Multiple layer upper for a shoe
11712087 · 2023-08-01
Assignee
Inventors
- Benjamin Alexander Thompsett (Nuremberg, DE)
- Raphael Curet (Nuremberg, DE)
- Ananda Aditya (Jakarta, ID)
- Quentin Ferrari (Erlangen, DE)
- No Kwang Park (Tangerang, ID)
Cpc classification
A43B3/0047
HUMAN NECESSITIES
B29D35/0054
PERFORMING OPERATIONS; TRANSPORTING
International classification
A43B5/02
HUMAN NECESSITIES
Abstract
The present invention relates to an upper for a shoe, including an inner layer; an outer layer overlapping the inner layer at least partially; wherein the outer layer includes a plurality of cuts; wherein the inner layer includes a plurality of protrusions; wherein each cut at least partially overlaps at least one protrusion; wherein each protrusion causes an extension in width of its corresponding cut when the shoe is worn.
Claims
1. An upper for a shoe, the upper comprising: an inner layer; an outer layer overlapping the inner layer at least partially; wherein the outer layer comprises a plurality of cuts; wherein the inner layer comprises a plurality of protrusions and a continuous layer connecting the plurality of protrusions, and the plurality of protrusions is located on an opposite side of the continuous layer from the outer layer; wherein each cut overlaps at least partially at least one protrusion such that each protrusion has at least one corresponding overlapping cut among the plurality of cuts; wherein each protrusion among the plurality of protrusions is configured to cause an extension in width of its at least one corresponding overlapping cut when the shoe is worn.
2. The upper according to claim 1, wherein the outer layer or the inner layer comprises rubber.
3. The upper according to claim 1, wherein the inner layer comprises a foam material.
4. The upper according to claim 1, wherein a material of the outer layer comprises a greater hardness in comparison to the inner layer.
5. The upper according to claim 1, wherein the outer layer and the inner layer comprise different thicknesses.
6. The upper according to claim 1, wherein the upper further comprises a textile layer that comprises a plurality of cuts coinciding with the plurality of cuts of the outer layer.
7. The upper according to claim 1, wherein an exterior texture of the outer layer comprises a plurality of protrusions.
8. The upper according to claim 1, wherein the protrusions of the inner layer are facing inwards, such that they point into a foot receiving cavity defined within the upper.
9. The upper according to claim 1, wherein the protrusions of the inner layer comprise a hemispherical shape, an elongated shape, or a rib shape.
10. The upper according to claim 1, wherein the inner layer comprises at least two unconnected portions, wherein each portion comprises at least one protrusion.
11. The upper according to claim 1, wherein the upper comprises a textile layer arranged on an outer surface of the outer layer.
12. A method of manufacturing the upper for a shoe of claim 1, the method comprising the steps: providing the inner layer; providing the outer layer, such that the outer layer overlaps the inner layer at least partially; providing the plurality of cuts in the outer layer; and providing the plurality of protrusions on the inner layer, such that each cut overlaps at least partially at least one protrusion such that each protrusion has a corresponding overlapping cut among the plurality of cuts and such that each protrusion is configured to cause the extension of width of its corresponding overlapping cut when the shoe is worn.
13. The method of manufacturing the upper for a shoe according to claim 12, further comprising the steps: providing a compression mold with two cavities and three plates; placing the outer layer in a first cavity between a first plate and a second plate; and placing the inner layer in a second cavity between the second plate and a third plate.
14. The method of manufacturing the upper for a shoe according to claim 12, further comprising the steps: providing a compression mold with three cavities and four plates; placing the outer layer in a first cavity between a first plate and a second plate; placing the textile layer in a second cavity between the second plate and a third plate; and placing the inner layer in a third cavity between the third plate and a fourth plate.
15. The method of manufacturing the upper for a shoe according claim 12, further comprising the steps: placing the inner layer and the outer layer in a mold at a first temperature and subsequently placing the inner layer and the outer layer in a mold at a second temperature, wherein the first temperature is higher than the second temperature.
16. The method of manufacturing the upper for a shoe according to claim 12, further comprising the step: arranging a lining underneath the inner layer.
17. The method of manufacturing the upper for a shoe according to claim 12, further comprising the step: arranging a textile layer on an outer surface of the outer layer.
18. The method of manufacturing the upper for a shoe according to claim 12, further comprising the step: arranging the inner layer only on the medial side of the upper.
19. An upper for a shoe, the upper comprising: an inner layer comprising a plurality of protrusions; an outer layer positioned outward of the inner layer, overlapping the inner layer at least partially, movable relative to the protrusions, and comprising a plurality of cuts, wherein each cut at least partially overlaps a protrusion among the plurality of protrusions such that each protrusion has a corresponding overlapping cut among the plurality of cuts; and wherein each protrusion among the plurality of protrusions is configured to cause an extension in width of its corresponding overlapping cut when the shoe is worn, and wherein the inner layer is movable relative to the outer layer such that each protrusion among the plurality of protrusions has a variable inward depth relative to its corresponding overlapping cut.
20. The upper of claim 19, wherein the inner layer is movable with respect to the outer layer between a first position in which the protrusions are covered by the outer layer and a second position in which each protrusion protrudes at least partially outward through its corresponding overlapping cut.
Description
BRIEF DESCRIPTION OF THE FIGURES
(1) In the following, exemplary embodiments of the invention are described with reference to the figures. These figures show:
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DETAILED DESCRIPTION
(19) Possible embodiments of the present invention will be described in the following detailed description primarily with reference to a shoe. It is emphasized, that the present invention is not limited by these embodiments.
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(21) The inner layer 12 may include a plurality of protrusions including shapes that can be described as hemispheres. In other embodiments the protrusion may include a spike-like shape, a rectangular shape, or a rib shape. Generally, the protrusion may have any arbitrary shape. The protrusions point inwardly, such that they face a wearer's foot when the shoe 10 is worn. In different embodiments the protrusions may be arranged in a different pattern, have different shapes or point in the opposite direction, e.g., such that their flat sides point inwardly. In the preferred embodiment the inner layer includes plurality of non-connected protrusions. In other embodiments the inner layer may include a continuous layer, wherein the at least two protrusions are connected to the continuous layer. In another embodiment the protrusions can may be connected to each other such that they form a perforated layer.
(22) The protrusions of the inner layer 12 extend into the cavity formed inside the upper such that the wearer can feel these protrusions as they exert a pressure onto the foot of the wearer, when the shoe 10 is worn. The wearer is pushing with the foot against the inwardly facing protrusions, causing the inner layer 12 to move outwards and partially through the cuts 13 of the outer layer 11 as shown in
(23) The cuts 13 in the outer layer 11 of the exemplary embodiment of
(24) The outer layer 11 of the exemplary embodiment shown in
(25) The principle of the present invention is demonstrated in the embodiment, which is shown in the
(26) The upper 20 shown in
(27) The inner layer 22 is characterized by a plurality of protrusions 24, which are shown in
(28) This configuration leads to the effect, that when no force is acting on the protrusions of the inner layer 21, the inner layer is generally not visible through the outer layer (see
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(33) In the embodiments of the
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(38) By varying the temperature, pressure as well as the time during the molding compression process one can achieve different mechanical properties like tension strength and/or binding strength of the respective layer of the shoe upper. The inner and the outer layer could also be combined at different stages and not in a single step as mentioned before. Likewise, the curing process can be achieved in one step or in a plurality of separate steps. In case of a process with a single step, one mold plate may act like a cutter as described with respect to
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(40) In
(41) In method step 82, the outer layer and the inner layer are pressed separately in a hot press for 20 seconds. The hot press process is defined by a pressure force of 160 kg/cm.sup.2 at a temperature of 180° C. In step 83, both layers are cooled down for 70 seconds with no excess pressure at a temperature of 10-15° C.
(42) After cleaning the layers in step 84, the outer layer and the inner layer are joined by a hot press step 85 with a duration of 180 seconds at a pressure of 160 kg/cm.sup.2 and a temperature of 180° C. Subsequently, the joined layers are cooled down in step 86 for 40 seconds with no excess pressure at a temperature of 10-15° C. Finally, the compressed layers are cleaned in step 87 (the resulting element 88 is denoted “element” in
(43) In a second alternative method 80B the hot press 82 can be done for 180 seconds and the cold press 83 for 40 seconds.
(44) Further, in the alternative method 80B, in step 84, the outer and the inner layer is cleaned, a primer is applied and both layers are baked separately at 50-55° C. for 180 seconds. A joining of the two layers occurs during a hot press step 85 for 25 seconds at a pressure of 20 kg/cm.sup.2 and a temperature of 150° C. Furthermore, a cold press step 86 can be applied with a pressure of 20 kg/cm.sup.2 and a duration of 20 seconds at a temperature of 10-15° C. The joined layers are cleaned in step 87 in the alternative method 80B.
(45) In some embodiments an additional textile layer between the outer layer and the inner lay as well as alternatively or additionally a textile layer on top of the outer layer can be provided in the group of process steps illustrated in
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(47) In step 814, the element 88 is subject to laser cleaning. Exemplary process parameters of this step include a mark speed of 700.000 mm/s, a jump speed of 2.000.000 mm/s, a frequency of 7 MHz and an energy of 60% of the maximum energy of the laser of 180 W. In step 815, which may be performed simultaneously with step 814, the upper element is conditioned for three hours.
(48) In step 816, the conditioned upper element and the laser cleaned element 88 are compressed and joined in hot press at a pressure of 20 kg/cm.sup.2 and a temperature of 150° for 25 seconds. This step is followed by a cold press step 917 with the same pressure, but a temperature of 10-15° C. for 20 seconds. In some embodiments, steps 816 and 817 of the manufacturing process can be combined into a single step.
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(50) In the following, embodiments of the additional aspect of the invention relating to an upper with a movable inner layer are described. 1. Upper for a shoe comprising: an inner layer; an outer layer overlapping the inner layer at least partially; wherein the outer layer comprises a plurality of cuts; wherein the inner layer comprises a plurality of protrusions; wherein each cut is associated with at least one protrusion; wherein the inner layer is movable with respect to the outer layer between a first position and a second position; wherein in the first position, the protrusions are covered by the outer layer and wherein in the second position, each protrusion protrudes through its associated cut at least partially. 2. Upper according to embodiment 1, wherein the upper further comprises a stretchable piece that connects the inner layer to the outer layer and/or an optional lining. 3. Upper according to embodiment 2, wherein the stretchable piece is located in the forefoot region of the upper. 4. Upper according to one of embodiments 1-3, wherein the inner layer comprises a non-stretchable material. 5. Upper according to embodiment 4, wherein the inner layer comprises thermoplastic polyurethane (TPU). 6. Upper according to one of embodiments 1-5, wherein the inner layer forms a lug at the heel region. 7. Upper according to one of embodiments 1-6, wherein the stretchable piece and/or the inner layer and/or the outer layer comprises rubber or a textile. 8. Upper according to one of embodiments 1-7, wherein the first position of the movable inner layer is an initial position. 9. Upper according to one of embodiments 1-8, wherein the second position of the movable inner is reached when the shoe is worn. 10. Upper according to one of embodiments 1-9, wherein the outer layer comprises a textile layer coated on both sides. 11. Upper according to embodiment 10, wherein the cuts in the coatings of the outer layer are smaller than the cuts in the textile layer. 12. Upper according to one of embodiments 1-11, wherein the material of the outer layer and the inner layer comprises different hardnesses. 13. Upper according to embodiment 12, wherein the material of the outer layer comprises a greater hardness in comparison to the inner layer. 14. Upper according to one of embodiments 1-13, wherein the upper comprises a lining arranged underneath the inner layer. 15. Upper according to one of embodiments 1-14, wherein an outer side of the outer layer comprises a texture. 16. Upper according to one of embodiments 1-15, wherein the protrusions of the inner layer point outwards, such that they protrude through the cuts of the outer layer, when the inner layer is in the second position. 17. Upper according to one of embodiments 1-16, wherein the upper comprises a textile layer arranged on an outer surface of the outer layer. 18. Upper according to embodiment 17, wherein the protrusions of the inner layer are only arranged on the medial and/or lateral side of the upper. 19. A shoe comprising: an upper according to one of embodiments 1-18; and a sole attached to the upper. 20. A method of manufacturing an upper for a shoe, comprising the steps: providing an inner layer; providing an outer layer, such that the outer layer overlaps the inner layer at least partially; providing a plurality of cuts in the outer layer; providing a plurality of protrusions on the inner layer, such that each cut is associated with at least one protrusion; and providing a movable inner layer with respect to the outer layer between a first position and a second position such that in the first position the protrusions are covered by the outer layer and in the second position, each protrusion protrudes through its associated cut at least partially. 21. Method of manufacturing an upper for a shoe according to embodiment 20, further comprising the steps: providing a compression mold with at least two plates. 22. Method of manufacturing an upper for a shoe according embodiments 21, further comprising the steps: providing that at least one of the mold plates acts as a cutter. 23. Method of manufacturing an upper for a shoe according to one of embodiments 21-22, wherein the material of outer layer and the inner layer comprises different hardnesses. 24. Method of manufacturing an upper for a shoe according to embodiment 23, wherein the material of the outer layer comprises a greater hardness in comparison to the inner layer. 25. Method of manufacturing an upper for a shoe according to one of embodiments 21-24, further comprising the step: providing a stretchable piece which connects the inner layer to the outer layer and/or an optional lining. 26. Method of manufacturing an upper for a shoe according to one of embodiments 21-25, further comprising the step: placing the stretchable piece in the forefoot region of the upper. 27. Method of manufacturing an upper for a shoe according to one of embodiments 21-26, wherein the inner layer comprises a non-stretchable material. 28. Method of manufacturing an upper for a shoe according to one of embodiments 21-27, wherein the inner layer comprises TPU or a textile. 29. Method of manufacturing an upper for a shoe according to one of embodiments 21-28, wherein the stretchable piece and/or the inner layer and/or the outer layer comprise rubber. 30. Method of manufacturing an upper for a shoe according to one of embodiments 21-29, further comprising the step: forming the inner layer in the heel region as a lug. 31. Method of manufacturing an upper for a shoe according to one of embodiments 21-30, further comprising the step: forming the outer layer as a textile layer and coating the textile layer on both sides. 32. Method of manufacturing an upper for a shoe according to embodiments 31, further comprising the step: forming the cuts in the coatings of the outer layer smaller than the cuts in the textile layer. 33. Method of manufacturing an upper for a shoe according to one of embodiments 21-31, further comprising the step: arranging a lining underneath the inner layer. 34. Method of manufacturing an upper for a shoe according to one of embodiments 21-33, further comprising the step: providing the outer side of the outer layer with a texture. 35. Method of manufacturing an upper for a shoe according to one of embodiments 21-34, further comprising the step: arranging the protrusions of the inner layer such that the protrusions face outwards and protrude through the cuts of the outer layer when the inner layer is in the second position. 36. Method of manufacturing an upper for a shoe according to one of embodiments 21-35, further comprising the step: arranging a textile layer on an outer surface of the outer layer. 37. Method of manufacturing an upper for a shoe according to embodiments 36, further comprising the step: arranging the protrusions only on the medial side of the upper.
(51) In any various embodiments, an upper comprising an inner layer and an outer layer, wherein the material of the outer layer and the inner layer comprises different hardnesses.
(52) In any various embodiments, wherein the upper further comprises a lining arranged underneath the inner layer.
(53) In any various embodiments, wherein the upper further comprises a textile layer arranged between the outer layer and the inner layer.
(54) In any various embodiments, wherein the inner layer is only arranged on the medial or lateral side of the upper.
(55) In any various embodiments, a shoe comprising an upper according to one of claims 1; and a sole attached to the upper.
(56) In any various embodiments, a method of manufacturing an upper for a shoe, wherein the first temperature is a range of 150-180° C. and the second temperature is in a range of 10-15° C.
(57) In any various embodiments, wherein the inner layer comprises a foam material.
(58) In any various embodiments, wherein the material of the outer layer and the inner layer comprises different hardnesses.
(59) In any various embodiments, wherein the material of the outer layer comprises a greater hardness in comparison to the inner layer.
(60) In any various embodiments, the method of manufacturing an upper for a shoe, further comprising the step: arranging a textile layer between the outer layer and the inner layer.
(61) In any various embodiments, the method of manufacturing an upper for a shoe, further comprising the step: providing a plurality of cuts coinciding with the cuts of the outer layer of the textile layer.
(62) In any various embodiments, the method of manufacturing an upper for a shoe, further comprising the step: providing an exterior texture of the outer layer with a plurality of protrusions.
(63) In any various embodiments, the method of manufacturing an upper for a shoe, further comprising the step: placing the protrusions of the inner layer facing inwards such they point in the direction of a foot of a wearer of the shoe.
(64) In any various embodiments, wherein the protrusions of the inner layer comprise a hemispherical shape, an elongated shape, or a rib shape.
(65) In any various embodiments, wherein the inner layer comprises at least two unconnected portions, wherein each portion comprises at least one protrusion.