter 214 has a greater thickness and thus reduces conformability, the perimeter 214 may, in an exemplary aspect, be less susceptible to fatigue failure from repeated acclimatization during pressure differential cycles.

8 shows the extension height 258 of the compliant portion 234 from the transition portion 224 . The height 258 is between 70 and 110 mm in aspects herein. The height 258 is between 80 and 100 mm in aspects herein. The height 258 is, in aspects herein, about (eg, within 10%) 90 mm. A conventional membrane may have a height that is sufficiently smaller than the compliant membrane 200 . In this example, the lower height prevents the membrane from enclosing multiple surfaces of the article, and thus a material susceptible to deformation (eg, foamed polymer in the sole) can deform under the directional compression of a conventional membrane. Instead, the compliant membrane 200, which has a greater height than conventional membranes, encloses at least a portion of the sole and upper, at a single pressure rather than a directional pressure (eg, linearly from the membrane towards the anchoring element). It is allowed to enclose the article.

In an exemplary aspect, the perimeter first surface 218 and the perimeter second surface 220 are positioned over the transitional second surface 230 . Further, in an exemplary aspect, as the compliant portion 234 extends (eg, upwardly in FIG. 8 ), the perimeter first surface 218 and the perimeter second surface 220 shift to the transitional second surface 230 . ) are considered to be located on the common side of This offset between the perimeter 214 and the transition 224 allows the compliant membrane 200 to more conform about the contained article in an inward direction with respect to the perimeter 222 . In other words, the offset in the vertical arrangement of the perimeter 214 and the transition 224 allows, in an exemplary aspect, to transmit a vertical displacement for horizontal conformance when a pressure differential is applied.

The compliant membrane 200 is formed of a compliant material. In one aspect, the compliant membrane is formed from a material composition comprising rubber (eg, natural rubber), silicon dioxide (eg, silica) and calcium carbonate. Additional materials may be included in the composition. In an exemplary embodiment, the material composition of the compliant membrane 200 consists of 75 wt % to 85 wt % rubber, 5 wt % to 15 wt % silicon dioxide. In an exemplary embodiment, the material composition of the compliant membrane 200 is comprised of 5 wt% to 15 wt% calcium carbonate, 5 wt% to 15 wt% silicon dioxide. In an exemplary embodiment, the material composition of the compliant membrane 200 is comprised of 8 wt % to 12 wt % of dispersible silica. In an exemplary embodiment, the material composition of the compliant membrane 200 consists of 75 vol % to 85 vol % rubber, 5 vol % to 15 vol % silicon dioxide. In an exemplary embodiment, the material composition of the compliant membrane 200 is comprised of 5 vol % to 15 vol % calcium carbonate, 5 vol % to 15 vol % silicon dioxide. In an exemplary embodiment, the material composition of the compliant membrane 200 is comprised of 8 vol % to 12 vol % dispersible silica. The percentage of the composition is determined prior to combining, in an exemplary embodiment.

It is contemplated that the compliant membrane is a single material extending between two or more portions. For example, it is contemplated that the compliant portion 234 and the transition portion 224 are formed of a common material such that the composition of the material forming the portions is homogeneous. Similarly, perimeter 214, transition 224, and compliant portion 234 are considered to be unitary and formed of a common material. A single entity is a single entity with a uniform material composition. For example, two or more portions of a compliant membrane may be created simultaneously. In one example, a molding operation for forming two or more parts by combining them may be performed. In an alternative manufacturing process, it is contemplated to subtractively form (eg, mill) a common material to form a compliant membrane. In this example, the parts formed by the subtractive method are monolithic as they all start with a common material source without subsequent joining.

The functional properties of the compliant membrane 200 can be quantified to provide a range of compliant membranes suitable for exemplary embodiments herein. For example, the compliant membrane 200 at least at the compliant portion 234 may have a hardness of 60 - 61 Asker C as measured on an ASKER Type C Durometer, in accordance with aspects herein. The compliant membrane 200 at least at the compliant portion 234 may have a maximum tensile strength of 84 to 90 kg/cm 3 , according to aspects herein. The maximum tensile strength can be tested using a test such as the ASTM D638-14 test prototol. The compliant membrane 200 at least at the compliant portion 234 may have a maximum elongation to failure of at least 540%, in accordance with aspects herein. The maximum elongation can be tested using a test such as the ASTM D-638 test prototol.

The material composition and resulting functional properties of the compliant membrane 200 are, in exemplary embodiments, a membrane that joins two or more portions of footwear without deforming or damaging a foamed polymer component, such as an EVA or PU midsole element. materials suitable for use as The material compositions provided herein for the compliant membrane 200 are contemplated to save labor, cost and/or materials. Operating at a lower pressure than a conventional membrane press, for example, to allow the membrane to conform to the pressed sub-article, reduces subsequent interventions to correct unintentional deformation of the pressed material. In addition, energy savings are achieved by using lower pressure requirements, with compliant membranes operating at lower pressures. Further, in an exemplary embodiment, operating a compliant membrane at a lower pressure using the material composition contemplated above allows the use of a thinner membrane, thereby reducing the use of material to form the membrane, thereby reducing material costs. is reduced

Referring to FIG. 9 , illustrated is a method 900 of making an article of footwear using a compliant membrane to join a footwear sole and a footwear upper, in accordance with aspects herein. At block 902 , the footwear upper is positioned on the securing element. The footwear upper may be a lasted upper having a last secured to a securing element. At block 904 , a compliant membrane, such as compliant membrane 200 provided herein, is closed over the footwear upper and footwear sole. In this example, the footwear upper and footwear sole are positioned at intended relative positions relative to each other. An adhesive or other bonding material may be applied prior to bonding the two components.

At block 906 , a pressure differential is created between both surfaces of the compliant membrane. For example, a pressurized fluid (eg, gas or liquid) may be inserted into a membrane cavity, in which the compliant membrane is more flexible than the other materials forming the membrane cavity. As a result, the membrane cavity deforms and conforms around the lasted upper and sole, creating a compressive force that secures the sole with the lasted upper. The compressive force is applied to both the upper and the sole at a plurality of surfaces including the junction between the sole and the upper. This enveloping compression maintains the sole in a defined position relative to the upper during the mating operation.

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

Other steps contemplated but not shown in FIG. 9 include, but are not limited to, application of thermal energy, extraction of thermal energy (eg, cooling), adjustment of time, pressure and/or temperature, and the like.

The following is a list of non-limiting exemplary parts provided in the drawings.

Press - 100 Fastening Elements - 102

Membrane Chamber - 104 Pressure Source - 106

Temperature Source - 108 Time Control - 110

Pressure Control - 112 Membrane Fixing - 114

Membrane Vessels - 116 Conformal Membrane - 200

compliant membrane first surface - 202 compliant membrane second surface - 204

Longitudinal - 206 Longitudinal Length - 208

Receiving cavity length 209 transverse - 210

Transverse Width - 212 Perimeter - 214

Peripheral Thickness - 216 Peripheral First Surface - 218

Peripheral second surface - 220 periphery - 222

Transition - 224 Transition thickness - 226

Transition First Surface - 228 Transition Second Surface - 230

Inward Direction - 232 Compliance - 234

compliant first surface - 235 Z-direction - 236

compliant second surface - 237 receiving cavity - 238

receiving cavity first half - 240 receiving cavity first half width - 242

receiving cavity second half - 244 receiving cavity second half width - 246

Conformal thickness - 248 Outsole - 250

Upper - 252 Toe end - 254

heel end - 256

Many different configurations of the various components shown, as well as components not shown, are possible without departing from the spirit and scope of the present disclosure. Embodiments of the present disclosure have been described in an illustrative rather than a restrictive sense. Other embodiments without departing from the scope of the present invention will be apparent to those skilled in the art. Those skilled in the art may develop alternative means of implementing the above-described improvements without departing from the scope of the present disclosure.

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

As used herein and in connection with the items listed below, the term "any item" or variations of similar terms are intended to be interpreted so that the features of the item may be combined in any combination. For example, exemplary item 4 may represent the method/apparatus of any one of items 1 to 3, wherein the features of items 1 and 4 may be combined, the elements of items 2 and 4 may be combined, and , the elements of item 3 and item 4 may be combined, the elements of item 1, item 2 and item 4 may be combined, and the elements of item 2, item 3 and item 4 may be combined, and item 1, item It is intended that the elements of item 2, item 3 and item 4 be construed to be capable of being combined and/or other variations are possible. Also, the term “any item” or similar variations of the term is intended to include “any one of the items” or other variations of such terms, as indicated by some of the examples above. It is also contemplated that an item may be devised as its claimed aspect.

Exemplary items

1. A compliant membrane for assisting bonding of a first article and a second article, the compliant membrane comprising: a perimeter having a thickness of 1 to 15 mm defining a perimeter of the compliant membrane; a transition portion having a thickness of 1 to 4 mm between the first surface and the second surface, the transition portion extending inside the periphery formed by the perimeter portion; and a compliant portion extending from the transition in the direction of the second surface and defining a receiving cavity and having a thickness of 1 to 4 mm, wherein the perimeter, the transition and the compliant portion are unitary structures comprising a common material composition. membrane.

2. The compliant membrane of item 1, wherein the first article is a foamed polymer-based article.

3. The compliant membrane of item 2, wherein the first article is a footwear midsole and the second article is a footwear upper.

4. The compliant membrane of any of items 1 to 3, wherein the perimeter further comprises a first surface and a second surface, wherein the perimeter first surface and the perimeter second surface are the transition portion as the compliant portion. and located on a common side of the second surface.

5. The compliant membrane of any of items 1 to 4, wherein the perimeter has a thickness of 8 to 12 mm.

6. The compliant membrane of any of items 1-5, wherein the perimeter defines a planar area of 0.08 to 0.15 m 2 .

7. The compliant membrane of any one of items 1 to 6, wherein the perimeter has a longitudinal length of 400 to 500 mm and a transverse length of 200 to 300 mm.

8. The compliant membrane of any of items 1 to 7, wherein the transition portion completely borders the compliant portion and connects the compliant portion and the periphery.

9. The compliant membrane of any of items 1 to 8, wherein the compliant portion has a durometer of 60 to 61 Asker C.

10. The compliant membrane of any one of items 1 to 9, wherein the compliant portion has a tensile strength of 84 to 90 kg/cm 3 .

11. The compliant membrane of any one of items 1 to 10, wherein the compliant portion has an elongation percentage of at least 540% elongation prior to failure thereof.

12. The compliant membrane of any of items 1-11, wherein the transition portion and the compliant portion have the same durometer, tensile strength or elongation.

13. The compliant membrane of any one of items 1 to 12, wherein the compliant portion extends in a range of 70 to 110 mm from the second surface of the transition portion.

14. The compliant membrane of any one of items 1 to 13, wherein the compliant portion extends in a range of 80 to 100 mm from the transition second surface.

15. The compliant membrane of any of items 1 to 14, wherein the receiving cavity is greater in the transverse direction in the first half of the longitudinal direction than the width in the transverse direction in the second half in the longitudinal direction. the greater width of the furnace, the compliant membrane.

16. The compliant membrane of any of items 1-15, wherein the compliant portion has a thickness of 2 mm.

17. The compliant membrane of any one of items 1 to 16, wherein the material composition comprises natural rubber, silicon dioxide and calcium carbonate.

18. The compliant membrane of any of items 1-17, wherein the material composition consists of 75 wt% to 85 wt% rubber, 5 wt% to 15 wt% silicon dioxide.

19. The compliant membrane of any of items 1-18, wherein the material composition consists of 5 wt% to 15 wt% silicon dioxide, 5 wt% to 15 wt% calcium carbonate.

20. The compliant membrane of any of items 1-19, wherein the material composition consists of dispersible silica in the range of 8 wt % to 12 wt % of the material composition.

21. A press having a compliant membrane for assisting in bonding of a first article to a second article, the press comprising: (1) a perimeter having a thickness of 1 to 15 mm defining a perimeter of the compliant membrane; (2) a transition portion having a thickness of 1 to 4 mm between the first surface and the second surface and extending inside the periphery formed by the periphery; (3) a compliant membrane extending from the transition in the direction of the second surface and defining a receiving cavity and comprising a compliant portion having a thickness of 1 to 4 mm, wherein the perimeter, the transition and the compliant portion comprise a common material composition a compliant membrane that is of a single structure; and a pressure source in fluid communication with the press to control a pressure differential of 0.5 to 3.9 bar between the first surface of the transition and the second surface of the transition.

22. A method of making an article of footwear using a compliant membrane for joining a footwear sole and a footwear upper, the method comprising: positioning the footwear upper on a securing element; closing the footwear upper on the anchoring element and the compliant membrane over the footwear sole portion, a first surface of the compliant membrane in contact with the footwear sole portion and the footwear upper, and wherein the compliant membrane (1) the compliant membrane a perimeter having a thickness of 5 to 15 mm forming an outer periphery of the membrane; (2) a transition portion having a thickness of 1 to 4 mm between the first surface and the second surface and extending inside the periphery formed by the periphery; (3) a unitary structure extending from the transition in the direction of the second surface and defining a receiving cavity and comprising a conforming portion having a thickness of 1 to 4 mm, wherein the perimeter, the transition and the conforming portion comprise a common material composition is-and; creating a pressure differential experienced on a first surface of the compliant membrane and a second surface opposite the compliant membrane, wherein the pressure at the second surface of the compliant membrane is greater than the pressure at the first surface; ; after a period of time, reducing the pressure differential.

23. The method according to item 22, wherein the pressure difference is in the range of 0.5 bar to 3.9 bar.

24. The method of item 22 or item 23, wherein the predetermined period of time is at least 25 seconds.

Claims (23)

A compliant membrane for assisting bonding of a first article and a second article, comprising:
a perimeter having a thickness between the perimeter first surface and the perimeter second surface, the perimeter defining a perimeter of the compliant membrane;
a transition portion having a thickness between the transition portion first surface and the transition portion second surface, the transition portion extending within a perimeter defined by the perimeter portion;
a conforming portion extending from the transition portion in the direction of the second surface and defining a receiving cavity;
wherein the perimeter, transition and compliant portions are unitary structures comprising a common material composition;
wherein both the perimeter first surface and the perimeter second surface are located on a common side of the transitional second surface as the compliant portion. The compliant membrane of claim 1 , wherein the first article is a foamed polymer-based article. The compliant membrane of claim 2 , wherein the first article is a footwear midsole and the second article is a footwear upper. The compliant membrane of claim 1 , wherein the perimeter has a thickness of between 8 and 12 mm. The compliant membrane of claim 1 , wherein the perimeter defines a plan area of 0.08 to 0.15 m 2 . The compliant membrane of claim 1 , wherein the perimeter has a longitudinal length of 400 to 500 mm and a transverse length of 200 to 300 mm. The compliant membrane of claim 1 , wherein the transition portion completely borders the compliant portion and connects the compliant portion and the periphery. The compliant membrane of claim 1, wherein the compliant portion has a durometer of 60 to 61 Asker C. The compliant membrane of claim 1 , wherein the compliant portion has a tensile strength of 84 to 90 kg/cm 3 . The compliant membrane of claim 1 , wherein the compliant portion has an elongation percentage of at least 540% elongation prior to failure thereof. The compliant membrane of claim 1 , wherein the transition portion and the compliant portion have the same durometer, tensile strength or elongation. The compliant membrane of claim 1 , wherein the compliant portion extends from 70 to 110 mm from the second surface of the transition portion. The compliant membrane of claim 1 , wherein the compliant portion extends from 80 to 100 mm from the transitional second surface. The compliant membrane of claim 1 , wherein the receiving cavity has a greater width in the transverse direction in the first half of the longitudinal direction than the width in the transverse direction in the second half of the longitudinal direction. The compliant membrane of claim 1 , wherein the compliant portion has a thickness of 2 mm. The compliant membrane of claim 1 , wherein the material composition comprises natural rubber, silicon dioxide and calcium carbonate. The compliant membrane of claim 1 , wherein the material composition comprises 75 wt % to 85 wt % rubber, 5 wt % to 15 wt % silicon dioxide. The compliant membrane of claim 1 , wherein the material composition comprises 5 wt % to 15 wt % silicon dioxide, 5 wt % to 15 wt % calcium carbonate. The compliant membrane of claim 1 , wherein the material composition comprises dispersible silica in the range of 8 wt % to 12 wt % of the material composition. A press having a compliant membrane for assisting in bonding of a first article to a second article, the press comprising:
A compliant membrane comprising:
(1) a perimeter having a thickness between the perimeter first surface and the perimeter second surface, the perimeter defining the perimeter of the compliant membrane;
(2) a transition having a thickness between the first surface of the transition and the second surface of the transition and extending within a perimeter defined by the perimeter; and
(3) a compliant portion extending from the transition portion in the direction of the second surface and defining a receiving cavity
wherein the perimeter, the transition and the compliant portion are a unitary structure comprising a common material composition, wherein both the perimeter first surface and the perimeter second surface are on a common side of the transitional second surface as the compliant portion a compliant membrane that is positioned; and
a pressure source fluidly coupled to the press to control a pressure differential between the first surface of the transition and the second surface of the transition
A press comprising a. A method of making an article of footwear using a compliant membrane for joining a footwear sole and a footwear upper, the method comprising:
positioning a footwear upper on the securing element;
closing a footwear upper on the securing element and a compliant membrane over the footwear sole portion, wherein a first surface of the compliant membrane is in contact with the footwear sole portion and the footwear upper, the compliant membrane comprising:
(1) a perimeter having a thickness between the perimeter first surface and the perimeter second surface and defining a perimeter of the compliant membrane;
(2) a transition having a thickness between the first surface of the transition and the second surface of the transition and extending within a perimeter defined by the perimeter;
(3) a conforming portion extending from the transition portion in the direction of the second surface and defining a receiving cavity;
wherein the perimeter, the transition and the compliant portion are a unitary structure comprising a common material composition, wherein both the perimeter first surface and the perimeter second surface are located on a common side of the transitional second surface as the compliant portion. step;
creating a pressure differential experienced on a first surface of the compliant membrane and a second surface opposite the compliant membrane, wherein the pressure at the second surface of the compliant membrane is greater than the pressure at the first surface step; and
after a predetermined period of time, reducing the pressure differential. 22. The method according to claim 21, wherein the pressure difference is between 0.5 bar and 3.9 bar. 22. The method of claim 21, wherein the predetermined period of time is at least 25 seconds.

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