Shoe with Composite Upper and Foam Element and Method of Making Same
AssigneeNIKE, Inc.
InventorsFrederick J. Dojan, Daniel A. Johnson, Shane S. Kohatsu, Chin-Chen Huang
Life of this patent
Estimating the term…
Abstract
A bonded mesh composite panel can be used to form a three-dimensional upper shell that includes extensions used for double-lasting and/or to otherwise provide a shelf to support foam padding. The foam padding may be, e.g., a foam midsole. The extensions of the upper shell may be located in a lower portion of the shell and may be bonded to the foam midsole in a heel, midfoot and/or forefoot regions.
Claims17
An article of footwear comprising:
- an upper having a bonded mesh composite panel, wherein
- a portion of the composite panel includes a substrate layer formed from a substrate material, the substrate layer having an inner side facing toward an interior of the article and an outer side facing away from the interior,
- the composite panel further includes a mesh layer formed from a mesh material, a portion of the mesh layer overlapping the substrate layer in one or more mesh/substrate overlap areas, the mesh layer having an inner side oriented toward the substrate layer outer side within the mesh/substrate overlap areas, and
- the composite panel further includes a skin layer formed from a skin material, a portion of the skin layer overlapping both the mesh and the substrate layers in one or more skin/mesh/substrate overlap areas, the skin layer having an inner side oriented toward the mesh and substrate layers within the skin/mesh/substrate overlap areas;
- and
- a foam midsole bonded to the composite panel, wherein the composite panel includes portions bonded to a bottom surface of the foam midsole.
A method of fabricating an article of footwear, comprising:
- positioning a plurality of panels into an assembly, wherein the assembly includes
- a substrate material panel having a first side and a second side,
- a mesh material panel having a first side facing away from the substrate material panel and a second side facing the substrate material panel, at least a portion of the mesh material panel overlapping the substrate material panel in a mesh/substrate overlap area, and
- a skin material panel having a first side facing away from the substrate material panel and a second side facing the substrate material panel, at least a portion of the skin material panel overlapping both the substrate material panel and the mesh material panel in a skin/mesh/substrate overlap area;
- creating a bonded mesh composite panel by
- compressing the assembly at a first temperature in a first pressing operation during which the first sides of the substrate material, mesh material and skin material panels face a compressible surface conforming to the assembly, and
- compressing the assembly at a second temperature in a second pressing operation during which the first sides of the substrate material, mesh material and skin material panels face a compressible surface conforming to the assembly, wherein the second pressing operation is performed after the first pressing operation and the second temperature is lower than the first temperature;
- subsequent to the second pressing operation, forming a three-dimensional upper shell from the composite panel;
- and
- bonding portions of the three-dimensional upper shell to a bottom surface of a foam midsole.
The method of clam 11, wherein bonding portions of the three-dimensional upper shell comprises bonding portions of the upper shell to surfaces of a heel region of the foam midsole so as to form a double lasted heel cup.
Dependencies are inferred from the claim text.