KR20110123237A - Unibody construction footwear and method for making the same - Google Patents

Abstract

The present invention discloses a shoe comprising a body structure. In the body structure, at least the upper is formed of one continuously folded synthetic material, consisting of layered material sheets.

Description

UNIBODY CONSTRUCTION FOOTWEAR AND METHOD FOR MAKING THE SAME}

The present invention relates to a shoe made by cutting, folding and assembling sheets of synthetic or composite-like material and a method of making the same. As described in detail below, such "unibody" construction shoes require only a small number of individual parts to be sewn, stitched or joined together and can be manufactured in a small time and at a low cost. Can be.

In one aspect, the invention relates to a shoe comprising a body structure, which body structure may be formed of at least one, two or three or more continuous and folded synthetic materials of at least an upper. The continuous, folded synthetic material consists of a layered sheeting structure. The sheet structure may comprise at least one layer, at least two layers, at least three layers, at least four layers, at least five layers, at least six layers, at least seven layers, at least eight layers, and the like, wherein the assembled composite material is It is not limited to this, as long as it can be folded in the form of a fully shaped shoe body structure or part thereof. Other materials may be inserted or incorporated into the seat structure to form a non-uniform planar structure that may be folded to form the body structure of the shoe. The synthetic material may include cushioning pod elements or pod fitting apertures. One or more cushion pod members may be bonded to one or more pod fitting holes in the body of the shoe. The layered sheet structure may be formed of resilient foam, rubber, other elastic materials or combinations thereof, leather, fabric, mesh or other sheet materials or any combination thereof. In addition, the layered seat structure and the assembled shoe may include one or more locking pod members and locking pod holes. In addition, the layered sheet structure may include a full layer, a partial layer, or a combination thereof. The layered sheet structure may comprise a tongue section, one or more cushioning padding elements, a folding line, and / or a reinforcement structure. Further, the layered sheet structure may comprise one or more electronic devices, mechanical devices or electro-mechanical devices.

The shoe may include an upper that may be attached to a prefabricated outsole assembly. The outsole assembly may include a sole pod element. The sole pod member may be exposed to the inside of the shoe to be in contact with the wearer of the shoe. The outsole assembly may include an outsole layer that may be in contact with the bottom of the upper. The outsole layer may extend to wrap around the sole pod member. The outsole assembly may include a midsole.

The body structure of the shoe may comprise an upper and an outsole, and may consist of one or more continuous, folded synthetic materials that include a layered seat structure. In one aspect, the synthetic material may be joined to one seam of the body structure. The body structure of the shoe may become non-uniform across different areas or areas of the shoe, and in different areas of the shoe may vary in thickness, texture, stiffness, hardness, color, breathability, shock absorbency, wear resistance, Flexibility or other performance characteristics. The shoes may include, but are not limited to, sneakers, casual shoes, sandals, formal shoes, industrial protective shoes, shoes suitable for medical personnel, and boots.

In another aspect, the present invention relates to a shoe manufacturing process (method) for manufacturing the above shoe, comprising: (i) providing a synthetic material comprising a sheet structure of at least one layer; And (ii) folding the synthetic material to form a body structure comprising one or more continuously folded synthetic shoes. The synthetic material may consist of at least one full layer of the sheet structure or at least one partial layer of the sheet structure. The seat structure may be precut internally to provide a cushion pod member or pod fitting hole. Further, in the fabrication process, after folding the synthetic material, the edge, end, vertex or corner portion of the synthetic material is formed, and the locking pod member and the locking pod hole are joined in place. Keep it. In another aspect, the synthetic material may be bonded to one seam. The manufacturing method may further comprise inserting or incorporating other materials or materials of different dimensions into the seat structure to form a non-uniform body structure of the shoe.

In another embodiment, the present invention relates to a shoe comprising an upper and an insole made of one or more continuous pieces or seat structures that can be folded. The shoe upper may consist of one or more continuous piece or seat structures ¬¬ with different materials in different areas of the shoe. In another embodiment, the present invention is directed to a shoe comprising an upper, midsole, and outsole consisting of one or more continuous piece or seat structures that can be folded. The upper may consist of one or more continuous piece or seat structures and may include other materials or materials of different dimensions located in different areas of the shoe.

The objects and other objects of the present invention can be more fully understood from the following detailed description, the accompanying drawings and the claims appended hereto.

The present invention can be more fully understood from the following detailed description, and the accompanying drawings are shown as an example of the present invention and are not limited thereto.

1 is an exploded perspective view showing a manufactured shoe in general.
Figure 2 is an exploded perspective view showing a manufactured shoe in general.
3 is a view showing a shoe upper generally manufactured.
Figure 4 is an exploded perspective view of a manufactured shoe in general.
FIG. 5 is a perspective view illustrating the insertion of an insole into a generally manufactured shoe upper-sole midsole assembly. FIG.
6 is an exploded perspective view showing a monolithic shoe upper.
7 is a side view showing the unitary shoe upper assembled;
8 is a side view showing the unitary shoe upper assembled;
9 illustrates various optional components of a monolithic shoe outsole assembly.
FIG. 10 is an exploded view highlighting individual cushion pod members, an array forming cushion padding members; FIG.
11 is an exploded view showing the entire layer used to fabricate a monolithic shoe assembly.
12 is an exploded view of a partial layer used to fabricate a monolithic shoe assembly.
13 is an exploded perspective view showing an optional embodiment of the present invention with the cushion padding member positioned relative to the entire layer.
14 is an exploded perspective view of an optional embodiment of the present invention, wherein the cushion padding member is bonded, glued, or attached to the entire layer.
15 is an exploded perspective view of an optional embodiment of the present invention in which the cushion padding member is bonded, glued, or attached to a folded entire layer of a three-dimensional structure suitably formed for a monolithic shoe upper.
16 is a perspective view of an optional insole member having a bottom surface;
17 is a sectional view of the insole member;
18 is an exploded view showing partial layers, entire layers, and insoles coupled to each other;
FIG. 19 shows a rear view of an optional embodiment of the present invention, wherein the layered composite assembly is suitably formed for a monolithic shoe upper with an insole member, an array of cushion pod members, a full layer and a partial layer, with a cross section of a human foot. To be folded into an architectural structure.
20 is a side view showing the unitary shoe upper assembled;
21 is a perspective view showing an outsole layer.
Fig. 22 is a side view showing the outsole layer.
Fig. 23 is a perspective view of the sole pad member.
Fig. 24 is a side view showing the sole pod member.
25 is a perspective view of a midsole member;
26 is a side view of the midsole member;
27 is a perspective view of a partial outsole cap;
28 is a side view of the partial outsole cap;
29 is a perspective view of a partial outsole member;
30 is a side view of the partial outsole member;
FIG. 31 is a rear view showing a cross-section of a human foot, with the insole member, the array of cushion pod members, the stratified composite assembly of the entire layer and the partial layer folded into a three-dimensional structure suitably formed for a monogram shoe upper.
FIG. 32 is a rear view showing an extension outsole layer folded over the sole pod member and the midsole member and positioned with a size to “wrap” or wrap it, with a cross section of the human foot;
FIG. 33 is a rear view showing an extended outsole layer folded over, “wrapping” or wrapping over a sole pod member and a midsole member, with a cross section of a human foot;
FIG. 34 is a partially exploded back view showing an extended outsole layer folded over, “wrapping” or wrapping over a sole pod member and a midsole member with a cross-section of a human foot and fitted with a partial outsole member or an entire outsole member; FIG.
FIG. 35 is a rear view showing an extended outsole layer folded over, “wrapping” or wrapping over a sole pod member and a midsole member, with a cross section of a human foot, fitted with a partial outsole member;
FIG. 36 is a rear view showing an extended outsole layer folded over, “wrapping” or wrapping over an outsole pod member and a midsole member, with a cross section of a human foot, fitted with the entire outsole member;
FIG. 37 is a rear view showing an extended outsole layer folded over, “wrapping” or wrapping over a sole pod member and a midsole member, with a cross section of a human foot, fitted with a partial outsole member or an entire outsole member;
FIG. 38 is a rear view of the unitary shoe upper assembled with the full layer and the second full layer, with a cross section of the human foot; FIG.
FIG. 39 is a unitary shoe assembled with a full layer and a second full layer having a cross-section of a human foot and having an extended outsole layer positioned and sized to “wrap” or wrap over the sole pod member and midsole member; Rear view showing the upper.
FIG. 40 is a unitary shoe assembled with a full layer and a second full layer with a cross-section of a human foot, having an extended outsole layer folded and positioned over the sole pod member and the midsole member and sized to “wrap” or wrap it. Rear view showing the upper.
FIG. 41 is a cross-section of a human foot, having an extended outsole layer that is folded over and positioned to “wrap” or wrap over the sole pod member and the midsole member, and fits with the partial outsole member; Rear view showing a monolithic shoe upper assembled with the entire layer.
FIG. 42 is an entire outsole layer and a second outsole layer having a cross-section of a human foot and having an outsole layer that is folded and positioned over the sole pod member and the midsole member and is sized to “wrap” or wrap therein and fits with the entire outsole member; Rear view showing a monolithic shoe upper assembled with the entire layer.
FIG. 43 has a cross-section of a human foot, with an extended outsole layer folded over the sole pod member and the midsole member and positioned to have a size to “wrap” or wrap and fit with the partial outsole member and the entire outsole member; Rear view showing a monolithic shoe upper assembled with a layer and a second whole layer.
FIG. 44 is a partially exploded back view showing an extended outsole layer folded over, “wrapping” or wrapping over a sole pod member and a midsole member, with a cross section of a human foot, fitted with a partial outsole member or an entire outsole member;
FIG. 45 is a rear view showing an extended outsole layer folded over, “wrapping” or wrapping over a sole pod member and a midsole member with a cross section of a human foot and fitting with a partial outsole member or an entire outsole member;
FIG. 46 has an extension outsole layer, with a cross section of a human foot, positioned with a size for folding and “wrapping” or wrapping over the sole pod member and the midsole member and fitting with the partial outsole member and the entire outsole member; Rear view showing a monolithic shoe upper assembled with a layer and a second whole layer.
FIG. 47 is a rear view of the unitary shoe upper assembly having an extension outsole member with a cross section of a human foot; FIG.
FIG. 48 is a rear view of a unitary shoe upper assembly having a partial outsole member and an extended entire outsole member, with a cross section of a human foot; FIG.
FIG. 49 is a rear view of a unitary shoe upper assembly having a partial outsole member and an extended entire outsole member, with a cross section of a human foot. FIG.
FIG. 50 is a rear view of a unitary shoe upper assembly having a sole member and a partial sole member and a full sole member, with a cross section of a human foot; FIG.
FIG. 51 is a rear view of a unitary shoe upper assembly having a sole member and a partial sole member and a full sole member, with a cross section of a human foot; FIG.
FIG. 52 is a rear view of the unitary shoe upper assembly having a sole member and a partial sole member and a full sole member, with a cross section of a human foot; FIG.
FIG. 53 is a rear view of a unitary shoe upper assembly having a sole member and a partial sole member and a full sole member, with a cross section of a human foot; FIG.
FIG. 54 is a rear view of the unitary shoe upper assembly having a full layer and a second full layer, with a cross section of a human foot; FIG.
55 is a perspective view of a partial outsole member;
Fig. 56 is a sectional view of an outsole member including an "arch".
FIG. 57 is a cross-sectional view of an outsole member assembled from two or more outsole components and joined by a stabilizer; FIG.
58 is a sectional view of a stabilizer;
FIG. 59 is a perspective view of a cushion substrate having cushion substrate members of various shapes, sizes, and textures (the structure shown in the figures conforms to certain forms and is represented by simplified rendering).
FIG. 60 is a perspective view of a cushion substrate having cushion substrate members of various shapes, sizes, and textures cut out from the cushion substrate (structures shown in the figures are consistent in form and represented in simplified rendering).
FIG. 61 is a perspective view showing cushion substrate members of various shapes, sizes, and textures cut out from a cushion substrate (structures shown in the figures are consistent with certain forms and represented by simplified rendering). FIG.
FIG. 62 is a perspective view of a cushion substrate having cushion substrate members of various shapes, sizes, and textures aligned to a sheet substrate (structures shown in the figures conform to a consistent fashion and are shown in simplified rendering).
FIG. 63 is a perspective view of a cushion substrate having cushion substrate members of various shapes, sizes, and textures aligned and positioned on a sheet substrate (structures shown in the figures are consistent in form and represented in simplified rendering).
64 is a perspective view showing a cushion substrate having a cushion substrate assembly aligned and positioned on a seat substrate contact surface (structures shown in the figures conform to a consistent fashion and are shown in simplified rendering).
FIG. 65 is a perspective view showing a cushion substrate aligned to a seat substrate (structure shown in the figures conforms to certain forms and is represented in simplified rendering). FIG.
FIG. 66 is a perspective view of a cushion substrate having a cushion substrate assembly aligned and positioned on the seat substrate contact surface (structures shown in the figures conform to a consistent fashion and are shown in simplified rendering).
FIG. 67 is a perspective view showing a cushion substrate having cushion substrate members of various shapes, sizes, and textures aligned and positioned on the sheet substrate contact surface (structures shown in the figures conform to a consistent format and are shown in simplified rendering).
FIG. 68 is a perspective view showing a cushion substrate in combination with another cushion substrate to form an array of cushion substrate members made of two different types of materials (the structure shown in the figures conforms to a consistent form and is shown in simplified rendering).
FIG. 69 is a perspective view showing a cushion substrate in combination with another partial cushion substrate to form an array of cushion substrate members made of two different types of materials (structures shown in the figures conform to certain forms and are shown in simplified rendering).
FIG. 70 is a perspective view of a cushioning substrate having a reinforcing structure that engages the cushion subassembly (structures shown in the figures conform to a consistent format and are shown in simplified rendering).
FIG. 71 is a perspective view of a reinforcing structure fitted to a cushion base assembly (structure shown in the figures is consistent with the form and represented by simplified rendering). FIG.
FIG. 72 is a perspective view showing a reinforcing structure aligned with and engaged with a cushion substrate assembly positioned on the surface of a sheet substrate (structures shown in the figures are consistent in form and represented in simplified renderings).
73 is a perspective view of a reinforcing structure positioned on a surface of a sheet substrate and fitted to a cushion substrate assembly adhered thereto (the cushion substrate and the cushion substrate member are consistent in form and represented in simplified rendering, and the structure shown in the figure is consistent in form) And represented as a simplified rendering).
FIG. 74 is a perspective view of a laminate cut and shaped to form an apparatus substrate (structures shown in the figures conform to a consistent format and are shown in simplified rendering).
FIG. 75 is a perspective view of a device substrate fitted to a cushion substrate assembly (structures shown in the figures conform to a consistent format and are shown in simplified rendering).
FIG. 76 is a perspective view of an apparatus substrate fitted to a cushion substrate assembly (structures shown in the figures conform to a consistent format and are shown in simplified rendering).
77 is a perspective view of a shoe upper.
78 is a perspective view of a shoe upper.
79 is a perspective view showing a sheet substrate adhered to a cushion substrate member (the structure shown in the drawing conforms to a certain form and is shown in simplified rendering).
FIG. 80 is a perspective view showing the front, right and left leafs of the sheet substrate folded along the sheet substrate folding line to form a three-dimensional form (structures shown in the figures correspond to a consistent format and are shown in simplified rendering) .
FIG. 81 is a perspective view of reinforcing structures of two different shapes and sizes (structures shown in the figures correspond to certain forms and are shown in simplified rendering).
FIG. 82 is a perspective view showing a reinforcing structure positioned relative to a folding up sheet substrate such that one or more holes engage with the cushion substrate member (structures shown in the figures conform to a consistent form and are represented in simplified rendering).
FIG. 83 is a perspective view showing a reinforcing structure positioned relative to the folding up sheet substrate such that one or more holes engage with the cushion substrate member (structures shown in the figures are consistent in form and represented in simplified rendering).
FIG. 84 is a perspective view showing a sheet substrate adhered to a cushion substrate member on the outside of the folding up sheet substrate (the structure shown in the drawing conforms to a certain form and is represented by simplified rendering).
FIG. 85 is a perspective view showing a sheet substrate adhered to a cushion substrate member on the outside of the folding up sheet substrate (the structure shown in the drawing conforms to a certain form and is represented by simplified rendering). FIG.
FIG. 86 is a perspective view showing a sheet substrate adhered to a cushion substrate member on the outside of the folding up sheet substrate (the structure shown in the drawing conforms to a certain form and is represented by simplified rendering).

As used herein, a "unibody" shoe is a free of layers of two-dimensionally positioned sheets of material that are folded in the form of a shoe and bonded or sewn together to form a permanent shape. -Refers to the configuration of an entire shoe comprising at least an upper, preferably an outsole portion of a shoe using a pre-cut assembly. The layers of the seat may suitably comprise several objects of various dimensions and shapes, and / or consist of different materials in strategically located sites on the seat, such that when the assembly is folded in the form of a shoe A combination of different seat material and objects in the same impression, in particular "character" and performance, is characteristic for other areas or areas of the foldable shoe. The “monolithic” shoe does not require the sewing (sewing) of several components or swatches of different materials to form a shoe upper in pieces. Rather, the entire upper is pre-cut, unfolded along a two-dimensional plane, and folded three-dimensionally to take the form of a shoe.

As used herein, "non-uniform" or "asymmetric" shoes are of varying color, thickness, texture (texture), resilience, flexibility, breathability various objects or materials, such as breathability, etc., and thus different properties, areas or regions of the sheet. By providing this zonal change to the seat, once the assembly of the seat is folded in the form of a shoe, because the object or other type of materials strategically integrated into the seat exhibits these various “characteristics”, Although the shoe is assembled from a substantially continuous sheet of synthetic material, the folded constructed shoe exhibits various properties in different areas of the shoe.

Shoe production is generally produced through labor and time intensive processes and requires cutting, sewing, gluing and assembling of many individual components and subcomponents. 1 shows the general steps for making a shoe by assembling three main components. These three main components typically comprise a shoe upper 1 consisting of fabric, leather or other suitable synthetic material; Shock-absorbing midsole (2); And an outsole 3 which is typically made of rubber, plastic, leather or other durable material.

As shown in Fig. 2, the shoe upper 1 is generally manufactured by cutting and assembling a plurality of subcomponents, and sewing, sewing and adhering these subcomponents to each other.

In general, the heel cannon (heel quarter) (8) is cut separately and the heel cannon component outer layer (9A) is heel cannon component padding (9B) and the heel cannon component lining ( It can be produced by bonding or sewing on the inner lining (9C). Similarly, the shoe “tongue” component 4 can be cut separately and made by adhering or sewing the tongue outer layer 5A to the tongue padding 5B and the tongue lining 5C. The heel counter 6 can be made by cutting the heel wall outer layer 7A, the heel wall component 7B and the heel wall lining 7C separately and adhering or sewing each other. The toecap component 10A and the front nose reinforcement 10B may be glued or sewn together and then bonded or sewn to a shoe vamp 11A. Other subcomponents similarly require assembly, sewing or gluing of separate parts or swatches in separate steps.

In general, the various subcomponents must be glued or sewn together to form the shoe upper 1. By way of example only, in separate steps the front nose component 10A should be glued or sewn to the shoe declaration 11A and the front nose reinforcement 10B, and the shoe declaration 11A is a front quarter configuration. It must be glued or sewn to element 11B. The shoe tongue component 4 should be glued or sewn to the shoe proclamation 11A, and the heel wall 6 and the heel cannula 8 should be glued or sewn to the front sheath component 11B. do.

The partially assembled shoe upper 1 is then sewn or glued to an innersole board 12 to form the shoe upper 1.

3 shows the shoe upper 1 completely or fully assembled.

4, the shoe upper 1 is sewn or glued to the shock absorbing midsole 2 and the outsole 3, and the shock absorbing midsole 2 is the shoe upper 1 and the outsole 3. "Sandwich" in between.

Finally, the sockliner 15 shown in FIG. 5 is inserted, positioned or glued to the finished shoe upper-midsole-sole assembly 14.

As described above, the general process for assembling and manufacturing a shoe requires cutting, sewing, gluing, and assembling a number of separate components and subcomponents, which are relatively time consuming and labor intensive. Provide other or additional properties to any portion or area of the shoe (eg, additional cushioning or shock absorbency for the front nose area, or higher stiffness for the heel area, or greater flexibility for the proclaimed area) To do this, the manufacturer must manufacture additional components, which must be sewn, glued or assembled to the shoe upper or outsole assembly, which adds cost and complexity of the final product.

The present invention overlays sheet materials along a plane, cuts or shapes the sheet materials, attaches, fits, bonds or glues them, and finally synthesizes them to form the body structure of the shoe. Or by folding and assembling an overlapping sheet of synthetic-like material into a three-dimensional shape. As described in more detail below, these monolithic shoes are lightweight and require fewer individual parts, each to be sewn, stitched or glued together, and can be assembled in less time and at lower cost. have. In addition, the components of the monolithic structure shoe are made by unfolding flat sheets of various materials, and the components can be unfolded and bonded or attached to these materials, thus providing a variety of electronic, mechanical or electro-mechanical devices and configurations. The elements can be more easily integrated into the shoe assembly.

It is generally known that a shoe body structure of uniform thickness can be produced by a method such as injection molding. For example, rubber booties or rubber shoe covers may be suitable for this type. However, these types of shoes are not made of synthetic material with multiple sheet layers. The present invention proposes the integration of non-uniform materials, such as materials with different performance characteristics, in different parts of the shoe. For example, individual portions or areas of a monolithic shoe may have a non-uniform thickness or a uniform thickness, but other synthetic materials, such as foam and mesh versus foam and leather or two fabrics or Other properties can be provided because they can be made from other synthetic materials, such as foams with foam cages sandwiched between mesh substrates.

In general, an unbalanced thickness or other characteristic of the fabricated shoe construction takes the additional step of bonding or sewing the swatches or components of different types of materials to each other, or in additional discrete steps to the plastic or thermoplastic polyurethane. It is achieved by adhering or sewing the required additional components or watches to the shoe, such as additional components made. These additional discrete steps add cost, time and complexity of shoe assembly.

Thus, shoes can generally be made by sewing or gluing swatches of different materials so that different components of the shoe have different characteristics (eg, elastic toe area versus solid heel area, etc.). However, no shoes are known which comprise a body structure wherein at least the upper is made of one synthetic material which is composed of sheets of layered material (layered sheets) having different thickness and performance characteristics throughout the material and is continuously folded. not. In a preferred embodiment, the present invention relates to a monolithic shoe structure made of one synthetic material composed of a sheet of layered synthetic material and continuously folded, wherein the layered material sheet is asymmetric in thickness and / or performance properties, and is a single continuous The composite material of the sheet has non-uniform composition, thickness and component materials in various areas of the shoe.

By adjusting the shape and type of component materials that can be used in the synthetic material and the pattern to be cut in each individual layer of the synthetic material, the present invention provides a variety of thicknesses, textures (textures) in various designated areas or areas of the shoe. It provides a method of introducing various non-uniformities or asymmetries to the desired areas or components of the shoe, such as, but not limited to, stiffness, flexibility, hardness, color, breathability, shock absorbency, and wear resistance. Control of the sides of such shoes by using common means may require sewing or adhering together a plurality of additional swatches or components made of different materials and sizes, or in separate or additional steps It may be necessary to sew or glue other materials or various feel materials to the outer body. The general method of making a shoe typically requires additional sewing or bonding of other materials or various feel materials to the body of the shoe. This involves at least two other things: (1) sewing or gluing another swatch made of different materials or combinations of materials, or (2) sewing additional pieces of material on the outer surface of the shoe in separate steps. Or adhesion. All of this adds to the cost, time and complexity of the shoe assembling.

In this regard, it is conceivable to selectively add, tap, glue, or sew the trimming and additional material to the monolith shoe after the monolith shoe has been folded and configured, but the monolith shoe itself May be considered to incorporate asymmetric or additional material in those layers that are folded to make up the monolithic shoe.

In another aspect of the present invention, the monolithic shoe requires only one connecting operation to join the layers together after the layers are folded to make the shoe. The connection of the layers may be formed in a number of ways, including a sewing, Velcro (Velcro ^®) single, adhesive and so on, but not limited to.

The invention also relates to a shoe having an upper and insole (or upper and midsole or outsole) made in a single continuous configuration that is folded and bonded to one another in one seam. Specifically, the upper of the shoe can be made into a single continuous piece with different materials in different areas of the shoe, so that the material can be made of composite layers, which are called "composite" complex).

As described above, the present invention is a fabric made from a single piece of uniform synthetic material forming the body and sewn together with a single seam, in which separate tongues of the same material are sewn to the upper and the foam mixed with each other It is distinguished from the configuration of shoes which are generally known, such as composites with).

Monolithic Shoe Upper Assembly

6-9 show the main components of a monolithic shoe.

6 and 7 illustrate several optional components of a monolithic shoe upper 33.

More specifically, FIG. 6 is cut, overlayed, stacked, positioned, fitted, glued or sewn in each layer to form a synthetic or synthetic-like material, among others. The components of the unitary shoe upper 33 are shown, such as sheets of various materials.

The components of the monogrammed shoe upper 33 shown in FIG. 6 are an insole member 16, an individual cushion pod member 20, an array forming the cushion padding member 19, an entire layer 23. And partial layer 29 optionally.

The monogrammed shoe upper 33 overlaps sheets of cut or precut material in various forms, and then the bottom folding line 24 and the top folding line 60 to form a three-dimensional monogrammed shoe upper 33. Assembled by folding the sheet of material along the same folding line.

7 and 8 show a unitary shoe upper 33 assembled from the various components shown in FIG. 6.

9 shows several optional components of a monolithic shoe outsole assembly. The components of the monolithic shoe outsole assembly shown in FIG. 9 are an outsole layer 34, a sole pod element 48 that is an array forming the outsole padding member 35 shown in FIG. 23, FIG. Optionally includes a partial outsole cap 50 and an entire outsole member 38, which are arrays forming the partial outsole member 37 shown in FIG.

Insole member

16 shows an optional insole member 16 having a bottom surface 17.

17 shows a cross section of the insole member 16. As shown in FIG. 17, the bottom surface 17 of the insole member 16 may optionally include a hole 18. The hole 18 may be shaped or sized to selectively engage or fit the one or more cushion pod members 20 as shown in FIG. 18.

Insole member 16 may optionally be made of a cushion or shock absorbing material or a material that provides structural rigidity to the insole or the entire shoe. 6, 16 and 17 show a flat insole member 16, but may optionally be of an arcuate or inclined shape or may be fabricated in various shapes, thicknesses and shapes. Alternatively, the insole member 16 may be embedded or attached to an electronic device, a mechanical device or an electro-mechanical device as shown in FIGS. 74-76.

Although FIG. 16 shows a single insole member 16, the monogrammed shoe may optionally include multiple insole members sandwiched in layer form or between other components.

In addition, FIG. 17 shows a hole 18 in the bottom surface 17, which hole may optionally be located at the upper end of the insole member 16.

Cushion pad member and cushion padding member

10 shows in more detail an individual cushion pod member 20 that is an array forming the cushion padding member 19.

The cushion pod member 20 is preferably formed of an elastic foam or rubber. Optionally, the cushion pod member 20 may be formed of plastic, elastomer, or the like, or other shock absorbing material including any combination of these materials. For this purpose ethylene vinyl acetate ("EVA") foams, olefin foams or polyolefin foams, polyurethane ("PU") foams, urethane based foams, thermoplastic foams or suitable impacts It will be appreciated that a wide variety of materials can be used, including other materials (including any combination of these materials) having absorption properties, adequate firmness or resistance to puncture or abrasion (wear resistance), and the like. It is not limited. The cushion pod member 20 may optionally be solid or perforated. Functionally, the cushion pod member is characterized by the type and material of the cushion pod member, the form of the cushion pod member, its size (including thickness), its number, its position and closeness to each other or other components. It can thus act as a cushion for impact, provide thermal insulation for cold heat, provide ventilation or air circulation, or provide a variety of firmness or flexibility for the entire assembly.

The cushion pod member 20 may be made of subcomponents of various sizes and shapes, including by way of example only as shown in FIGS. 68 and 69. By way of example only, the cushion pod member may be fabricated by bonding or bonding two or more different types of materials.

6 and 10 show a locking pod element 22, which may be formed in a size, shape, and position that can engage the locking pod hole 25 shown in FIGS. 6 shows a locking pod member 22 attached to one or more cushion pod members 20, but optionally the locking pod member may be self-supporting and may be attached or fitted to one or more entire layers, sublayers, or insole members. can be fitted. In addition, the locking pod hole 25 may optionally be located in one or more whole layer members, partial layer members or insole members.

Optionally, the one or more cushion pod members 20 may be of any size, shape, and location that engages the pod fitting holes 26 shown in FIGS. 6 and 11. 6 and 11 show the pod fitting holes 26 located in or cut out of the entire layer 23. However, the pod fitting holes may optionally be located in one or more entire layers, second outer layers or insole members. Optionally, if the monolithic shoe optionally includes one or more layers of cushion padding members layered or positioned on top of each other, the pod fitting aperture 26 is located on or in another cushion pod member or cushion padding member. It may be cut out.

As shown in FIG. 6, in one embodiment of the present invention, the bottom surface 21 of the one or more cushion pod members 20 is positioned continuously to the top surface 27 of the entire layer 23 and the one or more cushions. The pod member 20 may optionally be bonded, glued, sewn, fitted or attached to the top surface 27. Meanwhile, as described above, the one or more cushion pod members 20 may be configured to engage with the pod fitting holes 26.

By way of example only, the cushion pod member 20, such as the cushion pod member 20 shown in FIG. 10, may have various qualities and characteristics (only as an example, different shock absorbers) for other parts or areas of the shoe after the completed assembly. It is to be understood that it may be of various types of sizes, shapes, and positions and may be made of different materials to provide degree, structural robustness, breathability, coverage, etc.). However, the cushion pod member may have various shapes and dimensions (including irregular or asymmetrical shapes) and may be located in other areas of the synthetic material forming the body structure of the shoe. By way of example only, the heel collar cushion member 40 may be selectively formed and properly positioned such that once the entire assembly is folded, the “heel collar” area (such as a heel scalpel or heel wall) of the finished shoe is folded. Provide as much rigidity, structural preservation, suitable form or cushion as intended for the invention. Similarly, the heel cushion member 47, the side cushion member 44, and the front nose cushion member 41 each have varying degrees of firmness, structural preservation, suitable form or cushion on the heel, sidewall, or front nose area of the shoe. It can be included individually or in different combinations to provide. 10 shows a heel collar cushion member 40, a heel cushion member 47, a side cushion member 44 and a front nose cushion member 41 made of a single piece, but optionally they are side cushion subs. Like component 39, it may consist of multiple subcomponents.

Full layer (full layer)

6 and 11 illustrate the entire layer 23, optionally with natural or artificial fabrics, natural or artificial leather, mesh, stretch or flexible plastics, latex, silicone, other rubber materials, artificial or synthetic fibers. Or other types of materials that can optionally impart different breathability, stretchability, shock absorbency, weight, and structural preservation to the assembly. Optionally, the whole layer member may also be made of ethylene vinyl acetate ("EVA") foam, olefin or polyolefin foam, polyurethane ("PU") foam, urethane-based foam, thermoplastic foam, elastomer or suitable shock absorbing properties, suitable firmness or puncture. Or a sheet of other material (including any combination of materials) having resistance to abrasion (wear resistance) and the like.

6 shows a single whole layer 23, but is layered on top of each other or on top of each other or other subcomponents (such as cushion pod member 20 or cushion padding member 19 or sublayer 29). One or more whole layers may be used that are layered with, sandwiched between, or positioned adjacent to each other. By way of example only, the whole layer 23 may optionally be laminated with a cushioning pod member fitted between another whole layer, a partial layer or two whole layers, and optionally the whole layer 23 may also be laminated with one or more sublayers. It can be stacked together and layered together.

By way of example only, an appropriate material or combination of materials for the entire layer 23 may optionally be dependent upon the number of the full layer member and the partial layer member incorporated into the shoe assembly, or where the full layer member faces the outer surface of the shoe or the inner surface of the shoe. Or ie contact with the feet or the skin.

Alternatively, the entire layer 23 may optionally be embedded or attached to an electronic device, a mechanical device or an electro-mechanical device as shown in FIGS. 74 and 76.

Optionally, the entire layer 23 of one or more sheets can be cut into a shape that allows it to be folded along the bottom folding line 24 to form a three-dimensional configuration having a suitable shape for the monolithic shoe upper 33. It is understood that it can. Optionally, the entire layer 23 may include additional folding lines, such as the top folding line 60 as shown in FIG. 6 by way of example.

By way of example only, FIG. 6 shows an optional full layer tongue element 28 as part of a flat layer 23 that is laid flat in one embodiment of the present invention. 7 shows the same whole layer tongue member 28 in the same optional embodiment after the whole layer 23 has been folded into a three-dimensional configuration suitably formed for the monolithic shoe upper 33.

As described above, the entire layer 23 as shown in FIG. 11 includes a pod fitting hole 26 and one or more locking pod members 22 sized and positioned to engage one or more cushion pod members 20. It may optionally include a locking hole 25 in size and position for engagement with the. The pod fitting hole member and the locking hole member are merely illustrative and varying in the entire layer 23 including the heel area 42, the area corresponding to the “bottom” of the insole or shoe, the heel clasping area or the proclamation (forewing) area. May be located in areas.

When the entire layer 23 is folded along the folding line, the seam can be optionally welded or fused, glued or sewn, and optionally a piece of other material (fabric, leather, rubber, thermoplastic, etc.) is placed on the seam. And may be fused, glued or sewn.

Sublayer

6 and 12 show partial layers 29, optionally with natural or artificial fabrics, natural or artificial leather, stretch or flexible plastics, latex, neoprene, silicone, other rubber materials, artificial Or synthetic fibers, or other types of materials that can optionally impart different breathability, stretch, impact absorbency, weight, and structural preservation to the assembly. Optionally, the sublayer member may also be an ethylene vinyl acetate ("EVA") foam, an olefin or polyolefin foam, a polyurethane ("PU") foam, a urethane-based foam, a thermoplastic foam, an elastomer or suitable shock absorbing properties, suitable firmness or puncture. Or a sheet of other material (including any combination of materials) having resistance to abrasion (wear resistance) and the like.

FIG. 6 shows a single sublayer 29, but is layered on top of each other or on top of each other, such as other subcomponents (such as cushion pod member 20, cushion padding member 19, or entire layer 23). ) May be used one or more whole layers layered or sandwiched therebetween, or located adjacent to each other. By way of example only, the partial layer 29 may optionally be laminated with a cushion pod member sandwiched between the entire layer, an additional whole layer or a partial layer or material layer, and optionally the partial layer 29 may also be one or more portions. It can be laminated and layered with the layers.

Optionally, suitable materials or combinations of materials for sublayer 29 depend on the number of full-layer members and sublayer members incorporated in the shoe assembly, or whether the sublayer members face the outer surface of the shoe or the inner surface of the shoe (ie , Foot or skin).

Alternatively, the partial layer 29 may optionally be embedded or attached to an electronic device, a mechanical device or an electro-mechanical device as shown in FIGS. 74 and 76.

Optionally, one or more of the sublayers 29 of the sheet may be cut in such a way that it can be folded along the sublayer top folding line 43 and the sublayer bottom folding line 30, such that the monolayer shoe upper 33 It will be appreciated that a three dimensional configuration can be formed having an appropriate shape for the device.

In addition, the sublayer 29 may include a sublayer locking pod hole 31 that may be sized, shaped and positioned to engage the locking pod member 22. Although not shown in FIGS. 6 and 12, it may include an opening similar to the pod fitting hole 26 in size, shape, and position for engaging with one or more cushion pod members 20. The partial layer locking pod hole member and the pod fitting hole member may be located in various regions of the partial layer 29.

Optionally, the partial layer 29 may be positioned or layered to face the outer surface of the shoe while in contact with the entire layer 23. Alternatively, the partial layer 29 may be folded to a desired size, shape and position, and then welded or bonded to cover the "seam" of the entire layer 23 after being folded. In this regard, the sublayer 29 may be formed to optionally include an extension, such as the sublayer side member 32 shown in FIG. 6. Optionally, the partial layer side member 32 may be partially or wholly folded over the entire layer 23 or another example sublayer 29, and may cover, seal, or deposit, sew, glue or otherwise bond the "seam". Can be attached.

7 shows an optional embodiment of the assembled monolithic shoe upper 33, where the sublayer 29 is located below the entire layer 23 and the portions of the sublayer 29 (eg, sublayer). The side member 32), such as the side member 32, is folded and sealed over the "seam" created in the assembly when the entire layer 23 is folded into a three-dimensional structure.

In addition, the sublayer side member 32 is optionally made of a suitable size and shape and is made of a suitable stretch and resilient material including synthetic material to provide additional structural preservation for the monolithic shoe upper assembly and the fully assembled monolithic shoe. It can be made and attached to the unitary upper shoe assembly.

Embodiment of Shoe Upper Assembly

FIG. 13 illustrates an alternative embodiment of the present invention, including among other things a multiple cushion pod member 20, a heel collar cushion member 40, a side cushion member 44 and a side cushion subcomponent 39. A cushion padding member 19 is positioned relative to the entire layer 23.

FIG. 14 illustrates one optional embodiment of the present invention in which the cushion padding member 19 is bonded, glued, or attached to the entire layer 23.

15 illustrates an optional embodiment of the present invention, wherein after cushion padding member 19 is bonded, glued, or attached to entire layer 23, the entire layer 23 is top folding line 60 among others. Along the bottom folding line 24 is folded into a suitably formed three-dimensional structure to obtain a monolithic shoe upper 33. More specifically, FIG. 15 optionally shows a cross section of the human foot 46 with respect to the folded cushion padding member 47 and the whole layer assembly. 15 shows a cross-sectional view of the locking pod member 22 coupled to the heel cushion member 47 and the locking pod hole 25.

18 illustrates an optional embodiment of the present invention, wherein the insole member 16 is positioned adjacent to the folded cushion padding member and the entire layer assembly. FIG. 18 also shows an optional embodiment of another aspect of the present invention in which the partial layer 29 is positioned adjacent to the cushion padding member and the whole layer assembly.

19 illustrates an optional embodiment of the present invention, optionally with an insole member 16, a cushioned pod member 20 of the layered composite assembly, with a cross section of the human foot 46 with respect to the composite assembly of the folded layered layer. ), The entire layer 23 and the partial layer 29 are folded into a three-dimensional structure suitably formed to obtain a monolithic shoe upper 33. 19 is also selectively coupled to the insole member 16, the heel cushion member 47, and the partial layer locking pod hole 31 and the locking pod hole 25, which are selectively coupled to the multiple cushion pod member 20. The cross section of the locking pod member 22 is shown. 19 further shows a cross-sectional view of the heel collar cushion member 40 and folding the entire assembly along the sublayer top folding line 43 and the sublayer bottom folding line 30.

20 shows the unitary shoe upper 33 assembled. After the unitary shoe upper 33 is assembled, the assembly may optionally be sewn or glued to a midsole or outsole fabricated using an existing process.

In addition, the unitary shoe upper 33 may optionally be further assembled with the unitary shoe outsole assembly described below to form a unitary structure shoe.

Monolithic shoe outsole assembly

As described above, FIG. 9 shows an outsole layer 34, a bottom pod member 48, an array forming the outsole padding member 35, a midsole member 36, a partial outsole cap 50, and a partial outsole member 37. And various optional components of a monolithic outsole assembly such as the entire outsole member 38. A monolithic shoe outsole assembly can be made by using one or more of the components or combinations thereof described above.

21 and 22 illustrate an optional outsole layer 34. As shown in FIG. 31, the outsole layer 34 may optionally include an outsole layer hole 61 positioned and sized to engage one or more bottom pod members 48. The outsole layer 34 may optionally include natural or artificial fabrics, natural or artificial leather, mesh, flexible or flexible plastics, rigid plastics or rubber, latex, neopyrene, silicone, other rubber materials, artificial or synthetic fibers, or the assembly It can be made of any combination that can selectively impart different breathability, elasticity, impact absorbency, weight, and structural preservation.

Alternatively, the outsole layer 34 may be embedded or attached to an electronic device, a mechanical device or an electro-mechanical device as shown in FIGS. 74-76.

23 and 24 show optional bottom pod members 48, which are arrays forming outsole padding members 35. Optionally, bottom pod member 48 may be made of foam or other impact absorbing material, such as rubber, plastic, elastomer, and the like, and may include any combination of these materials. Functionally, the cushion pod member depends on the size (including thickness), type and material of the individual bottom pod member, the shape of the cushion pod member, its number, its position and closeness to each other or other components. It can act as a cushion against impact, provide insulation against cold heat, provide ventilation or air circulation, or provide a variety of firmness or flexibility for the entire assembly.

It will be appreciated that the bottom pod member 48 may be comprised of, but is not limited to, other combinations of materials and subcomponents of various sizes and shapes, including arrangements similar to those shown in FIGS. 68 and 69. have.

In one embodiment of the invention, optionally, the one or more bottom pod members 48 are positioned and sized to engage the midsole opening 49 in the midsole member 36.

25 and 26 show optional midsole member 36. Optionally, the midsole member 36 may include a midsole hole 49 and may be suitably formed to otherwise or additionally couple to one or more bottom pod members 48.

Alternatively, the midsole member 36 may be made of foam or rubber, or may be made of other shock absorbing materials, such as plastics, elastomers, and the like, including any combination of these materials. Functionally, the midsole member 36 may act as a cushion for impact, shock absorbing, or varying rigidity for the entire assembly depending on the size (including thickness) and type and the material used to form the midsole member 36. Or provide flexibility.

Also, optionally, the midsole member 36 may be embedded or attached to an electronic device, a mechanical device, or an electro-mechanical device, as shown in FIGS. 74-76.

27 and 28 show optional partial outsole cap 50, which is an array forming partial outsole member 37. Optionally, the partial outsole cap 50 may be made of foam or other shock absorbing material, such as rubber, plastic, elastomer, and the like, and include any combination of these materials. Functionally, the cushion pod member is cushioned against impact depending on the size (including thickness), type and material of the individual partial outsole cap, its form, its number, its position and closeness to each other or other components. It can act as a shock absorber, provide abrasion resistance, or provide a variety of firmness or flexibility over the entire assembly.

It will be appreciated that the partial outsole cap 50 may consist of, but is not limited to, other combinations of materials and subcomponents of various sizes and shapes, including arrangements similar to those shown in FIGS. 68 and 69. have.

29 and 30 show an optional outsole member 38. Optionally, outsole member 38 may be made of foam or other shock absorbing material, such as rubber, plastic, elastomer, and the like, and may include any combination of these materials. Functionally, the outsole member 38 acts as a cushion for impact, absorbs shock, provides abrasion resistance, or provides a variety of tightness to the entire assembly, depending on the size (including thickness), type and material of the outsole member 38. It can also provide flexibility.

Optionally, outsole member 38 may include an outsole lock 51 and may be formed to engage another or additionally one or more bottom pod members 48 or partial outsole cap 50. have.

Alternatively, the outsole member 38 may be embedded or attached to an electronic device, a mechanical device, or an electro-mechanical device, as shown in FIGS. 74-76.

FIG. 31 illustrates an optional embodiment of the present invention, wherein the insole member 16, the entire layer, with a cross section of the human foot 46 relative to the composite assembly of the folded layer layer (ie, monogrammed shoe upper 33). With 23 and sublayer 29, the layered composite assembly is folded into a suitably formed three-dimensional structure to obtain monolithic shoe upper 33. 19 also shows a cross-sectional view of the insole member 16 selectively coupled to the multiple cushion pod member 20, among others.

31 also shows another alternative aspect of the invention, wherein the outsole layer 34 is selectively coupled to the multi-bottom pod member 48 by the outsole layer 34 by the outsole layer aperture 61, Bottom pod member 48 is selectively coupled to midsole member 36 by midsole holes 49 shown in FIGS. 25 and 26, and partial outsole cap 50 is coupled or attached to bottom pod member 48. The entire outsole member 38 is coupled or attached to the partial outsole cap 50, the bottom pod member 48, or both.

Optionally, the monogrammed shoe outsole assembly is folded and bonded, sewn, glued, or attached to the layered composite assembly (ie, monogrammed shoe upper 33) as shown in FIG. In one embodiment of the invention, the outsole layer 34 or the multi-bottom pod member 48 or both are bonded, sewn, glued, or attached to the monogrammed shoe upper 33.

32 and 33 illustrate another optional embodiment of the present invention wherein the entire layer 23 optionally includes an opening, ie, a full layer bottom pod hole 63 that engages the bottom pod member 48. In this embodiment, the bottom pod member 48 contacts the sole of the shoeer foot 46.

32 also shows another optional aspect of the present invention, wherein the extension outsole layer 52 has a predetermined size and is folded over and " wraps around the bottom pod member 48 and the midsole member 36. Or to wrap. In this optional embodiment, the extension outsole layer 52 is selectively coupled to the multiple bottom pod member 48 by extension outsole layer apertures 62.

FIG. 33 shows an extension outsole layer 52 that is folded around, “wrapping” or surrounding the bottom pod member 48 and midsole member 36.

34, 37 and 44-45, the partial outsole member 37 or the entire outsole member 38, or a combination thereof, is selectively coupled, sewn, or bonded to the assembly shown in FIGS. 32-33. Or may be attached.

35 shows the assembly shown in FIGS. 32-33 that is coupled, sewn, glued, or attached to the partial outsole member 37. FIG. 36 shows the assembly shown in FIGS. 32-33 that is bonded, sewn, glued, or attached to the entire outsole member 38. Finally, FIGS. 37 and 45 show the assemblies shown in FIGS. 32-33 that are joined, sewn, glued, or attached in a combination of the partial outsole member 37 and the entire outsole member 38.

31 to 37 show a monolithic shoe upper 33 having a single monolayer 23, but optionally monolithic shoe upper 33 may be a monolithic shoe upper 33 or one or more sublayers 29 or a combination thereof. It can be seen that it can include a combination of.

38 to 40 show a cross section of a monolithic shoe upper 33 optionally assembled with a full layer 23 and a second full layer 53. In this optional embodiment, the heel collar cushion member 40 and the heel cushion member 47, among others, are selectively fitted between the entire layer 23 and the second entire layer 53.

41-43 and 46, the partial outsole member 37, the entire outsole member 38, or both, may optionally be joined, sewn, glued, or attached to the assembly shown in FIG. FIG. 41 shows the assembly shown in FIG. 40 coupled, sewn, glued, or attached to the partial outsole member 37. FIG. 42 shows the assembly shown in FIG. 40 bonded, sewn, glued, or attached to the entire outsole member 38. Finally, FIGS. 43 and 46 show the assembly shown in FIG. 40 bonded, sewn, glued, or attached in a combination of a partial outsole member 37 and an entire outsole member 38.

It will be appreciated that the overall outsole member 38 may vary in dimensions and sizes, including thickness and height. In one optional embodiment of the present invention, the circumferential edge of the entire outsole member 38 may have a size and shape that may extend into the monogrammed shoe upper 33. 47-48 show the assembly shown in FIG. 33 coupled, sewn, glued, or attached to the entire extended outsole member 54. FIG. 49 shows the assembly shown in FIG. 40 coupled, sewn, glued, or attached to the entire extended outsole member 54.

41-43 and 50-54, outsole layer 34, with partial outsole member 37, full outsole member 38, extended full outsole member 54, or a combination thereof. (Combined as shown in FIGS. 50 to 52 as the outsole member 55) or the extension outsole layer 52 can be used for various optional combinations and substitutions.

In addition, it can be appreciated that the invention optionally does not need to include a partial outsole member 37, an entire outsole member 38, or an extended entire outsole member 54 as shown in FIG. 53.

43, 45 and 52, various alternative combinations and substitutions are possible by using one or more entire layers 23 in the unitary shoe upper 33 to be assembled. By way of example only, a single whole layer 23 may optionally be used together as shown in FIGS. 46 and 52, or alternatively the whole layer 23 and the second whole layer 53 are also shown in FIG. 54. Likewise it can be used with multiple layers of cushion padding member 19, for example.

29, 30 and 55 show the outsole member 38 as consisting of a single flat continuous piece. However, it will be appreciated that the outsole member 38 may optionally be curved or "arched" three-dimensional.

56 shows a cross-section of an alternative embodiment of the outsole member 38 incorporating an "arched" shape.

Also optionally, as shown in FIG. 57, the outsole member 38 may be assembled from two or more separate outsole components 56, 57, which are separated by a stabilizer 58. It can be seen that it can be combined.

As shown in FIG. 58, stabilizer 58 may optionally include stabilizer holes 59, or is positioned with a size and shape that can engage one or more bottom pod members 48.

Single shoe upper and outsole component assembly and construction process

The present invention also relates to a process (method) of manufacturing the monolithic structure shoe described above.

59-61, in one embodiment of the present invention, cushioning substrate 69 is used to form cushion substrate members of various sizes and shapes.

As shown in FIG. 59, the cushion substrate 69 is cut along the substrate cutting line 102.

FIG. 60 illustrates one embodiment of the invention in which the various cushion substrate members cut the cushion substrate 69 while leaving holes 103 and 76 in the cushion substrate 69. The material from which the cushion substrate 69 is cut may be used to selectively produce cushion substrate members of various sizes and shapes, as described below. A cushioning substrate 69 with material removed from the holes 103, 76 is shown in FIG. 60 like the rest of the cushioning substrate 77.

60 and 61 are selectively from a cushion substrate 69 that includes a bottom substrate member 104, a side substrate member 64, a heel cap substrate member 65, and a heel collar substrate member 66 by way of example only. The various cushioning base members which were comprised are shown. As shown in FIG. 61, the various cushion base members are selectively positioned relative to each other to form the cushion base assembly 67.

In this embodiment of the invention, the various cushion substrate members are selectively positioned and aligned with respect to their position in the monolithic shoe upper 33. Optionally, the side substrate member 64 may be positioned relative to the proclaimed side 70 of the monogrammed shoe upper 33, and the heel collar substrate member 66 may be positioned at the heel buckle 71 of the monogrammed shoe upper 33. And at least one bottom substrate member 104 may be positioned relative to the toe 68 of the unitary shoe upper 33.

The bottom substrate member 104 fabricated in the manner described above may optionally be used to form the cushion pod member 20. Also, optionally, the bottom substrate member 104 may be used to form the bottom pod member 48 or the cushion subcomponent 37. Side substrate member 64 may optionally be used to form side cushion subcomponent 39 or side cushion member 44. The heel cap base member 65 may optionally be used to form the heel cushion member 47.

Another embodiment

62 to 64 show another embodiment of the present invention.

62 shows a cushion substrate 69 that cuts along the substrate cutting line 102. The cushion substrate 69 is positioned or aligned with respect to the sheeting substrate 72. Optionally, the substrate cutting line 102 can be positioned or aligned with respect to the sheet substrate cutting line 73.

In order to facilitate the assembly of the components described below, one or more cushioning substrates 69 may be positioned or aligned with respect to one or more sheet substrate cutting lines 74 in one example in the seat substrate 72 of adjacent sheets. It can be seen that.

FIG. 63 shows the cushion substrate 69 aligned and positioned with respect to the sheet substrate contact surface 75 of the sheet substrate 72.

64 shows a cushion substrate assembly 67 (bottom substrate member 104, side substrate member 64, heel cap substrate member 65, and heel collar substrate attached to the sheet substrate contact surface 75 of the sheet substrate 72. Optionally including member 56).

Optionally, adhesive is applied to the various cushioning substrate members, the adhesive is applied to the contact surface or portion of the cushion substrate 69, and then selectively removed the adhesive from the area comprising the contact surface or portion of the remaining cushion substrate 77. Thereafter, the cushion substrate assembly 67 or the cushion substrate assembly 67 may be attached to the sheet substrate contact surface 75 by a variety of means, such as by masking only the cushion substrate assembly 67 or the individual cushion substrate member to be attached to the sheet substrate contact surface 75. Individual cushioning base members can be attached. It will be appreciated that any or any of these methods for forming a material for attachment to another can be used.

As further shown in FIG. 64, the remaining cushion substrate 77 is removed leaving the cushion substrate assembly 67 or individual cushion substrate member attached to the sheet substrate contact surface 75.

The final assembly may further proceed to form components for the monolith shoe upper 33 shown in FIG. 8 or the monolithic outsole assembly shown in FIG. 9.

The sheet substrate 72 described above may optionally be used to form the insole member 16, the entire layer 23, or the partial layer 29. Also, optionally, the sheet substrate 72 may be used to form the outsole layer 34, the midsole member 36, and the entire outsole member 38.

Another embodiment

65 and 67 show yet another embodiment of the present invention. FIG. 65 shows the cushion substrate 69 positioned and aligned with respect to the seat substrate 72 to leave various distances between the cushion substrate and the seat substrate. Also, optionally, the cushion substrate 69 may contact the sheet substrate 72. Also, optionally, the substrate cutting line 102 may be positioned or aligned with respect to the sheet substrate cutting line 73.

Also, optionally, the cushion substrate 69 may be cut along the substrate cutting line 102 before being positioned or aligned with respect to the sheet substrate 72.

It is understood that the example cushion substrate 69 may be positioned relative to the sheet substrate 72 and may be aligned with respect to the sheet substrate cutting line 74.

As shown in FIG. 66, the cushion substrate assembly 67 or the individual cushion substrate members can selectively push, press or “punch” the cushion substrate 69 to form a sheet substrate ( 72 may be in contact with and pressed against the sheet substrate contact surface 75.

If the cushion substrate 69 is not cut along the substrate cutting line 102 before being positioned or aligned with respect to the sheet substrate 72, the cushion substrate 69 may be cut along the substrate cutting line 102, and a single The cushioning substrate 69 may be pushed, pressed or "punched" in a step or substantially continuous step.

In any case, once the cushion substrate assembly 67 or the individual cushion substrate member can selectively cut, push, press or punch the cushion substrate 69, they can be transferred from the cushion substrate 69 to the individual cushion substrate member. The remaining cushioning substrate 77 with holes 103 and 76 corresponding to the position remains.

FIG. 67 shows a cushion base assembly 67 (bottom base member 104, side base member 64, heel cap base member 65, and heel collar base) in contact with the sheet base contact surface 75 of the sheet base 72. Optionally including member 66). The cushion substrate assembly 67, the individual cushion substrate members may be formed by contacting the sheet substrate contact surface by a variety of means including glue or cement, adhesive film, heating or microwave or radio-wave active adhesive, double-sided adhesive film, and the like. And may be attached to 75. It is understood that these or any other method for forming a material for attachment to another can be used.

Also, optionally, a hole may be formed in the sheet substrate 72, or an indentation may be cut out or indented in the sheet substrate contact surface 75 of the sheet substrate 72. The holes are sized and shaped to engage with the cushion substrate assembly 67 or the individual cushion substrate members, and optionally "lock" them. Selective examples of these are shown in FIGS. 70 and 71 and 81 and 82.

The final assembly may further proceed to form components for the monolith shoe upper 33 shown in FIG. 8 or the monolithic outsole assembly shown in FIG. 9.

It is understood that the sheet substrate 72 described above may optionally be used to form the insole member 16, the entire layer 23, or the partial layer 29. Also, optionally, the sheet substrate 72 may be used to form the outsole layer 34, the midsole member 36, and the entire outsole member 38.

It is understood that the procedures shown in FIGS. 62-64 and 65-67 can be used to form the composite material shown in FIGS. 77 and 78. 77 and 78 illustrate a shoe upper in which the top and sidewalls (or proclamations) are made by layering or “sandwiching” foam members (such as cushion pod members 20) between sheets or layers of flat material. An example is shown and the present invention is not limited thereto. Figures 77 and 78 show the "declaration" of a shoe made of foam member 99 in which the "declaration" is sandwiched between the outer layer 100 and the inner layer 101, where the outer layer 100 is made of mesh, The foam member 99 is partially visible underneath.

Other cushion base assembly method

It is understood that the cushion substrate 69 is used to form cushion substrate members of various shapes and sizes (including thickness). In addition, the cushion substrate 69 and the cushion substrate member may be foam, rubber, silicone, latex, natural or artificial fabric, natural or artificial leather, mesh, elastic or flexible plastic or other rubber or plastic material, artificial or synthetic fibers, or It is understood that other types of materials may be selectively fabricated including, but not limited to, any combination of these materials.

It is further understood that one or more types of materials may optionally be used to form the cushion base member.

FIG. 68 illustrates another embodiment of the present invention, comprising a bottom base member 104 coupled with another bottom base member 80 and a heel collar base member 66 coupled with another heel collar base member 81. Likewise, the cushion member 69 is bonded to or optionally bonded to the other cushion substrate 79 to form an array of cushion substrate members made of two different types of materials.

By way of example only, alternatively, the method described in FIG. 68 can be used to fabricate the bottom pod member 48 as shown in FIGS. 23 and 53, with the upper half of the bottom pod member 48 being either foam or It may be made of other softer cushion materials, and the lower half of the bottom pod member 48 may be made of rubber or other materials that are elastic and wear resistant.

Alternatively, the method shown in FIG. 68 may also be used to fabricate the cushion pod member 20 as shown in FIGS. 10 and 19, where the upper half of the cushion pod member 20 is foam or other. It may be made of a softer cushion material, and the lower half of the bottom pod member 20 may be made of rubber or other materials that are elastic and wear resistant.

FIG. 69 illustrates another embodiment of the present invention wherein the cushion substrate 69 is bonded or selectively bonded with other partial cushion substrates 82 to form an array of cushion substrate members, a portion of which is a single type. Of material (such as the side substrate member 64 and at least a portion of the bottom substrate member 104), and some of the other two types of materials (as shown in FIG. 69 with the other partial heel collar substrate member 83). Such as engagement of the heel collar substrate member 66).

By varying the type of material used to form the cushioning substrate 69, the number, shape, size (including thickness), position and alignment of the other cushioning substrate 79 and other partial cushioning substrates 82 and appropriate substrates can be determined. It is understood that many other various cushion substrate assemblies 67 and individual cushion substrate members can be fabricated.

Optional reinforcement structure

In another embodiment of the present invention, it is cut from the cushion substrate 69, the sheet substrate 72 or other materials of suitable size, shape and composition to form a reinforcing structure 84 as shown in FIGS. 70 and 71. Holes may be formed.

As shown in FIG. 70, the reinforcement structures 84 may be formed to include voids 86 or reinforcement structure holes 85, which may be cushion substrate assemblies 67 or individual cushion substrate members, cushion padding. It may be sized and shaped to engage member 19 or individual cushion pod member 20, outsole padding member 35 or individual bottom pod member 48, or locking pod member 22.

By way of example only, FIG. 71 shows a reinforcing structure 84 fitted with a cushion substrate assembly 67 with at least one bottom substrate member 104 coupled to at least one reinforcing structure hole 85.

FIG. 72 shows a reinforcing structure 84 aligned with and engaged with a cushion substrate assembly 67 located on the surface of the seat substrate 72.

73 shows a reinforcement structure 84 fitted to a cushion substrate assembly 67 positioned on and bonded to the surface of the seat substrate 72.

It will be appreciated that the reinforcing structures 84 may have various shapes (including thicknesses) and sizes. In addition, the reinforcing structures 84 are held together, taking into account structural preservation, and other layered components, such as the sheet substrate 72 or the entire layer 23 or the partial layer 29, form a monolithic shoe upper 33. It can be seen that it can optionally be used to "lock" or seal the seam that is formed when folded three-dimensionally to

As an example only, FIG. 79 shows the sheet substrate 111 to which the cushion substrate member 117 is adhered.

As shown in FIG. 80, the front 113, right 114, and left 112 leaves of the sheet substrate 111 are folded along the sheet substrate folding line 115 to form a three-dimensional shape. . 80 shows the unfolded left leaf 112 of the sheet substrate 111 for purposes of illustration.

81 shows a reinforcing structure-reinforcing structure 118 and a reinforcing structure 120 having two different optional shapes and sizes. Reinforcing structure 118 includes a hole 119, and the reinforcing structure 120 includes a hole 121. The reinforcing structure member can have a variety of shapes and dimensions, and the size, location and placement of the holes can be varied.

As shown in FIG. 82, the reinforcing structure 118 may be positioned relative to the folding up sheet substrate 111 such that one or more holes 119 may engage one or more cushion substrate members 117. have.

83 shows a reinforcing structure 120 positioned with respect to the folding up sheet substrate 111 and having a different shape and size, in which one or more holes engage one or more cushion substrate members 117.

It is understood that the cushion base member 117 may be adhered to any side of the sheet base 111. Optionally, the cushion base member 117 may be adhered to both sides of the sheet base 111.

84 shows the sheet substrate 111 to which the cushion substrate member 117 is adhered. However, in this case, the cushion base member 117 is adhered to the outer side 123 rather than the inner side 122. In FIG. 84, the reinforcing structure 118 is positioned relative to the outer side 123 of the folding up sheet substrate 111, such that one or more holes 119 engage with one or more cushion substrate members 117.

84 and 85 show another perspective view of the sheet substrate 111 having the cushion substrate member 117 adhered to the outer side 123 of the sheet substrate 11. 85 and 86 illustrate a reinforcing structure 118 positioned relative to the outer side 123 of the folding up sheet substrate 111, whereby one or more holes 119 engage one or more cushion substrate members 117. will be.

Optionally embedded device

Another advantage of monolithic shoes is that it is very easy to integrate various electronic, mechanical and electro-mechanical devices into the shoe in the process of assembling monolithic shoes. In part, the monolithic shoe is assembled from a flat layer or "sheet" material that is assembled and folded in the form of a three-dimensional shoe (as opposed to the small pieces and components that must be sewn or glued together). It is possible to apply "inprint" or flat "etch" electronic circuits and devices to the flat sheet material used in the assembly.

74 and 76 illustrate various alternative ways of embedding, layering, or attaching electronic devices, mechanical devices, and electro-mechanical devices, wiring, and electrical networks to one or more component layers of a monolithic shoe. .

74 shows a laminate 91 cut and formed to form the device substrate 86.

In another embodiment of the present invention, the device substrate 86 is merely illustrative of one or more cushion substrate assemblies 67 or individual cushion substrate members, cushion padding members 19 or individual cushion pod members 20, outsole padding members. Optionally, device substrate holes 78 can be positioned and sized and shaped to selectively engage 35 or individual bottom pod member 50 or locking pod member 22.

By way of example only, FIGS. 75 and 76 show device substrate 86 selectively fitted to cushion substrate assembly 67, with at least one bottom substrate member 104 coupled to at least one device substrate hole 78. do.

As shown in FIG. 74, various electronic devices, mechanical devices, and electro-mechanical devices may optionally be applied to or attached to the surface of the device substrate 86. Also optionally, electrical devices, electronic devices, and electro-mechanical devices may be coupled to or embedded in holes press-in or cut out of the device substrate 86.

By way of example only, a sensor 93 (eg, such as a pedometer), optionally as shown in FIG. 74, may be attached to the device substrate 86.

In addition, as an example only, a power source 92 (such as a battery or piezoelectric power generator or other similar power generating device) may optionally be coupled to or embedded in the aperture of the device substrate 86.

Also, optionally, an interface port 94 or an input / output device 97 may be attached to the device substrate 86 and may be connected to the sensor 93 and power source 92 via a wiring 95. have.

It is understood that the type of electrical devices, electronic devices, and electro-mechanical devices that may be attached to or coupled to the device substrate 86 or the location of the device on or within the device substrate 86 is not limited. By way of example only, an electronic display 96 (such as only a soft organic light emitting diode ("OLED") display or a light emitting polymer ("LEP") display) may be selectively attached to the device substrate 86, as an example. It is understood that the wiring 95 can be connected to the power supply 92.

Moreover, the apparatus base material 86 may be a sheet base material 72 shown in FIGS. 62-67, the reinforcement structure 84 shown in FIGS. 70-73, the insole member 16 shown in FIGS. 6, 11, and 12, or It is understood that further progress may be made to form the entire layer 23 or partial layer 29, or the outsole layer 34 or midsole member 36, or the entire outsole member 38 shown in FIG. 9.

75 and 76 illustrate an optional embodiment of the present invention, wherein the device substrate 86 having the device substrate aperture 78 is adapted to engage a cushion substrate assembly 67 or a portion of an individual bottom substrate member 104. And the assembly is attached to the sheet substrate contact surface 75 of the sheet substrate 72. The entire assembly can then be cut and incorporated into the monolithic shoe.

As shown in FIG. 74, the device substrate 86 is aligned with the front portion 87 relative to the toe of the finished shoe, and the right wall 89 is aligned with respect to the right side of the finished shoe, and the left wall 88 is aligned to the left of the finished shoe, and the heel wall 90 may be positioned to align with the rear or heel portion of the completed shoe. When the entire assembly is folded into a suitable three-dimensional form, the left wall 88, right wall 89 and heel wall 90 are erected almost orthogonally from the other side of the device substrate 86.

The invention is not to be limited in scope by the specific embodiments described herein. Indeed, various modifications of the invention in addition to the embodiments described herein will become apparent to those skilled in the art from the foregoing description and the accompanying drawings. Such modifications are intended to fall within the scope of the appended claims. The following embodiments illustrate the invention by way of example and not by way of limitation.

Embodiments

Example 1.

The procedure for making a shoe upper for a typical casual shoe is described herein. Three EVA foam sheets are cut in advance. Foam materials have different colors (red, gray, blue), may have different thicknesses, and may also be composed of other types of materials. The foam sheet is cut in large quantities into a large block of foam material. Foam pieces cut from the three foam sheets (red, gray, blue) are mixed and matched to make up the assembled workpiece. In this case, the individual pieces in the assembled foam workpiece have different thicknesses. This can lead to higher stiffness and cushioning properties. Nearly infinite variations in the size, shape, composition, etc. of the components are possible. Many of these assembled workpieces are laid out in a suitable pattern.

A first substrate layer (in this case a black open mesh to form the "outer skin" of the shoe) is laid on the assembled foam workpiece. Optionally, a nylon sheet may be placed over the assembly prior to lamination to absorb excess glue and to protect the fabric / heat platen. The workpiece is heated and pressurized. The assembled foam workpiece is bonded to the first substrate layer (black-open mesh). The workpiece is cut along an appropriate pattern.

Optionally, additional trimming, cushioning, and the like may be added and further laminated to the assembly (in this case, further cut foam pieces providing additional cushioning are laminated).

A second substrate layer (in this case a green fabric to form the "inner" or lining of the shoe) is laid on the workpiece on the side opposite from the bordered side with respect to the black-open mesh. The workpiece is positioned and stacked below the hot pressing platen. The second substrate layer is trimmed to leave substantially the laminated portions on the workpiece.

The workpiece here has a complex shape and configuration. Certain areas of the flat workpiece are made of a material that is thicker, made of a different material, or of a different color than the other areas bounded on both sides with the first and second substrates.

The shoe upper consists of a flattened foam. Additional trimming may be placed on and stacked on the workpiece. In this case, a thin TPU piece (thermoplastic polyurethane) previously coated with a HAM film is placed on the workpiece and pressed with a heating platen. Additional trimmings (and logos) may be laminated to the assembly as needed. The flat workpiece is folded to form the shape of a shoe. It forms a single seam that is glued or sewn. The shoe upper is ready to be glued to the outsole. And the outsole is bonded to the upper.

Example 2.

The sandal produced by the monolithic process is described. The shoe is a front nose-open sandal, and the "upper" (upper strap) and the sockliner (lining) consist of a single continuous piece. By layering and fitting different materials (e.g., pod and foot arch supports) into a single sheet of continuous material, the different parts of the shoe (i.e. insole / insole vs. strap) have different properties. Can have

There are provided three sheets of EVA foam that are precoated with an HMA film. The foam material has different colors (one blue and two grays) and different thicknesses (one thick gray foam sheet and one thin foam sheet). The three sheet foams are cut. The cut material is removed from the foam sheet material, leaving a lattice of thin gray foam material or thick gray foam material and blue foam material. The cut blue foam piece (formed as an elliptic cylinder) and the thick gray arch reinforcement fit into a thick gray lattice of foam material.

Separate foam sheets are cut to provide a layer that will include the strap. Here a workpiece is assembled that includes positioning a grooved material of thick gray lattice assembled into a separate foam sheet. A first substrate layer (in this case a green fabric) is placed on top of the assembled foam workpiece. The workpiece is heated and pressurized. The assembled foam workpiece is bonded to the first substrate layer (green fabric).

One piece of TPU (thermoplastic polyurethane) is cut along an appropriate pattern substantially overlapping the perimeter with the assembled workpiece. The TPU is aligned with the workpiece and stacked on the side opposite to the side on which the first substrate layer is stacked. Here the upper of the shoe which is not assembled and not folded is formed. The upper is folded and the upper is ready to be bonded to the outsole. When the outsole is bonded to the folded upper, the final sandals are constructed.

Example 3.

Another optional embodiment of the present invention, namely another process for assembling a shoe upper for running shoes, is described together with the finished shoe.

Optionally, the cushion substrate 69 has its top and bottom surfaces covered with an adhesive 69A layer, as shown in FIG. 87. In one optional embodiment of the invention, the adhesive 69A is a hot-melt adhesive ("HMA") film that is activated by heating or by heating and pressurization. However, it is understood that any composition, glue or bonding agent capable of bonding or attaching various composites made from the cushioning substrate 69 to any suitable whole or partial layer member for this purpose may be used.

88 shows a cushion substrate 69 (optionally laminated with a layer of adhesive 69A) cut along substrate cutting line 102 to define an example of a first replaceable cushion pod member 221A. It is understood that the cushion substrate 69 can be cut into a variety of other optional shapes and dimensions to form other cushion pod members of appropriate shape and dimensions. It is also understood that optionally several examples of the first replaceable cushion pod member 221A can be fabricated from a single example cushion substrate 69 as shown in FIG. 88.

As shown in FIG. 89, one or more example cut first replaceable cushion pod members 221A may be obtained from the cushion substrate 69, leaving holes 103 and the remaining cushion substrate 77.

By selecting appropriate cushioning substrates of various thicknesses, colors, textures and components and repeating the steps shown in FIGS. 87-89 and described in connection with the figures, for example, as can be seen in FIG. Various alternative cushion pod members can be fabricated, such as the second replaceable cushion pod member 222 and the third replaceable cushion pod member 223.

91 shows a composite set of composite cushion pod members 221B, with components and components (second replacement cushion pod member) from the second replaceable cushion pod member 222 and the third replaceable cushion pod member 223. Components 222A and third replacement cushion pod member components 223A), and assembled by incorporating these components and components into the first replaceable cushion pod member 221A.

92 illustrates a non-limiting example synthetic cushion pod member 221B.

93 and 94, the same or different composite cushion pod members 221B in multiple cases can be positioned in a suitable arrangement.

FIG. 95 shows outer full layer sheet 233A positioned adjacent composite pod member 221B in multiple cases.

The outer whole layer sheet 233A is laminated or bonded to the composite cushion pod member 221B as shown in FIGS. 96 and 97. 96 and 97 show two opposing sides of the synthetic cushion pod member 221B.

Optionally, the laminated workpiece may be cut along the shoe upper cutting line 202 as shown in FIGS. 98 and 99 to form the first upper assembly workpiece 224 shown in FIGS. 100 and 101. have.

Optionally, additional cushioning members, such as the heel sac cushion member 225 shown in FIGS. 102 and 103, may be bonded to the first upper assembly workpiece 224.

Optionally, the inner whole layer sheet 225A may be laminated or bonded on the exposed side of the composite cushion pod member 221B as shown in FIGS. 104 and 105. Also optionally, the composite cushion pod member may be laminated or bonded to the composite cushion pod member 221B before being cut along the shoe upper cutting line 202.

106 and 107 show side views of the workpiece after the stack of inner whole layer 225B and outer whole layer 233B for the cushion pod member.

108 and 109 show the final second upper assembly workpiece 226.

110 and 111, the sublayer member 229 (optionally, the sublayer member components) may be provided on the second upper assembly workpiece 226 to provide protection against additional structural preservation or wear resistance, and the like. 229A, 229B, 229C and 229D) may optionally be bonded.

112 and 113 show the final shoe upper assembly 227.

As shown in FIGS. 113-116, shoe upper assembly 227 is folded and coupled along upper assembly seam 228. The seams can be selectively bonded, sewn, glued, deposited or taped with strips formed from sublayers or reinforcing materials (such as thermoplastics, by way of example only).

117 through 119, a shoe last 229 or an appropriate mold may optionally be inserted into the folded shoe upper assembly 227 to further form the shoe body structure. Optionally, tongue member 231 may be bonded, heat-pressurized, or sewn to shoe upper assembly 227, and eyelet hole 231 may be drilled or drilled as shown in FIG. 117. . Also optionally, as shown in FIG. 119, midsole 12 may be bonded, glued, sewn or fused to folded shoe upper assembly 227.

120 illustrates a folded shoe upper assembly 227 positioned relative to the outsole member 230.

121 and 122, the folded shoe upper assembly 227 is selectively firmly adhered or bonded, fused, sewn or sewn to the outsole member 230 to complete the assembly of the shoe.

Those skilled in the art can recognize or identify many equivalents to the specific embodiments of the invention specifically described herein using conventional methods. Such equivalents are included in the claims.

Claims (35)

A shoe comprising a body structure in which at least an upper is formed by one continuous folded synthetic material comprising a layered sheet material. The method of claim 1,
A shoe in which another material is inserted into the sheet material to form a non-uniform body structure of the shoe. The method of claim 1,
Said synthetic material comprising a cushion pod member. The method of claim 1,
And the synthetic material comprises a pod fit hole. The method of claim 1,
The cushion pod member is coupled to the pod fitting hole. The method of claim 1,
At least one layered sheet consists of foam or rubber or combinations thereof. The method of claim 1,
At least one layered sheet includes a locking pod member and a locking pod hole. The method of claim 1,
The layered sheet material is a whole layer, a partial layer or a combination thereof. The method of claim 1,
At least one layered sheet includes an electronic device, a mechanical device or an electro-mechanical device. The method of claim 1,
At least one layered sheet comprises a tongue area. The method of claim 1,
At least one layered sheet includes a cushion padding member. The method of claim 1,
At least one stratified sheet comprising a folding line. The method of claim 1,
At least one layered sheet includes a reinforcing structure. The method of claim 1,
Wherein the upper is attached to a prefabricated outsole assembly. The method of claim 14,
The outsole assembly includes a sole pod member. The method of claim 15,
The sole pad member is exposed to the inside of the shoe to be in contact with the wearer of the shoe. The method of claim 14,
The outsole assembly includes a outsole layer in contact with the bottom of the upper. The method of claim 17,
And the outsole layer extends to wrap around the outsole pod member. The method of claim 14,
The outsole assembly includes a midsole. The method of claim 1,
Wherein the body structure comprising the upper and the outsole is comprised of one continuously folded synthetic material comprising a layered sheet material. The method of claim 1,
Said synthetic material being bonded to one seam of said body structure. The method of claim 2,
Wherein the non-uniform body structure consists of areas of thickness, texture, stiffness, hardness, color, breathability, shock absorption, wear resistance, or flexibility of the shoe. The method of claim 1,
The shoes are sneakers, casual shoes, sandals or formal shoes. As a method for manufacturing a shoe according to claim 1,
(i) providing a synthetic material comprising at least one layer of sheet material; And
(ii) folding said synthetic material to form a body structure comprising one continuously folded synthetic shoe. The method of claim 24,
And wherein the composite layer of the sheet consists of at least one full layer and at least one sublayer of the sheet. The method of claim 24,
And precutting or cutting the at least one sheet to a size and a circumference to form the shoe body structure that is finished when folded. The method of claim 24,
And precutting or cutting the at least one sheet to provide a cushion pod member or pod fitting hole. The method of claim 24,
Stacking the layers of sheet material together. The method of claim 24,
After folding the synthetic material, shaping the ends of the material and holding in place by engaging the locking pod member with the locking pod hole. The method of claim 24,
Bonding the synthetic material to one seam. The method of claim 24,
Inserting a material different from the sheet material into the sheet material to form a non-uniform body structure of the shoe. A shoe comprising an upper and an insole formed by folding a single continuous piece. 33. The method of claim 32,
Wherein the upper is formed by folding a single continuous piece and formed of a different material in different areas of the shoe. A shoe comprising an upper, midsole, and outsole formed by folding a single continuous piece. 35. The method of claim 34,
Wherein the upper is formed by folding a single continuous piece and formed of a different material in different areas of the shoe.

Images