Patent Application
20180125155
This application is related to and claims priority benefits from German Patent Application No. DE 10 2016 221 676.7, filed on Nov. 4, 2016 and entitled METHOD AND APPARATUS FOR JOINING A SOLE ELEMENT WITH AN UPPER ELEMENT, the content of which is hereby incorporated by reference in its entirety.
The present invention relates to a method and an apparatus for joining a sole element with an upper element as well as to a shoe comprising such a sole element joined with an upper element.
In the manufacture of sports shoes, it is often necessary to permanently join individual components of the sports shoe, e.g., a sole with an upper. One option is to mechanically join the components, for example by screwing or riveting the components. However, this may be disadvantageous, for example with respect to the look of the sports shoe, its weight and/or the durability or resilience of the joining.
A further possibility is to glue the components together. This option may have the disadvantage that gluing typically requires complex pretreatment of the components. It may be necessary, particularly in the case of plastic components, to first roughen and prime the surfaces of the components and to pre-dry the adhesive used for joining the components in an oven. In addition, adhesives used for the gluing of plastic components are often harmful to a worker and/or environmentally hazardous.
In particular for joining plastic components, various welding methods have been developed. For example, applicant disclosed in EP 3 053 471 A1 a method for the manufacture of sporting goods, in particular a shoe, wherein the method comprises the steps of providing a first component with a first connection surface and a second component with a second connection surface, activating at least one portion of the first connection surface by providing heat energy without contact, and connecting the first component with the second component by joining the first connection surface and the second connection surface.
However, a common disadvantage of the known methods is that the joining of the plastic components cannot be provided with sufficient quality in an accurate and reproducible manner. Moreover, many of the joining methods of the prior art involve a high amount of human labor, which makes the final product costly and also leads to undesired product deviations.
Therefore, the underlying problem of the present invention is to provide improved methods and apparatuses for joining a sole element with an upper element of a sports shoe in order to at least partly overcome some or all of the above mentioned deficiencies of the prior art.
The terms “invention,” “the invention,” “this invention” and “the present invention” used in this patent are intended to refer broadly to all of the subject matter of this patent and the patent claims below. Statements containing these terms should be understood not to limit the subject matter described herein or to limit the meaning or scope of the patent claims below. Embodiments of the invention covered by this patent are defined by the claims below, not this summary. This summary is a high-level overview of various embodiments of the invention and introduces some of the concepts that are further described in the Detailed Description section below. This summary is not intended to identify key or essential features of the claimed subject matter, nor is it intended to be used in isolation to determine the scope of the claimed subject matter. The subject matter should be understood by reference to appropriate portions of the entire specification of this patent, any or all drawings, and each claim.
According to certain examples, a method for joining a sole element with an upper element includes: (a) positioning the sole element and the upper element in a defined first position with respect to each other with a positioning system; (b) positioning the sole element and the upper element in a second position and applying a joining agent to at least one of the sole element or the upper element with the positioning system; and (c) joining the sole element with the upper element by positioning with the positioning system the sole element in contact with the upper element in a third position, where the third position is defined with respect to the first position.
In some embodiments, the defined first position is determined without contact of the sole element and the upper element. In various embodiments, the defined first position is determined by an ultrasonic method or 3D scanning method. According to certain aspects, the defined first position is determined by a contact between the sole element and the upper element.
According to various examples, positioning the sole element and the upper element in the defined first position includes applying in the defined first position a predefined contact force between the sole element and the upper element. In some embodiments, the predefined contact force is less than a maximum contact force.
In various cases, the joining agent is configured to soften a contacting surface of the sole element or the upper element. In some examples, the joining agent comprises heat, and the method further includes inserting a heat source between the sole element and the upper element after step (b). According to some cases, the joining agent comprises an infrared heat source.
In certain examples, the distance between the first position and the third position is from 0.1 mm-5 mm. In some embodiments, the positioning system includes at least one of: a base plate configured to support the sole element; a lateral clamping mechanism configured to hold the sole element at least on two opposite sides; and a holding aim configured to support the portion of the upper element. In various embodiments, the positioning system further includes a moveable lateral clamping mechanism, and the method further includes laterally compressing the sole element with the lateral clamping mechanism before step (a) or step (c). In various cases, the positioning system further includes a holding arm having an end with a last around which the upper element is arranged. In some cases, the method further includes the step of covering a portion of the sole element with a cover element prior to joining the sole element and the upper element.
According to some examples, the sole element includes a midsole with expanded thermoplastic polyurethane. In various cases, the upper element comprises an upper of a shoe. In certain aspects, the method further includes the step of joining a further sole element with a further upper element positioning the further sole element and the further upper element in the third position with the positioning system. According to various examples, a shoe includes a sole element and an upper element joined together.
According to certain examples, an apparatus for joining a sole element and an upper element includes a positioning system. In some examples, the positioning system includes: (a) means for positioning the sole element and the upper element in a defined first position with respect to each other; (b) means for operating the sole element and the upper element in a second position for applying a joining agent to the sole element or the upper element; and (c) means for joining the sole element with the upper element by positioning the sole element and the upper element in a third position of the positioning system, where the third position is defined with respect to the first position.
Various implementations described in the present disclosure can include additional systems, methods, features, and advantages, which cannot necessarily be expressly disclosed herein but will be apparent to one of ordinary skill in the art upon examination of the following detailed description and accompanying drawings. It is intended that all such systems, methods, features, and advantages be included within the present disclosure and protected by the accompanying claims.
Possible embodiments of the present invention are further described in the following detailed description, with reference to the following figures:
The above mentioned problem is at least partially solved by a method for joining a sole element with an upper element, comprising the following steps: (a) operating a positioning system to position the sole element and the upper element in a defined first position with respect to each other; (b) operating the positioning system to position the sole element and the upper element in a second position for applying a joining agent to the sole element and/or the upper element and (c) joining the sole element with the upper element by operating the positioning system to position the sole element in contact with the upper element in a third position of the positioning system, wherein the third position is defined with respect to the first position.
Whereas in the prior art mentioned above joining a sole element with an upper element, for example a midsole with an upper for a sports shoe, is carried out simply by providing heat energy to the surface of the elements and joining them immediately afterwards, the present invention is based on a different approach: Here, in a first step, a positioning system may be operated to position the sole element and the upper element in a defined first position with respect to each other. Such a defined first position may be determined and thus used as a reference so that different parameters may be based thereon for the further method steps, e.g., a contact force or a pressure to be applied by the positioning system for joining the sole element with the upper element.
It is to be noted that after the defined first position has been reached there may be more than one joining step, for example if a number of essentially identical sole elements and upper elements are to be joined.
By operating the positioning system in the third position, which is defined with respect to the first position, so that the sole element and the upper element are in contact with each other, a more accurate and reliable interconnection between the sole element and the upper element may be achieved. The joining agent, for example heat, may soften or in another way modify at least a part of the sole element and/or the upper element. The third position, which is defined with respect to the first position and wherein the two elements are joined to each other, compensates for such a softening or other changes of the elements and thus assures an improved joining process. At the same time, it facilitates an automation of the joining process. Therefore, the whole manufacturing process of the sports shoe may become more efficient.
Another benefit is that the inventive method enables a welding of multiple shoes in one production cycle. The method is easily adaptable to soles which are different in size and/or shape.
For defining the first positon and consequently the third position, the remaining distances between a center of the sole element and a center of the upper element may, for example, be measured. Since the position of the sole element and the upper element will never fully coincide during and after joining the two elements, such distances allow a reproducible definition of the first and third position. Other measurements are conceivable as well, for example the remaining distance between a lower side of the sole element and an upper edge of the upper element. In other embodiments, the first and/or the third position may also be indirectly measured or defined, for example, by reaching a certain contact force between the two elements or by observing a certain amount of deformation of one or both elements.
In some embodiments, the defined first position may be determined without contact of the sole element and the upper element. Moreover, the defined first position may be determined by an ultrasonic method and/or 3D scanning method. Such embodiments may scan the external shape of the sole element for defining the first position without moving the two elements so that the automation of the manufacturing process of the sports shoe may be facilitated.
In some embodiments, the defined first position may be determined by a contact between the sole element and the upper element. Moreover, the positioning system may apply in the defined first position a predefined contact force between the sole element and the upper element. Furthermore, the predefined contact force may be less than a maximum contact force available from the positioning system. Thus, the apparatus for the joining process may be able to provide additional contact force, which may be necessary to reach the third position after the activation of the joining agent and which assures a reliable joining.
In some embodiments, the joining agent may soften a contacting surface of the sole element and/or the upper element. The joining agent may comprise heat. Softening the sole element and/or the upper element may provide the possibility that a tight bond between at least a portion of the sole element and at least a portion of the upper element may be formed, a chemical bond and/or a mechanical bond. What kind of bond is formed and how stable this bond is will for example depend on the amount of heat energy provided, the temperature the contacting surface is heated to, the degree of activation, the materials involved, the kind of post-processing or curing, and so forth. As a result, sports shoes comprising sole elements reliably joined with upper elements may be provided.
In some embodiments, the heat may be provided by a heat source inserted between the sole element and the upper element after step b. Such an inserting of the heat source between the two elements may further simplify the process as both elements may be heated up simultaneously. For example, the sole element may be arranged below the heat source and the upper element may be arranged above the heat source and vice versa. It is also conceivable that the sole element may be arranged on the left of the heat source and the upper element may be arranged on the right side of the heat source and vice versa. However, in all of these embodiments, the footprint of an apparatus for performing the described method may be reduced as only a single heat source may be needed.
The joining agent may comprise an infrared heat source. An infrared heat source may provide different wavelengths, for example: near-infrared, short-wavelength infrared, mid-wavelength infrared, long-wavelength infrared and far-infrared, wherein the specific wavelength to be used can be adapted depending on the materials of the two components to be joined. An advantage of using infrared radiation is thus that it is easy to produce and to apply to the sole and upper element. The amount of heat energy provided to a surface by infrared radiation may, for example, be controlled by adjusting the output power of the source, the intensity of the radiation, the size or emitted wavelength of the infrared heat source, the distances of the source to the surface, the view factor of the surface, i.e., how much of the emitted energy the target surface receives, or the emissivity of the surface material, etc. Moreover, the use of infrared radiation does not impose any particular requirements, such as electrical conductivity, on the material of the two elements. It is therefore particularly suited for joining plastic components.
In some embodiments, the defined first position and the third position may differ by a distance of 0.1 mm-5 mm, preferably 0.5 mm-2 mm. The inventors have surprisingly found that such values for the difference between the defined first and third position may provide a good comprise between an unintended joining of some portions of the sole element with the upper element, which would then later be visible, and a sufficient contact force to reliably join the sole element with the upper element.
In some embodiments, the positioning system may comprise one or more of the following positioning elements: a base plate supporting the sole element; a lateral clamping mechanism to hold the sole element at least on two opposite sides; and a holding arm supporting the upper element. All of these embodiments follow the same idea of providing a more stable way for securing the sole element and the upper element. For example, the sole element may be arranged on the base plate and the lateral clamping mechanism may hold it on its lateral side and its medial side so that the occurring forces during the joining process may be distributed uniformly. Moreover, the holding arm supporting the portion of the upper element provides the possibility that the upper element may be moved reliably between the various positions so that the automation of the overall process may be further improved.
In some embodiments, the positioning system may comprise a moveable lateral clamping mechanism adapted to laterally compress the sole element before step (a) and/or step (c). Moreover, the positioning system may comprise a holding arm having an end with a last around which the upper element is arranged. These embodiments follow the same idea as mentioned above of providing a further improvement of the automation of the joining process. By using a moveable lateral clamping mechanism to laterally compress the sole element before step (a) and/or step (c), the sole element may be better secured during the positioning in the defined first position as reference position. Moreover, the sole element may be slightly deformed by the pressure of the lateral clamping mechanism so that the sole element may bend slightly convex towards the upper element which may be beneficial for the joined process. Alternatively or additionally, the sole element may also be better secured during the contact during the actual joining process. As a result, the joining process of the sole element with the upper element may be carried out in a more accurate and thus reproducible manner.
The method may further comprise the step of providing a cover element adapted to cover a portion of the sole element prior to joining the sole element and the upper element. The cover element may protect visible portions of the sole element, e.g., the boundary portion, during step of applying the joining agent to the sole element and/or the upper. Similarly, the cover element may also protect portions of the upper element.
In some embodiments, the sole element may comprise a midsole, preferably a midsole comprising expanded thermoplastic polyurethane (eTPU). Moreover, the upper element may comprise an upper of a shoe.
In one embodiment, the method further comprises the step of joining a further sole element with a further upper element by operating the positioning system to position the further sole element and the further upper element in the third position of the positioning system. As a result, a whole process of joining a plurality of sole elements with a plurality of upper elements may be provided with the above mentioned advantages.
According to another aspect, the present invention relates to a shoe comprising a sole element and an upper element, wherein the sole element and the upper element have been joined by a method according to the invention. Such a shoe will have superior quality in that there is no delamination of the sole from the upper.
According to still another aspect, the present invention relates to an apparatus for joining a sole element with an upper element comprising a positioning system, wherein the positioning system comprises (a) means for positioning the sole element and the upper element in a defined first position with respect to each other, (b) means for operating the sole element and the upper element in a second position for applying a joining agent to the sole element and/or the upper element and (c) means for joining the sole element with the upper element by positioning the sole element and the upper element in a third position of the positioning system, wherein the third position is defined with respect to the first position. Moreover, the apparatus may be further adapted to perform any of the methods according to the invention as mentioned above.
The subject matter of embodiments of the present invention is described here with specificity to meet statutory requirements, but this description is not necessarily intended to limit the scope of the claims. The claimed subject matter may be embodied in other ways, may include different elements or steps, and may be used in conjunction with other existing or future technologies. This description should not be interpreted as implying any particular order or arrangement among or between various steps or elements except when the order of individual steps or arrangement of elements is explicitly described.
Possible embodiments and variations of the present invention are described in the following with particular reference to a sole element and an upper element, in particular for a sports shoe. However, the concept of the present invention may identically or similarly be applied to any sporting goods such as shirts, pants or sports equipment such as a ball, racket, etc., wherein different components are joined to each other by joining methods, for example bonding, curing, welding, etc.
It is also to be noted that individual embodiments of the invention are described in greater detail below. However, it is clear to the person skilled in the art that the design possibilities and optional features described in relation to these specific embodiments can be further modified and combined with one another in a different manner within the scope of the present invention and that individual steps or features can also be omitted where they appear to be unnecessary. In order to avoid redundancies, reference is made to the explanations in the previous sections, which also apply to the following detailed description.
In one embodiment, the sole element may comprise a midsole, preferably a midsole comprising eTPU, and the upper element may comprise an upper of a shoe.
The method 100 continues with a step 120 of operating the positioning system to position the sole element and the upper element in a second position for applying a joining agent to the sole element and/or the upper element. For example, the joining agent may comprise heat from an infrared heat source which may be inserted between the sole element and the upper element after the separating step 120. Thus, the heat from the infrared heat source may soften and thus activate a contacting surface of the sole element and/or the upper element. If the contacting surface of at least one of the two elements may comprise a material that becomes adhesive when subjected to a certain amount of infrared heat energy or a material that enters into a chemical reaction with a material of the surface of the other element when heated above a certain activation temperature. Such materials can have the advantage that they are easily handled when not activated and only become adhesive/reactive selectively upon activation.
Method 100 continues with a step 130 of joining the sole element with the upper element by operating the positioning system to position the sole element in contact with the upper element in a third position of the positioning system, wherein the third position is defined with respect to the first position. For example, the defined first and third position may differ by a distance of 0.1 mm-5 mm, preferably 0.5 mm-2 mm. Joining the sole element with the upper element may further comprise forming a bond between at least one portion of the surface of the sole element and at least one portion of the surface of the upper element. The bond may comprise a chemical bond and/or a mechanical bond. What kind of bond is formed and how stable this bond is will for example depend on the amount of heat energy provided, the temperature of the surface of the sole element is heated to, the degree of activation, the materials involved, the kind of post-processing or curing, and so forth. It is also conceivable to use other methods in order to achieve a bonding between the sole element and the upper element such as: gluing, welding, high frequency welding, ultrasonic welding, laser welding, crimping, sewing, screwing, riveting, fusing, clipping, sealing, subjecting to a heat pressure treatment, exposing to a steam treatment.
As shown in
Some or all of the above method steps may be carried out automatically in order to make the manufacture of sports shoes more efficient. In fact, the described method may be integrated into a fully automated manufacture of sports shoes.
The method 100 reduces the overall process time for joining a sole element with an upper element in a reproducible manner, wherein the sole element joined with upper element will be manufactured to a sports shoe having extraordinary quality.
Corresponding to method step 110, a defined first position may be determined, e.g., by a determining entity of the positioning system, by a contact between the sole element 210 and the upper element 220 by operating a positioning system to position the two elements (as indicated by the two double line arrows), for example by two electrical cylinders (not shown). The determining entity may use one or more reference points on the sole element and the upper element or any support of the respective element to determine the defined first position (not shown in
In one embodiment, a quick response (QR) code may be printed onto the sole element 210 so that different information about the sole element 210 (e.g., material properties, shape, density, melting temperature, etc.) may be obtained by reading the QR code and the defined first position of the positioning system may be determined based thereon. A means for reading the QR code may be included in the determining entity. It is also conceivable that any other code may be used such as UPC code, Micro QR code, Secure QR-code, iQR-Code or Frame QR, etc.
The defined first position of the positioning system may be used as a reference position (as indicated by the dashed line 211) and may be set to some reference value, e.g., 0 mm as indicated on the right scale. The positioning system may, for example, define the first position as a position, wherein a predefined contact force between the sole element 210 and the upper element 220 is achieved. The contact force may be measured via the motor power by using an external load cell. In the described embodiment, the predefined contact force may be less than the maximum contact force available from the positioning system. This provides the possibility to further increase the contact force during the further steps of the described method as explained below.
Corresponding to method step 120, the sole element 210 and the upper element 220 are then operated in a second position (as indicated by the two vertical double line arrows 213 in the middle of
Corresponding to method step 130, the sole element 210 may be positioned in contact with the upper element 220 by operating the positioning system (as indicated by the two double line arrows 217) in a third position. The third position of the sole element 210 and the upper element 220 is defined with respect to the first position. Thus, the sole element 210 is reliably joined with the upper element 220. The first and third position may differ by a distance of 0.1 mm-5 mm, preferably 0.5 mm-2 mm, for example by 1 mm. This means, for example, that parts of the positioning system, for example the two electrical cylinders, may be elongated by 1 mm more than the defined first position as reference position in order to provide more contact force. Such a difference of two positions between the sole element 210 in the upper element 220 may provide enough pressure to join the two elements after one or both of them have been subject to the heat treatment of the infrared source 230 or some other kind of activation. It is also conceivable that other differences between the first and the third position may be used for providing other pressures depending on the material properties of the two elements.
In one embodiment, the positioning system may comprise a base plate supporting the midsole 310 which is not shown but would be therefore below the midsole 310 in
Moreover, the movable clamping mechanism 300a may be equipped with six mechanical sliders (below the brackets 315 and thus not shown in
In one embodiment, the brackets 315 may be manufactured by an additive manufacturing method. Additionally or alternatively, the brackets 315 may comprise aluminum or other suitable metals.
In one embodiment, the cover element 317 may be manufactured by an additive manufacturing method. Additionally or alternatively, the cover element may comprise aluminum of other suitable metals.
As can be seen in
In the following, further examples are described to facilitate the understanding of the invention:
1. A method (100) for joining a sole element (210; 310) with an upper element (220; 320), the method comprising the following steps:
2. The method (100) of claim 1, wherein the defined first position is determined without contact of the sole element and the upper element.
3. The method (100) of claim 2, wherein the defined first position is determined by an ultrasonic method and/or 3D scanning method.
4. The method (100) of claim 1, wherein the defined first position is determined by a contact between the sole element (210; 310) and the upper element (220; 320).
5. The method (100) of claim 4, wherein the positioning system applies in the defined first position a predefined contact force between the sole element (210; 310) and the upper element.
6. The method (100) of claim 5, wherein the predefined contact force is less than a maximum contact force available from the positioning system.
7. The method (100) of any of the preceding claims, wherein the joining agent softens a contacting surface of the sole element (210; 310) and/or the upper element (220; 320).
8. The method (100) of any of the preceding claims, wherein the joining agent comprises heat.
9. The method (100) of the claim 8, wherein the heat is provided by a heat source (230; 330) inserted between the sole element (210; 310) and the upper element (220; 320) after step b.
10. The method (100) of any of the preceding claims, wherein the joining agent comprises an infrared heat source.
11. The method (100) of one of the claims 4-10, wherein the defined first position and the third position differ by a distance of 0.1 mm-5 mm, preferably 0.5 mm-2 mm.
12. The method (100) of any of the preceding claims, wherein the positioning system comprises one or more of the following positioning elements:
13. The method (100) of claim 12, wherein the positioning system comprises a moveable lateral clamping mechanism (315) adapted to laterally compress the sole element (210; 310) before step a. and/or step c.
14. The method (100) of claim 12 or 13, wherein the positioning system comprises a holding arm (325) having an end with a last around which the upper element (220; 320) is arranged.
15. The method (100) of one of the claims 12-14, further comprising the step of providing (132) a cover element (317) adapted to cover a portion of the sole element (210; 310) prior to joining the sole element (210; 310) and the upper element (220: 320).
16. The method (100) of any of the preceding claims, wherein the sole element (210; 310) comprises a midsole (310), preferably a midsole comprising expanded thermoplastic polyurethane, eTPU.
17. The method (100) of any of the preceding claims, wherein the upper element (220; 320) comprises an upper of a shoe.
18. The method (100) of any of the preceding claims, further comprising the step of: Joining a further sole element with a further upper element (220; 320) by operating the positioning system to position the further sole element and the further upper element (220; 320) in the third position of the positioning system.
19. Shoe comprising a sole element with an upper element, wherein the sole element and the upper element (220; 320) have been joined by a method of any of the preceding claims.
20. Apparatus for joining a sole element and an upper element (220; 320) comprising a positioning system, wherein the positioning system comprises
21. Apparatus according to claim 20, wherein the apparatus is further adapted to perform a method of one of the claims 1-18.
It should be emphasized that the above-described aspects are merely possible examples of implementations, merely set forth for a clear understanding of the principles of the present disclosure. Many variations and modifications can be made to the above-described embodiment(s) without departing substantially from the spirit and principles of the present disclosure. All such modifications and variations are intended to be included herein within the scope of the present disclosure, and all possible claims to individual aspects or combinations of elements or steps are intended to be supported by the present disclosure. Moreover, although specific terms are employed herein, as well as in the claims that follow, they are used only in a generic and descriptive sense, and not for the purposes of limiting the described invention, nor the claims that follow.
| Number | Date | Country | Kind |
|---|---|---|---|
| 102016221676.7 | Nov 2016 | DE | national |
