TWI783861B - Conforming membrane for manufacturing footwear, press and method of manufacturing an article of footwear using a conforming membrane - Google Patents

Abstract

A low-pressure operation conforming membrane for manufacturing an article of footwear includes a perimeter portion having a thickness in a range of 1 to 15 millimeters forming an outer perimeter of the conforming membrane. The conforming membrane also includes a transition portion having a thickness in a range of 1 to 4 millimeters between a first surface and a second surface with the transition portion extending interior to the outer perimeter. The conforming membrane also includes a conforming portion extending from the transition portion in a direction of the second surface and forming a receiving cavity, the conforming portion having a thickness in a range of 1 to 4 millimeters. The perimeter portion, the transition portion, and the conforming portion are a unitary construction comprising a common material composition.

Description

Conformal film for shoemaking, press and method for making footwear using conformal film

This invention relates to a press membrane for joining two articles.

Traditionally, footwear has been manufactured by bonding the sole to a lasted upper portion. Pressure, temperature and/or time are adjusted to achieve the bond between the sole and lasted upper. The application of pressure may be accomplished by means of a press which effectively assists in supplying a compressive force between the sole and the lasted upper when adhesive or other joining material joins the sole to the lasted upper.

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

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

The manufacture of shoes, such as sneakers, is traditionally carried out by joining different parts. For example, an upper is a portion of footwear that extends around a wearer's foot to secure the footwear to the wearer. The upper may be formed from a variety of materials, such as leather, membranes, textiles, printed materials, and the like. In some examples, an upper is a portion of a shoe that includes securement structures (eg, lacing holes for shoelaces), an ankle opening that allows donning and doffing of a wearer's foot, and other structures. The shape of the upper is determined in part as it engages with other parts. In some manufacturing situations, cobblers lasts (also called "shoe lasts") are embedded in (or formed around) the shoe upper so that the shoe upper takes on the shape of the shoe last. When the upper is placed on or otherwise formed around a last, the combination is often referred to as a "lasted upper". A lasted upper is an upper that has a last to provide support and dimensional guidance to the upper during the manufacturing process. As additional parts/components are engaged with the lasted upper, the shape of the upper becomes more stable such that once the last is removed, the dimensional shape of the upper is maintained or at least influenced by the last.

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

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

Traditionally the upper is joined to the sole. In some examples, the upper and sole are joined via a sewing operation. In another example, the upper and the sole are bonded through a bonding process. The bonding process may be accomplished using soldering, fusion and/or adhesive bonding. In an exemplary aspect, an adhesive material (eg, liquid, paste, film) is applied to at least one of the sole-contacting surface of the upper and/or the upper-contacting surface of the sole. The adhesive may be reactive or activated to facilitate bonding (eg, mechanical and/or chemical bonding) between the upper and sole. The engagement may be enhanced by applying pressure (eg, applying a force through the upper to the sole and/or applying a force through the sole to the upper). In addition to pressure, it is contemplated that thermal energy (eg, heat) may also be applied to the upper and/or sole to assist in engaging the upper and sole. In addition, it is contemplated that providing a defined period of time to apply heat and/or pressure to the upper and/or sole may assist in achieving engagement between the upper and sole. As will be discussed below, the conformal film effectively provides sufficient pressure at the intended location to assist in joining the upper and sole, such as by using adhesive or other bonding material.

However, in some conventional joining techniques, when used to join a compressible sole element (e.g., EVA, PU, or other foamed polymer-based materials) to a lasted upper, the application of pressure during the joining process can result in a compressible sole A permanent unintended deformation occurs and thus deforms the compressible sole in an unintended shape when joined to the upper. In other words, conventional presses lacking the conformable membranes provided herein can result in deformation of the sole that is at least partially maintained after engagement of the upper with the deformed sole. As previously noted, the construction of an article of footwear may rely on the successive layering and joining of multiple materials and parts to maintain the shape of the upper defined by the last once the last is removed after joining has occurred. However, if a lasted upper is engaged with a sole that has been deformed by a conventional press, once the last is removed after joining the sole and upper, the sole may return (completely or partially) to the original, undeformed shape of the sole. shape. This return of the sole to its pre-deformed shape after engagement with the upper may cause the upper to deform relative to the shape of the upper defined by the last. Accordingly, conventional presses that apply pressure to the sole to assist in joining the sole to the upper may introduce deformation of the sole during the squeezing operation, which leads to unintended deformation of the sole and/or upper after the squeezing operation.

It should be understood that different sole materials may be more prone to unintended permanent deformation. Therefore, conventional presses may produce acceptable results for some shoe material combinations. However, as material advances and the use of greater quantities of materials (eg, foamed polymers) are used in forming components of footwear, advances in presses have enabled the integration of these materials into footwear. For example, soles formed from certain materials create an unsatisfactory bond (eg, bond gaps) when conventional presses are used to join the sole to the lasted upper. When extrusion from a conventional press is applied to the last for longer than a specified time (eg, 30 seconds, 25 seconds), the material deforms and results in insufficient bonding. Additionally, reduced force can be applied to compensate for the non-conformal nature of conventional presses. However, a reduction in force (or time) may result in insufficient engagement (eg, incomplete bonding). Additionally, conventional presses may cause one or more portions (e.g., foamed sole portion) A change in appearance occurs.

Accordingly, aspects provided herein pertain to a conformal film for assisting in joining a first article to a second article. A conformal membrane is one that conforms to a lasted upper and sole to enclose the Membrane for last upper and sole. The multidirectional compressive force provided by the conformal membrane secures the sole and lasted upper for bonding/joining processes without deforming the foamed material (eg, sole). This is in contrast to conventional presses, which are unable to sufficiently conform around a lasted upper and sole and/or rely on higher pressures to induce conformality of the compact. As opposed to the multi-directional compressive force provided by a conformal membrane, traditional presses concentrate pressure in a more linear fashion across the sole. Furthermore, conventional presses that can have "conformable" membranes can only be "conformable" at significantly higher pressures than provided in connection with aspects herein.

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

Furthermore, it is envisioned to implement the conformal membrane in the manufacture of footwear such that a method of manufacturing an article of footwear utilizing a conformal membrane for engaging the sole and upper includes positioning the upper on a fixation element (e.g., an extruded support) . The method includes capping the conformal membrane on the upper on the securing element and on the sole. In this example, the first surface of the conformal film contacts the sole and the upper. The conformal film can be the conformal film set forth in the preceding paragraph or any derivative provided herein. The method proceeds with the step of reducing the pressure differential after a predetermined period of time (eg, greater than 25 seconds, greater than 30 seconds, greater than 35 seconds). In an exemplary aspect, the pressure differential may be in the range of 0.5 bar to 3.9 bar (ie, 50 kPa to 390 kPa).

Conformal membranes and contemplated methods of use provide a tool to join uppers and soles with less deformation of the upper and/or sole relative to conventional presses (eg, membrane presses). In some examples, the properties (e.g., thickness and material composition) of the conformal film enable the film to conform around the sole and upper to span multiple surfaces (e.g., Pressure (and in some instances heat) is applied by the toe box, the heel counter, the inner side of the upper, the outer side of the upper, the transition across the sole to the upper (eg, the biteline), the sidewall of the sole). This is in contrast to conventional laminates of thicker or different material composition that are applied at higher pressures (eg, 4 bar or greater) extending linearly across the sole and/or upper (unlike from multiple directions around opposite), resulting in deformation of the sole and/or upper during the squeezing operation.

Referring to the drawings in general and to FIG. 1 in particular, there is shown a press 100 for securing a lasted upper 252 and a sole 250 to a securing element 102 in accordance with aspects herein. Note that the press 100 is adapted to maintain the relative position of the upper and sole while the upper and sole are engaged. For example, the adhesive may be applied (eg, sprayed, brushed, rolled, applied, printed) to the sole, the upper, or a combination of the sole and the upper. Furthermore, it is contemplated that upper 252 and/or sole 250 may be formed from one or more materials (eg, hot melt adhesives, meltable polymers) that may be bonded to other components under pressure and/or heat. Sole 250 and upper 252 then have pressure exerted by conformal membrane 200 housed in membrane container 116 (eg, lid). Because membrane container 116 is positioned over sole 250 and upper 252 , the combination of the components is at least partially received within receiving cavity 238 of conformal membrane 200 . The receiving cavity is deliberately deformed (e.g., molded or otherwise formed) from the planar configuration of the conformal film 200 such that the various surfaces of the shoe to be formed (e.g., medial, lateral, toe at toe end 254, heel end 256 heel counter, bite line) is contacted by the conformal film 200 during the extrusion operation. Membrane container 116 may be secured to press 100 in a closed, operative arrangement by a membrane retainer 114 (eg, a releasable latch mechanism). Membrane retainer 114 is effective to hold membrane container 116 and associated conformal membrane 200 in position relative to the article of footwear to which pressure will be applied.

With regard to pressure, it is contemplated that pressure may be applied to sole 250 and upper 252 by press 100 in one or more ways. For example, the fixation element 102 may effectively apply a linear force, such as by a cylinder, linear actuator, or the like. This linear force is transferred via last 120 (as best seen in FIG. 3 ) to upper 252 and sole 250 where conformal membrane 200 contacting upper 252 and/or sole 250 encounters resistance to the linear force. Additionally or alternatively, it is contemplated that securing element 102 effectively adjusts the position of upper 252 and sole 250 within receiving cavity 238 . For example, the immobilization element 102 may raise or lower (with reference to the depicted vertical position of the press 100 of FIG. 1 ) the shoe assembly based on expected pressure, assembly size, assembly shape, and the like. Stationary element 102 may be stationary and non-movable in some aspects.

Pressure may alternatively or additionally be generated by press 100 by pressurization of conformal membrane 200 . In an exemplary aspect also depicted in FIG. 3 , a positive pressure relative to ambient pressure may be introduced into the volume enclosed by membrane container 116 and conformal membrane 200 . The increased pressure creates a pressure differential across opposing surfaces of the conformal membrane 200 . As conformal membrane 200 deforms under the pressure differential, the pressure differential causes conformal membrane 200 to conform around upper 252 and sole 250 . It is this deformation that causes conformal membrane 200 to wrap around portions of upper 252 and sole 250 , creating pressure that holds upper 252 and sole 250 in a fixed relative position during the joining operation. Depending on the pressure differential, sufficient pressure may be applied to upper 252 and sole 250 to assist in joining (eg, bonding via adhesive curing) these components. Exemplary pressure differentials include 0.5 bar up to 3.9 bar relative to ambient pressure. In an exemplary aspect, above 3.9 bar, the conformal film may mechanically fail after a certain number of extrusion cycles or the extruded article may undesirably and permanently deform during the extrusion operation. Although pressure differentials above 0.5 bar and below 3.9 bar are contemplated, aspects herein are implemented with pressure differentials within the ranges provided to reduce unintended deformation of the extruded article. The less conformal membranes of conventional presses can operate at pressure differentials of 4 bar or higher to conform and conform to the extruded article. This increased pressure can make conventional press films conform, but it can damage or otherwise undesirably deform the extruded article (eg, a portion of an article of footwear). Accordingly, implementations of conformal films provided herein operate at lower pressure differentials to achieve conformality of the film to the extruded article compared to conventional press films. In additional aspects, the pressure differential is expressed in atmospheric pressure at 1 to 3 bar, 1 to 2 bar, 1 to 1.5 bar, 1 to 1.3 bar, 1 to 1.2 bar, 1.1 to 1.4 bar and/or 1.25 to 1.35 bar within the bar range. Flexibility is provided by selecting various pressure differential conditions based on the materials to be bonded, extrusion time, film conformality, etc. Accordingly, based on the factors contemplated herein, various pressure differential ranges may be applied to achieve bonding of the shoe components while minimizing unintended permanent deformation of the shoe components.

FIG. 2 illustrates a press 100 with a membrane vessel 116 in a closed and fixed configuration, according to aspects herein. The closed arrangement is a configuration that enables the press 100 to effectively apply pressure to the shoe assembly during the joining operation. The input mechanism of the press 100 is also shown. Time control 110 , pressure control 112 and temperature control 118 are shown. The input mechanism enables the user to adjust the parameters of the same name (eg, time, temperature, pressure). However, it is contemplated that one or more of the input mechanisms may be omitted or altered in exemplary aspects. For example, computer instructions may be communicated to the press from a controller that controls the time, pressure and/or temperature applied to specific (or general) components. Furthermore, it is contemplated that in some instances one or more of time, temperature, or pressure may not be adjusted.

FIG. 3 is a cross-sectional view taken along cutting line 3 - 3 of FIG. 2 , according to aspects herein. A toe-to-heel perspective view is provided to illustrate securing element 102 holding last 120 in a position that enables upper 252 and sole 250 to be contacted by conformal membrane 200 . FIG. 3 illustrates conformal membrane 200 during a pressure differential causing conformal membrane 200 to conform to lasted upper 252 and sole 250 . Pressure source 106 provides an exemplary pressure source to create a pressure differential. A pressure source may provide compressible or incompressible material (eg, gas or liquid) into the membrane chamber 104 from an external source (eg, tanks, pumps, and compressors). Membrane chamber 104 is surrounded and formed by membrane container 116 and conformal membrane 200 . Membrane chamber 104 is effective to receive pressurized material (eg, pressurized gas) and provide a volume for the pressurized material to surround and apply force to portions of conformal membrane 200 from within conformal membrane 200 . Pressure can be controlled using one or more mechanisms (eg, regulators, etc.). Unlike conventional laminations that operate at 4 bar and above, the aspects herein are contemplated to operate at lower pressures (e.g., 0.5 bar to 3.9 bar), so conventional macro-level control of pressure can be achieved. This results in unintended permanent deformation of the extruded article, since macroscopic level controls (eg analog regulators with a tolerance of 1 bar or greater) have large tolerances for pressure operation. This large tolerance will result in a larger pressure differential at the conformal membrane provided herein, resulting in unintended permanent deformation of the extruded article. Thus, in the exemplary aspect, such macroscopic level control of pressure differentials of 4 bar or greater cannot effectively control pressure differentials having a range of 0.5 bar to 3.9 bar. Furthermore, in the exemplary aspect, such macroscopic level control of pressure differentials of 4 bar or greater is not effective for controlling pressure differentials having a range of 1 bar to 2 bar. Aspects herein therefore contemplate upgrading the pressure control mechanism to micro-level control (eg, a digital regulator with a tolerance of 0.9 bar or less) that is capable of comparably to the pressure of conventional presses. The mechanism maintains the pressure differential within tighter tolerances. Increased pressure tolerance control may provide better durability of conformal membranes (eg, reduced pressurization potential) and allow for more consistent operation at the lower pressures provided herein. In other words, in the exemplary aspects herein, since the aspects herein contemplate operating at lower pressure differentials than standard presses, greater control over pressure differentials would gain from conformal membrane presses the result of.

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

FIG. 3 presents three regions of conformal film 200 . Peripheral portion 214 , transition portion 224 , and conformal portion 234 are discussed in more detail below in FIGS. 4-8 . As depicted in FIG. 3 , conformal membrane 200 surrounds and surrounds upper 252 and portions of sole 250 on multiple surfaces and from multiple directions. It is this conformality with multiple surfaces and components that enables conformal membrane 200 to effectively bond upper 252 and sole 250 .

As previously provided, the low conformal (or non-conformal) membranes of conventional presses instead permanently deform the sole 250 during the extrusion operation (e.g., compressing the foam) because they do not adequately conform. shape and thus exert a more concentrated and unidirectional pressure on the sole. Unacceptable permanent deformation of the extruded part can also result from conventional dies operating at higher pressures (e.g., 4 bar and above) to achieve a certain degree of alignment between the traditional die and the extruded component. Degree of conformality. The use of higher pressure differentials on conventional presses compensates for less conformal film materials, which translates into potentially damaging forces being applied to the article being extruded. This unintended deformation can be further exaggerated if thermal energy is applied to the process to activate or cure the bonding material. This increased thermal energy may cause the material forming the sole (eg PU, EVA) to become more compliant and thus more prone to undesired deformation under certain pressure from a press. Thus, with a compliant membrane that surrounds the various surfaces of the components to be joined from multiple directions, the pressure of the press is applied at more directional angles across a greater surface area, making possible unexpected The same material that deforms can effectively bond the conformal membrane 200 .

FIG. 4 illustrates a perspective view of a conformal film 200 according to aspects herein. For reference purposes, longitudinal direction 206 and transverse direction 210 are generally shown. As contemplated, a conformal membrane is used in conjunction with footwear that has a receiving cavity formed in a similar shape to the portion of the footwear that is intended to receive it. This normal and expected deformation is placed under a pressure differential that limits creases or other membrane deviations to form a compliant conformity with the underlying shoe component. In other words, in some instances, the receiving cavity has a similar shape to the article it is expected to conform to under a certain pressure differential. This coordination between the shape of the receiving cavity and the article of footwear results in a more consistent conformation of the membrane with the components to be engaged under certain pressure differentials.

Peripheral portion 214 , transition portion 224 , and conformal portion 234 of conformal film 200 are depicted in FIG. 4 . Additionally, outer perimeter 222 is depicted as forming the outermost portion of conformal film 200 . Also shown is the conformal film second surface 204 . Conformal film second surface 204 is opposite conformal film first surface 202 , as best seen in FIG. 8 .

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

FIG. 7 illustrates a plan view of the conformal film 200 shown in FIGS. 4-6 , according to aspects herein. Several exemplary positional elements are depicted in FIG. 7 . For example, a first receiving cavity half 240 and a receiving cavity second half 244 are depicted along the longitudinal direction 206 . Additionally, a series of arrow indicators 232 are depicted to show the "inner" direction relative to the outer perimeter 222 in the plan view plane of the conformal film 200 .

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

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

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

8 illustrates a cross-section along cut line 8-8 of conformal film 200 of FIG. 4, in accordance with aspects herein. The perimeter portion 214 has a perimeter first surface 218 and a perimeter second surface 220 with a thickness 216 defined therebetween. The transition portion 224 has a transition portion first surface 228 and a transition portion second surface 230 with a thickness 226 defined therebetween. The conformal portion 234 has a conformal portion first surface 235 and a conformal portion second surface 237 with a thickness 248 defined therebetween.

The thickness of conformal portion 234, transition portion 224, and peripheral portion 214 affects the ability of conformal membrane 200 to conform to an article under a given pressure differential. The historic film in the historic press can have greater thickness in various sections. Larger thicknesses may traditionally have been implemented to enable longer lifetimes of the materials forming traditional membranes during industrial applications. However, the conformal film 200 can operate under different conditions (e.g., temperature, pressure, time) to bond from different materials and/or form more compliant parts, and thus can have thinner (e.g., smaller) components than conventional films. thickness of. In some examples, as the thickness of a portion of the conformal film decreases, the conformal film can become more compliant and able to conform to the underlying article. However, if the thickness is reduced too much, the conformal film can suffer from fatigue and failure in practical industrial applications. Accordingly, in exemplary aspects, a range of various thicknesses is contemplated to provide sufficient compliance to the conformal film 200 while achieving a sufficient service life.

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

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

In an exemplary aspect, the perimeter thickness 216 may be greater than the transition thickness 226 to increase life, useful life, and concentration of compressive energy around the received article. Because the thickness of the conformal film affects functional properties (eg, elongation), conformal film 200 is more susceptible to deformation due to pressure differentials at locations having a smaller thickness (ie, thinner regions). Thus, by reducing the thickness of conformal film 200 at receiving cavity 238 and proximate the article to be received, conformal film 200 conforms more around the received article than at peripheral portion 214 having a greater thickness. . In an exemplary aspect, peripheral portion 214 is less prone to fatigue failure due to repeated conformality during pressure differential cycling due to the greater thickness of peripheral portion 214 resulting in less conformality.

FIG. 8 illustrates the extension height 258 of the conformal portion 234 from the transition portion 224 . According to aspects herein, height 258 is in the range of 70 millimeters to 110 millimeters. According to aspects herein, height 258 is in the range of 80 millimeters to 100 millimeters. According to aspects herein, height 258 is about 90 millimeters (eg, within 10%). Conventional films may have a height that is significantly smaller than conformal film 200 . In these examples, the small height inhibits the membrane from surrounding multiple surfaces of the article, and thus materials that are prone to deformation under the directional compression of conventional membranes (eg, the foamed polymer of a shoe sole) can deform. Conformal membrane 200 , having a greater height than conventional membranes, is instead allowed to encircle the sole and at least a portion of the upper, thereby encapsulating the article with unitary pressure rather than directional pressure (eg, linearly from the membrane toward the fixation element).

In an exemplary aspect, the perimeter first surface 218 and the perimeter second surface 220 are positioned above the transition second surface 230 . Additionally, since conformal portion 234 extends (eg, upwardly in FIG. 8 ), it is contemplated in the exemplary aspect that peripheral portion first surface 218 and peripheral portion second surface 220 are positioned on the edge of transition portion second surface 230 . same side. This offset between the perimeter portion 214 and the transition portion 224 provides greater conformability of the conformal film 200 around the received article in an inward direction relative to the outer perimeter 222 . In other words, in the exemplary aspect, the offset in vertical placement of peripheral portion 214 and transition portion 224 enables a shift in vertical placement versus horizontal conformality as a pressure differential is applied.

The conformal film 200 is formed from a conformal material. In one aspect, the conformal film is formed from a material comprising rubber (eg, natural rubber), silicon dioxide (ie, silica), and calcium carbide. Additional materials may be included in the composition. In an exemplary aspect, the material composition of the conformal film 200 is composed of 75% to 85% by weight rubber and 5% to 15% by weight silica. In an exemplary aspect, the material composition of the conformal film 200 is composed of 5% to 15% by weight calcium carbide and 5% to 15% by weight silicon dioxide. In an exemplary aspect, the material composition of conformal film 200 consists of 8% to 12% by weight dispersible silica. In an exemplary aspect, the material composition of the conformal film 200 is composed of 75% to 85% by volume rubber and 5% to 15% by volume silicon dioxide. In an exemplary aspect, the material composition of conformal film 200 is composed of 5% to 15% by volume calcium carbide and 5% to 15% by volume silicon dioxide. In an exemplary aspect, the material composition of the conformal film 200 consists of 8% to 12% by volume of dispersible silica. In an exemplary aspect, the percentages of composition are determined prior to combination.

It is contemplated that the conformal membrane is a unitary material extending between two or more parts. For example, it is contemplated that conformal portion 234 is formed of the same material as transition portion 224 such that the composition of the material forming the portions is homogeneous. Similarly, it is contemplated that peripheral portion 214, transition portion 224, and conformal portion 234 are unitary and formed from a common material. A unitary construct is a single entity with a uniform material composition. For example, two or more portions of a conformal film can be produced simultaneously. In an example, a molding operation combining to form two or more parts may be performed. In an alternative manufacturing process, it is contemplated to reduce-form (eg, grind) a common material to form a conformal film. In this example, the parts formed by subtraction are unified because they all start from a common source material without subsequent joining.

The functional properties of the conformal film 200 can be quantified to provide a range of conformal films suitable for the exemplary aspects herein. For example, according to aspects herein, at least the conformal film 200 located in the conformable portion 234 may have a hardness of 60 to 61 Asker C when measured on an Asker Type C durometer. According to aspects herein, at least conformal film 200 located in conformal portion 234 may have a maximum tensile strength in the range of 84 kilograms per cubic centimeter (kg/cm ³ ) to 90 kilograms/cm 3 . Maximum tensile strength can be tested using testing protocols such as ASTM D638-14. According to aspects herein, at least conformal film 200 located in conformal portion 234 may have a maximum elongation of at least 540% until failure. The maximum elongation can be tested using a test such as the ASTM D-638 test protocol.

In an exemplary aspect, the material composition and resulting functional properties of the conformal film 200 provide a suitable material as a film to join two or more shoe parts without compromising the foamed polymer component (e.g., EVA or PU). midsole element) deforms or damages the material composition provided herein for conformal membrane 200 to save labor, cost, and/or material. For example, operating at lower pressures than conventional membrane presses to achieve conformality of the membrane to the underlying extruded article reduces subsequent intervention to correct unintended deformations of the extruded material. Additionally, energy savings are achieved by using lower pressure requirements through conformal membranes that operate at lower pressures. Additionally, in an exemplary aspect, operating a conformal membrane at a lower pressure for a contemplated material composition enables thinner membranes that reduce the material used to form the membrane, which in turn reduces Material costs.

Turning to FIG. 9 , FIG. 9 illustrates a method 900 of manufacturing an article of footwear utilizing a conformal film to join a sole and an upper in accordance with aspects herein. At a block 902, the upper is positioned on the securing element. The upper may be a lasted upper, wherein the last is fixed to the fixing element. At block 904, a conformal film (eg, conformal film 200 provided herein) is capped over the upper and sole. In this example, the upper and sole are positioned in desired relative positions. An adhesive or other bonding material may be applied prior to joining the two components.

At a block 906, a pressure differential is created between opposing surfaces of the conformal membrane. For example, a pressurized fluid (eg, gas or liquid) can be injected into the membrane cavity, where the conformal membrane is more compliant than other materials that form the membrane cavity. As a result, the cavity deforms and conforms around the lasted upper and sole, thereby creating a compressive force to secure the sole and lasted upper. Compressive forces are applied to both the upper and the sole at multiple surfaces including the interface between the sole and upper. This enveloping compression holds the sole in a defined position relative to the upper during the joining operation.

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

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

The following is a non-limiting exemplary list of components provided in the drawings. - Presses - 100 - Fixing elements - 102 -Membrane chamber—104 - Stressors - 106 - Temperature source - 108 - time control - 110 - Pressure control - 112 - Membrane fixings - 114 - Membrane container - 116 -Conformal film—200 - Conformal Membrane First Surface - 202 - Conformal Membrane Second Surface - 204 - Portrait orientation - 206 -Longitudinal length—208 -Length of receiving cavity—209 - Landscape orientation - 210 - Horizontal width - 212 -Periphery—214 -Peripheral Thickness—216 - Perimeter first surface - 218 -Second surface of peripheral portion—220 -Outer Perimeter—222 - Transitions - 224 -Transition thickness—226 - first surface of transition - 228 - second surface of transition part - 230 - Internal direction - 232 - Conformal part - 234 - Conformal first surface - 235 -Z direction—236 - Conformal part second surface - 237 - Receiving cavity - 238 -The first half of the receiving chamber—240 -Width of the first half of the receiving cavity—242 -Second half of receiving cavity—244 - Receiver second half width - 246 - Conformal part thickness - 248 - soles - 250 - Upper - 252 - toe end - 254 - heel end - 256

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

It is understood that certain features and subcombinations have utility, can be employed without reference to other features and subcombinations, and are contemplated to be within the scope of the claimed claims. Not all steps listed in the various figures need to be performed in the particular order described.

Use of the term "any of the examples" or similar variations of said term herein in connection with the examples listed below is intended to be construed such that the features of the examples may be combined in any combination. For example, Exemplary Example 4 may indicate a method/apparatus as described in any one of Examples 1 to 3, which is intended to be interpreted such that the features of Example 1 and Example 4 may be combined, the features of Example 2 and Example 4 The elements can be combined, the elements of example 3 and example 4 can be combined, the elements of example 1, example 2 and example 4 can be combined, the elements of example 2, example 3 and example 4 can be combined, example 1, example 2, The elements of Example 3 and Example 4 may be combined, and/or other modifications may be made. Furthermore, the term "any of the examples" or similar variations of that term is intended to include "any of the examples" or other variations of that term, as indicated by some of the examples provided above. Furthermore, it is contemplated that examples may be drafted as aspects claimed herein. Example:

1. A conformal film for aiding in joining a first article to a second article, the conformal film comprising: a peripheral portion having a thickness in the range of 1 millimeter to 15 millimeters forming an outer periphery of the conformal film a transition portion having a thickness between the first surface and the second surface in the range of 1 mm to 4 mm, wherein the transition portion extends inwardly of the outer perimeter formed by the peripheral portion; and a conformal portion, extending from the transition portion in the direction of the second surface and forming a receiving cavity, the conformal portion has a thickness in the range of 1 mm to 4 mm, wherein the peripheral portion, the transition portion and the conformal portion The shape part is a unitary structure comprising a common material composition.

2. The conformal film of example 1, wherein the first article is a foamed polymeric article.

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

4. The conformal film of any one of examples 1 to 3, wherein the peripheral portion further comprises a first surface and a second surface, both the peripheral portion first surface and the peripheral portion second surface are all positioned on the same side of the transitional second surface as the conformal portion.

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

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

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

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

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

10. The conformal film of any one of examples 1 to 9, wherein the conformal portion has a tensile strength in the range of 84 kg/cm3 to 90 kg/cm3.

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

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

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

14. The conformal film of any one of examples 1 to 13, wherein the conformal portion extends in the range of 80 mm to 100 mm from the transition portion second surface.

15. The conformal film of any one of examples 1 to 14, wherein the receiving cavity has a width in the transverse direction at a first half in the longitudinal direction that is greater than a second half in the longitudinal direction. The width along the transverse direction that half-sections have.

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

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

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

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

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

21. A press having a conformal membrane for assisting in joining a first article with a second article, the press comprising: a conformal membrane comprising: (1) a peripheral portion having a thickness in the range of 1 mm to 15 mm forming the outer perimeter of the conformal film; (2) a transition portion having a thickness in the range of 1 mm to 4 mm between the first surface and the second surface , wherein the transition portion extends toward the inside of the outer periphery formed by the peripheral portion; and (3) a conformal portion extends from the transition portion along the direction of the second surface and forms a receiving cavity, the the conformal portion has a thickness in the range of 1 millimeter to 4 millimeters, wherein the peripheral portion, the transition portion, and the conformal portion are of unitary construction comprising a common material composition; and a pressure source, associated with the press Fluidly coupled to control a pressure differential between the transitional first surface and the transitional second surface from 0.5 bar to 3.9 bar.

22. A method of making an article of footwear utilizing a conformal film for joining a sole to an upper, the method comprising: positioning the upper on a fixation element; capping the conformal film on On the upper and the sole on the fixing element, wherein the first surface of the conformal membrane contacts the sole and the upper, the conformal membrane comprises: (1) a peripheral portion, having a thickness in the range of 5 mm to 15 mm forming the outer perimeter of the conformal membrane; (2) a transition portion having a thickness in the range of 1 mm to 4 mm between the first surface and the second surface, wherein the transition portion extends inwardly of the outer periphery formed by the peripheral portion; and (3) a conformal portion extends from the transition portion along the direction of the second surface and forms a receiving cavity, the conformal portion the shaped portion has a thickness in the range of 1 millimeter to 4 millimeters, wherein the peripheral portion, the transition portion, and the conformal portion are of unitary construction comprising a common material composition; and the conformal film produced on the a pressure differential experienced across a first surface and an opposing second surface of said conformal membrane, wherein the pressure at said second surface of said conformal membrane is a pressure greater than the pressure at said first surface; And after a predetermined period of time, the pressure differential is reduced.

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

24. The method of any one of examples 22 to 23, wherein the predetermined time period is at least 25 seconds.

3-3: Cutting line 8-8: Cutting line 100:press 102: fixed element 104: membrane chamber 106: Stressors 108: heating source 110: time control 112: Pressure control 114: Membrane fixture 116: film container 118: Temperature control 120: shoe last 200: Conformal film 202: conformal film first surface 204: second surface of conformal film 206: Portrait direction 208: Length 209: length of receiving cavity 210: Horizontal direction 212: width 214: peripheral part 216: Peripheral thickness 218: the first surface of the peripheral part 220: the second surface of the peripheral part 222: Outer perimeter 224: Transition Department 226: Transition thickness 228: first surface of transition part 230: the second surface of the transition part 232: Internal Direction 234: Conformal Department 235: The first surface of the conformal part 236: z direction 237: The second surface of the conformal part 238: receiving cavity 240: The first half of the receiving cavity 242: maximum width 244: The second half of the receiving cavity 246: width 248: Conformal part thickness 250: sole 252: Upper 254: toe end 256: follow-up 258: height 900: method 902, 904, 906, 908: block

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

Figure 1 illustrates a press with a conformal membrane, according to aspects herein.

Figure 2 illustrates the press shown in Figure 1 in a closed and fixed configuration, according to aspects herein.

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

4 illustrates a perspective view of a conformal film, according to aspects herein.

5 illustrates a side view of the conformal film shown in FIG. 4, according to aspects herein.

6 illustrates a front view of the conformal film shown in FIG. 4, according to aspects herein.

7 illustrates a plan view of the conformal film shown in FIG. 4, according to aspects herein.

8 illustrates a cross-sectional view of a conformal film taken along cut line 8-8 of FIG. 4, in accordance with aspects herein.

9 depicts a flowchart illustrating an exemplary method of making an article of footwear with a conformal film, according to aspects herein.

100:press

102: fixed element

114: Membrane fixture

116: film container

200: Conformal film

238: receiving cavity

250: sole

252: Upper

254: toe end

256: follow-up

Claims (23)

A conformal film for shoemaking for assisting in joining a first article and a second article, the conformal film comprising: a peripheral portion having a thickness between a peripheral portion first surface and a peripheral portion second surface, forming an outer perimeter of the conformal membrane; a transition portion having a thickness between a transition portion first surface and a transition portion second surface, wherein the transition portion extends inwardly of the outer perimeter formed by the perimeter portion; and a conformal portion extending from the transition portion in the direction of the second surface of the transition portion and forming a receiving cavity, wherein the peripheral portion, the transition portion, and the conformal portion are of unitary construction comprising a common material composition ; wherein both the peripheral portion first surface and the peripheral portion second surface are positioned on the same side of the transition portion second surface as the conformal portion. The conformal film of claim 1, wherein the first article is a foamed polymer-based article. The conformal film of claim 2, wherein the first article is a midsole and the second article is an upper. The conformal film of claim 1, wherein the peripheral portion has a thickness in the range of 8 millimeters to 12 millimeters. The conformal film of claim 1, wherein the outer perimeter defines a planar area of 0.08 square meters to 0.15 square meters. The conformal film of claim 1, wherein the outer perimeter has A longitudinal length in the range of 400 mm to 500 mm and a transverse length in the range of 200 mm to 300 mm. The conformal film of claim 1, wherein the transition portion completely borders the conformal portion and joins the conformal portion with the peripheral portion. The conformal film of claim 1 , wherein the conformable portion has a durometer hardness in the range of 60 Asker C to 61 Asker C. The conformal film of claim 1 , wherein the conformal portion has a tensile strength in the range of 84 kilograms per cubic centimeter (kg/ ^cm3 ) to 90 kilograms per cubic centimeter. The conformable film of claim 1, wherein said conformable portion has a percent elongation of at least 540% elongation prior to failure of said conformable portion. The conformal film of claim 1, wherein the transition portion and the conformal portion have the same durometer hardness, tensile strength, or elongation. The conformal film of claim 1, wherein the conformal portion extends from the second surface of the transition portion in a range of 70 millimeters to 110 millimeters. The conformal film of claim 1, wherein the conformal portion extends from the second surface of the transition portion in a range of 80 mm to 100 mm. The conformal film of claim 1, wherein the first half of the receiving cavity in the longitudinal direction has a width along the transverse direction that is greater than the width along the width of the second half in the longitudinal direction. width in the transverse direction. The conformal film of claim 1, wherein the conformal portion has a thickness of 2 millimeters. The conformal film of claim 1, wherein the material composition includes natural rubber, silicon dioxide, and calcium carbide. The conformal film of claim 1 , wherein the material composition comprises, by weight, 75% to 85% rubber and 5% to 15% silica. The conformal film of claim 1, wherein the material composition comprises, by weight, 5% to 15% silicon dioxide and 5% to 15% calcium carbide. The conformal film of claim 1, wherein the material composition comprises dispersible silica in the range of 8% to 12% by weight of the material composition. A press having a conformal membrane for assisting in joining a first article to a second article, the press comprising: a conformal membrane comprising: (1) a peripheral portion having a first surface of the peripheral portion and a second surface of the peripheral portion; a thickness between two surfaces forming the outer periphery of the conformal membrane; (2) a transition portion having a thickness between a transition portion first surface and a transition portion second surface, wherein the transition portion extends toward the periphery and (3) a conformal portion extending from the transition portion in the direction of the second surface of the transition portion and forming a receiving cavity, wherein the peripheral portion, the transition portion and the conformal portion is a unitary construction comprising a common material composition, wherein both the peripheral portion first surface and the peripheral portion second surface are positioned at the transition portion second as the conformal portion on the same side of the surface; and a pressure source fluidly coupled with the press to provide the transition portion first surface The pressure differential between the transition and the second surface. A method of making an article of footwear utilizing a conformal film for joining a sole to an upper, the method comprising: positioning the upper on a securing element; capping the conformal film on the On the shoe upper and the shoe sole on the fixing element, wherein the first surface of the conformal membrane contacts the shoe sole and the shoe upper, the conformal membrane includes: (1) a peripheral portion having a a thickness between the first surface of the peripheral portion and the second surface of the peripheral portion forming the outer periphery of the conformal film; (2) a transition portion having a thickness between the first surface of the transition portion and the second surface of the transition portion, wherein the transition portion extends inwardly of the outer perimeter formed by the peripheral portion; and (3) a conformal portion extending from the transition portion along the direction of the second surface of the transition portion and forming a receiving cavity, wherein The peripheral portion, the transition portion, and the conformal portion are a unitary construction comprising a common material composition, wherein both the peripheral portion first surface and the peripheral portion second surface are compatible with the conformal portion are located on the same side of the second surface of the transition portion; and create a pressure differential across the first surface of the conformal membrane and the opposing second surface of the conformal membrane, wherein at the the pressure at the second surface of the conformal membrane is a greater pressure than the pressure at the first surface of the conformal membrane; and after a predetermined period of time, the pressure differential is reduced. The method of claim 21, wherein the pressure differential is at 0.5 bar to 3.9 bar range. The method of claim 21, wherein the predetermined time period is at least 25 seconds.

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