Patent Application
20210321723
The invention relates generally to the field of wearable product such as footwear and particularly, but not exclusively, to a shoe upper blank and a shoe upper, and a method of manufacturing thereof.
Various kinds of footwear such as athletic shoes in different constructions are available in the market. In general, a shoe in its typical form comprises a shoe upper which covers a foot of the wearer; and a sole or a shoe bottom which comprises the bottom portion of the shoe for supporting the foot and engaging the ground. Traditionally, blanks for shoe uppers are formed by stepwise connection of the relevant parts and components via, for example, stitching, sewing and/or binding by using adhesives and/or heat fusion techniques. In order to enhance the aesthetic appeal of the shoes as formed, decorative elements, patterns or designs are very often provided at the shoe uppers, for example, by stitching of the desired patterns and/or sewing or attaching of decorative components and/or ornaments thereon. However, all these processes are known to be time consuming as well as labor intensive, which will inevitably translate to greater costs. In addition, automation of such shoe making processes will become difficult as substantial manual operation and craftsmanship will generally still be required.
An object of the present invention is to provide a wearable product such as a shoe and a blank for such a product, and a method of manufacturing and/or processing thereof, in which the aforesaid shortcomings are mitigated or at least to provide a useful alternative.
Another object of the invention is to mitigate or obviate to some degree one or more problems associated with known manufacturing methods of wearable products such as shoes, and/or one or more parts thereof such as shoe uppers and/or shoe upper blanks.
The above object is met by the combination of features of the main claims; the sub-claims disclose further advantageous embodiments of the invention.
One skilled in the art will derive from the following description other objects of the invention. Therefore, the foregoing statements of object are not exhaustive and serve merely to illustrate some of the many objects of the present invention.
In a first main aspect, the invention provides a method of processing a sheet material for use in the manufacture of a products. The method comprises providing a sheet material having a first surface and a second surface; providing a two-dimensional mark on the first surface of the sheet material; arranging one or more strengthening members at one or more of the first surface and the second surface of the sheet material; imposing an indentation on said first surface of the sheet material; wherein at least part of the indentation is arranged with respect to one or more of at least part of the two-dimensional mark and at least part of the one or more strengthening members to create a three-dimensional mark on said first surface.
In a second main aspect, the invention provides a method of manufacturing a product comprising the step of forming a blank from a sheet material processed according to the method of the first main aspect to form a shoe upper.
In a third main aspect, the invention provides a blank for at least part of a manufactured product. The blank comprises a sheet material shaped in accordance with the at least part of a manufactured product, the sheet material comprising a two-dimensional mark on a surface of the sheet material; one or more strengthening members arranged on one or more sides of the sheeting material; wherein one or more of at least part of the two-dimensional mark and at least part of the one or more strengthening members are positioned with respect to an indentation formed in the sheet material to thereby provide a three-dimensional mark on said surface.
In a fourth main aspect, the invention provides a shoe upper. The shoe upper comprises the blank according to the third main aspect.
The summary of the invention does not necessarily disclose all the features essential for defining the invention; the invention may reside in a sub-combination of the disclosed features.
The foregoing and further features of the present invention will be apparent from the following description of preferred embodiments which are provided by way of example only in connection with the accompanying figures, of which:
The following description is of preferred embodiments by way of example only and without limitation to the combination of features necessary for carrying the invention into effect.
Reference in this specification to “one embodiment” or “an embodiment” means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the invention. The appearances of the phrase “in one embodiment” in various places in the specification are not necessarily all referring to the same embodiment, nor are separate or alternative embodiments mutually exclusive of other embodiments. Moreover, various features are described which may be exhibited by some embodiments and not by others. Similarly, various requirements are described which may be requirements for some embodiments but not other embodiments.
In the claims hereof, any element expressed as a means for performing a specified function is intended to encompass any way of performing that function. It is thus regarded that any means that can provide those functionalities are equivalent to those shown herein.
The present invention relates to a blank for a wearable product or a part of a wearable product such as a shoe upper and a method of manufacturing thereof. Referring to
In one embodiment, the shoe upper blank 10 preferably comprises one or more strengthening members 70 arranged at the sheet material 20, and more particularly, at one or more of the upper surface 21 and the lower surface 22 of the sheet material 20. The one or more strengthening members 70 are provided with an aim to enhance or to reinforce mechanical properties such as strength, resilience and/or wear resistance of the formed shoe upper blank.
Preferably, at least part of the two-dimensional marks 30 on the sheet material 20 and/or the strengthening members 70 are arranged to position with respect to one or more respective indentations 40 formed in the sheet material 20 to thereby provide one or more three-dimensional marks 50 on the surface, as shown in
In one embodiment, the strengthening members 70 are preferably formed of materials such as polymeric materials and/or leather materials. More preferably, the polymeric materials may comprise polyurethane (PU) materials, such as thermoplastic urethane (TPU) sheet materials. The leather materials may comprise genuine leather (such as, but are not limited to, napa leather and nubuck leather, etc.) and synthetic leather (such as, but are not limited to, PU microfiber leather and microfiber suede leather, etc.). The strengthening members 70 are preferably to be of a thickness of about 0.1 mm to about 5 mm, and more preferably, about 0.15 mm to about 3.5 mm. In one preferred embodiment, the strengthening members 70 may exhibit a tensile strength of about 10 MPa to about 100 MPa; a hardness (Shore A) of about 50 to about 100; and a density of about 1 g/cm3 to about 5 g/cm3, and more preferably, about 1 g/cm3 to about 2 g/cm3. In one specific embodiment, the strengthening members 70 formed of thermoplastic urethane (TPU) sheet materials having a thickness of about 0.5 mm to about 0.6 mm are found to demonstrate physical properties as shown in Table 1 below:
In one further embodiment, the strengthening members 70 may optionally comprise or be provided with one or more marks 72 such as one or more two-dimension marks 72 on its surfaces such as the upper surface. The marks 72 can be formed by any known marking means, such as those as applicable to the marking of the two-dimensional marks 30 of the sheet material 20 as described above. For example, the mark 72 can be provided by writing, drawing, painting, staining, printing and/or stamping on at least part of the surface of the strengthening member 70. The marks 72 may further comprise one or more of a line, a pattern, a color, an icon, a picture, a shape, a word, a symbol and/or a decorative element. For example, at least part of the surface of the strengthening members 70 can be filled with one or more colors and/or patterns. The marks 72 may also be provided by any known printing techniques, such as but not limited to, sublimation printing, silk screen printing and/or digital printing, etc. In one further embodiment, marks 72 can be formed by scanning the appearance of a fabric material having the desired texture and/or arrangement, for example, a fabric with decorative stitched patterns by a suitable scanner; optionally editing the scanned images by a computer software; and subsequently, printing of such images onto the surface of the strengthening members 70 via, for example, a computer controlled printer, etc.
The printed surfaces of the sheet material 20 along with the strengthening members 70 will then be pressed in a mold to thereby impose one or more indentations 40 on the blank material. Particularly, at least part of each indentation 40 is arranged with respect to at least part of a respective two-dimensional pattern 30 and/or at least part of the strengthening member 70 to create a three-dimensional mark 50 on the printed surface. In one embodiment, at least part of the indentation 40 is preferred to be arranged with respect to, and to coincide with at least part of the two-dimensional pattern 30 and/or the strengthening member 70 to create the three-dimensional mark 50 to thereby mimic a desired textural effect such as a knitted, stitched, sewed fabric pattern and/or any design of decorative textures on the blank material. As shown in
After arranging the strengthening members 70 at the mold surface, the sheet material 20 is then placed onto the mold 60, with the upper surface 21 carrying the two-dimensional marks 30 being arranged to face and to overlay at least partially the strengthening members 70. Preferably, the sheet material 20 is positioned relative to the mold 60 by aligning the two-dimensional pattern 30 with the mold pattern of the mold 60 to thereby increase precision of the next pressing step, with the alignment being preferably assisted by using a positioning means such as one or more pins 64 arranged at the mold 60 adapted to engage one or more corresponding through holes at the sheet materials for positioning.
In another embodiment, additional strengthening members 70B may further be arranged at the lower surface 22 of the sheet material 20 after the sheet material 20 is placed on top of the strengthening members 70 and the mold 60, as shown in
The next step is to apply pressure onto the sheet material 20 along with the strengthening members 70, 70B via the mold 60 to thereby impose the indentations 40 onto the printed surface. This pressing step may further be assisted by or be conducted under heat treatment and/or vacuum suction, such as by heating the sheet material 20 and/or the mold 60, and/or by applying vacuum to the process with an aim to enhance efficacy of the pressing step. After the pressing step which may optionally be conducted under heat and/or vacuum, a cooling step may also be provided to the molding process. The cooling step is found to be advantageous to the formation of the indentations 40 and particularly, in forming more distinct three-dimensional patterns 50 based on the indentations 40. In one specific embodiment, the pressing step can be conducted under pressure at about 25 kg/cm to about 80 kg/cm, heat treatment at about 80 deg C. to about 200 deg C. for about 30 seconds to about 90 seconds, and subsequently, cooling at about 0 deg C. to about 20 deg C. under the pressure of about 25 kg/cm to about 80 kg/cm for about 10 seconds to about 60 seconds.
After the provision of the 3-D marks 40 or patterns 50 on the blank material, the sheet blank material may then be cut in accordance with the outline of the part or all of the shoe upper or the printed area of the part or all of the shoe upper to form the blank 10. In one embodiment, the blank 10 is preferred to be formed in one single piece and be configured in a substantially U or V-shape having a closed end at one longitudinal end and an open end at the opposite longitudinal end of the blank 10. The blank 10 is also preferred to be symmetric in shape along a central longitudinal axis, such that a shoe upper with symmetric left and right sides can be formed by for example, shaping and/or folding of the blank 10 about its central longitudinal axis.
As described earlier, the provision of the strengthening members 70 at the blank material is beneficial in enhancing mechanical properties at selected regions or locations of the shoe blank 10, at which enhanced or reinforced mechanical properties such as mechanical strength, wear resistance and/or material resilience, etc. are desired or required. The strengthening members 70 can be arranged at one side or both sides of the sheet material 20, and that for the strengthening members 70 which are arranged on the upper side or surface 21 of the sheet material 20, they may further serve to decorate the shoe blank 10, especially when they are priorly printed with various colors and/or patterns 72.
The improved mechanical properties are found to include, but are not limited to, tensile strength, percentage elongation, tear strength, burst strength and/or abrasion, etc. and that comparison of these parameters of a shoe blank prepared with and without the strengthening members 70 are shown in Table 2 below. Specifically, the mechanical tests were conducted by using the prepared shoe blank sample as shown in
The shoe blank 10 may further comprise one or more shoe parts and/or accessories connected to the sheet material 20, for example, the shoelace rings and/or a shoe tongue (not shown). In one further embodiment, the sheet material 20 may be punched or pierced to provide one or more through holes which can be used as a passageway for a shoelace, and/or for the fitting of one or more eyelets, loops and/or hooks for tying a shoelace. Alternatively, the through holes may serve a decorative purpose, for example, to allow a bottom layer material attached underneath the sheet material 20, preferably having a different color to the printed surface, to be visible via the through holes, etc.
The present invention further relates to a shoe upper and a method of manufacturing thereof. Particularly, the shoe upper blank 10 as described above can be processed to form a shaped shoe upper. For example, the shoe upper can be formed by one or more of connecting, shaping, sewing, stitching, adhering and/or heat fusing steps of at least part of the blank 10. In one embodiment, the blank 10 may be connected via one or more connecting means, for example, via hot melt film pressing stitching or the like. Preferably, the shoe upper can be formed by shaping and connecting only one single blank. The present invention is therefore advantageous in providing a one-step manufacturing method, which significantly simplifies the manufacturing process for a shoe upper compared to the conventional, multi-step manufacturing process for a shoe upper. The one-step process reduces, minimises or negates the part-by-part sewing, stitching and/or in general, connecting operation in putting the various components of a conventional shoe upper blank together.
Although a footwear or a shoe in the form of a sport shoe is illustrated in the drawings, a person skilled in the relevant art would appreciate that the present invention is limited to any specific shoe types as described or illustrated. Instead, the present invention can be used to form various kinds wearable products such as, but are not limited to, footwear or shoes including boots, sandals, thongs, slippers and footwear with or without heels, and/or any wearable products or accessories of apparel such as bags, handbags, belts head or wrist bands or the like.
In general, the present invention provides a blank for a wearable product or a part of a wearable product such as a shoe upper, and a method of manufacturing thereof. The blank, preferably in a one-piece configuration, comprises a sheet material shaped in accordance with a shoe upper, and one or more strengthening members for providing the blank with an enhanced mechanical support. The present invention is advantageous in providing a simple, fast and versatile method in preparing a shoe upper blank with a texture of, for example, a knitted, stitched and/or sewed effect, without the need of an actual knitting, stitching and/or sewing step at the blank or the shoe upper. The two-dimensional mark and thus the resulting three-dimensional pattern can be any computer generated or processed graphics, photos and/or images, which can be readily produced and printable onto the sheet material by known printing methods. The processing steps are relatively simple, fast and non-expensive, which allows the three-dimensional, textural patterns be generated and reproduced at high efficiency and consistency. Furthermore, the provision of the strengthening members to the blank material is beneficial in enhancing or reinforcing mechanical properties at selected regions of the shoe blank, of which an improved mechanical strength, resilience and/or durability are achievable. The strengthening members may priorly be printed with decorative colors and/or patterns such that, when being provided at the upper side of the shoe blank, provides further decorative effects to the overall shoe blank design.
The present invention is beneficial in allowing a semi- or fully automated process in the making of shoe, which significantly simplifies the conventional, multi-steps manufacturing process, as well as enhances quality and reproducibility of the resulting shoes. The present invention also assists in reducing, minimising or negating some or most of the traditional manual operations generally required in a shoe making process, which are known to be cost and labour demanding.
The present description illustrates the principles of the present invention. It will thus be appreciated that those skilled in the art will be able to devise various arrangements that, although not explicitly described or shown herein, embody the principles of the invention and are included within its spirit and scope.
Moreover, all statements herein reciting principles, aspects, and embodiments of the invention, as well as specific examples thereof, are intended to encompass both structural and functional equivalents thereof. Additionally, it is intended that such equivalents include both currently known equivalents as well as equivalents developed in the future, i.e., any elements developed that perform the same function, regardless of structure.
While the invention has been illustrated and described in detail in the drawings and foregoing description, the same is to be considered as illustrative and not restrictive in character, it being understood that only exemplary embodiments have been shown and described and do not limit the scope of the invention in any manner. It can be appreciated that any of the features described herein may be used with any embodiment. The illustrative embodiments are not exclusive of each other or of other embodiments not recited herein. Accordingly, the invention also provides embodiments that comprise combinations of one or more of the illustrative embodiments described above. Modifications and variations of the invention as herein set forth can be made without departing from the spirit and scope thereof, and, therefore, only such limitations should be imposed as are indicated by the appended claims.
In the claims which follow and in the preceding description of the invention, except where the context requires otherwise due to express language or necessary implication, the word “comprise” or variations such as “comprises” or “comprising” is used in an inclusive sense, i.e. to specify the presence of the stated features but not to preclude the presence or addition of further features in various embodiments of the invention.
It is to be understood that, if any prior art publication is referred to herein, such reference does not constitute an admission that the publication forms a part of the common general knowledge in the art.
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/CN2019/103002 | 8/28/2019 | WO | 00 |
