Method of manufacturing a sole assembly formed from a plurality of preforms
阅读说明:本技术 制造由多个预成型件形成的鞋底组件的方法 (Method of manufacturing a sole assembly formed from a plurality of preforms ) 是由 蒂·L·温 天猜·柴萨姆雷杰 吴家宜 林玉辰 于 2015-04-01 设计创作,主要内容包括:本申请涉及一种制造由多个预成型件形成的鞋底组件的方法。一种形成鞋底组件的方法,所述方法包括:将不同颜色的多个预成型件设置在一起以形成鞋底组件预成型件;以及将所述鞋底组件预成型件放置在模具组件的第一部分的凹部中。使所述鞋底组件预成型件受热持续预先确定量的时间,使得所述多个预成型件彼此结合以形成鞋底组件。(The present application relates to a method of manufacturing a sole assembly formed from a plurality of preforms. A method of forming a sole assembly, the method comprising: disposing a plurality of preforms of different colors together to form a sole assembly preform; and placing the sole component preform in a recess of a first portion of a mold assembly. Heating the sole assembly preform for a predetermined amount of time such that the plurality of preforms bond to one another to form a sole assembly.)
1. A sole assembly, comprising:
a core portion including a lower surface and a rib extending downwardly from the lower surface, wherein the rib defines a shoulder extending around at least a portion of the core portion;
a first insert contained within and bonded to the core portion; and
a peripheral portion joined to the core portion, wherein the peripheral portion forms at least a portion of an outer periphery of the sole assembly, wherein the peripheral portion includes an aperture defining an interior lip, and wherein the interior lip is positioned on the shoulder of the core portion.
2. The sole assembly of claim 1, wherein an outer peripheral edge of the first insert is completely surrounded by the core portion and contained within a first interior recess defined by the ribs of the core portion.
3. The sole assembly of claim 1, wherein the perimeter portion completely surrounds an outer perimeter of the core portion.
4. The sole assembly of claim 1, wherein a surface of the aperture abuts an outer perimeter of the rib.
5. The sole assembly of claim 1, wherein a lower surface of the core portion, a lower surface of the first insert, and a lower surface of the perimeter portion include a plurality of grooves and lugs or protrusions.
6. The sole assembly of claim 1, wherein the core portion has a first color, the first insert has a second color different from the first color, and the perimeter portion has a third color different from the first color and the second color.
7. The sole assembly of claim 1, wherein each of the core portion, the first insert, and the perimeter portion is an ethylene vinyl acetate material.
8. The sole assembly of claim 1, wherein the perimeter portion forms an entire outer perimeter of the sole assembly.
9. The sole assembly of claim 1, wherein the core portion, the first insert, and the perimeter portion have different hardnesses from one another.
10. The sole assembly of claim 1, wherein the first insert is located in a forefoot region of the sole assembly.
Technical Field
Aspects of the present invention relate generally to methods of manufacturing sole assemblies, and in particular, to methods of manufacturing sole assemblies formed from multiple preforms of different colors.
Background
Conventional articles of athletic footwear include two primary elements: an upper and a sole assembly. The upper provides a covering for the foot that comfortably receives the foot and secures the foot in position relative to the sole assembly. In addition, the upper may have a configuration that protects the foot and provides ventilation, thereby cooling the foot and removing perspiration. The sole assembly is secured to a lower portion of the upper and is generally positioned between the foot and the ground. In addition to attenuating ground reaction forces, the sole assembly may, for example, provide traction, control foot motions (e.g., by resisting eversion), and impart stability. Accordingly, the upper and the sole assembly operate cooperatively to provide a comfortable structure that is suited for a wide variety of activities, such as walking and running. An insole may be provided within the upper and adjacent to the plantar (i.e., lower) surface of the foot to enhance footwear comfort, and is typically a thin, compressible member.
The sole assembly may incorporate multiple layers. Some shoes include only a midsole, while other shoes may also include an outsole secured to a bottom surface of the midsole. The midsole is traditionally secured to the upper along the length of the upper, primarily responsible for attenuating ground reaction forces. The midsole may also form the ground-contacting element of the footwear. In such embodiments, the midsole may include texturing, such as protrusions and recesses or grooves, to improve traction. The outsole (when present) forms the ground-contacting element and may be fashioned from a durable, wear-resistant material.
The midsole may be primarily formed from a resilient polymer foam material, such as Ethylene Vinyl Acetate (EVA), that extends the entire length of the footwear. The properties of the polymer foam material of the midsole are primarily dependent upon factors including the spatial configuration of the midsole and the specific characteristics of the material selected for the polymer foam, including the density of the polymer foam material. By varying these factors throughout the midsole, the relative stiffness and degree of ground reaction force attenuation may be varied to meet the specific requirements of the activity for which the footwear is intended to be used. In addition to polymer foam materials, conventional midsoles may include, for example, one or more fluid-filled bladders and moderators.
The sole assembly may be formed from multiple portions, some or all of which have different colors. When EVA is formed in the mold assembly, the boundaries between the differently colored portions may become blurred, thereby reducing the aesthetics of the footwear.
It would be desirable to provide a method of manufacturing a sole assembly for an article of footwear that reduces or overcomes some or all of the difficulties inherent in prior known processes. Particular objects and advantages will be apparent to those skilled in the art (i.e., those who are knowledgeable or experienced in this field of technology) in view of the following disclosure of the invention and detailed description of certain embodiments.
Disclosure of Invention
The principles of the present invention may be used to advantage to provide a method of manufacturing a sole assembly formed from a plurality of preforms. According to certain embodiments, the preforms have different colors.
According to a first aspect, a method of forming a sole assembly includes: disposing a plurality of preforms of different colors together to form a sole assembly preform; and placing the sole component preform in a recess in a first portion of a mold assembly. The sole component preform is heated for a predetermined amount of time such that the plurality of preforms bond to one another to form a sole component.
According to another aspect, a method of forming a sole assembly includes: a first preform having a first color, a second preform having a second color, and a third preform having a third color are disposed together to form a sole assembly preform. The sole component preform is placed in a recess of a first portion of a heated mold component. The mold assembly is closed such that the second portion of the mold assembly is positioned above and in contact with the first portion. The sole component preform is heated for a predetermined amount of time such that the first, second, and third preforms bond to one another to form the sole component. The mold assembly is opened and the sole assembly is removed therefrom.
According to yet another aspect, a method of forming a sole assembly includes: a first preform having a first color is formed in a recess of a first mold assembly, a bottom surface of the recess including a plurality of surface irregularities. A plurality of second preforms having a second color are formed in the plurality of first recesses of the second mold assembly. A third preform having a third color is formed in the second recess of the second mold assembly. The first preform, the second preform, and the third preform are disposed together to form a sole assembly preform. The sole component preform is placed in a recess in the first portion of the heated third mold component. The third mold assembly is closed such that the second portion of the third mold assembly is positioned above and in contact with the first portion. The sole assembly preform in the third mold assembly is heated for a predetermined amount of time such that the first, second, and third preforms bond to one another to form the sole assembly. The third mold assembly is opened and the sole assembly is removed therefrom. The sole assembly is allowed to cool and then trimmed.
The present application further provides the following:
1) a method of forming a sole assembly, comprising the steps of:
disposing a plurality of preforms of different colors together to form a sole assembly preform;
placing the sole assembly preform in a recess in a first portion of a mold assembly;
closing the mold assembly such that a second portion of the mold assembly is positioned above and in contact with the first portion;
heating the sole assembly preform for a predetermined amount of time such that the plurality of preforms bond to one another to form a sole assembly.
Opening the mold assembly; and
removing the sole assembly from the mold assembly.
2) The method of 1), wherein the plurality of preforms comprises a first preform, a second preform, and a third preform.
3) The method of 2), wherein the plurality of preforms comprises a plurality of second preforms.
4) The method of 1), wherein the plurality of preforms have different performance characteristics.
5) The method of 1), wherein a first preform of the plurality of preforms is formed in a first preform mold assembly.
6) The method of 5), wherein a bottom surface of the recess of the first preform mold assembly includes at least one surface irregularity.
7) The method of 6), wherein the at least one surface irregularity comprises one of a protrusion and a recess.
8) The method of 1), wherein a second preform and a third preform of the plurality of preforms are formed in a second preform mold assembly.
9) The method of 8), wherein the second and third preforms have different colors.
10) The method of 8), wherein a bottom surface of each of the first and second recesses of the second preform mold assembly includes at least one surface irregularity.
11) The method of 10), wherein the at least one surface irregularity on the bottom surface of each of the first and second recesses comprises one of a protrusion and a recess.
12) A method of forming a sole assembly, comprising the steps of:
disposing a first preform having a first color, a second preform having a second color, and a third preform having a third color together to form a sole assembly preform;
placing the sole component preform in a recess in a first portion of a heated mold component;
closing the mold assembly such that a second portion of the mold assembly is positioned above and in contact with the first portion;
heating the sole component preform for a predetermined amount of time such that the first, second, and third preforms bond to one another to form a sole component;
opening the mold assembly; and
removing the sole assembly from the mold assembly.
13) The method of 12), wherein the sole assembly preform is formed using a plurality of second preforms having the second color.
14) The method of 12), wherein the first preform, the second preform, and the third preform have different performance characteristics.
15) The method of 12), wherein the first preform is formed in a first preform mold assembly.
16) The method of 12), wherein the second preform and the third preform are formed in a second preform mold assembly.
17) A method of forming a sole assembly, comprising the steps of:
forming a first preform having a first color in a recess of a first mold assembly, a bottom surface of the recess comprising a plurality of surface irregularities;
forming a plurality of second preforms having a second color in the plurality of first recesses of the second mold assembly;
forming a third preform having a third color in a second recess of the second mold assembly;
disposing the first preform, the second preform, and the third preform together to form a sole assembly preform;
placing the sole component preform in a recess in a first portion of a heated third mold component;
closing the third mold assembly such that a second portion of the third mold assembly is above and in contact with the first portion;
heating the sole assembly preform in the third mold assembly for a predetermined amount of time such that the first, second, and third preforms bond to one another to form a sole assembly;
opening the third mold assembly;
removing said sole assembly from said third mold assembly;
allowing the sole assembly to cool; and
trimming the sole assembly.
The reader will further appreciate the features and advantages of the sole assembly disclosed herein that are made for footwear, in accordance with the following detailed description of certain embodiments.
Drawings
FIG. 1 is an elevational view of an article of footwear including an upper and a sole assembly.
Figure 2 is a top view of the bottom of the sole assembly of figure 1.
Figure 3 is a perspective view, in exploded form, of the sole assembly of figure 1.
FIG. 4 is a perspective view of a first mold assembly used to form a core portion of the sole assembly of FIG. 3.
FIG. 5 is a perspective view of a second mold assembly used to form the insert and peripheral portion of the sole assembly of FIG. 3.
Fig. 6 is a cross-sectional view of the bottom plate, sidewall plates and core plate of the mold assembly of fig. 5 in a closed position and in abutting relationship.
FIG. 7 is a cross-sectional view of the bottom, side wall, core and top plates of the mold assembly of FIG. 5 in a closed position and in abutting relationship.
FIG. 8 is an elevation view of a third mold assembly having a top plate and a bottom plate, shown in exploded form, further showing a preform prior to being disposed in the bottom plate.
FIG. 9 is a front view of the third mold assembly of FIG. 8 showing a preform in a recess of the bottom plate.
Fig. 10 is an elevation view of the third mold assembly of fig. 8, shown in a closed state.
The drawings described above are not necessarily to scale, should be understood to provide a schematic representation of certain embodiments of the invention, and are merely conceptual views and illustrative of the principles involved. Some features of the mold assembly used to fabricate the sole assembly have been enlarged or distorted relative to others to facilitate explanation and understanding. In the drawings, the same reference numerals have been used for similar or identical components and features shown in various alternative embodiments. The mold assemblies for sole assemblies and methods of making such sole assemblies disclosed herein will have configurations and components determined, in part, by the intended application and environment in which they are used.
Detailed Description
Article of
For example,
It should be appreciated that in some embodiments,
As shown in the embodiment of FIG. 2,
In certain embodiments, the
The EVA can also include various components, including blowing agents. The blowing agent may have a weight percentage between about 10% to about 20%. For example, suitable blowing agents include azodicarbonamide. In certain embodiments, peroxide-based curing agents, such as dicumyl peroxide, may be used. The amount of curing agent may be between about 0.6% to about 1.5%. EVA may also include leveling agents, processing aids, and waxes. For example, mixtures of light aliphatic hydrocarbons may be included, e.g.And 60 NS. EVA may also include other components, such as mold release agents (e.g., stearic acid), activators (e.g., zinc oxide), fillers (e.g., magnesium carbonate), pigments, and clays.
As shown in fig. 2,
The preforms of the components of
An aperture 50 extending through the perimeter portion preform 36 'defines an internal lip 52 that is positioned over the shoulder 48 of the core portion preform 32'. As shown in fig. 2, in the finished article of
As shown in fig. 3 herein,
A method of forming
The
The core portion preform 32' is formed in a known manner in the
A second
For illustrative purposes, the perimeter portion preform 36 ' with the insert preform 34 ' positioned in the perimeter portion preform 36 ' and formed in the second
As shown in fig. 6, the
After heated EVA is injected into the
All preforms (i.e., core portion preform 32 ', insert preform 34 ', and perimeter portion preform 36 ') each having a different color are then preassembled into a single
In certain embodiments,
In a known manner,
By inserting the entire
In certain embodiments, as shown in FIG. 2 and described above, the
Thus, while there have been shown, described, and pointed out fundamental novel features of various embodiments, it will be understood that various omissions, substitutions, and changes in the form and details of the devices illustrated, and in their operation, may be made by those skilled in the art without departing from the spirit and scope of the invention. For example, it is expressly intended that all combinations of those elements and/or steps which perform substantially the same function in substantially the same way to achieve the same results are within the scope of the invention. The invention also fully contemplates and contemplates the replacement of elements from one described embodiment to another. It is the intention, therefore, to be limited only as indicated by the scope of the claims appended hereto.
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