KR102567119B1 - Conforming membrane for manufacturing footwear - Google Patents

Abstract

A low pressure actuation compliant membrane (200) for manufacturing an article of footwear includes a perimeter (214) having a thickness (216, 226, 248) of 1 to 15 mm forming a perimeter (222) of the compliant membrane (200). . The compliant membrane 200 may also be formed between the first surface 202, 204, 218, 220, 228, 230, 235, 237 and the second surface 202, 204, 218, 220, 228, 230, 235, 237. It has a thickness 216, 226, 248 of 1 to 4 mm, and includes a transition portion 224 extending inside the outer circumference 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 forms a receiving cavity 238 . and a conforming portion 234 having a thickness 216, 226, 248 of 1 to 4 mm. The periphery 214, the transition 224 and the conforming portion 234 are a unitary component comprising a common material composition.

Description

Conforming membrane for footwear manufacturing {CONFORMING MEMBRANE FOR MANUFACTURING FOOTWEAR}

It relates to a press membrane used when combining two articles.

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

Aspects of the present disclosure contemplate a compliant membrane for assisting in bonding a first article to a second article. The compliant membrane includes a periphery having a thickness of 1 to 15 mm forming an outer perimeter of the compliant membrane. The compliant membrane also includes a transition portion between the first surface and the second surface having a thickness of 1 to 4 mm. The transition portion extends inside the periphery formed by the periphery. The compliant membrane also includes a compliant portion extending upwardly from the transition portion in the direction of the second surface and forming a receiving cavity. The compliant portion has a thickness of 1 to 4 mm. The peripheral portion, the transition portion and the conforming portion are unitary components comprising a common material composition.

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

The present invention will be described in detail with reference to the accompanying drawings.
1 shows a press with a compliant membrane, in accordance with an aspect of the present invention.
Figure 2 shows the press of Figure 1 in a closed and fixed configuration, in accordance with an aspect of the present invention.
Figure 3 is a cross-sectional view of the press taken along line 3-3 of Figure 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 an aspect 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 plan 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 chart showing an exemplary method of manufacturing an article of footwear with a compliant membrane, in accordance with an aspect of the present invention.

Conventionally, the manufacture of footwear, such as sports shoes, is carried out by combining different parts. For example, a footwear upper is a portion of an article of footwear that extends around a wearer's foot to secure the article to the wearer. The upper may be formed of various materials such as leather, film, fabric, printed matter, and the like. In some instances, the upper is a portion of footwear that includes securing structures such as lacing openings for laces, ankle openings to allow removal of the wearer's foot, and other structures. The shape of the upper is determined in part when the upper is joined to other parts. In some manufacturing scenarios, cobblers lasts, referred to as “lasts,” are inserted into the upper (or the upper is formed around the last) so that the upper takes 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 to the upper during the manufacturing process. As additional parts/components are combined with the lasted upper, the shape of the upper is further solidified so that, once the last is removed, the dimensional shape is maintained or at least influenced by the last.

Another common component of an article of footwear is the sole. A sole may be referred to as a “floor unit” in some instances. A sole may be a collection of multiple 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., which in combination form a sole. The outsole is usually a part that extends between the upper and the ground at the bottom where the wearer of footwear moves.

The outsole can be formed from a variety of materials. For example, soles may be formed from leather, felt, textiles, and/or polymeric materials (eg, natural or synthetic). Different parts of the sole may be formed from different materials. For example, the outsole (e.g. ground contact portion) may be formed of rubber (e.g. synthetic or natural) and the midsole may be formed of a foamed polymer (e.g. ethylene-vinyl acetate (EVA), polyurethane (PU)). can As discussed below, the compliant membrane may be adapted to assist in bonding a sole and upper constructed 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 instances, the upper and the sole are joined through a stitching operation. In another example, the upper is joined to the sole through a bonding process. The joining process may be accomplished by welding, fusion and/or adhesive bonding. In an exemplary embodiment, 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 a bond (eg, a mechanical bond and/or a chemical bond) between the upper and the sole. The fit may be improved through the application of pressure, such as applying a force through the upper to the sole and/or applying a force through the sole to the upper. In addition to pressure, it is contemplated that thermal energy (eg, heat) may be applied to the upper and/or the sole to assist in bonding 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 to achieve a bond between the upper and the sole. As discussed below, the compliant membrane is effective in providing sufficient pressure at 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 compressible sole element (e.g., EVA, PU, or other foamed polymer-based material) and a lasted upper, the application of pressure is applied to the compressible sole during the bonding process. causes permanent and unintended deformation of the sole, thus deforming the compressible sole into an unintended shape when bonded to 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 at least partially maintained after engagement of the deformed sole with the upper. As noted above, the construction of an article of footwear may rely on the successive lamination and joining of materials and parts to maintain the shape of the upper dictated by the last once the last is removed after joining has occurred. However, when combining the lasted upper with a sole deformed by a conventional press, once the last is removed after joining the sole and the upper, the sole returns to the original undeformed form of the sole (completely or partially) can return. By returning the outsole to its shape before deformation after coupling with the upper, deformation of the upper relative to the shape of the upper as determined by the last may be caused. Accordingly, a conventional press that applies pressure to the sole to assist in bonding the sole and the upper may cause deformation of the sole during the press operation, resulting in unintended damage to the sole and/or upper after the press operation. Transformation can happen.

It is understood that different sole materials may be more susceptible to unintentional permanent deformation. As a result, conventional presses can produce acceptable results for some footwear material combinations. However, as materials evolve and more materials (eg, expanded polymers) are utilized in the components forming the article of footwear, advances in the press allow for the incorporation of these materials into articles of footwear. For example, when a conventional press is used to join a sole and a lasted upper, the sole formed of certain materials creates an unsatisfactory bond (eg, bond gap). If the application of pressure from a conventional press continues for a certain time (eg, 30 seconds, 25 seconds), the material deforms and causes insufficient bonding. In addition, the application of reduced force can 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, a conventional press may not outwardly deform one or more portions (e.g., a foam outsole) when a force is applied linearly through the press, as opposed to the enveloping manner achieved by aspects of the compliant membranes provided herein. can make 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 a lasted upper to wrap the lasted upper and outsole with a compressive force normal to various surfaces (e.g., sole ground contact surface, sole sidewall, upper medial portion, upper exterior portion, upper heel end, upper toe box). and a membrane that conforms to the outsole. This multi-directional 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 portion. This is in contrast to conventional presses which do not sufficiently conform around the lasted upper and sole and/or rely on higher pressures to cause conformation of the press material. Instead, conventional presses concentrate pressure through the outsole in a more linear fashion, as opposed to the multi-directional compressive force provided by a compliant membrane. Further, conventional presses that may have a "compliant" membrane may only be "compliant" when under significantly higher pressures than are provided in connection with aspects herein.

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

[0018] [0018] An aspect also relates to manufacturing an article of footwear, such that a method of manufacturing an article of footwear using a compliant membrane for bonding a footwear sole portion and a footwear upper includes positioning the footwear upper on a securing element (e.g., a press support). Consider implementing a compliant membrane. The method includes closing the compliant membrane over the footwear upper and the footwear sole portion on the securing element. In this example, the first surface of the compliant membrane contacts the footwear sole portion 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 the contemplated method of use provide a tool for joining the upper and sole with reduced deformation of the upper and/or sole compared to conventional presses (eg, membrane presses). In some instances, the properties of the compliant membrane, such as thickness and material composition, may be adjusted to various surfaces (e.g., toe box, heel counter, inner upper, outer upper, outsole) while bonding the upper and the sole at lower pressures. allows the membrane to conform around the sole and upper to apply pressure (and in some instances heat) across the transition from the to the upper (e.g., biteline, sidewall of the sole) . This is a more linear motion that extends linearly through the sole and/or upper (as opposed to ambient from multiple directions) at higher pressures (e.g., 4 bar or more) which cause 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 to the drawings generally and specifically to FIG. 1 , there is shown a press 100 according to this aspect having a lasted upper 252 secured to a fastener 102 and a sole 250. . At a high level, the press 100 is adapted to hold the upper and sole in position relative to each other while engaged. For example, the 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 heat. Sole 250 and upper 252 then have pressure applied by compliant membrane 200 contained within membrane container 116 (eg, lid). As membrane container 116 is positioned over sole 250 and upper 252 , the combination of components is at least partially housed within receiving cavity 238 of compliant membrane 200 . The receiving cavity is such that during the press operation, the various surfaces of the footwear that are formed (e.g., medial, lateral, toe box at toe end 254, heel counter at heel end 256, bite line) form conforming membrane 200. is an intentional deformation (eg, molded or otherwise formed) of the compliant membrane 200 from its planar configuration to allow it to be contacted by the The membrane vessel 116 may be secured in a closed working configuration to the press 100 by means of a membrane anchor 114, such as a releasable latching mechanism. Membrane anchor 114 is effective to hold membrane container 116 and associated compliant membrane 200 in position relative to the article of footwear upon which pressure is applied.

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

Pressure may alternatively or additionally be created by press 100 through pressurization of compliant membrane 200 . In the exemplary aspect also shown in FIG. 3 , a positive pressure relative to the ambient pressure can be introduced to 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 sole 250 as the compliant membrane 200 deforms under the pressure differential. This deformation causes compliant membrane 200 to wrap around a portion of upper 252 and sole 250 to create pressure that holds upper 252 and sole 250 in fixed relative positions during the engagement operation. Depending on the pressure difference, sufficient pressure may be applied to the upper 252 and the outsole 250 to assist in bonding (eg, bonding through adhesive curing) of these components. Exemplary pressure differentials include from 0.5 bar to 3.9 bar relative to ambient pressure. Above 3.9 bar, in an exemplary embodiment, the compliant membrane may fail mechanically after numerous press cycles, or the article being pressed may inadvertently become permanently deformed during the press operation. Although pressure differentials of less than or greater than 0.5 bar to 3.9 bar are contemplated, embodiments 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 more 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 introduce unintended deformations into a pressed article, such as a portion of an article of footwear. Accordingly, embodiments of conformable membranes provided herein operate at lower pressure differentials than conventional press membranes to achieve conformation 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 to be bonded, the press time, the degree of compliance of the membrane, and the like. Thus, based on the factors contemplated herein, various pressure differential ranges may be applied to achieve bonding of the footwear components while minimizing unintended permanent deformation of the footwear components.

2 shows a press 100 with a membrane vessel 116 in a closed and fixed configuration, according to 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 unit 110, a pressure control unit 112 and a temperature control unit 118 are shown. The input mechanism allows the user to adjust parameters of the same name (eg time, temperature, pressure). However, in an exemplary aspect, omitting or altering one or more of the input mechanisms is contemplated. For example, computer commands can be communicated to the press from a controller that controls the time, pressure and/or time applied to specific (or general) components. 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 according to an aspect of the present disclosure. A toe-to-heel perspective view showing retaining element 102 holding last 120 in position allowing upper 252 and sole 250 to be contacted by compliant membrane 200. is provided. 3 shows the compliant membrane 200 during a pressure differential that conforms the compliant membrane 200 to the lasted upper 252 and sole 250 . Pressure source 106 provides an exemplary source of the pressure forming the pressure differential. The pressure source may provide compressible or incompressible material (eg, gas or liquid) into the membrane chamber 104 from an external source (eg, tanks, pumps, and compressors). The membrane chamber 104 is closed and formed by the membrane container 116 and the compliant membrane 200 . The membrane chamber 104 is effective to receive a pressurized material (eg, compressed air) and to provide a volume such that the pressurized material encloses and exerts a force on a portion of the compliant membrane 200 from within the membrane chamber 200. . Pressure may be controlled by one or more mechanisms such as a regulator or the like. Unlike conventional press membranes operating above 4 bar, embodiments herein contemplate operating at lower pressures (e.g., 0.5 to 3.9 bar), so conventional macro-level control of pressure is Level controls (eg analog regulators with tolerances of 1 bar or more) have large operating tolerances for pressure, which can lead to unintended permanent deformation of the pressed article. Such large tolerances can cause larger pressure differentials in the compliant membranes provided herein, which can cause unintended permanent deformation of the pressed article. As such, macro level control of this pressure for pressure differentials greater than 4 bar is not effective for controlling pressure differentials between 0.5 and 3.9 bar in an exemplary embodiment. In addition to this, macro level control of pressure for pressure differentials of 4 bar or more is not effective for controlling pressure differentials of 1 to 2 bar in an exemplary embodiment. Therefore, an aspect of the present application is to upgrade the pressure control mechanism to a micro-level control (e.g., a digital regulator with a tolerance of 0.9 bar or less) capable of maintaining a pressure difference within a tighter tolerance range than the pressure mechanism of a conventional press. consider that Increased pressure tolerance control can increase the durability of a compliant membrane (eg, reduce the likelihood of overpressurization) and allow for more consistent operation at lower pressures provided herein. In other words, since aspects herein contemplate operating at lower pressure differentials than standard presses, in an exemplary aspect of the present application, increased control of the pressure differential increase results from the compliant membrane press.

3 also shows an optional heating 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 to heat the pressurized material outside the membrane chamber 104 and introduce it at an elevated (or lowered) temperature relative to ambient conditions. Heat may be used to activate, melt or harden one or more materials, such as a bonding material. For example, a low-melt adhesive having a lower deformation temperature (eg, melting temperature) than the membrane, upper, and sole may be disposed between the upper and sole. Before or after conforming the compliant membrane 200 around portions of the sole and upper, heat may be generated or applied to activate the low-melt adhesive. The thermal energy can then be reduced while maintaining pressure from the compliant membrane 200 until the low-melt adhesive (or any bonding material) has achieved sufficient bonding between the components. In aspects contemplated herein, it is contemplated that the heating source 108 is optional and may be omitted entirely.

3 introduces three areas of a compliant membrane 200 . Perimeter 214, transition 224 and conform 234 are described in more detail below in FIGS. 4-8. As shown in FIG. 3 , compliant membrane 200 wraps around and surrounds upper 252 and a portion of sole 250 from multiple directions on multiple surfaces. This conformability to multiple surfaces and components allows compliant membrane 200 to effectively couple upper 252 and sole 250 .

Instead, as suggested above, the less compliant (or non-conforming) membrane of a conventional press, during press operation, does not compress the foam material because it is not sufficiently compliant and therefore applies a more intensive and one-way pressure to the sole. Like compression, it can permanently deform sole 250. This permanent deformation, which results in unacceptable pressed parts, also results in the removal of conventional press membranes at higher pressures (e.g., 4 bar) to achieve a certain level of conformity to the pressed components. It can come from working. The higher pressure differential used in conventional presses compensates for the less compliant membrane material, which leads to potentially 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 outsole (eg PU, EVA) more flexible and therefore more susceptible to unintentional deformation under pressure from the press. As such, with a flexible membrane that surrounds the different surfaces of the components to be joined from multiple directions, the pressure of the press is applied at multiple directional angles over a larger surface area, which can deform unintentionally under conventional membranes. The same materials present are effectively bonded by the compliant membrane 200 .

4 is a perspective view of a compliant membrane 200 according to 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 general shape of the portion of the article of footwear to be received. This general and intentional deformation limits wrinkles or other membrane deviations when placed under pressure differentials that create smooth conformability to the underlying footwear component. In other words, in some instances, the receiving cavity has a shape similar to an article intended to conform under a pressure difference. This adjustment between the receiving cavity shape and the article of footwear allows for more uniform compliance by the membrane to the mating components under pressure differentials.

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

5 is a side view of a compliant membrane 200 according to 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 according to aspects herein.

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

The conforming 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 transverse direction 210 . Because the storage cavity is shaped to conform to the article of footwear, in this example, the maximum width 242 of storage cavity first half 240 is any width of storage cavity second half 244 [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 circumference 222 . The compliant membrane 200 has a width 212 in a transverse direction 210 measured from an outer circumference 222 . Length 208 is considered to be between 400 and 500 mm in an exemplary aspect. Length 208 is considered 425 to 475 mm in an exemplary aspect. Length 208 is considered to be between 450 and 465 mm in an exemplary aspect. Width 212 is considered to be between 200 and 300 mm in an exemplary aspect. Width 212 is considered to be between 210 and 250 mm in an exemplary aspect. Width 212 is considered 220 to 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 . Length 209 is considered to be between 350 and 450 mm in an exemplary aspect. Length 209 is considered to be between 375 and 425 mm in an exemplary aspect. Length 209 is considered to be between 395 and 415 mm in an exemplary aspect. Maximum width 242 is considered to be between 150 and 250 mm in an exemplary aspect. Maximum width 242 is considered to be between 175 and 225 mm in an exemplary aspect. Maximum width 242 is considered 190-210 mm in an exemplary aspect. The receiving cavity length 209 and width 242 are selected to provide a receiving cavity sufficiently dimensioned for the component to be received, while limiting excess compliant membrane material, in an exemplary aspect. For example, the length and width of the receiving cavity 238 may be similar to the dimensions of the component being accommodated, so as to achieve easy insertion and extraction without causing unintended deformation as the membrane conforms to the subcomponent. may be 1 to 10% greater 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 between which a thickness 216 is defined. Transition 224 has a transition first surface 228 and a transition second surface 230, with a thickness 226 defined between these surfaces. The compliant portion 234 has a compliant first surface 235 and a compliant second surface 237 with a thickness 248 defined between these surfaces.

The thickness of the conforming portion 234, transition portion 224, and perimeter portion 214 affect the ability of the conforming membrane 200 to conform to an article under a differential pressure. A traditional membrane in a traditional press may have a greater thickness in the various parts. 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 may be operated under different conditions (eg, temperature, pressure, time) as a result of more flexible components formed and/or bonded from different materials, and thus may be thinner (eg, thinner) than conventional membranes. , less) thickness. As the thickness in a portion of the compliant membrane in some instances 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 from fatigue and failure during practical industrial applications. As such, in an exemplary aspect, a range of different thicknesses are contemplated to provide the compliant membrane 200 with sufficient conformability while achieving a sufficient service life.

Perimeter thickness 216 is considered to be between 1 and 15 mm, according to an exemplary aspect. Perimeter thickness 216 is considered to be between 5 and 15 mm, according to an exemplary aspect. Perimeter thickness 216 is considered to be 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 to be between 1 and 4 mm, according to an exemplary aspect. Transition thickness 226 is considered to be about 2 mm, according to an exemplary aspect. Compliance thickness 248 is considered to be between 1 and 4 mm, according to an exemplary aspect. Compliance thickness 248 is considered to be about 2 mm, according to an exemplary aspect. The perimeter thickness 216 , the transition thickness 226 and the compliant thickness 248 may be the same in an exemplary aspect. Peripheral thickness 216 , transition thickness 226 and/or compliant thickness 248 can be different, in exemplary aspects.

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

In an exemplary aspect, the perimeter thickness 216 may be greater than the transition thickness 226 to increase service life, and concentration of compressive energy around the stored article. As the thickness of the compliant membrane affects its functional properties (eg, elongation), the compliant membrane 200 is more susceptible to pressure differential deformation at locations where the thickness is smaller (eg, thinner regions). . Thus, by reducing the thickness of the compliant membrane 200 in the storage cavity 238 and near the stored items, the compliant membrane 200 becomes more compliant around the stored items than at the perimeter 214, which has a greater thickness. do. Because the perimeter 214 has a greater thickness and hence reduced conformability, the perimeter 214 may, in an exemplary aspect, be less susceptible to fatigue failure due to repeated compliance during pressure differential cycles.

8 shows the extension height 258 of the compliant portion 234 from the transition portion 224 . Height 258 is between 70 and 110 mm in an embodiment herein. The height 258 is between 80 and 100 mm in an embodiment herein. Height 258 is about (eg, to within 10%) 90 mm in an aspect herein. Conventional membranes may have a height that is sufficiently less than the compliant membrane 200 . In this example, the lower height prevents the membrane from enclosing the various surfaces of the article, so that materials susceptible to deformation (eg, the foamed polymer of the outsole) may deform under directional compression of conventional membranes. Instead, the compliant membrane 200, which has a greater height than conventional membranes, encloses the outsole and at least a portion of the upper, so that it exerts a single pressure rather than a directional pressure (e.g., linearly from the membrane towards the fixation element). It is allowed to enclose the article.

In an exemplary aspect, the perimeter first surface 218 and the perimeter second surface 220 are located above the transition second surface 230 . Further, in an exemplary aspect, as the compliant portion 234 extends (e.g., upwards in FIG. 8), the perimeter first surface 218 and the perimeter second surface 220 form the transition second surface 230. ) is considered to be located on the common side of This offset between the periphery 214 and the transition 224 allows for further compliance of the compliant membrane 200 about the contained item in an inward direction relative to the periphery 222 . In other words, the offset in the vertical arrangement of the perimeter 214 and the transition 224 allows, in an exemplary aspect, the transfer of vertical displacement for horizontal compliance 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 composed 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 consists of 8 wt % to 12 wt % 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 composed 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 consists of 8 vol % to 12 vol % dispersible silica. The percentage of composition is, in an exemplary embodiment, determined prior to combining.

The compliant membrane is considered to be a single material extending between two or more parts. For example, conforming portion 234 and transition portion 224 are considered to be formed of a common material such that the composition of the material forming the portions is homogeneous. Similarly, the perimeter 214, transition 224 and conform 234 are considered to be unitary and formed of a common material. A unitary component is a single entity having a uniform material composition. For example, two or more parts of a compliant membrane may be produced simultaneously. In one example, a molding operation may be performed to form two or more parts in combination. 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 bonding.

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

The material composition and resulting functional properties of the compliant membrane 200 are, in an exemplary embodiment, a membrane that joins two or more footwear parts without deforming or damaging a foamed polymer component such as an EVA or PU midsole element. It provides materials suitable for use as The material compositions provided herein for the compliant membrane 200 are contemplated to save manpower, cost, and/or materials. Operating at lower pressures than conventional membrane presses, eg, to allow the membrane to conform to the pressed underlying article, reduces subsequent intervention to correct unintended deformation of the pressed material. Additionally, energy savings are achieved by taking advantage of lower pressure requirements with compliant membranes operating at lower pressures. Additionally, in an exemplary aspect, operating the compliant membrane at lower pressures using the material compositions contemplated above allows the use of thinner membranes, reducing the use of materials to form the membranes, thereby reducing material costs. is reduced

Referring to FIG. 9 , a method 900 of manufacturing an article of footwear using a compliant membrane to join a footwear sole portion and a footwear upper is illustrated, in accordance with aspects herein. At block 902, the footwear upper is positioned over the securing elements. The footwear upper may be a lasted upper in which the last is 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 relative to each other in an intended relative position. An adhesive or other bonding material may be applied prior to joining 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) can be injected into the membrane cavity, where the compliant membrane is more flexible than other materials forming the membrane cavity. As a result, the membrane cavities deform and conform around the lasted upper and sole, creating a compressive force that secures the sole to the lasted upper. The compressive force is applied to both the upper and the sole at a number of surfaces including the junction between the sole and the upper. This enveloping compression holds the sole in place relative to the upper during engagement.

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 length of time suitable to allow bonding 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.

The following is a non-limiting and illustrative list of parts presented in the drawings.

Presses - 100 Fixing elements - 102

Membrane Chamber - 104 Pressure Source - 106

Temperature Source - 108 Time Control - 110

Pressure Control - 112 Membrane Fixing - 114

Membrane Vessel - 116 Compliant Membrane - 200

Conformable Membrane First Surface - 202 Conformable Membrane Second Surface - 204

Longitudinal - 206 Longitudinal Length - 208

Storage Cavity Length 209 Transverse - 210

Transverse Width - 212 Perimeter - 214

Peripheral Thickness - 216 Peripheral First Surface - 218

Peripheral Second Surface - 220 Perimeter - 222

Transition - 224 Transition Thickness - 226

Transition First Surface - 228 Transition Second Surface - 230

Internal Direction - 232 Compliance - 234

Conformal First Surface - 235 Z-direction - 236

compliant second surface - 237 receiving cavity - 238

Storage Cavity First Half - 240 Storage Cavity First Half Width - 242

Storage Cavity Second Half - 244 Storage Cavity Second Half Width - 246

Compliance 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 with the intention of being illustrative rather than restrictive. Other embodiments will be apparent to those skilled in the art without departing from the scope of the present invention. One skilled in the art may develop alternative means of implementing the foregoing improvements without departing from the scope of the present disclosure.

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

Variations of the term "any item" or similar terms used herein and in connection with items listed below are intended to be construed so that the features of the item may be combined in any combination. For example, exemplary item 4 may represent a method/device of any one of items 1 to 3, which may combine features of item 1 and item 4, elements of item 2 and item 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, the elements of item 2, item 3 and item 4 may be combined, and the elements of item 1 and item 4 may be combined 2, item 3 and item 4 are intended to be interpreted such that the elements may be 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 term, as shown by some of the examples above. Also, items are contemplated as being envisioned as their claimed aspects.

illustrative item

1. A compliant membrane for assisting in joining a first article and a second article, a periphery having a thickness of 1 to 15 mm forming an outer periphery of the compliant membrane; a transition portion having a thickness of 1 to 4 mm between the first surface and the second surface and extending inside the circumference formed by the periphery; comprising a conforming portion extending from the transition portion in the direction of the second surface and forming an accommodating cavity and having a thickness of 1 to 4 mm, wherein the peripheral portion, the transition portion and the conforming portion are a unitary structure 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 clauses 1-3, wherein the perimeter further comprises a first surface and a second surface, the perimeter first surface and the perimeter second surface comprising the transition portion as the compliant portion. located on the common side of the second surface.

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

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

7. The compliant membrane of any of clauses 1-6, wherein the periphery 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 clauses 1-7, wherein the transition completely borders the compliant and connects the compliant and periphery.

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

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

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

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

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

14. The compliant membrane of any of clauses 1-13, 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 clauses 1 to 14, wherein the receiving cavity has a width greater than a width in the transverse direction in the second longitudinal half, in the transverse direction in the first longitudinal half. A compliant membrane, which has a greater width to .

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

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

18. The compliant membrane of any of clauses 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 clauses 1 to 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 clauses 1-19, wherein the material composition consists of dispersible silica ranging from 8 wt % to 12 wt % of the material composition.

21. A press having a compliant membrane for assisting in joining a first article and a second article, the press comprising: (1) a periphery having a thickness of 1 to 15 mm forming an outer periphery of the compliant membrane; (2) a transitional portion having a thickness of 1 to 4 mm between the first surface and the second surface and extending inside the outer circumference formed by the peripheral portion; (3) a compliant membrane comprising a conforming portion extending from the transition portion in the direction of the second surface, forming a receiving cavity, and having a thickness of 1 to 4 mm, wherein the peripheral portion, the transition portion, and the conforming portion comprise a common material composition; A conformable membrane that is a unitary structure that; and a pressure source fluidly coupled with the press to control a pressure differential between the transition first surface and the transition second surface between 0.5 and 3.9 bar.

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

23. The method of item 22, wherein the pressure differential 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 (30)

A compliant membrane for joining a footwear sole and a footwear upper, comprising:
a perimeter having a thickness between the perimeter first surface and the perimeter second surface, the perimeter defining the perimeter of the compliant membrane;
a transition portion having a thickness between the transition portion first surface and the transition portion second surface, and extending inside the outer circumference formed by the peripheral portion;
a conforming portion extending from the transition portion in a direction of the second surface of the transition portion and forming an accommodating cavity;
wherein the perimeter, transition and conforming 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 transition second surface as the compliant part. The compliant membrane according to claim 1 , wherein the footwear sole portion is a foamed polymer-based article. The compliant membrane according to claim 1 , wherein the perimeter has a thickness of 8 to 12 mm. The compliant membrane of claim 1 , wherein the perimeter defines a planar area of 0.08 to 0.15 m 2 . The compliant membrane according to claim 1 , wherein the periphery has a longitudinal length of 400 to 500 mm and a transverse length of 200 to 300 mm. A compliant membrane according to claim 1 , wherein the transition completely borders the conforming portion and connects the conforming 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 80 to 100 mm from the second surface of the transition portion. The compliant membrane according to claim 1 , wherein the receiving cavity has a greater transverse width in the first longitudinal half than a transverse width in the second longitudinal half. 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 joining an article of footwear and a footwear upper, the press comprising:
As a compliant membrane,
(1) a perimeter having a thickness between a perimeter first surface and a perimeter second surface and forming an outer periphery of the compliant membrane;
(2) a transition portion having a thickness between the transition portion first surface and the transition portion second surface, and extending inside the outer circumference formed by the peripheral portion; and
(3) a conforming portion extending from the transition portion in the direction of the second surface of the transition portion and forming an accommodating cavity.
wherein the perimeter, transition and conforming portions are unitary structures comprising a common material composition, and wherein both the perimeter first surface and the perimeter second surface are on a common side of the transition second surface as the conforming portion. a compliant membrane to be positioned; and
A pressure source in fluid communication with the press to control a pressure differential between the transition first surface and the transition second surface.
A press containing a. delete delete delete A press configured to maintain a relative position with respect to each other in a state in which the upper and the sole are coupled,
A membrane chamber closed and formed by the membrane container and the compliant membrane according to claim 1, the membrane chamber receiving a pressure member, the volume of which pressure member encloses and exerts a force on a portion of the compliant membrane from within the membrane chamber. a membrane chamber effectively configured to provide;
a membrane fixing portion, the membrane fixing portion being configured such that the membrane container can be secured to the press by the membrane fixing portion in a closed working configuration; and
a securing element configured to hold the upper in a position such that the upper and the sole are brought into contact by the compliant membrane;
Which includes, press. 24. The press of claim 23, wherein the membrane anchor is further configured such that the membrane anchor effectively holds the membrane container and the compliant membrane in position relative to the article of footwear upon which pressure is applied. 24. The press of claim 23, further comprising one or more mechanisms for controlling the pressure. 24. The press of claim 23, further comprising a heating source, wherein the heating source is a resistive heating element, an infrared heating element, or an induction heating element. 24. The press according to claim 23, wherein the pressure member is compressed air. 24. The press of claim 23, wherein the membrane anchor is a releasable mechanism. 26. The press of claim 25, wherein the at least one mechanism is a regulator. delete