WO2010037035A1 - Procédé pour une production de chaussures efficace et localisée - Google Patents

Procédé pour une production de chaussures efficace et localisée Download PDF

Info

Publication number
WO2010037035A1
WO2010037035A1 PCT/US2009/058628 US2009058628W WO2010037035A1 WO 2010037035 A1 WO2010037035 A1 WO 2010037035A1 US 2009058628 W US2009058628 W US 2009058628W WO 2010037035 A1 WO2010037035 A1 WO 2010037035A1
Authority
WO
WIPO (PCT)
Prior art keywords
shoe
outsole
midsole
module
components
Prior art date
Application number
PCT/US2009/058628
Other languages
English (en)
Inventor
Melody Crisp
Original Assignee
Nike International Ltd.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Nike International Ltd. filed Critical Nike International Ltd.
Priority to JP2011529323A priority Critical patent/JP5639062B2/ja
Priority to US13/122,712 priority patent/US20110232008A1/en
Priority to BRPI0919470A priority patent/BRPI0919470A8/pt
Priority to CN200980147380.9A priority patent/CN102227738B/zh
Priority to EP09816999.8A priority patent/EP2335198A4/fr
Publication of WO2010037035A1 publication Critical patent/WO2010037035A1/fr

Links

Classifications

    • A—HUMAN NECESSITIES
    • A43—FOOTWEAR
    • A43B—CHARACTERISTIC FEATURES OF FOOTWEAR; PARTS OF FOOTWEAR
    • A43B9/00—Footwear characterised by the assembling of the individual parts
    • G—PHYSICS
    • G06—COMPUTING; CALCULATING OR COUNTING
    • G06Q—INFORMATION AND COMMUNICATION TECHNOLOGY [ICT] SPECIALLY ADAPTED FOR ADMINISTRATIVE, COMMERCIAL, FINANCIAL, MANAGERIAL OR SUPERVISORY PURPOSES; SYSTEMS OR METHODS SPECIALLY ADAPTED FOR ADMINISTRATIVE, COMMERCIAL, FINANCIAL, MANAGERIAL OR SUPERVISORY PURPOSES, NOT OTHERWISE PROVIDED FOR
    • G06Q10/00—Administration; Management
    • G06Q10/06—Resources, workflows, human or project management; Enterprise or organisation planning; Enterprise or organisation modelling
    • A—HUMAN NECESSITIES
    • A43—FOOTWEAR
    • A43D—MACHINES, TOOLS, EQUIPMENT OR METHODS FOR MANUFACTURING OR REPAIRING FOOTWEAR
    • A43D2200/00—Machines or methods characterised by special features
    • A43D2200/20—Machines including a carousel with different working posts around a turning table

Definitions

  • Shoe production is a labor-intensive process that has changed little despite advancements in automation over the past 100 years.
  • most shoe manufacturing operations today require a significant amount of manual input. For example, one worker may cut, form, align, and stitch an upper piece of a shoe. While this process may utilize a number of machines, there is still a significant amount of human input required that can introduce variation between any two different uppers. This upper shoe piece may then be passed to another worker who may then add embroidery or other embellishments, which also require a significant amount of human input. These high levels of human input can introduce undesired variations in the finished shoe-product. Further, the large amount of human labor required in the making of shoes has limited the ability to produce on-demand custom shoes at a price deemed acceptable by most customers.
  • the present invention offers several practical applications in the technical arts, not limited to methods for the production of specific types of shoes that are herein described.
  • the present invention relates to efficient shoe manufacturing methods and systems that reduce the specialized human labor required to manufacture a pair of shoes while avoiding the high costs and special maintenance requirements often associated with highly automated manufacturing equipment.
  • Systems and methods in accordance with the present invention may be used to produce multiple models of custom shoes at a single shoe manufacturing facility. For example, one customer may order a particular model of shoe while a second customer may order a different model of shoe, yet both shoe models may be manufactured at the same facility by utilizing overlapping workflows.
  • FIG. 1 illustrates a diagram of a shoe component-manufacturing facility for the manufacture of custom shoe components in accordance with an embodiment of the present invention
  • FIG. 2 illustrates a flowchart of a method of efficiently manufacturing multiple models of custom shoes at a single manufacturing facility in accordance with an embodiment of the present invention
  • FIG. 3 illustrates a flowchart of an outsole manufacturing workflow for a running shoe for the outsole/midsole module in accordance with an embodiment of the present invention
  • FIG. 4 illustrates a flowchart of a midsole manufacturing workflow for a running shoe for the outsole/midsole module in accordance with an embodiment of the present invention
  • FIG. 5 illustrates a flowchart of a workflow for a running shoe for the priming and adhesive module in accordance with an embodiment of the present invention
  • FIG. 6 illustrates a flowchart of a workflow for joining an outsole and a midsole into a midsole-outsole on a running shoe in accordance with an embodiment of the present invention
  • FIG. 7 illustrates a flowchart of a workflow for customizing an upper for a running shoe in accordance with an embodiment of the present invention
  • FIG. 8 illustrates a flowchart of a workflow for assembling an upper for a running shoe in accordance with an embodiment of the present invention
  • FIG. 9 illustrates a flowchart of a workflow for lasting and quality control for a running shoe in accordance with an embodiment of the present invention
  • FIG. 10 illustrates a flowchart of an outsole manufacturing workflow for a basketball shoe for the outsole/midsole module in accordance with an embodiment of the present invention
  • FIG. 11 illustrates a flowchart of a midsole manufacturing workflow for a basketball shoe for the outsole/midsole module in accordance with an embodiment of the present invention
  • FIG. 12 illustrates a flowchart of a workflow for a basketball shoe for the priming and adhesive module in accordance with an embodiment of the present invention
  • FIG. 13 illustrates a flowchart of a workflow for joining an outsole and a midsole into a midsole-outsole on a basketball shoe in accordance with an embodiment of the present invention
  • FIG. 14 illustrates a flowchart of a workflow for customizing an upper for a basketball shoe in accordance with an embodiment of the present invention
  • FIG. 15 illustrates a flowchart of a workflow for assembling an upper for a basketball shoe in accordance with an embodiment of the present invention
  • FIG. 16 illustrates a flowchart of a workflow for lasting and quality control for a basketball shoe in accordance with an embodiment of the present invention
  • FIG. 17 illustrates a flowchart of an outsole manufacturing workflow for a skate shoe for the outsole/midsole module in accordance with an embodiment of the present invention
  • FIG. 18 illustrates a flowchart of a midsole manufacturing workflow for a skate shoe for the outsole/midsole module in accordance with an embodiment of the present invention
  • FIG. 19 illustrates a flowchart of a workflow for a skate shoe for the priming and adhesive module in accordance with an embodiment of the present invention
  • FIG. 20 illustrates a flowchart of a workflow for joining an outsole and a midsole into a midsole-outsole on a skate shoe in accordance with an embodiment of the present invention
  • FIG. 21 illustrates a flowchart of a workflow for customizing an upper for a skate shoe in accordance with an embodiment of the present invention
  • FIG. 22 illustrates a flowchart of a workflow for assembling an upper for a skate shoe in accordance with an embodiment of the present invention
  • FIG. 23 illustrates a flowchart of a workflow for lasting and quality control for a skate shoe in accordance with an embodiment of the present invention
  • FIG. 24 illustrates a work flow diagram of a shoe component-manufacturing facility for the manufacture of custom shoe components in accordance with an embodiment of the present invention
  • FIG. 25 illustrates a schematic of a module configuration for use in shoe production in accordance with an embodiment of the present invention
  • FIG. 26 illustrates a system for producing and assembling shoe components in accordance with an embodiment of the present invention.
  • FIG. 27 illustrates a flowchart of a workflow of a shoe manufactured through a process in accordance with an embodiment of the present invention.
  • Embodiments of the invention may provide a method for efficiently producing shoes that may meet the demands of a geographic location.
  • a production facility for efficient production of shoes may be divided into particular modules, wherein a module may refer to an area of distributive labor or of specificity relating to one or more aspects of the shoemaking process, such as embroider or production of midsoles.
  • one or more modules may be designed to best benefit the working environment of individual operators such that the interaction between the operator and the machines in an operator's module are ergonomically designed to be conducive to the worker's good health.
  • Each module may be referred to as a "module.” As a shoe component moves through modules, different processes and modifications may occur that comprise the steps in the overall manufacture of a shoe.
  • a shoe article wherein a shoe article may be a final shoe or a partially final shoe or a component of a final shoe, may be produced only after a customer order has been received.
  • a customer order may contain custom shoe parameters that pertain to one or more shoes produced for a given consumer.
  • each shoe since each shoe may be custom-made, each shoe may have a variety of characteristics according to each customer's request (e.g., a left- foot men's size 9 in blue with medium- level hardness may be paired with a right-foot men's size 9.5 with high-level hardness in red).
  • the order may be tracked throughout the production system so as to notify one or more operators of the unique characteristics of each order.
  • the customer order may be presented to one or more operators on one or more sheets of paper. Each sheet of paper may travel to an appropriate operator so as to indicate to the operator what modifications to make to the shoe and/or shoe component the operator is modifying.
  • the operator may then select the desired characteristics, such as a preferred color, from a source of materials within the modularized production facility, or the operator may select the desired design and/or markings from a series of program choices on a computer system.
  • the operator may search through a pre-defined set of designs available for printing and/or embroidering and/or etching onto a material and may program the computer to print and/or embroider and/or etch the design onto a material.
  • the operator may input a design or program supplied by the customer as a customized design on one or more shoe components.
  • an operator can access information pertaining to a customer order throughout the shoe component-manufacturing facility by having the customer information stored on a database that is accessible to an operator in the shoe component-manufacturing facility.
  • An operator may access the customer order information through a computer interface at or near one or more modules in the shoe-components manufacturing facility.
  • An operator may also access information pertaining to the customer through the use of one or more bar codes.
  • a bar code may access customer order info from a database that may contain all of the necessary information for the production of a customer's order of one or more shoes.
  • a bar code may be used to access all information related to one or more shoe components, or may be used to access particular information related to one or more shoe components.
  • a bar code may be associated with each characteristic aspect and/or component of a shoe.
  • a bar code may be associated with the color which is desired to have on the background of a shoe component.
  • a bar code may be associated with the components and/or designs desired to be reflected on an upper.
  • a bar code may be associated with to selection of components from a marketplace. For instance, one bar code may represent men's running shoes size 9, whereas another bar code may represent women's basketball shoes size 7.
  • the use of bar codes may be associated with or supplanted by the use of number codes to supply the characteristics of a customer's order. For example, if a barcode is damaged or if a barcode reader is simply not working, an operator may input a number code to reflect the characteristic customer information associated with an order of one or more shoes.
  • the production of the outsole and/or midsole may begin before a customer places an order.
  • An outsole and/or midsole may also be produced on an as-needed basis after a customer order is received for the production of one or more shoes.
  • shoe component-manufacturing facility 100 an exemplary operating environment suitable for implementing embodiments of the present invention is shown and designated generally as shoe component-manufacturing facility 100.
  • Shoe component- manufacturing facility 100 is but one example of a suitable manufacturing environment and is not intended to suggest any limitation as to the scope of use or functionality of the invention. Neither should the shoe component-manufacturing facility 100 be interpreted as having any dependency or requirement relating to any one or combination of components illustrated.
  • FIG. 1 shows the floor layout of six shoe component-manufacturing modules organized by the processes performed by an operator associated with a module.
  • the six modules represented in FIG. 1 include: the Outsole and Midsole module; the Midsole, Outsole, Upper Prime and Adhesive module; the Final Assembly & Stockfit module; the Upper Customization module; the Upper Forming and Stitching module; and the Lasting, De- Lasting, Quality Control and Packing module.
  • the Outsole and Midsole module may contain injection mold pre-forming machine 102 that may be used to produce phylon biscuits.
  • the Outsole and Midsole module may also contain midsole marketplace 108 that may store phylon biscuits for use in forming midsoles.
  • the Outsole and Midsole module may also contain press 106, that may specifically be a Kingstead Quick Open Press, that may be used for characterizing phylon biscuits as being right-oriented shoes, left-oriented shoes, or neutral-oriented shoes may.
  • the Outsole and Midsole module may also contain a microwave heat source to pre-heat the phylon biscuit.
  • the Outsole and Midsole module may also contain stabilization oven 110 that may be used to stabilize midsoles and may also decrease the volume of midsoles.
  • the Outsole and Midsole module may also contain a wash/dry are 112.
  • the Outsole and Midsole module may also contain a midsole marketplace 104.
  • the Outsole and Midsole module may also contain injection mold rubber machine 116 that may be used to produce outsoles.
  • the Outsole and Midsole module may also contain a wash/dry area 114 that may be used to wash outsoles with an alkaline or acid wash.
  • the Outsole and Midsole module may also contain an outsole marketplace 118.
  • the Midsole, Outsole, Upper Prime and Adhesive module may contain midsole marketplace 104 and outsole marketplace 118.
  • the Midsole, Outsole, Upper Prime and Adhesive module may also contain primer and adhesive area 120. In another method, the primer area and adhesive area may be two separate areas.
  • the Midsole, Outsole, Upper Prime and Adhesive module may also contain chemical storage area 156 that may contain chemicals related to one or more processes in the manufacturing of shoe components and/or shoe articles in the shoe-components manufacturing facility 100.
  • the Midsole, Outsole, Upper Prime and Adhesive module may also contain infrared (IR) oven 122.
  • IR infrared
  • the Midsole, Outsole, Upper Prime and Adhesive module may also contain a standard oven wherein one or more shoe articles may undergo manufacturing processes, such as having adhesive activated.
  • the Final Assembly & Stockfit module may contain IR oven 122.
  • the Final Assembly & Stockfit module may also contain a bladder press 124 that may be used to fit a midsole and outsole together.
  • the Final Assembly & Stockfit module may also contain standard press 126.
  • the Final Assembly & Stockfit module may also contain chiller 128 that may be used to set the adhesive of a midsole-outsole shoe article.
  • the Final Assembly & Stockfit module may also contain swing arm stage post 130.
  • the Upper Customization module may contain Eco-Solvent Printer 132 and print desk 134 and dye sub printer 136.
  • the Upper Customization module may also contain custom clicker 138 that may be used to modify material used in upper customization and a tooling area 160 that may contain tools related to one or more processes in the manufacturing of one or more shoe components and/or one or more shoe articles in the shoe-components manufacturing facility 100.
  • the Upper Customization module may also contain laser 140 that may be used to etch material used in upper customization and a laser/embroidery desk 146.
  • the Upper Customization module may also contain dye sub press 142.
  • the Upper Customization module may also contain left embroidery machine 162 and may contain right embroidery machine 164.
  • the Upper Customization module may also contain tooling area 166 that may contain tools related to one or more processes in the manufacturing of one or more shoe components and/or one or more shoe articles in the shoe-component manufacturing facility 100.
  • the Upper Customization module may also contain radio frequency (RF) Welder 148 wherein RF Welder 148 may include an RF staging area that may be used to temporarily store shoe components in the process of producing a shoe.
  • RF Welder 148 may include an RF staging area that may be used to temporarily store shoe components in the process of producing a shoe.
  • the Upper Forming and Stitching module may contain RF Welder 148 wherein RF Welder 148 may include an RF staging area that may be used to temporarily store shoe components in the process of producing or modifying a shoe article.
  • the Upper Forming and Stitching module may also contain marketplace 150 that may be used to temporarily store and make easily available customizable parts needed to complete production of a shoe or shoe article.
  • the Upper Forming and Stitching module may also contain material storage 168 that may contain materials and/or shoe components related to one or more processes in the manufacturing of shoe components and/or shoe articles in shoe- component manufacturing facility 100.
  • the Upper Forming and Stitching module may also contain final trim clicker 144 and wing arm staging area 130.
  • the Upper Forming and Stitching module may also contain market clicker 170, heat press 172, cooling rack 174, cutting press 176, heel former 178, post stitch 180 and strobel stitch 182.
  • the Lasting, De-Lasting, Quality Control and Packing module may contain swing arm staging area 130.
  • the Lasting, De-Lasting, Quality Control and Packing module may also contain lasting area 152, final quality control 154, lacing and packing 156 and storage material 184.
  • the first step in the production of the outsole may utilize injection rubber mold machine 102.
  • Different-sized and/or -shaped molds may be used to produce a range of outsoles for a range of shoe sizes and styles.
  • Various types and/or colors of rubber may also be used to produce outsoles with different functional and/or aesthetic properties.
  • indicating marks such as dotted lines
  • different colors of shoe components may have a functional component, such as adding an easily seen color, such as bright yellow, to one or more shoe components to make a shoe-wearer more visible.
  • a functional component such as adding an easily seen color, such as bright yellow
  • different rubbers with a higher slippage may be placed along a shoe component in order to minimize the extent to which mud or other outside components stick to the shoe- wearer' s one or more shoes.
  • the operator of injection rubber mold machine 102 may determine the number of each size, style, color, etc. of outsoles to make initially based on an indicator of outsoles required in outsole marketplace 118.
  • an indicator may include a pre-set range of expected sales for that store.
  • a number of outsoles may also be created upon receipt of an indication of depleting inventory of a particular size, style, color, etc.
  • the pre-set range of sales may be projected for a day or for another period of time, such as a week or a month or a season.
  • the operator of injection rubber mold machine 102 alternatively or additionally may determine which size of outsole to make based on the quantity of outsoles of that size remaining in outsole marketplace 118.
  • Outsole marketplace 118 of may comprise a plurality of temporary storage methods, with each temporary storage method corresponding to a particular style, size, color, functional property, etc.
  • a temporary storage method may comprise placing newly formed outsoles for size 9 in a first-come-first- serve (i.e. FIFO) queue.
  • a temporary storage method may consist of an operator placing each newly formed outsole into a bin associated with one or more properties of that outsole (e.g., outsoles for men's size 9 are in one bin while outsoles for men's size 5 are in another bin).
  • a temporary storage method may comprise placing all newly formed outsoles into a bin and then allowing the operator to remove the appropriately sized outsole from the bin when needed, e.g. by choosing an outsole based on sight variation between different sized outsoles or by textured indications of different sized outsoles.
  • the operator may then decide to manufacture outsoles of that size.
  • Outsoles may also be produced in direct response to an order, and may be made having the style, size, color, functional properties, etc. specified in an order.
  • Wash/dry area 114 may comprise one or more cleaning steps to clean the shoe and remove any residue from the rubber.
  • rubber residue may be caused by the oils and stearic acid used during a curing process.
  • a curing process may eliminate the use of stearic acid in the curing process and/or reduce the amount of oil used in the curing process, thereby reducing or eliminating the need for wash/dry area 114.
  • This curing process may reduce or eliminate the rubber residue produced during the curing process and may reduce or eliminate the need for one or more cleaning steps.
  • the outsole could be ready for priming directly after it is formed in injection rubber mold machine 116. After washing, if any, the outsole may be dried. For example, the outsole may be dried using wash/dry area 114.
  • the outsole may be dried by placing it in a sufficient heated, sufficiently de-humidified area (e.g. place the one or more shoes next to a window to dry). The operator may remove the dried outsole from wash/dry 114 and place it into outsole marketplace 118 to be available for use.
  • Outsole marketplace 118 and midsole marketplace 104 may be comprised of one or more temporary storage methods wherein midsoles may be stored in bins that are arranged according to size, style, color, or other attributes of the components stored in the bins.
  • Outsole marketplace 118 and midsole marketplace 104 may store outsoles and midsoles that have been produced upon receipt of an indication of anticipation of customer orders.
  • Outsole marketplace 118 and midsole marketplace 104 may also contain outsoles or midsoles produced upon receiving a specific customer order.
  • outsoles and/or midsoles produced upon receipt of a customer order may bypass outsole marketplace 118 and/or midsole marketplace 104 and move directly onto further production steps. Still more embodiments may be obvious to one of ordinary skill in the art.
  • midsole may begin before a customer places an order.
  • a midsole may also be produced on an as-needed basis upon the receipt of a customer order for one or more shoes. Further, a midsole may be produced as a result of the receipt of an indication that the quantity and character of midsoles remaining in midsole marketplace 104 should be adjusted.
  • a pre-measured volume of raw, unblown EVA pellets may be injected into a mold at injection mold pre-form 102 that is heated to approximately 100° Celsius.
  • the temperature of the mold may be hot enough to melt the EVA pellets to conform to the shape of the mold, but not hot enough to activate the EVA's blowing agent.
  • the product is an injection phylon biscuit, hereinafter referred to as a "biscuit,” that may be stored prior to activating the blowing agent to fabricate a midsole.
  • Different volumes of EVA pellets may be associated with different shoe sizes, styles, densities and or hardnesses of portions of a midsole.
  • the base polymer that is used in the injection phylon biscuit process may differ based on the ultimate hardness characteristic that is desired in the midsole of a shoe.
  • Each set of shoes may contain one or more biscuits of varying volumes and dimensions comprising the midsole of each shoe.
  • the hardness of one or more biscuits in a midsole may be customized to vary laterally and/or vary lengthwise across the shoe. Such a characteristic may, for example, prevent mild pronation in shoe users, such as runners, or simply enhance comfort.
  • the biscuit may be removed and placed into biscuit marketplace 108. From biscuit marketplace 108, the biscuits may be taken out on an as- needed basis.
  • an operator may take one or more biscuits that are in accordance with the customer's order.
  • operator may take the one or more biscuits from the marketplace and place them in a machine that exposes the one or more biscuits to a source of microwave radiation.
  • one or more biscuits may be placed in a Magic Chef MCB780W 1.2 kilowatt microwave and exposed to microwave radiation at high power for a period of sixty-five seconds.
  • an operator may place each biscuit into press 106 which may be designated for left shoes and right shoes or a combination of both.
  • the operator may load the left shoe designation or right shoe designation of press 106, and may use press 106 to configure each biscuit as "left” or "right.” The operator may then unload each biscuit from press 106.
  • Press 106 may not be limited to holding only one biscuit, but may hold a plurality of biscuits at any given time. Moreover, the pressing of the biscuits need not be in sync with respect to each biscuit in press 106, but rather, may be designed to have multiple biscuits loading and pressing and unloading at any given time.
  • an operator of a module may bypass the step of using a press 106 to designate a shoe article as being oriented "left” or “right”, and may simply use a lathe or a pair of shears or one or more blades to shape the biscuit by hand.
  • An operator may also use another type of machine to designate each biscuit as being oriented "left” or “right” before placing each biscuit into a neutral, un- oriented press 106.
  • An operator may also keep the biscuit as a neutral designation, such that each shoe part is interchangeable as being used for a left shoe and/or a right shoe.
  • the temperature is sufficient to activate a blowing agent in the biscuit.
  • This blowing agent may degrade the polymer chains and start a foaming process which increases the volume of the biscuit approximately 200% to conform to the shape of the press.
  • the a curing agent within the biscuit working at a slower reaction rate than the blowing agent may begin to cross-link polymer chains to hold the form of the augment biscuit.
  • an operator may unload the augmented midsole from press 106 and load the augmented midsole into stabilization oven 110.
  • the augmented midsole may be approximately 75° Celsius.
  • the augmented midsole may enter stabilization oven 110 at a temperature that is higher or lower than 75° Celsius.
  • the augmented midsole may be as hot as the highest temperature achieved in the press 106 and may be transferred at that same temperature into the stabilization oven 110.
  • the stabilization process in stabilization oven 110 may be comprised of three or more cooling stages in which the temperature may decrease from approximately 75° Celsius to approximately 45° Celsius.
  • the stabilization process in stabilization oven 110 may be conducted over a greater number of steps through the use of water and or air as mediums of cooling.
  • additional media and/or chemical solutions may be used to enhance the cooling process in the stabilization process of stabilization oven 110.
  • the stabilizing process may decrease the volume of the augmented midsole by approximately 20% such that the midsole resulting from the stabilization process is approximately 160% of the original biscuit volume.
  • the stabilizing process may be modified to increase or decrease the percentage change seen in the volume of the augmented midsole.
  • any form of stabilization method may be used to stabilize one or more augmented biscuits, including immersion into water or other liquid at a desired temperature.
  • augmented biscuits may be stabilized through the use of an aerosol solution or exposure to air at a desired temperature.
  • Another method of changing the volume of an augmented midsole may be to modify the midsole by hand, e.g. by the use of a lathe or the use of one or more cutting tools or the use of a second mold from which the augmented midsole may be placed in to decrease volume either by using pressure to shrink volume or using pressure to press a desired form from the augmented midsole and subsequently cutting and/or trimming off any undesired excess material.
  • an operator may unload the biscuit from stabilization oven 110 and load the biscuit into wash/dry table 112 wherein a sonic bath may be used to clean one or more midsoles. Wash/dry table 112 may use one or more cleaning stages to clean a midsole.
  • the stabilization of the augmented biscuit may be combined with wash/dry table 112.
  • the biscuit may be unloaded from stabilization oven 110 and loaded into another type of cleaning machine and/or solvent and/or solution wash.
  • each biscuit unloaded from stabilization oven 110 may be hand- polished by one or more operators.
  • midsole marketplace 104 and outsole marketplace 118 may be comprised of a series of different classes of outsoles and the one or more midsoles described above.
  • the outsoles and the one or more midsoles associated with the customer's order may be removed from outsole marketplace 118 and midsole marketplace 104, respectively, if available. If one or more midsoles or outsoles of a customer's order are not available in midsole marketplace 104 or outsole marketplace 118, respectively, the necessary component or components may be made on a per-order basis.
  • the outsole and one or more midsoles may be primed with an UV- activated primer at area 120.
  • the primer may be placed on the one or more midsoles within 24 hours of its being activated. In an alternative embodiment, the primer can be placed on each outsole and midsole prior to entering outsole marketplace 118 or midsole marketplace 104, respectively.
  • each component may be placed in infrared oven 122. Once in the oven, the temperature may be increased to approximately 55° Celsius. At a sufficiently high temperature, the primer may be activated. Each component may then be removed from the infrared oven and an adhesive may be applied at prime and adhesive area 120. Each component may then be loaded into infrared oven 122, where it may be heated to approximately 55° Celsius, at which point the adhesive may be activated. Each component may then be removed from infrared oven 122. In an alternative embodiment, each component may have adhesive applied at prime and adhesive area 120 and then loaded into a standard oven to be heated. The standard oven may be heated, at which point the adhesive may be activated.
  • the outsole and the one or more midsoles may be pressed together.
  • the outsole and the one or more midsoles may be hand-fit together through the use of bladder press 124 and standard press 126.
  • the outsoles and midsoles may be loaded into a pressing alignment machine that works to fit the outsole and one or more midsoles together.
  • Chiller 128 may decrease the temperature of the outsole-midsole, to approximately 0° Celsius, allowing the adhesive to set.
  • the outsole-midsole may be set out to cool for a sufficient amount of time as is necessary to reduce the temperature of the adhesive to a point that it sets the adhesive.
  • the outsole-midsole may be sent to the staging area at swing arm post 130.
  • the production of the upper may begin when the customer places an order for one or more shoes.
  • an operator may load a piece of synthetic material (e.g., synthetic leather, polyester, or mesh, etc.) onto eco-solvent printer 132.
  • the synthetic material may be white, which may allow customer to request synthetic material to be printed with one or more desired aesthetic elements pertaining to the customer's order.
  • the synthetic material may be dyed to customize the customer's order for one or more shoes.
  • an operator may load a natural material (e.g. cotton or natural leather) onto eco-solvent printer 132.
  • the desired color of a material may be loaded into eco-solvent printer 132. Loading a desired color of a material may reduce or eliminate steps for dyeing material.
  • eco-solvent printer 132 may then load to eco-solvent printer 132.
  • Eco-solvent printer 132 may then print to dye sub printer 136.
  • eco-solvent printer 132 may print.
  • eco-solvent printer 132 may cut out a customized synthetic from an original piece of synthetic material. In another method, the customized synthetic may be cut with the use of shears or a blade or the use of a press.
  • the operator may load a piece of customized synthetic into laser 140.
  • the operator may then input the specifications given by the customer and may start the laser etching job, if applicable.
  • the operator may remove the piece of customized synthetic and may load it into dye sub press 142.
  • the dye sub press 142 may be used to imprint designs, such as a Nike swoosh, onto material.
  • the operator may remove the laser cut upper from the dye sub press 142 and load the upper into embroidery machine 146.
  • the operator may then start embroidering machine 146, customizing the upper by embroidering a desired set of designs using a desired set of colors.
  • the operator can then unload the customized upper from embroidering machine 146 and deliver it to radio frequency welder 148.
  • the upper and outsole-midsole may be retrieved by an operator.
  • the operator may also retrieve a kit of the remaining shoe components from marketplace 150.
  • the remaining shoe components are composed in a "kit" wherein an operator can, for example, retrieve the remaining components needed for a Men's size 9 running shoe.
  • one or more operators may retrieve one or more remaining shoe components from a marketplace of kit components. After the shoe components are gathered, the operator may utilize radio frequency welder 148 to combine the components. After the parts of the upper have been assembled, the operator may make one or more final cuts with final trim clicker 144 to define the shape of an upper.
  • the upper may be cut by an operator using visual judgment and or expertise to guide the operator in knowing where and/or at which angle and/or how much to cut. Swing arm 130 may then stitch the upper to the outsole-midsole. In another example, the upper may be stitched by an operator using visual judgment and or expertise to guide the operator in knowing where and/or at which angle and/or how much to cut. This sub-assembly may then be sent to lasting area 152.
  • a method 200 for the efficient manufacturing of multiple models of custom shoes at a single manufacturing facility such as the facility disclosed above, is illustrated.
  • a first customer may place an order for a first model of shoe and one or more customization parameters particular to that customer' s order.
  • a second customer may place an order for a second model of shoe and one or more customization parameters particular to that customer's order.
  • both the first and second customers' shoes may be manufactured in the same facility efficiently, at a reasonable cost and within a reasonable amount of time.
  • the physical footprint of a manufacturing facility capable of producing multiple models of shoes may also be reduced.
  • shoe model options may be presented to a customer.
  • Shoe model options presented in step 205 may include, for example, a running shoe model, a basketball shoe model, and a skate shoe model.
  • other shoe models, both athletic and non- athletic may be alternatively or additionally comprise available shoe model options presented in step 205.
  • Step 205 may optionally comprise, for example, all available shoe model options that are available to be made on-site at a connected or local shoe manufacturing facility.
  • shoe model options may comprise shoe models capable of being made on-site at a connected or local shoe manufacturing facility along with shoe models not capable of being made on-site at a connected or local shoe manufacturing facility.
  • Step 205 may comprise, for example, presenting information describing the available shoe model options, along with an indication of local manufacturing availability for each particular model, to a customer on a computer using a graphical user interface.
  • a customer's shoe model selection may be received.
  • step 210 may comprise receiving a user selection of a presented shoe model from within a graphical user interface.
  • a customer may select a checkbox associated with a basketball shoe model, for instance, to indicate that he or she would like to order a basketball shoe.
  • step 215 functional options for the selected shoe model may be presented to the customer.
  • step 215 may be performed, for example, within a graphical user interface operating on a computer.
  • Functional options may include parameters such as shoe size.
  • Other types of options that may be selected in step 215 may include outsole hardness options, support options, motion control options, outsole texture options, outsole material options, and the like. It should be appreciated that step 215 need not necessarily be presented after step 205 and step 210, but that in many instances the functional options available may depend upon the shoe model selected.
  • functional options relating to foot motion control may be relevant to a running shoe and therefore made available for customer selection after a customer has selected a running shoe model, while motion control options are not relevant for a basketball shoe, and therefore need not be available for basketball shoe models.
  • site-manufacturing information specific to each functional option may be indicated. For example, some functional options may be available for shoes manufactured on- site at a connected or local manufacturing facility, while others may only be available at a non-local manufacturing facility.
  • One or ordinary skill in the art will readily appreciate any number of other types of functional options that are relatively specific to one or more particular model type of shoe.
  • step 220 a customer's functional options selection may be received. Similarly to step 210, step 220 may be performed, for example, within a graphical user interface operating on a computer. For example, step 220 may comprise receiving a user selection of a specific functional option, such as midsole hardness, within a graphical user interface. For example, a customer may select a checkbox associated with an indication of midsole hardness to indicate that he or she would like the midsoles on his or her shoes to be of a specific hardness.
  • aesthetic options for the selected shoe model and/or functional options may be presented to the customer. Step 225 may occur using a graphical user interface on a computer, similarly to step 205 and step 215.
  • step 225 may depend, at least in part, upon the model option selected by a customer and/or the functional options selected by a customer. However, it is also possible that aesthetic options may exist entirely or partially independent of model and/or functional options, in which case step 225 may occur prior to or in conjunction with step 205 and/or step 215. For example, options regarding shoe color may not depend upon shoe model or functional options. On the other hand, options relating to the color of a particular functional element, for example, will necessarily be dependent upon whether that functional element has been selected, either as part of a shoe model selection or as a functional option. Also, similarly to step 205, site-manufacturing information specific to each aesthetic option may be indicated. For example, some aesthetic options may be available for shoes manufactured on- site at a connected or local manufacturing facility, while others may only be available at a non-local manufacturing facility.
  • the aesthetic option selections may be received from the customer.
  • Step 230 may be performed, for example, by receiving customer selections using a pointing device in a graphical user interface on a computer, for example, by clicking checkboxes appropriate for each aesthetic option selected.
  • step 235 a customer's site manufacturing options may be presented.
  • step 235 may be performed, for example, within a graphical user interface operating on a computer.
  • Site manufacturing options presented in step 235 may comprise, for instance, an option for on-site manufacture at a connected or local manufacturing facility, the option for manufacture at a specific local or non-local facility, or an option to indicate no site-manufacturing preference. It may be appreciated that the options presented in this step may be influenced by the customer's selection of shoe model in step 210, the customer's selection of functional shoe options in step 220, and/or the customer's selection of aesthetic options in step 230.
  • step 215 might not present such a manufacturing option to the user.
  • step 220 or and aesthetic option in step 230 might not be included in the list of manufacturing options in step 235.
  • Step 235 may comprise, for example, presenting to the user a list of options comprising all sites where a particular model of shoe with the particular selected functional and aesthetic options may be manufactured.
  • step 240 a customer's site manufacturing selection may be received. Similarly to step 210, step 240 may be performed, for example, within a graphical user interface operating on a computer. For example, step 240 may comprise receiving a user selection of a presented manufacturing facility from within a graphical user interface. For example, a customer may select a checkbox associated with an local manufacturing facility to indicate that he or she would like his or her shoes to be manufactured on- site at a connected or local manufacturing facility.
  • step 245 pickup options for the selected shoe model may be presented to the customer.
  • step 245 may comprise presenting a list of options to the user comprising the option of picking up the shoes at the store where an order has been placed, the option of picking up the shoes from a connected or local manufacturing facility, the option of having the shoes delivered to a different store location, and the option of having the shoes delivered to the customer at his or her residence.
  • the options presented in this step may be tailored to reflect the customer' s manufacturing site selection in step 240.
  • step 245 may present the user with the option of picking his or her shoes up from the store or from a connected or nearby manufacturing facility.
  • the options presented in step 245 might not comprise the option to pick up the shoes at a nearby manufacturing facility.
  • step 250 a customer' s pickup selection may be received.
  • step 250 may be performed, for example, within a graphical user interface operating on a computer.
  • Step 250 may comprise, for instance, receiving a user selection of a pickup option from within a graphical user interface.
  • a customer may select from a dropdown list to indicate that he or she would like his or her shoes to be available for pickup at the store in which the order was placed.
  • step 250 may comprise receiving an indication that the user would prefer to have his or her order mailed to his or her residence.
  • step 250 may comprise receiving an indication that the user would prefer to have his or her order delivered to another store site for pickup.
  • a workflow may be initiated in a facility designated by the user in step 240 to construct an outsole in accordance with the shoe model option selected by the customer.
  • the workflow may also incorporate the functional options, and/or aesthetic options selected by a customer. For example, if, in step 210, the customer selected a basketball shoe model, a basketball shoe workflow may be initiated in the outsole manufacturing compartment. It should be noted that the specific basketball shoe workflow for any particular basketball shoe may vary to some degree such that the customer's particular functional and/or aesthetic selections be incorporated into the final basketball shoe yet the workflow may still be considered a basketball shoe workflow (as opposed to being a skate shoe workflow). Alternatively, had the customer selected a running shoe model in step 210, for instance, a running shoe workflow may be initiated to construct an outsole in accordance with a running shoe model.
  • step 255 need not necessarily incorporate a different workflow for each shoe model, as some shoe models may exhibit a certain amount of overlap in certain component manufacturing compartments.
  • a workflow for a skate shoe outsole may be similar enough to a workflow for a basketball shoe outsole such that there need be only one outsole workflow for the production of both basketball and skate shoe outsoles.
  • each component for these shoes can similarly share a workflow; while the workflow for a basketball shoe outsole may converge with the workflow for a skate shoe outsole such that a single outsole workflow common to both shoe models may be utilized, for instance, the workflows for each shoe may diverge significantly in the production of their respective midsoles such that separate midsole workflows need be maintained.
  • Different shoe model workflows may thus be implemented in various component manufacturing compartments with varying degrees of overlap. These overlapping, diverging and converging workflows allow for the efficient manufacture of multiple models of shoes in a single manufacturing facility while at the same time reducing physical footprint of said manufacturing facility.
  • step 255 need not be necessarily initiated by a specific selection by a specific customer. For example, a predetermined level of inventory of outsoles having various characteristics may be maintained. Outsoles in three different colors may be made in each available size for each of three different models of shoes available at a facility, for instance. Outsoles may then be used from the inventory based upon customer orders. Whenever a given model, size, and color of outsole begins to run low in inventory, an operator may then initiate a workflow for that model to construct additional outsoles meeting those parameters. In this way, step 255 may be performed in a way that is responsive to the shoe model, functional options, and/or aesthetic options selected by customers, while not being directly initiated by those customer selections. Further, step 255 may be performed in different ways for different types of outsoles, for example by using an inventory system to initiate workflows for commonly used outsoles and initiating workflows that produce less commonly used outsoles only in response to orders requiring them.
  • a workflow for the production of a midsole may be initiated in accordance with the shoe model; functional and/or aesthetic options may also be incorporated in accordance with the customer's selected options.
  • each shoe model may not necessarily have its own specific workflow but rather may share a workflow with another shoe model.
  • a workflow for a particular shoe model may vary to some degree to allow for the functional and/or aesthetic customizations selected by the user to be incorporated into the shoe model.
  • step 260 need not be initiated in response to any given shoe order by a particular customer, but may instead optionally utilize an inventory system to initiate workflows to produce midsoles having the desired characteristics.
  • initiating workflows to produce midsoles may be performed in different ways for different types of midsoles, for example by using an inventory system to initiate workflows for commonly used midsoles and initiating workflows to produce less commonly used midsoles only in response to orders requiring them.
  • Step 265 a workflow may be initiated to ready the outsole and midsole to be affixed together in accordance with the selected shoe model; functional options and aesthetic options desired by the customer may also be incorporated.
  • Step 265 may comprise, for example, removing from outsole marketplace one or more outsoles appropriate to the customer's order, removing from midsole marketplace one or more midsoles appropriate to customers order, skiving the edges of the removed midsole(s) and outsole(s), placing the removed midsole(s) and outsole(s) in infrared oven, priming the removed midsole(s) and outsole(s), and again placing the removed midsole(s) and outsole(s) in infrared oven.
  • each shoe model may not necessarily have its own specific workflow at step 265 but rather may share workflows with other shoe models.
  • a workflow for a particular shoe model may vary to some degree to allow for the functional and/or aesthetic customizations selected by the user to be incorporated into the shoe model.
  • any and/or all workflows for any and/or all compartments may advantageously take similar amounts of time to complete, allowing for completed components to be complete at similar times.
  • the workflows from steps 255 and 260 may produce components that arrive at similar times so that they may be readied in step 265 without the need to delay initiating a workflow in step 265 to wait for certain necessary components to arrive.
  • step 255 may comprise initiating a basketball shoe workflow that comprises the steps of (1) injection molding a rubber outsole taking approximately 220 seconds of machine time and approximately 15 seconds of human time, (2) removing flash and staging the outsole in a finished outsole marketplace taking approximately 5 seconds of human time, (3) removing the outsole from the finished marketplace taking approximately 5 seconds of human time, (4) alkaline washing the outsole taking approximately 50 seconds of machine time, (5) acid washing the outsole taking approximately 50 seconds of machine time, (6) drying the outsole taking approximately 90 seconds of machine time, (7) removing the outsole from the drying oven taking approximately 2 seconds of human time, and (8) staging the outsole in the outsole marketplace taking approximately 3 seconds of human time.
  • the workflow for producing a basketball shoe outsole in this example may take approximately 350 seconds. This being the case in this example, it may be advantageous for the workflow utilized in step 260 to similarly take approximately 350 seconds so that the parts may arrive at similar times so that step 265 may proceed without undue delay.
  • a workflow for the production of a basketball midsole in step 260 may comprise (1) injection molding a biscuit taking approximately 30 seconds of machine time, (2) placing the biscuit in biscuit marketplace taking approximately 10 seconds of human time, (3) heat pressing the biscuit taking approximately 420 seconds of machine time and approximately 20 seconds of human time, (4) loading the biscuit into a stabilization oven taking approximately 5 seconds of human time, (5) heating the biscuit to produce a midsole taking approximately 3600 seconds of machine time, (6) removing the biscuit from the stabilization oven taking approximately 5 seconds of human time, (7) water washing the midsole taking approximately 600 seconds of machine time, (8) drying the midsole and staging it in midsole staging marketplace taking approximately 300 seconds of machine time and approximately 5 seconds of human time, (9) removing the midsole from midsole staging marketplace taking approximately 2 seconds of human time, and (10) staging the midsole for assembly taking approximately 3 seconds of human time.
  • step (5) for instance may in this example take approximately 3600 seconds
  • the stabilization may be done by a load stabilization oven that may comprise a unit that allows multiple midsoles to be in the process of stabilization at once. So, for instance, a first basketball midsole workflow may be initiated, and steps (1), (2), (3) and (4) may be performed on a first biscuit. In step (5), the first biscuit may need to remain in the stabilization oven for approximately 3600 seconds to become a first midsole.
  • a second midsole workflow basketball or otherwise, may be initiated, starting with step (1) for that particular workflow, and progressing up to the step in that particular workflow wherein the second biscuit is loaded into the stabilization oven, for example.
  • two separate workflows are in progress, each having progressed up to and being currently in the stabilization step; accordingly, two or more different biscuits, associated with different models of shoe or not, may be in the stabilization oven in different stages of stabilization at any given time. Any number of workflows may thus be initiated be in varying stages of progress and overlap in such a manner.
  • the first midsole may be removed from the stabilization oven and the first initiated basketball midsole workflow may be resumed at step (6).
  • a second workflow may be initiated to produce a basketball shoe outsole. This second workflow may be completed and a third basketball outsole workflow may be initiated and completed.
  • any number of workflows may be thus initiated while the first midsole workflow from the above example remains in step (5).
  • the midsole workflow of the original example may be resumed at step (6) to complete the first midsole.
  • these workflows may overlap in any advantageous manner as would be obvious to one of ordinary skill in the art.
  • each workflow may be tailored to overlap such that a new midsole will emerge in an amount of time similar to the amount of time it takes to produce other shoe components in this or other shoe component manufacturing compartments. This may advantageously allow various components to arrive at similar times to undergo a joining workflow for instance.
  • a midsole may be produced approximately every 350 seconds to coincide with the amount of time it takes to execute an outsole workflow from the example used in step 255.
  • step 270 one or more customization workflows for an upper for a particular shoe model may be initiated in accordance with the shoe model; again, functional options, and/or aesthetic options selected by a customer may be incorporated.
  • each shoe model may not necessarily have its own specific workflow but rather may share a workflow with another shoe model.
  • a workflow for a particular shoe model may vary to some degree to allow for the functional and/or aesthetic customizations selected by the user to be incorporated into the shoe model.
  • step 270 may be performed without regard to any particular order by a customer, in practice the customization attainable in a shoe upper will likely result in step 270 being performed in response to a specific customer order.
  • step 270 may initiate a workflow to construct an upper for a running shoe having a red color.
  • step 270 may initiate a workflow to construct uppers for other types of shoe models, such as basketball shoes or skate shoes; these workflows may further incorporate any of a variety of functional characteristics, such as additional ankle support, side ventilation, and other similar functional options, with any of a variety of aesthetic options, such as particular colors, stitching patterns, insignia, and the like.
  • step 270 may comprise initiating a basketball shoe upper customization workflow comprising (1) printing echo- solvent customization taking approximately 120 seconds of machine time and approximately 30 seconds of human time, (2) cutting vamp liner and vamp qtr. taking approximately 30 seconds of human time, (3) laser customization taking approximately 120 seconds of machine time and approximately 30 seconds of human time, (4) embroidery customization taking approximately 120 seconds of machine time and approximately 30 seconds of human time, (5) delivering parts to heat press taking approximately 5 seconds of human time, and (6) checking the marketplace and cutting the parts if needed, taking approximately 6 seconds of human time.
  • the basketball workflow in this example may take approximately 491 seconds.
  • this process may, similarly to steps 255, 260, and 265, use varying degrees of temporally overlapping workflows such that an upper may be produced in a shorter amount of time more similar to the amount of time it takes to produce other components in this or other compartments utilizing different workflows.
  • temporally overlapping workflows may be utilized such that a customized upper, of any model type, may be produced approximately every 350 seconds.
  • step 270 may comprise initiating a running shoe upper customization workflow in response to having received certain customer model selection input.
  • This workflow might comprise, for example, (1) printing echo- solvent customization taking approximately 120 machine seconds and approximately 30 human seconds, (2) cutting vamp liner and vamp qtr. taking approximately 30 human seconds, (3) print dye sublimation customization taking approximately 120 machine seconds and approximately 20 human seconds, (4) press dye sub. customization taking approximately 12 machine seconds and approximately 10 human seconds, (5) laser customization taking approximately 120 machine seconds and approximately 30 human seconds, (6) embroidery customization taking approximately 120 machine seconds and approximately 30 human seconds, (7) delivering customized parts to radiofrequency welding marketplace taking approximately 5 human seconds, and (8) checking radiofrequency welding marketplace and cutting parts if needed, taking approximately 6 human seconds.
  • a customized running shoe upper may be constructed in approximately 613 seconds. It should be noted that this process may, similarly to previous steps utilizing workflows, use varying degrees of temporally overlapping workflows such that a running upper may be produced in a shorter amount of time more similar to the amount of time it takes to produce other components in this or other compartments utilizing different workflows. For example, temporally overlapping workflows may be utilized such that a customized running upper, of any model type, may be produced approximately every 350 seconds. It should be noted also that it will be obvious to one of ordinary skill in the art how, in these examples, this running shoe upper customization workflow overlaps similar machines, skills, and work areas involved in the basketball shoe upper customization workflow given as an example above.
  • step 275 one or more workflows for further manufacturing an upper for a particular shoe model may be initiated in accordance with the shoe model; again, functional options, and/or aesthetic options selected by a customer may be incorporated.
  • each shoe model may not necessarily have its own specific workflow but rather may share a workflow with another shoe model.
  • a workflow for a particular shoe model may vary to some degree to allow for the functional and/or aesthetic customizations selected by the user to be incorporated into the shoe model.
  • step 275 may be performed without regard to any particular order by a customer, in practice the customization attainable in a shoe upper will likely result in step 275 being performed in response to a specific customer order, or, more specifically, to the upper piece produced in step 270.
  • step 275 may initiate a workflow to stitch an upper for a running shoe according to the user selections, said upper having been produced and customized according the user selections in step 270.
  • step 275 may comprise initiating a basketball upper forming and stitching workflow comprising (1) gathering parts from marketplace taking approximately 15 seconds of human time, (2) assembling the upper pieces taking approximately 20 seconds of machine time and approximately 30 seconds of human time, (3) activating heat press taking approximately 10 seconds of machine time and approximately 2 seconds of human time, (4) loading the parts into cooling rack taking approximately 60 seconds of machine time and approximately 1 second of human time, (5) cutting final trim taking approximately 15 seconds of human time, (6) heel forming taking approximately 180 seconds of machine time and approximately 20 seconds of human time, (7) post stitching taking approximately 30 seconds of human time, (8) strobel stitching taking approximately 40 seconds of human time, and (9) delivering the upper to lasting station taking approximately 5 seconds of human time.
  • the basketball upper forming and stitching workflow in this example may take approximately 428 seconds. It should be noted that the process in the above example may, similarly to steps 255, 260, 265, and 270, use varying degrees of temporally overlapping workflows such that an upper may be produced in a shorter amount of time more similar to the amount of time it takes to produce other components in other compartments utilizing different workflows. For example, in step (6), while waiting for a machine to stitch the heel, the operator may initiate another workflow for the same or another model of shoe.
  • step 275 may comprise initiating a running shoe upper radiofrequency welding and stitching workflow.
  • This workflow might comprise, for example, (1) gathering parts from radiofrequency welding marketplace taking approximately 15 seconds of human time, (2) assembling upper pieces taking approximately 30 seconds of human time, (3) activating the radiofrequency welding cycle taking approximately 10 seconds of machine time and approximately 10 seconds of human time, (4) cutting final trim taking approximately 15 seconds of human time, (5) stitching upper to sole taking approximately 60 seconds of human time, and (6) delivering to final quality control area taking approximately 5 seconds of human time.
  • This example workflow may thus take approximately 145 seconds. It should be noted that this process may, similarly to previous steps utilizing workflows, use varying degrees of temporally overlapping workflows such that a running shoe upper may be produced in a shorter amount of time more similar to the amount of time it takes to produce other components in this or other compartments utilizing different workflows.
  • temporally overlapping workflows may be utilized such that a customized running upper, of any model type, may be produced approximately every 350 seconds. It should be noted also that it will be obvious to one of ordinary skill in the art how, in these examples, this running shoe upper radiofrequency welding and stitching workflow overlaps similar machines, skills, and work areas involved in the basketball upper forming and stitching workflow given as an example above.
  • a workflow may be initiated such that the outsole, midsole, and upper may be affixed together to form the selected shoe model in accordance with the selected shoe model; functional options and aesthetic options desired by the customer may also be incorporated.
  • Step 280 may comprise, for example, matching the appropriate outsole, the appropriate midsole, and a specially customized upper to form a single shoe as ordered by a customer. It should be noted that similarly to steps 255, 260, 265, 270, and 275, each shoe model may not necessarily have its own specific workflow at step 280 but rather may share workflows with other shoe models. Also similarly to step 255, 260, 265, 270, and 275, a workflow for a particular shoe model may vary to some degree to allow for the functional and/or aesthetic customizations selected by the user to be incorporated into the shoe model.
  • step 280 may comprise (1) applying adhesive to the upper produced by step 275, the midsole produced by step 260, and the outsole produced by step 255 taking approximately 75 human seconds, (2) placing the parts in oven taking approximately 120 machine seconds, (3) hand fitting the parts together taking approximately 75 human seconds, (4) pressing the parts taking approximately 30 machine seconds and approximately 10 human seconds, (5) chilling the parts taking approximately 60 machine seconds and approximately 5 human seconds.
  • the workflow in this example may take approximately 460 seconds. It should be noted that, like the other steps utilizing workflows in this example, and number of workflows may be temporally overlapped to lower the amount of time it takes to complete step 280 as would be appreciated by one of ordinary skill in the art.
  • a workflow may be initiated to quality control, lace and last the customized combined shoe component; functional options and aesthetic options desired by the customer may also be incorporated.
  • each shoe model may not necessarily have its own specific workflow at step 280 but rather may share workflows with other shoe models.
  • a workflow for a particular shoe model may vary to some degree to allow for the functional and/or aesthetic customizations selected by the user to be incorporated into the shoe model.
  • step 285 may comprise (1) quality control checking and lasting the combined shoe component taking approximately 90 seconds of machine time and approximately 90 seconds of human time, (2) quality control checking and de-lasting the combined shoe component taking approximately 30 seconds of human time, (3) lacing the combined shoe component taking approximately 60 seconds of human time, and (4) packing the shoe taking essentially no time.
  • the workflow in this example may take approximately 270 seconds. It should be noted that, like the other steps utilizing workflows in this example, and number of workflows may be temporally overlapped to change the amount of time it takes to complete step 285 as would be appreciated by one of ordinary skill in the art.
  • step 290 the customized shoe may be delivered to a customer in accordance with the customer's selected pickup options from step 245.
  • Step 290 may further include inspection and approval by a customer, payment, etc. It should be appreciated that while step 290 may occur geographically distant from the location at which all or parts of the other steps of method 200 are performed, one desirable attribute of method 200 is that it permits the localized manufacture of shoes to custom orders. Such localized manufacturing can be more responsive to local needs and preferences than remote manufacturing, and can provide reduced inventory and shipping costs. Accordingly, step 290 may occur geographically near, in fact in the same larger facility, as does the remainder of steps of method 200.
  • an illustrative method for creating an outsole for a running shoe is referenced generally by the numeral 300.
  • an injection rubber mold outsole is created by way of an injection-mold process.
  • rubber is injected into a mold that forms an outsole.
  • an outsole may be carved and/or cut from a piece of rubber.
  • an outsole is cured.
  • an outsole may be cured using stearic acid and oils. This combination may cause blooming of the rubber, resulting in rubber residue which may not be desired on an outsole.
  • flash is removed from the outsole.
  • One method of removing flash from the outsole includes cutting and/or removing and/or trimming undesired excess rubber. Another method of removing flash may be to hand- wipe or hand-pick the flash off the rubber outsole.
  • the outsole is staged in an outsole pre-wash marketplace. In one alternative, the number and character (e.g., size, shape, color, etc.) of outsoles placed into a marketplace are based on an expectation of demand.
  • an order is received.
  • An illustrative method for receiving an order includes receiving an order manually.
  • an order may be received by uploading details of an order through a web interface.
  • steps 305-320 are not performed until after an order is received. In that alternative, the outsole is produced on an as-needed basis, not as a result of a projected market demand.
  • the outsole is removed from the outsole pre-wash marketplace.
  • the outsole is washed.
  • the outsole is washed by way of an alkaline solution.
  • the outsole may go directly from step 315, where the flash is removed from the outsole, to step 335, where the outsole is washed.
  • the outsole is washed.
  • the outsole is washed by way of an acid solution.
  • the washing steps 335 and/or 340 may be a means of removing excess rubber residue created by the curing process at step 310.
  • a curing process may be used wherein stearic acid is not used, thereby reducing or minimizing the rubber residue produced.
  • the cleaning steps 335 and/or 340 would be reduced in time and/or materials, or could be eliminated.
  • the outsole is dried in an oven. In another way, an outsole may be dried in any way that is capable of producing heat that dries the outsole to a desired dryness within a desired period of time.
  • the outsole is removed from the oven. In another method, the outsole may be removed from another heating device that has been used to take away moisture from the outsole mold.
  • the outsole is staged in an outsole staging marketplace. In another method, where there is little or no rubber excess produced from the curing process 315, the outsole may go directly from the curing process 315 to being staged in the outsole staging marketplace 355.
  • the outsole may go from the curing process 315 to a cleaning step 335 wherein the outsole is wiped with a material, such as a cloth, to remove the excess rubber.
  • the outsole may either go directly from the curing process 315 to a cleaning step 335, or may go from the curing process 315 to an outsole marketplace 320 before being removed from an outsole marketplace 330.
  • the outsole would be able to skip the time spent in an outsole marketplace 320-330 when an order is received prior to the production of the outsole (e.g. when the outsole is produced on an as- needed basis).
  • an illustrative method for creating a midsole for a running shoe is referenced generally by the numeral 400.
  • a pre-specified volume of EVA pellets are loaded into an injection mold.
  • the selection of the type of polymer injected at step 402 may be correlated to the desired hardness associated with the customer order of the resulting midsole.
  • the EVA pellets are processed in the same mold at the same conditions, thus the introduction of EVA pellets with longer polymer chains will result in an increased hardness compared to EVA pellets that are introduced with shorter polymer chains, because the longer polymer chains will not be able to break down to the same extent as shorter polymer chains under the same reaction conditions.
  • the injection mold is then heated to 100° Celsius to form the volume of EVA pellets into a biscuit.
  • the EVA pellets may be heated to a temperature that may be hot enough to form the EVA pellets into the form of a biscuit and yet may not be hot enough to activate the foaming agent within the phylon.
  • the reaction conditions of the mold may be changed to influence the extent that a given polymer is allowed to break down, thereby resulting in a variety of different hardnesses.
  • the biscuit is then removed from the injection mold.
  • the biscuit is then staged into a biscuit marketplace.
  • an order is received.
  • An illustrative method for receiving an order includes receiving an order manually.
  • an order may be received by uploading details of an order through a web interface.
  • the biscuit is removed from the biscuit marketplace.
  • biscuit is then loaded into a heat press.
  • the biscuit may go directly from being removed from an injection mold 406 to being loaded into a heat press 430.
  • the right heat press and the left heat press may be operated concurrently.
  • the biscuit is then heated to 172° Celsius.
  • the biscuit may be heated to a temperature that may be hot enough to activate the foaming agent.
  • the biscuit is removed from the heat press.
  • the biscuit is loaded into a stabilization oven.
  • the stabilization oven the biscuit is cooled to a lower temperature that allows the biscuit to become the desired size as a midsole.
  • the biscuit may be placed into an air stabilization oven and the temperature may be lowered to 75° Celsius.
  • the process by which air is passed over a biscuit in a stabilization oven may be through the use of one or more air knife centrifugal blowers.
  • the biscuit may have its temperature lowered over three stages.
  • the temperature of the biscuit may be lowered from 75° Celsius to 65° Celsius.
  • the temperature of the biscuit may be lowered from 65° Celsius to 55° Celsius.
  • the temperature of the biscuit may be lowered from 55° Celsius to 45° Celsius.
  • the cooling stages of 448-452 may be done in three or more stages.
  • the step at 444 of lowering biscuit temperature to 75° Celsius may be adjusted to a higher or lower temperature.
  • one or more biscuits may be stabilized using a series of baths of water that may range from 90° Celsius to 45° Celsius. The temperature of the biscuit may decrease from 90° Celsius to 75° Celsius, then 75° Celsius to 45° Celsius, wherein the time within each bath may be spread evenly.
  • the midsole is removed from the stabilization oven.
  • the midsole is loaded into one or more sonic baths.
  • the midsole is washed.
  • step 458 may be removed and the midsole may be washed while it is still in a dual stabilization-oven- sonic-bath device.
  • the midsole is removed from the sonic bath.
  • the midsole is loaded into one or more drying ovens.
  • the midsole is dried.
  • the midsole is removed from the one or more drying ovens.
  • the midsole is loaded into a midsole staging marketplace.
  • an illustrative method for applying primer and adhesive on a running shoe is referenced generally by the numeral 500.
  • a customer order is received.
  • the customer order contains specifications for the characteristics associated with one or more desired running shoes, such as size or style or color.
  • an outsole fitting the characteristics defined in the customer order is removed from the outsole staging marketplace.
  • a midsole fitting the characteristics defined in the customer order may be removed from the midsole staging marketplace.
  • a midsole and an outsole are primed.
  • the primed midsole and the primed outsole may be placed in an infrared (hereinafter "IR") oven.
  • IR infrared
  • the midsole and outsole may be removed from the IR oven.
  • adhesive may be applied to the midsole and the outsole.
  • the midsole and the outsole are placed in an IR oven.
  • an illustrative method for joining an outsole and a midsole into a midsole-outsole on a running shoe is referenced generally by the numeral 600.
  • the outsole and the midsole are removed from the IR oven.
  • the outsole and midsole are fit together to form a midsole-outsole.
  • the midsole- outsole is loaded into a stockfit press.
  • the midsole-outsole is heated. The heat may allow the adhesive to more permanently bind the components of the midsole-outsole.
  • the midsole-outsole is removed from the stockfit press.
  • the midsole- outsole is loaded into a chiller.
  • the chiller is used to cool down the midsole-outsole to approximately 0° Celsius to allow the adhesive to set.
  • the midsole- outsole may be placed in a more temperate area where the midsole-outsole may be left to cool over a longer period of time.
  • the temperature of the midsole- outsole is lowered.
  • the press may be turned off and the midsole-outsole may be left to cool in the press until the heat dissipates.
  • the press may be wired with both a heating component and a cooling component such that a shoe article, such as a midsole-outsole, may be heated and cooled in one location.
  • having a dual heating and cooling press would both save room and would also eliminate the risk of having components of a shoe article become misaligned or fall apart during the period they are moved between the heat press and the chiller.
  • the midsole-outsole is removed from the chiller.
  • the midsole-outsole is delivered to the swing arm post staging area.
  • an illustrative method for customizing an upper for a running shoe is referenced generally by the numeral 700.
  • an order is received.
  • An illustrative method for receiving an order includes receiving an order manually.
  • an order may be received by uploading details of an order through a web interface.
  • material associated with the order for the upper e.g. synthetic leather or mesh or polyester, etc.
  • the eco-solvent printer and dye sub printer are loaded with material, such as desired colors, associated with an order.
  • the dye sub printer is used to print desired designs and/or markings on the desired material used for the upper.
  • the eco-solvent printer is used to print desired designs and/or markings on the desired material used for the upper.
  • a customized synthetic is cut out from the desired material according to the specifications characterizing an order.
  • the customized synthetic is loaded into a laser.
  • the laser is loaded with the specification of the design associated with the order.
  • the laser etches a customized design onto the customized synthetic.
  • the dye sub press is loaded.
  • the customized synthetic is removed from the laser.
  • the right embroidery machine is loaded with the customized synthetic.
  • the left embroidery machine is loaded with the customized synthetic.
  • the embroidery machines are loaded with design specifications associated with the order.
  • left and right parts are embroidered using the left embroidery machine and right embroidery machine, respectively.
  • the left part and right part are removed from the embroidery machines.
  • the customized parts are delivered to the radio frequency (hereinafter "RF") welding staging area.
  • RF radio frequency
  • an illustrative method for assembling an upper for a running shoe is referenced generally by the numeral 800.
  • customized parts for the upper are retrieved from the RF welding staging area.
  • a kit is retrieved from the marketplace which contains necessary parts associated with the customer order.
  • an upper is assembled from the customized parts.
  • an RF welding cycle is activated, binding together the assembled upper constructed of the customized parts.
  • a final trim is cut on the upper to define the final shape of the upper.
  • the midsole-outsole is retrieved from the swing arm staging area.
  • the upper is stitched to the midsole-outsole.
  • an illustrative method for lasting and quality control for a running shoe is referenced generally by the numeral 900.
  • the shoe component is retrieved from the swing arm area.
  • a quality control check is performed and the upper is lasted.
  • a quality control check is performed on the lasted upper and the upper is then de-lasted.
  • a quality control check is performed and the upper is laced.
  • a quality control check is performed and the shoe is packed.
  • an illustrative method for creating an outsole for a basketball shoe is referenced generally by the numeral 1000.
  • an injection rubber mold outsole is created by way of an injection-mold process.
  • rubber is injected into a mold that forms an outsole.
  • an outsole may be carved and/or cut from a piece of rubber.
  • an outsole is cured.
  • an outsole may be cured using stearic acid and oils. This combination may cause blooming of the rubber, resulting in rubber residue which may not be desired on an outsole.
  • flash is removed from the outsole.
  • One method of removing flash from the outsole includes cutting and/or removing and/or trimming undesired excess rubber. Another method of removing flash may be to hand- wipe or hand-pick the flash off the rubber outsole.
  • the outsole is staged in an outsole pre-wash marketplace. In one alternative, the number and character (e.g., size, shape, color, etc.) of outsoles placed into a marketplace are based on an expectation of demand.
  • an order is received.
  • An illustrative method for receiving an order includes receiving an order manually.
  • an order may be received by uploading details of an order through a web interface.
  • steps 1005-1020 are not performed until after an order is received.
  • the outsole is produced on an as-needed basis, not as a result of a projected market demand.
  • the outsole is removed from the outsole pre-wash marketplace.
  • the outsole is washed. In one method, the outsole is washed by way of an alkaline solution. In another method, the outsole may go directly from step 1015, where the flash is removed from the outsole, to step 1035, where the outsole is washed.
  • the outsole is washed. In one method the outsole is washed by way of an acid solution.
  • the washing steps 1035 and/or 1040 may be a means of removing excess rubber residue created by the curing process at step 1010.
  • a curing process may be used wherein stearic acid is not used, thereby reducing or minimizing the rubber residue produced.
  • the cleaning steps 1035 and/or 1040 would be reduced in time and/or materials, or could be eliminated.
  • the outsole is dried in an oven.
  • an outsole may be dried in any way that is capable of producing heat that dries the outsole to a desired dryness within a desired period of time.
  • the outsole is removed from the oven.
  • the outsole may be removed from another heating device that has been used to take away moisture from the outsole mold.
  • the outsole is staged in an outsole staging marketplace.
  • the outsole may go directly from the curing process 1015 to being staged in the outsole staging marketplace 1055.
  • the outsole may go from the curing process 1015 to a cleaning step 1035 wherein the outsole is wiped with a material, such as a cloth, to remove the excess rubber.
  • the outsole may either go directly from the curing process 1015 to a cleaning step 1035, or may go from the curing process 1015 to an outsole marketplace 1020 before being removed from an outsole marketplace 1030.
  • an illustrative method for creating a midsole for a basketball shoe is referenced generally by the numeral 1100.
  • a pre-specified volume of EVA pellets are loaded into an injection mold.
  • the selection of the type of polymer injected at step 1102 may be correlated to the desired hardness associated with the customer order of the resulting midsole.
  • the EVA pellets are processed in the same mold at the same conditions, thus the introduction of EVA pellets with longer polymer chains will result in an increased hardness compared to EVA pellets that are introduced with shorter polymer chains, because the longer polymer chains will not be able to break down to the same extent as shorter polymer chains under the same reaction conditions.
  • the injection mold is then heated to 100° Celsius to form the volume of EVA pellets into an biscuit.
  • the EVA pellets may be heated to a temperature that may be hot enough to form the EVA pellets into the form of a biscuit and yet may not be hot enough to activate the foaming agent within the phylon.
  • the reaction conditions of the mold may be changed to influence the extent that a given polymer is allowed to break down, thereby resulting in a variety of different hardnesses.
  • the biscuit is then removed from the injection mold.
  • the biscuit is then staged into a biscuit marketplace.
  • an order is received.
  • An illustrative method for receiving an order includes receiving an order manually.
  • an order may be received by uploading details of an order through a web interface.
  • the biscuit is removed from the biscuit marketplace.
  • biscuit is then loaded into a heat press.
  • the biscuit may go directly from being removed from an injection mold 1106 to being loaded into a heat press 1130.
  • the right heat press and the left heat press may be operated concurrently.
  • the biscuit is then heated to 172° Celsius.
  • the biscuit may be heated to a temperature that may be hot enough to activate the foaming agent.
  • the biscuit is removed from the heat press.
  • step 1140 the biscuit is loaded into a stabilization oven.
  • the stabilization oven the biscuit is cooled to a lower temperature that allows the biscuit to become the desired size as a midsole.
  • step 1144 the biscuit is lowered to a temperature 75° Celsius.
  • steps 1148-1152 the biscuit has its temperature lowered over three stages.
  • the temperature of the biscuit is lowered from 75° Celsius to 65° Celsius.
  • the temperature of the biscuit is lowered from 65° Celsius to 55° Celsius.
  • step 1154 the temperature of the biscuit is lowered from 55° Celsius to 45° Celsius.
  • the cooling stages of 1148-1152 may be done in three or more stages.
  • the step at 1144 of lowering biscuit temperature to 75° Celsius may be adjusted to a higher or lower temperature.
  • the midsole is removed from the stabilization oven.
  • the midsole is loaded into one or more sonic baths.
  • the midsole is washed.
  • step 1158 may be removed and the midsole may be washed while it is still in a dual stabilization-oven-sonic -bath device.
  • the midsole is removed from the sonic bath.
  • the midsole is loaded into one or more drying ovens.
  • the midsole is dried.
  • the midsole is removed from the one or more drying ovens.
  • the midsole is loaded into a midsole staging marketplace.
  • an illustrative method for applying primer and adhesive on a basketball shoe is referenced generally by the numeral 1200.
  • a customer order is received.
  • the customer order contains specifications for the characteristics associated with one or more desired basketball shoes, such as size or style or color.
  • an outsole fitting the characteristics defined in the customer order is removed from the outsole staging marketplace.
  • a midsole fitting the characteristics defined in the customer order may be removed from the midsole staging marketplace.
  • a midsole and an outsole are primed.
  • the primed midsole and the primed outsole may be placed in an IR oven.
  • the midsole and outsole are removed from the IR oven.
  • adhesive may be applied to the midsole and the outsole.
  • the midsole and the outsole are placed in an IR oven.
  • FIG. 13 an illustrative method for joining an outsole and a midsole into a midsole-outsole on a basketball shoe is referenced generally by the numeral 1300.
  • the outsole and the midsole are removed from the IR oven.
  • the outsole and midsole are fit together to form a midsole-outsole.
  • the midsole-outsole is loaded into a stockfit press.
  • the midsole-outsole is heated. The heat may allow the adhesive to more permanently bind the components of the midsole- outsole.
  • the midsole-outsole is removed from the stockfit press.
  • the midsole-outsole is loaded into a chiller.
  • the chiller is used to cool down the midsole- outsole to approximately 0° Celsius to allow the adhesive to set.
  • the midsole-outsole may be placed in a more temperate area where the midsole-outsole may be left to cool over a longer period of time.
  • the temperature of the midsole-outsole is lowered.
  • the press may be turned off and the midsole-outsole may be left to cool in the press until the heat dissipates.
  • the press may be wired with both a heating component and a cooling component such that a shoe article, such as a midsole-outsole, may be heated and cooled in one location.
  • a dual heating and cooling press would both save room and would also eliminate the risk of having components of a shoe article become misaligned or fall apart during the period they are moved between the heat press and the chiller.
  • the midsole-outsole is removed from the chiller.
  • the midsole-outsole is delivered to the swing arm post staging area.
  • an illustrative method for customizing an upper for a basketball shoe is referenced generally by the numeral 1400.
  • an order is received.
  • An illustrative method for receiving an order includes receiving an order manually.
  • an order may be received by uploading details of an order through a web interface.
  • material associated with the order for the upper e.g. synthetic leather or mesh or polyester, etc.
  • the eco- solvent printer and dye sub printer are loaded with material, such as desired colors, associated with an order.
  • the dye sub printer is used to print desired designs and/or markings on the desired material used for the upper.
  • the eco-solvent printer is used to print desired designs and/or markings on the desired material used for the upper.
  • a customized synthetic is cut out from the desired material according to the specifications characterizing an order.
  • the customized synthetic is loaded into a laser.
  • the laser is loaded with the specification of the design associated with the order.
  • the laser etches a customized design onto the customized synthetic.
  • the dye sub press is loaded.
  • the customized synthetic is removed from the laser.
  • the right embroidery machine is loaded with the customized synthetic.
  • the left embroidery machine is loaded with the customized synthetic.
  • the embroidery machines are loaded with design specifications associated with the order.
  • left and right parts are embroidered using the left embroidery machine and right embroidery machine, respectively.
  • the left part and right part are removed from the embroidery machines.
  • the customized parts are delivered to the heat press marketplace.
  • uppers are checked for excess material and cut when needed.
  • an illustrative method for forming and stitching an upper for a basketball shoe is referenced generally by the numeral 1500.
  • customized parts for the upper are retrieved from the heat press marketplace.
  • a kit is retrieved from the marketplace which contains necessary parts associated with the customer order.
  • an upper is assembled from the customized parts.
  • the assembled upper parts are loaded into a heat press.
  • the heat press is activated and the assembled upper parts are heated. The temperature reached is high enough that the adhesive used to bind parts is activated.
  • the parts are removed from the heat press.
  • the parts are placed on a cooling rack.
  • the parts are removed from the cooling rack.
  • a heel is formed by stitching. In an alternative, the heel may be formed by another binding method.
  • the parts are post-stitched.
  • the parts are strobel stitched.
  • the parts are delivered to a lasting station.
  • an illustrative method for lasting and quality control for a basketball shoe is referenced generally by the numeral 1600.
  • the shoe component is retrieved from the lasting station.
  • a quality control check is performed and the upper is lasted.
  • a quality control check is performed on the lasted upper and the upper is then de-lasted.
  • a quality control check is performed and the upper is laced.
  • a quality control check is performed and the shoe is packed.
  • an illustrative method for creating an outsole for a skate shoe is referenced generally by the numeral 1700.
  • an injection rubber mold outsole is created by way of an injection-mold process.
  • rubber is injected into a mold that forms an outsole.
  • an outsole may be carved and/or cut from a piece of rubber.
  • an outsole is cured.
  • an outsole may be cured using stearic acid and oils. This combination may cause blooming of the rubber, resulting in rubber residue which may not be desired on an outsole.
  • flash is removed from the outsole.
  • One method of removing flash from the outsole includes cutting and/or removing and/or trimming undesired excess rubber. Another method of removing flash may be to hand- wipe or hand-pick the flash off the rubber outsole.
  • the outsole is staged in an outsole pre-wash marketplace. In one alternative, the number and character (e.g., size, shape, color, etc.) of outsoles placed into a marketplace are based on an expectation of demand.
  • an order is received.
  • An illustrative method for receiving an order includes receiving an order manually.
  • an order may be received by uploading details of an order through a web interface.
  • steps 1705-1720 are not performed until after an order is received.
  • the outsole is produced on an as-needed basis, not as a result of a projected market demand.
  • the outsole is removed from the outsole pre-wash marketplace.
  • the outsole is washed. In one method, the outsole is washed by way of an alkaline solution. In another method, the outsole may go directly from step 1715, where the flash is removed from the outsole, to step 1735, where the outsole is washed.
  • the outsole is washed. In one method the outsole is washed by way of an acid solution.
  • the washing steps 1735 and/or 1740 may be a means of removing excess rubber residue created by the curing process at step 1710.
  • a curing process may be used wherein stearic acid is not used, thereby reducing or minimizing the rubber residue produced.
  • the cleaning steps 1735 and/or 1740 would be reduced in time and/or materials, or could be eliminated.
  • the outsole is dried in an oven.
  • an outsole may be dried in any way that is capable of producing heat that dries the outsole to a desired dryness within a desired period of time.
  • the outsole is removed from the oven.
  • the outsole may be removed from another heating device that has been used to take away moisture from the outsole mold.
  • the outsole is staged in an outsole staging marketplace.
  • the outsole may go directly from the curing process 1715 to being staged in the outsole staging marketplace 1755.
  • the outsole may go from the curing process 1715 to a cleaning step 1735 wherein the outsole is wiped with a material, such as a cloth, to remove the excess rubber.
  • the outsole may either go directly from the curing process 1715 to a cleaning step 1735, or may go from the curing process 1715 to an outsole marketplace 1720 before being removed from an outsole marketplace 1730.
  • the outsole would be able to skip the time spent in an outsole marketplace 1720-1730 when an order is received prior to the production of the outsole (e.g. when the outsole is produced on an as-needed basis).
  • an illustrative method for creating a midsole for a skate shoe is referenced generally by the numeral 1800.
  • a pre-specified volume of EVA pellets are loaded into an injection mold.
  • the selection of the type of polymer injected at step 1802 may be correlated to the desired hardness associated with the customer order of the resulting midsole.
  • the EVA pellets are processed in the same mold at the same conditions, thus the introduction of EVA pellets with longer polymer chains will result in an increased hardness compared to EVA pellets that are introduced with shorter polymer chains, because the longer polymer chains will not be able to break down to the same extent as shorter polymer chains under the same reaction conditions.
  • the injection mold is then heated to 170° Celsius to form the volume of EVA pellets into a biscuit.
  • the EVA pellets may be heated to a temperature that may be hot enough to form the EVA pellets into the form of a biscuit and yet may not be hot enough to activate the foaming agent within the phylon.
  • the reaction conditions of the mold may be changed to influence the extent that a given polymer is allowed to break down, thereby resulting in a variety of different hardnesses.
  • the biscuit is then removed from the injection mold.
  • the biscuit is then staged into a biscuit marketplace.
  • an order is received.
  • An illustrative method for receiving an order includes receiving an order manually.
  • an order may be received by uploading details of an order through a web interface.
  • the biscuit is removed from the biscuit marketplace.
  • biscuit is then loaded into a heat press.
  • the biscuit may go directly from being removed from an injection mold 1806 to being loaded into a heat press 1830.
  • the right heat press and the left heat press may be operated concurrently.
  • the biscuit is then heated to 172° Celsius.
  • the biscuit may be heated to a temperature that may be hot enough to activate the foaming agent.
  • the biscuit is removed from the heat press.
  • the biscuit is loaded into a stabilization oven.
  • the biscuit In the stabilization oven, the biscuit is cooled to a lower temperature that allows the biscuit to become the desired size as a midsole.
  • the biscuit is lowered to a temperature 75° Celsius.
  • the biscuit has its temperature lowered over three stages.
  • the temperature of the biscuit is lowered from 75° Celsius to 65° Celsius.
  • the temperature of the biscuit is lowered from 65° Celsius to 55° Celsius.
  • the temperature of the biscuit is lowered from 55° Celsius to 45° Celsius.
  • the cooling stages of 1848-1852 may be done in three or more stages.
  • the step at 1844 of lowering biscuit temperature to 75° Celsius may be adjusted to a higher or lower temperature.
  • the midsole is removed from the stabilization oven.
  • the midsole is loaded into one or more sonic baths.
  • the midsole is washed.
  • step 1858 may be removed and the midsole may be washed while it is still in a dual stabilization-oven-sonic -bath device.
  • the midsole is removed from the sonic bath.
  • the midsole is loaded into one or more drying ovens.
  • the midsole is dried.
  • the midsole is removed from the one or more drying ovens.
  • the midsole is loaded into a midsole staging marketplace.
  • an illustrative method for applying primer and adhesive on a skate shoe is referenced generally by the numeral 1900.
  • a customer order is received.
  • the customer order contains specifications for the characteristics associated with one or more desired skate shoes, such as size or style or color.
  • an outsole fitting the characteristics defined in the customer order is removed from the outsole staging marketplace.
  • a midsole fitting the characteristics defined in the customer order may be removed from the midsole staging marketplace.
  • a midsole and an outsole are primed.
  • the primed midsole and the primed outsole may be placed in an IR oven.
  • the midsole and outsole are removed from the IR oven.
  • adhesive may be applied to the midsole and the outsole.
  • the midsole and the outsole are placed in an IR oven.
  • FIG. 20 an illustrative method for joining an outsole and a midsole into a midsole-outsole on a skate shoe is referenced generally by the numeral 2000.
  • the outsole and the midsole are removed from the IR oven.
  • the outsole and midsole are fit together to form a midsole-outsole.
  • the midsole- outsole is loaded into a stockfit press.
  • the midsole-outsole is heated. The heat may allow the adhesive to more permanently bind the components of the midsole-outsole.
  • the midsole-outsole is removed from the stockfit press.
  • the midsole- outsole is loaded into a chiller.
  • the chiller is used to cool down the midsole-outsole to approximately 0° Celsius to allow the adhesive to set.
  • the midsole- outsole may be placed in a more temperate area where the midsole-outsole may be left to cool over a longer period of time.
  • the temperature of the midsole-outsole is lowered.
  • the press may be turned off and the midsole- outsole may be left to cool in the press until the heat dissipates.
  • the press may be wired with both a heating component and a cooling component such that a shoe article, such as a midsole-outsole, may be heated and cooled in one location.
  • a dual heating and cooling press would both save room and would also eliminate the risk of having components of a shoe article become misaligned or fall apart during the period they are moved between the heat press and the chiller.
  • the midsole-outsole is removed from the chiller.
  • the midsole-outsole is delivered to the swing arm post staging area.
  • an illustrative method for customizing an upper for a skate shoe is referenced generally by the numeral 2100.
  • an order is received.
  • An illustrative method for receiving an order includes receiving an order manually.
  • an order may be received by uploading details of an order through a web interface.
  • material associated with the order for the upper e.g. synthetic leather or mesh or polyester, etc.
  • the eco-solvent printer and dye sub printer are loaded with material, such as desired colors, associated with an order.
  • the dye sub printer is used to print desired designs and/or markings on the desired material used for the upper.
  • the eco-solvent printer is used to print desired designs and/or markings on the desired material used for the upper.
  • a customized synthetic is cut out from the desired material according to the specifications characterizing an order.
  • the customized synthetic is loaded into a laser.
  • the laser is loaded with the specification of the design associated with the order.
  • the laser etches a customized design onto the customized synthetic.
  • the dye sub press is loaded.
  • the customized synthetic is removed from the laser.
  • the right embroidery machine is loaded with the customized synthetic.
  • the left embroidery machine is loaded with the customized synthetic.
  • the embroidery machines are loaded with design specifications associated with the order.
  • left and right parts are embroidered using the left embroidery machine and right embroidery machine, respectively.
  • the left part and right part are removed from the embroidery machines.
  • the customized parts are delivered to the heat press marketplace.
  • uppers are checked for excess material and cut when needed. Note that some of the decorative techniques disclosed above may not be applicable to each shoe model and therefore some of the steps disclosed above may be omitted. For instance, not all shoe models may require embroidery or laser etching. Moreover, different components of an upper may proceed through different steps, in different orders, and at different times.
  • an illustrative method for forming and stitching an upper for a skate shoe is referenced generally by the numeral 2200.
  • customized parts for the upper are retrieved from the heat press marketplace.
  • a kit is retrieved from the marketplace which contains necessary parts associated with the customer order.
  • an upper is assembled from the customized parts.
  • the assembled upper parts are loaded into a heat press.
  • the heat press is activated and the assembled upper parts are heated. The temperature reached is high enough that the adhesive used to bind parts is activated.
  • the parts are removed from the heat press.
  • the parts are placed on a cooling rack.
  • the parts are cooled from.
  • the parts are removed from the cooling rack.
  • a heel is formed by stitching. In an alternative, the heel may be formed by another binding method.
  • the parts are post-stitched.
  • the parts are strobel stitched.
  • the parts are delivered to a lasting station.
  • an illustrative method for lasting and quality control for a skate shoe is referenced generally by the numeral 2300.
  • the shoe component is retrieved from the lasting station.
  • a quality control check is performed and the upper is lasted.
  • a quality control check is performed on the lasted upper and the upper is then de-lasted.
  • a quality control check is performed and the upper is laced.
  • a quality control check is performed and the shoe is packed.
  • Work flow diagram 2400 may represent a physical configuration of a factory floor, but may also be viewed as a generalized work flow methodology.
  • a plurality of modules may be utilized in the efficient fabrication of shoes in accordance with the present invention.
  • Each module may be operated by at least one operator 2401 at each module.
  • These modules may vary, but may comprise, as in the example of FIG. 24, cutting and kitting module 2402, customization module 2404, forming and stitching module 2406, midsole and outsole fabrication module 2410, and stockfit and assembly module 2408.
  • Cutting and kitting module 2402 may cut shoe upper components from an inventory of raw upper materials. At least one of the raw upper components may comprise a customizable gray good. The cut shoe upper materials may then be assembled into kits. In embodiments, the kits comprise all of the upper elements necessary to form an entire shoe upper. The kits may then be temporarily stored.
  • cutting and kitting module 2402 may cut out the components required for the fabrication of a shoe upper and prepare those assorted pieces into a kit that may be used in the construction and customization of a shoe.
  • Materials used in the cutting and kitting module 2402 may be stored in a material storage 2413.
  • the raw materials used to create the shoe components may be supplied by vendors that may or may not apply a hot melt lamination across to the raw materials.
  • the lamination treatment may aid in the construction of the shoe components, as the lamination may be used to adhere the shoe components. As such, if materials for the shoe components do not yet have a hot melt lamination as supplied from the vendors, a hot melt lamination may be applied to the raw material.
  • raw materials retrieved from storage 2413 may have a hot melt lamination applied to the materials at hot melt lamination press 2412. However, if materials supplied from vendors already have a hot melt lamination applied, hot melt lamination press 2412 may not be needed in diagram 2400.
  • a component cutting machine 2414 may be used to modify the materials into shoe components.
  • Component cutting machine 2414 may comprise an auto-cutting machine that may utilize blades, lasers, and/or any other cutting methodology or tool to cut the fabrics used to construct a shoe upper into one or more pieces for fabrication. Fabric may be held in place using suction, clamps, etc. when used by an auto-cutting machine such as one that may be used by component cutting machine 2414.
  • the material used in the fabrication of a shoe upper may comprise gray goods that may be readily customized through printing, dying, embroidering, etc. Cut components may be stored in a component marketplace 2416. Once cut components are stored in the marketplace, the cut components may be assembled into kits.
  • kits may comprise the upper components required to assemble an upper for a single shoe or the uppers for a pair of shoes.
  • storage 2413 and marketplace 2416 may comprise a vertical carousal.
  • a single kit of upper components may be utilized to assemble a shoe of a single size or a shoe of any of a plurality of sizes.
  • a single kit might be able to be used to fabricate and assemble a shoe having men's size 8, 9, or 10.
  • Upper kits may be provided from cut components stored in marketplace 2416 on an as-needed basis as shoe orders are processed. Cutting and kitting module 2402 may thereafter respond to shortages for particular components of marketplace 2416 by cutting and kitting the needed types of upper materials.
  • the kit may be customized in customization module 2404.
  • customization module 2404 may retrieve temporarily stored kits from cutting and kitting module 2402.
  • Customization module 2404 may then layer the shoe upper components of the kit into a flat framed assembly with multiple layers.
  • Customization module 2404 may then customize at least a portion of the shoe upper components by applying decoration to the shoe upper components.
  • customization module 2404 may comprise a plurality of discrete stations, but no single shoe upper need necessarily be processed by every station in customization module 2404.
  • a operator such as operator 2401
  • Print files may be related to order customization as input by a customer at a customer input receiver 2422.
  • print files may be sent to an eco-solvent printer 2420 and/or a digital printer dye sublimation stations.
  • eco-solvent printer 2420 may be used to print graphics for application to a shoe upper from the kit.
  • digital printing dye sublimation station 2422 may be used to sublimate designs and/or graphics onto a shoe upper.
  • the upper customization may also utilize a lamination heat press 2424 to laminate designs onto shoe upper components.
  • dye sublimation patterns printed at 2422 may be applied using dye sublimation heat press 2426.
  • customization trim work may be performed at station 2428, where station 2428 may comprise a first trim clicker.
  • a first trim clicker may be used to modify material used in upper customization.
  • laser customization such as customized cutting and/or etching, may be performed at laser customization station 2430.
  • a plurality of embroidery stations 2432 may be used to apply embroidered customization to shoe uppers.
  • shoe components may be embroidered once they are loaded into an embroidery machine. After the embroidery of the one or more shoe components, the shoe components may be unloaded from the embroidery machines.
  • the number of embroidery stations may be one or more, although the utilization of four embroidery stations 2432 as illustrated in FIG. 24 may prove desirable.
  • Desk 2434 may also be used in the customization of the shoe upper.
  • Forming and stitching module 2406 may form the upper.
  • Forming and stitching module 2406 may receive the customized shoe upper components.
  • the customized shoe upper components may be placed on a flat frame to keep the components in place.
  • the frame may be loaded into a solid state (SS) RF press 2436 to perform RF welding on the components of the shoe upper.
  • SS solid state
  • the flat frame may be loaded into a heat press 2438.
  • Heat press 2438 may be used to form the upper from heat-activated components. Whether press 2436 and/or press 2438 are used, a press is used to join the components of the shoe upper. Once the shoe components are joined together at press 2436 and/or press 2438, the joined shoe components are cut using shuttle cutter 2440.
  • Shuttle cutter 2440 removes excess material from the joined shoe components. After shuttle cutter 2440 has removed excess material, the joined shoe components are removed from the flat frame. Further, stitching that is desired may be performed to form an upper at stitching stations such as flat-stitch station 2442, zigzag-stitch station 2444, post- stitch station 2448, and gather- stitch station 2454, all of which may be used to stitch shoe components in the form of a shoe upper. Additionally, a hot melt sprayer 2446 may be used to affix shoe components to other shoe components and/or a shoe upper in order to hold components into place as the shoe upper is being formed. Toe-forming component 2450 may be used in the formation of the toe of an upper.
  • stitching stations such as flat-stitch station 2442, zigzag-stitch station 2444, post- stitch station 2448, and gather- stitch station 2454, all of which may be used to stitch shoe components in the form of a shoe upper.
  • a hot melt sprayer 2446 may be used to aff
  • Heel-former component 2452 may be used in the formation of the heel of an upper.
  • Strobel-stitch component 2456 may be used to affix a strobel to a shoe upper for lasting.
  • Toe-condition component 2458 may be used to condition the shoe upper and/or shoe components as part of lasting. For instance, at toe-condition component 2458, the shoe upper and/or shoe components may be exposed to steam to soften the shoe components.
  • lasting component 2460 may be used after the attachment of a strobel to last a shoe upper prior to affixing a midsole and/or outsole. As such, module 2406 may then form the customized shoe upper components into a three-dimensional shoe upper. Further, module 2406 may affix a strobel to the formed shoe upper. Additionally, module 2406 may last the formed shoe upper and strobel.
  • Midsole and outsole component 2410 may fabricate shoe midsoles and shoe outsoles for use in conjunction with lasted uppers for the assembly of shoes.
  • the midsoles and outsoles may be formed in a variety of fashions and from a variety of materials.
  • Midsoles may be formed from phylon materials, and outsoles may be formed from latex rubber. Possible systems and processes for use in midsole and outsole module 2410 are described elsewhere herein.
  • Midsoles and/or outsoles may be provided to stockfit and assembly module 2408 using a marketplace system, or may be provided on an order-by-order basis.
  • Stockfit and assembly module 2408 may receive the lasted and formed shoe upper and strobel from the forming and stitching module 2406. Additionally, module 2408 may receive the shoe midsoles and shoe outsoles from midsole and outsole module 2410. Module 2408 may then assemble the shoe midsole, the shoe outsole, and the lasted and formed shoe upper and strobel into a shoe.
  • midsoles, outsoles, and/or lasted shoe uppers may be received at vented table 2462.
  • adhesive may be applied to the bottom of a midsole and to the top of an outsole.
  • the midsole-outsole combination may then be placed into an IR oven such as IR oven 2462.
  • the adhesive on the shoe midsole and the shoe outsole may then be activated at IR oven 2462.
  • the shoe midsole and the shoe outsole may then be set at bladder press station 2466, where the midsole and outsole are pressed together to form a seal.
  • a block press 2468 may be used to press the midsole and outsole together to form a seal.
  • the midsole-outsole may be delivered to bite mark machine 2470 to be marked for adhesive.
  • midsole-outsole may have a shoe upper placed over midsole-outsole to determine the extent of adhesive coverage needed.
  • the midsole-outsole and the shoe upper may then have adhesive applied at vented table 2472.
  • the shoe upper and the midsole- outsole may be placed in IR over 2474.
  • the adhesive applied to the shoe upper and to the midsole-outsole may be activated.
  • the shoe upper and midsole-outsole may then be pressed together at block press 2468.
  • the shoe may be set at chiller 2476. Once the shoe has been set, the shoe may be de-lasted at de-lasting station 2478. Further, the shoe may be checked for quality control and packaged at table 2480.
  • FIG. 25 a schematic 2500 of a module configuration for use in shoe production in accordance with the present invention is illustrated.
  • shoes may be manufactured using a single cutting and kitting module 2530 and a single outsole and midsole module 2540 in conjunction with two modules to perform customization, forming and fitting, and stockfit and assembly.
  • the operation of customization, forming and fitting, and stockfit and assembly may be performed in a first section 2510 and/or at a second section 2520.
  • First section 2510 may include a first customization module 2512, a first forming and fitting module 2514, and a first stockfit and assembly module 2516.
  • the first customization module 2512 may receive completed kits for shoe uppers from cutting and kitting module 2530.
  • customization module 2512 may pass the customized shoe upper to first forming and fitting module 2514.
  • First forming and fitting module 2514 may form the shoe upper and then pass the formed shoe upper to first stockfit and assembly module 2516.
  • First stockfit and assembly module 2516 may receive formed shoe uppers from first forming and fitting module 2514 and may receive outsoles and midsoles from outsole and midsole module 2540.
  • First stockfit and assembly module 2516 may assemble and complete a shoe, and thereafter pass the completed shoe to a completed product queue 2518.
  • a second section 2520 may comprise a second customization module 2522, a second forming and fitting module 2524, and a second stockfit and assembly module 2526.
  • Second customization module 2522 may receive kits for the fabrication of shoe uppers from cutting and kitting module 2530. Second customization module 2522 may then perform any required customization for a shoe upper. Second customization module 2522 may thereafter pass a customized shoe upper to second forming and fitting module 2524, which may then form the required shoe upper. Second forming and fitting module 2524 may then pass a formed shoe upper to second stockfit and assembly module 2526. Second stockfit and assembly module 2526 may receive formed shoe uppers from second forming and fitting module 2524 and may receive outsoles and midsoles from outsole and midsole module 2540.
  • Stockfit and assembly module 2526 may pass completed shoes to complete product queue 2528.
  • Completed product queue 2518 and completed product queue 2528 may be combined into a single completed product queue, and may represent the point at which a customer receives a customized shoe or pair of shoes. All of the modules illustrated in FIG. 25 may be co-located at a single geographical location. However, first section 2510 and first completed product queue 2518 may be located remote from second section 2520 and second completed product queue 2528, from cutting and kitting module 2530, and/or from outsole and midsole module 2540. Similarly, second section 2520 and second completed product queue 2528 may be located remotely from first section 2510 and first completed product queue 2518, from cutting and kitting module 2530, and from outsole and midsole module 2540. The use of a single cutting and kitting module 2530 and/or a single outsole and midsole module 2540 for two or more modules for customization, forming and fitting, and stockfit and assembly may be advantageous to maximize the production of shoes for a set of modules.
  • FIG. 26 illustrates a system 2600 for producing and assembling shoe components in accordance with an embodiment of the present invention.
  • System 2600 comprises a customer input receiver 2640.
  • Receiver 2640 receives customer input related to, for example, a customer's customization of shoes. For example, a customer may input into receiver 2640 an order for red shoes.
  • System 2600 further comprises a marketplace 2610 that stores shoe components.
  • marketplace 2610 serves as a temporary storage bin for a first shoe component.
  • a first shoe component may be produced at a first module 2620.
  • First module 2620 may comprise a first shoe component-manufacturing module that produces at least a first shoe component upon receiving an indication 2612 from marketplace 2610 to produce the first shoe component.
  • Indication 2612 may be sent to first module 2620 from marketplace 2610 when a threshold amount of the first shoe component stored in marketplace 2610 has fallen below a predefined threshold amount.
  • one or more first shoe components may comprise shoe upper components, midsoles, and/or outsoles.
  • System 2600 may also comprise a second module 2630, where second module
  • 2630 produces one or more second shoe components in response to receiving customer input 2642 from customer input receiver 2640.
  • customizable components may be produced by second module 2630, where second shoe components may be produced by modifying shoe components supplied from marketplace 2610 to second module 2630.
  • the shoe components supplied from marketplace 2610 to second module 2630 may comprise first shoe components produced at first module 2620.
  • the one or more first components and the one or more second components may be assembled at third module 2650.
  • the one or more first components may be delivered 2614 to third module 2650 from marketplace 2610. Additionally and/or alternatively, the one or more first components may be delivered 2624 to third module 2650 from first module 2620. Further, the one or more second components may be delivered 2632 to third module 2650 from second module 2630. After the one or more first components and the one or more second components are assembled at third module 2650, one or more completed shoes may be delivered 2652 to completed product queue 2660.
  • FIG. 27 illustrates a flowchart 2700 of a workflow of a shoe manufactured through a process.
  • the process comprises steps performed in shoe manufacturing modules, such as cutting and kitting module 2710, customization module 2720, forming module 2730, outsole and midsole module 2740, and stockfit and assembly module 2750.
  • cutting and kitting module 2710 a plurality of raw materials required for a multilayered shoe upper are provided at step 2712. Further, at step 2714 in module 2710, raw materials are cut into the components of the multilayered shoe upper. Additionally, at module 2710, the components necessary to make a single multilayered shoe upper are placed in kits at step 2716.
  • a kit is received at step 2722.
  • the shoe upper components are assembled into multiple layers. The multiple layers are aligned on a flat frame.
  • the multiplayer upper components are customized by applying decoration to at least one layer of the multilayer shoe upper components. The customization of step 2426, occurring at customization module 2420, is performed while the multilayer shoe upper components are on a flat frame.
  • the multilayer upper components are joined to form one integral shoe upper at step 2732 while the multilayer shoe upper components are on the frame.
  • the excess upper material is cut from the shoe upper.
  • the joined shoe upper is removed from the frame.
  • the formed shoe upper is then formed into a three-dimensional shoe upper at step 2738.
  • a strobel is stitched to the formed shoe upper at step 2739.
  • a shoe midsole is formed at step 2742. Further, a shoe outsole is formed at step 2744, still in outsole and midsole module 2740. In stockfit and assembly module 2750, the shoe midsole is attached to the shoe upper at step

Landscapes

  • Engineering & Computer Science (AREA)
  • Business, Economics & Management (AREA)
  • Human Resources & Organizations (AREA)
  • Strategic Management (AREA)
  • Economics (AREA)
  • Entrepreneurship & Innovation (AREA)
  • Educational Administration (AREA)
  • Game Theory and Decision Science (AREA)
  • Development Economics (AREA)
  • Marketing (AREA)
  • Operations Research (AREA)
  • Quality & Reliability (AREA)
  • Tourism & Hospitality (AREA)
  • Physics & Mathematics (AREA)
  • General Business, Economics & Management (AREA)
  • General Physics & Mathematics (AREA)
  • Theoretical Computer Science (AREA)
  • Footwear And Its Accessory, Manufacturing Method And Apparatuses (AREA)

Abstract

L'invention concerne des procédés et des systèmes de production de chaussures efficaces qui permettent de réduire la main d'oeuvre spécialisée pour fabriquer une paire de chaussures, tout en évitant les coûts élevés et les exigences de maintenance spéciales souvent associées à un équipement de fabrication automatisé. Les procédés et les systèmes selon l'invention peuvent être utilisés pour produire plusieurs modèles de chaussures personnalisées dans une installation de fabrication de chaussures unique à l'aide de plusieurs flux d'opérations qui se chevauchent, ce qui permet de réduire l'empreinte physique sur l'installation de fabrication. En outre, des modes de réalisation de l'invention peuvent fournir des procédés et des systèmes de production de chaussures efficaces permettant de satisfaire les exigences de lieux géographiques particuliers, ce qui permet d'éviter d'avoir recours à l'importation de chaussures produites dans d'autres lieux.
PCT/US2009/058628 2008-09-26 2009-09-28 Procédé pour une production de chaussures efficace et localisée WO2010037035A1 (fr)

Priority Applications (5)

Application Number Priority Date Filing Date Title
JP2011529323A JP5639062B2 (ja) 2008-09-26 2009-09-28 効率的および局所的なシューズの生産方法
US13/122,712 US20110232008A1 (en) 2008-09-26 2009-09-28 Method For Efficient And Localized Production Of Shoes
BRPI0919470A BRPI0919470A8 (pt) 2008-09-26 2009-09-28 Método para produção eficiente e localizada de sapatos
CN200980147380.9A CN102227738B (zh) 2008-09-26 2009-09-28 高效的本地化鞋类制造方法
EP09816999.8A EP2335198A4 (fr) 2008-09-26 2009-09-28 Procédé pour une production de chaussures efficace et localisée

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US19449608P 2008-09-26 2008-09-26
US61/194,496 2008-09-26

Publications (1)

Publication Number Publication Date
WO2010037035A1 true WO2010037035A1 (fr) 2010-04-01

Family

ID=42060129

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/US2009/058628 WO2010037035A1 (fr) 2008-09-26 2009-09-28 Procédé pour une production de chaussures efficace et localisée

Country Status (6)

Country Link
US (1) US20110232008A1 (fr)
EP (1) EP2335198A4 (fr)
JP (1) JP5639062B2 (fr)
CN (1) CN102227738B (fr)
BR (1) BRPI0919470A8 (fr)
WO (1) WO2010037035A1 (fr)

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20150101134A1 (en) * 2013-10-16 2015-04-16 Adidas Ag Three-Dimensional Shoe Manufacturing
WO2015075018A1 (fr) 2013-11-19 2015-05-28 Pigini S.R.L. Installation permettant la fabrication de chaussures
US9681709B2 (en) 2013-10-16 2017-06-20 Adidas Ag Two-dimensional shoe manufacturing
GB2550116A (en) * 2016-05-04 2017-11-15 Texon Man Ltd A method and apparatus for footwear moulding

Families Citing this family (54)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US7752775B2 (en) 2000-03-10 2010-07-13 Lyden Robert M Footwear with removable lasting board and cleats
US9934478B1 (en) * 2000-09-22 2018-04-03 Jda Software Group, Inc. Generating an ordering of workflow items given a partial ordering and extension data
US8755925B2 (en) * 2011-11-18 2014-06-17 Nike, Inc. Automated identification and assembly of shoe parts
US8960745B2 (en) 2011-11-18 2015-02-24 Nike, Inc Zoned activation manufacturing vacuum tool
US8858744B2 (en) 2011-11-18 2014-10-14 Nike, Inc. Multi-functional manufacturing tool
US8849620B2 (en) 2011-11-18 2014-09-30 Nike, Inc. Automated 3-D modeling of shoe parts
US8958901B2 (en) * 2011-11-18 2015-02-17 Nike, Inc. Automated manufacturing of shoe parts
US10552551B2 (en) * 2011-11-18 2020-02-04 Nike, Inc. Generation of tool paths for shore assembly
US9451810B2 (en) 2011-11-18 2016-09-27 Nike, Inc. Automated identification of shoe parts
US9010827B2 (en) 2011-11-18 2015-04-21 Nike, Inc. Switchable plate manufacturing vacuum tool
US8966775B2 (en) 2012-10-09 2015-03-03 Nike, Inc. Digital bite line creation for shoe assembly
CN104366909B (zh) * 2012-10-29 2016-06-08 东莞市意利自动化科技有限公司 一种自动入楦机
CN104432980B (zh) * 2012-10-29 2016-06-08 东莞市意利自动化科技有限公司 一种自动入楦机
DE102013002519B4 (de) 2013-02-13 2016-08-18 Adidas Ag Herstellungsverfahren für Dämpfungselemente für Sportbekleidung
US20140263290A1 (en) * 2013-03-15 2014-09-18 Nike, Inc. Microwave Treatment Of Materials
US9277787B2 (en) * 2013-03-15 2016-03-08 Nike, Inc. Microwave bonding of EVA and rubber items
US9781778B2 (en) 2013-03-15 2017-10-03 Nike, Inc. Customized microwaving energy distribution utilizing slotted wave guides
US9955536B2 (en) 2013-03-15 2018-04-24 Nike, Inc. Customized microwave energy distribution utilizing slotted cage
CN104068562B (zh) * 2013-10-11 2016-08-31 吴桂伟 全自动画线、激光切割机
US8747711B1 (en) 2013-10-18 2014-06-10 Nike, Inc. Method of manufacturing rubber and polyolefin sole assembly
TW201517831A (zh) * 2013-11-07 2015-05-16 Li-Lin Guo 鞋底鞋面自動上膠系統
TW201517830A (zh) * 2013-11-07 2015-05-16 Li-Lin Guo 鞋底鞋面自動上膠方法
CN106663134A (zh) 2014-06-23 2017-05-10 耐克创新有限合伙公司 鞋类设计工具
US9839253B2 (en) 2014-12-10 2017-12-12 Nike, Inc. Last system for braiding footwear
DE102015202013B4 (de) 2015-02-05 2019-05-09 Adidas Ag Verfahren zur Herstellung eines Kunststoffformteils, Kunststoffformteil und Schuh
US10060057B2 (en) 2015-05-26 2018-08-28 Nike, Inc. Braiding machine with non-circular geometry
US10238176B2 (en) 2015-05-26 2019-03-26 Nike, Inc. Braiding machine and method of forming a braided article using such braiding machine
US10280538B2 (en) 2015-05-26 2019-05-07 Nike, Inc. Braiding machine and method of forming an article incorporating a moving object
CA2988005C (fr) * 2015-06-03 2021-12-28 To-A-T Ip B.V. Procede et machine pour la preparation de semelles interieures
US9920462B2 (en) 2015-08-07 2018-03-20 Nike, Inc. Braiding machine with multiple rings of spools
US20170172259A1 (en) * 2015-12-17 2017-06-22 Pou Chen Corporation Multi-Axis Automatic Shoe Sole Processing Apparatus and Method of the Same
CN105590238A (zh) * 2015-12-24 2016-05-18 曹晶晶 一种定制鞋方法、系统及终端设备
DE102016209046B4 (de) 2016-05-24 2019-08-08 Adidas Ag Verfahren zur herstellung einer schuhsohle, schuhsohle, schuh und vorgefertigte tpu-gegenstände
DE102016208998B4 (de) * 2016-05-24 2019-08-22 Adidas Ag Verfahren und System zum automatischen Herstellen von Schuhen sowie Schuh
DE102016209045B4 (de) 2016-05-24 2022-05-25 Adidas Ag Verfahren und vorrichtung zum automatischen herstellen von schuhsohlen, sohlen und schuhe
DE102016209044B4 (de) 2016-05-24 2019-08-29 Adidas Ag Sohlenform zum Herstellen einer Sohle und Anordnung einer Vielzahl von Sohlenformen
CN105877002B (zh) * 2016-06-13 2017-09-12 信泰(福建)科技有限公司 一种带环圈护眼的鞋面及其制造方法
EP3261044B1 (fr) * 2016-06-21 2021-05-05 DESMA Schuhmaschinen GmbH Système de fabrication personnalisée de produits médicaux ou vestimentaires
CN106108256A (zh) * 2016-06-28 2016-11-16 特步(中国)有限公司 一种高档运动鞋自动化智能化制作工艺
DE102016223980B4 (de) 2016-12-01 2022-09-22 Adidas Ag Verfahren zur Herstellung eines Kunststoffformteils
US10810523B2 (en) * 2016-12-20 2020-10-20 Koninklijke Philips N.V. Method of providing fabrication environment
CN106723665A (zh) * 2016-12-30 2017-05-31 佛山世科智能技术有限公司 一种平底鞋个性化定制方法及定制系统
DE102017205830B4 (de) 2017-04-05 2020-09-24 Adidas Ag Verfahren für die Nachbehandlung einer Vielzahl einzelner expandierter Partikel für die Herstellung mindestens eines Teils eines gegossenen Sportartikels, Sportartikel und Sportschuh
JP2019067029A (ja) * 2017-09-29 2019-04-25 株式会社Ｉｄｅｅ 商品提供システム、商品提供装置、および商品提供方法
CN109537177A (zh) * 2018-12-26 2019-03-29 陈雪源 一种袜子以及袜子鞋面的缝头方法
DE102019200130A1 (de) * 2019-01-08 2020-07-09 Adidas Ag Verfahren und Vorrichtung zum Aushärten
US10342287B1 (en) * 2019-01-08 2019-07-09 Hot Shots Ventures, LLC Corrective footwear for leg length discrepancy
CN110367649A (zh) * 2019-06-01 2019-10-25 姜友文 单面上胶制鞋方法
CN110876510A (zh) * 2019-12-02 2020-03-13 湖南力鼎体育用品有限公司 一种鞋底组合的方法
IT202000001459A1 (it) * 2020-01-24 2021-07-24 Trere Innovation S R L Struttura e procedimento di realizzazione di una scarpa con tomaia in maglia.
KR102555311B1 (ko) * 2020-11-09 2023-07-14 삼덕통상 주식회사 신발 부재의 자동화 제조시스템
US20220206460A1 (en) * 2020-12-24 2022-06-30 Asics Corporation Shoe form manufacturing assistance apparatus and shoe form manufacturing system
US12109775B2 (en) * 2021-12-22 2024-10-08 Puma SE Method for producing a sole of a shoe
IT202200024213A1 (it) * 2022-11-24 2024-05-24 Alberto Olivero S R L Sistema di produzione di un prodotto di pelletteria personalizzato

Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20020152638A1 (en) 2001-03-12 2002-10-24 E. S. Originals, Inc. Shoe having a fabric outsole and manufacturing process thereof and system for customized ordering thereof
US20030033207A1 (en) * 2001-08-09 2003-02-13 Litke Kenneth S. Computerized article customization system and method for use thereof
US6805825B1 (en) * 1997-12-22 2004-10-19 Macleod Norman William Manufacture of footwear
US6977023B2 (en) * 2001-10-05 2005-12-20 High Voltage Graphics, Inc. Screen printed resin film applique or transfer made from liquid plastic dispersion
US20080189194A1 (en) * 2006-12-22 2008-08-07 Vitality, Inc. Systems and methods for customized fitting, building and selling of footwear, and footwear assemblies formed from such methods

Family Cites Families (19)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US1961318A (en) * 1930-07-14 1934-06-05 L Q White Shoe Company System for manufacturing shoes
US2878523A (en) * 1954-01-18 1959-03-24 Int Vulcanizing Corp Method of making rubber shoes
CA1097011A (fr) * 1977-08-22 1981-03-10 Eric J. Hurst Appareil et methode de moulage par coulee des elements de chaussure
GB8715543D0 (en) * 1987-07-02 1987-08-12 Varley C Apparatus for receiving articles
US5632057A (en) * 1989-09-20 1997-05-27 Lyden; Robert M. Method of making light cure component for articles of footwear
US6558784B1 (en) * 1999-03-02 2003-05-06 Adc Composites, Llc Composite footwear upper and method of manufacturing a composite footwear upper
US7107235B2 (en) * 2000-03-10 2006-09-12 Lyden Robert M Method of conducting business including making and selling a custom article of footwear
US6769203B1 (en) * 2000-04-28 2004-08-03 Bauer Nike Hockey Inc. Skate boot
US20020154114A1 (en) * 2000-11-30 2002-10-24 Christensen Thomas Kragh Method and system for customising build-to-order products
US6755141B2 (en) * 2001-04-03 2004-06-29 Otabo Llc Method for stitching a work piece using a computer controlled, vision-aided sewing machine
KR100542039B1 (ko) * 2002-07-02 2006-01-10 삼성탈레스 주식회사 이동통신장치의 프레임동기신호 발생장치
CA2489868A1 (fr) * 2002-07-03 2004-01-15 High Voltage Graphics, Inc. Procede d'impression et de moulage d'un article floque
US20060112594A1 (en) * 2004-12-01 2006-06-01 Nike, Inc. Method of manufacturing an upper for an article of footwear
US20070039209A1 (en) * 2005-08-22 2007-02-22 Fila Luxembourg S.A.R.L. Method and system for providing a customized shoe
US7945343B2 (en) * 2006-12-18 2011-05-17 Nike, Inc. Method of making an article of footwear
WO2008106462A1 (fr) * 2007-02-26 2008-09-04 Crocs, Inc. Systèmes et procédés de fabrication de chaussures
US8544191B2 (en) * 2007-04-10 2013-10-01 Reebok International Limited Smooth shoe uppers and methods for producing them
US8151488B2 (en) * 2008-11-06 2012-04-10 Nike, Inc. Linked articles
US7958993B2 (en) * 2009-09-18 2011-06-14 Nike, Inc. Footwear customization kit

Patent Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US6805825B1 (en) * 1997-12-22 2004-10-19 Macleod Norman William Manufacture of footwear
US20020152638A1 (en) 2001-03-12 2002-10-24 E. S. Originals, Inc. Shoe having a fabric outsole and manufacturing process thereof and system for customized ordering thereof
US7179414B2 (en) * 2001-03-12 2007-02-20 E.S. Originals, Inc. Shoe manufacturing method
US20030033207A1 (en) * 2001-08-09 2003-02-13 Litke Kenneth S. Computerized article customization system and method for use thereof
US6977023B2 (en) * 2001-10-05 2005-12-20 High Voltage Graphics, Inc. Screen printed resin film applique or transfer made from liquid plastic dispersion
US20080189194A1 (en) * 2006-12-22 2008-08-07 Vitality, Inc. Systems and methods for customized fitting, building and selling of footwear, and footwear assemblies formed from such methods

Non-Patent Citations (1)

* Cited by examiner, † Cited by third party
Title
See also references of EP2335198A4

Cited By (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20150101134A1 (en) * 2013-10-16 2015-04-16 Adidas Ag Three-Dimensional Shoe Manufacturing
US9681709B2 (en) 2013-10-16 2017-06-20 Adidas Ag Two-dimensional shoe manufacturing
US10028552B2 (en) 2013-10-16 2018-07-24 Adidas Ag Two-dimensional shoe manufacturing
US10426230B2 (en) * 2013-10-16 2019-10-01 Adidas Ag Three-dimensional shoe manufacturing
US10463114B2 (en) 2013-10-16 2019-11-05 Adidas Ag Two-dimensional shoe manufacturing
US11330870B2 (en) 2013-10-16 2022-05-17 Adidas Ag Three-dimensional shoe manufacturing
WO2015075018A1 (fr) 2013-11-19 2015-05-28 Pigini S.R.L. Installation permettant la fabrication de chaussures
GB2550116A (en) * 2016-05-04 2017-11-15 Texon Man Ltd A method and apparatus for footwear moulding
GB2550116B (en) * 2016-05-04 2018-05-16 Texon Man Limited A method and apparatus for footwear moulding

Also Published As

Publication number Publication date
JP2012504068A (ja) 2012-02-16
EP2335198A1 (fr) 2011-06-22
BRPI0919470A8 (pt) 2017-10-10
US20110232008A1 (en) 2011-09-29
JP5639062B2 (ja) 2014-12-10
CN102227738A (zh) 2011-10-26
CN102227738B (zh) 2015-03-18
EP2335198A4 (fr) 2013-12-25
BRPI0919470A2 (fr) 2017-08-22

Similar Documents

Publication Publication Date Title
US20110232008A1 (en) Method For Efficient And Localized Production Of Shoes
US11297901B2 (en) Shoe with composite upper and method of making the same
US11311080B2 (en) Shoe with composite upper and foam element and method of making same
US20180000195A1 (en) Thermoforming footwear method
US8578535B2 (en) Composite shoe upper and method of making same
JP6576024B2 (ja) スピードファクトリ３Ｄ（Ｓｐｅｅｄｆａｃｔｏｒｙ３Ｄ）
US20110225845A1 (en) Shoe With A Flat Formed Shoe Upper
CN107028285A (zh) 补片放置方法及所制得的产品
JP5610545B2 (ja) 靴の特注製造のための効率的な方法及びシステム
KR20120092626A (ko) 복합물 신발 갑피 및 그 제조 방법
CN1471453A (zh) 带有织物外底的鞋和其制造方法
US11041264B2 (en) Stitching system for a shoe upper
CN105747377A (zh) 一种鞋子制作工艺
Boër et al. The EUROShoE project

Legal Events

Date Code Title Description
WWE Wipo information: entry into national phase

Ref document number: 200980147380.9

Country of ref document: CN

121 Ep: the epo has been informed by wipo that ep was designated in this application

Ref document number: 09816999

Country of ref document: EP

Kind code of ref document: A1

REEP Request for entry into the european phase

Ref document number: 2009816999

Country of ref document: EP

WWE Wipo information: entry into national phase

Ref document number: 2011529323

Country of ref document: JP

Ref document number: 2009816999

Country of ref document: EP

NENP Non-entry into the national phase

Ref country code: DE

WWE Wipo information: entry into national phase

Ref document number: 13122712

Country of ref document: US

REG Reference to national code

Ref country code: BR

Ref legal event code: B01E

Ref document number: PI0919470

Country of ref document: BR

ENP Entry into the national phase

Ref document number: PI0919470

Country of ref document: BR

Kind code of ref document: A2

Effective date: 20110328