Embodiments provide a lamination machine and lamination process for laminating a membrane to a three-dimensional (3D) target surface of an article, such as a footwear article, glove, clothing article, backpack, or other article. The lamination machine may include an inflatable former that is permeable to air. The inflatable former may have a shape that generally corresponds to a shape of the target surface. The membrane and target surface may be arranged on the former, with a heat-activated adhesive disposed between the membrane and the target surface. The lamination machine may further include a pump to pump heated compressed air into the former. The heated compressed air may inflate the former to press the membrane against the target surface and to activate the adhesive to bond the membrane to the target surface.

Embodiments provide a lamination machine and lamination process for laminating a membrane to a three-dimensional (3D) target surface of an article, such as a footwear article, glove, clothing article, backpack, or other article. The lamination machine may include an inflatable former that is permeable to air. The inflatable former may have a shape that generally corresponds to a shape of the target surface. The membrane and target surface may be arranged on the former, with a heat-activated adhesive disposed between the membrane and the target surface. The lamination machine may further include a pump to pump heated compressed air into the former. The heated compressed air may inflate the former to press the membrane against the target surface and to activate the adhesive to bond the membrane to the target surface.

A method and kit are provided for the customization of footwear comprising an upper which is partially or totally made of thermoformable material. The method provides for selectively heating the portions made of thermoformable material of the footwear, while leaving the remaining portions of the footwear at a substantially unchanged temperature, and for applying to the thermoformable material portions a pressure sufficient to adapt their shape to the specific morphology of the user's foot. This allows to customize even footwear comprising delicate portions, which would be damaged if subjected to high temperatures. The method may provide for customizing a footbed, partially or totally made of thermoformable material, to the specific morphology of the user's foot sole. The kit is compact, preferably transportable and capable of autonomously carrying out all the steps of the method.

A method and kit are provided for the customization of footwear comprising an upper which is partially or totally made of thermoformable material. The method provides for selectively heating the portions made of thermoformable material of the footwear, while leaving the remaining portions of the footwear at a substantially unchanged temperature, and for applying to the thermoformable material portions a pressure sufficient to adapt their shape to the specific morphology of the user's foot. This allows to customize even footwear comprising delicate portions, which would be damaged if subjected to high temperatures. The method may provide for customizing a footbed, partially or totally made of thermoformable material, to the specific morphology of the user's foot sole. The kit is compact, preferably transportable and capable of autonomously carrying out all the steps of the method.

An upper for an article of footwear, the upper including a base layer defining a least a portion of the upper and polymer threads stitched to the base layer. The polymer threads may include a core composed of a first material and a coating composed of a second material, where the melting point of the first material is higher than the melting point of the second material. The polymer threads may be bonded to the base layer by the coating of the polymer threads. The polymer threads may include one or more polymer thread sets stitched in pattern(s) on area(s) of an outer surface of the base layer to provide targeted characteristics to area(s) on the upper. In some embodiments, the polymer threads may be bonded to the base layer with heat and/or pressure.

A method for assembling shoe components includes the steps of: providing at least two shoe components, a shoe last and a film unit; placing the at least two shoe components on an outer surface of the shoe last; removably covering an assembly of the at least two shoe components and the shoe last with the film unit such that the film unit and the shoe last cooperatively define a confining space therebetween; and pumping air out of the confining space and heating the at least two shoe components to shrink and deform the film unit so as to press the at least two shoe components to adhere tightly to each other.

A method for assembling shoe components includes the steps of: providing at least two shoe components, a shoe last and a film unit; placing the at least two shoe components on an outer surface of the shoe last; removably covering an assembly of the at least two shoe components and the shoe last with the film unit such that the film unit and the shoe last cooperatively define a confining space therebetween; and pumping air out of the confining space and heating the at least two shoe components to shrink and deform the film unit so as to press the at least two shoe components to adhere tightly to each other.

Methods for manufacturing at least a portion of an upper for an article of footwear that include thermo-forming a pattern on the upper. The methods may include disposing a skin for forming an upper over and inflatable bladder and disposing a mold insert between the skin and a surface of a mold cavity. The mold insert may include a mold pattern including surface features formed in the mold insert. The inflatable bladder may be inflated such that the skin is pressed against the mold insert within a heated mold cavity to form a pattern on an exterior surface of the skin and cause the skin to take on the shape of at least a portion of an upper. In some embodiments, the surface features may be disposed in a gradient pattern configured to provide varying degrees of one or more characteristics to different areas of an upper.

Methods for manufacturing at least a portion of an upper for an article of footwear that include thermo-forming a pattern on the upper. The methods may include disposing a skin for forming an upper over and inflatable bladder and disposing a mold insert between the skin and a surface of a mold cavity. The mold insert may include a mold pattern including surface features formed in the mold insert. The inflatable bladder may be inflated such that the skin is pressed against the mold insert within a heated mold cavity to form a pattern on an exterior surface of the skin and cause the skin to take on the shape of at least a portion of an upper. In some embodiments, the surface features may be disposed in a gradient pattern configured to provide varying degrees of one or more characteristics to different areas of an upper.

The present invention relates to a shoe insert that is inflatable or otherwise conformable to the interior of a shoe and provides protection against the shoe collapsing or otherwise becoming deformed during transport, shipment or handling. The shoe insert is capable of being inflated in a left or right orientation and can be provided with branding and other merchandising information.