Methods of Vacuum Forming Articles of Wear

Patent metadata

Field	Value
Publication number	US-2016136869-A1
Application number	US-201414540451-A
Country	US
Kind code	A1
Filing date	Nov 13, 2014
Priority date	Nov 13, 2014
Publication date	May 19, 2016
Grant date	—

Abstract

Described are methods of two-dimensionally and three-dimensionally forming an article of wear using vacuum forming in an automated process. In the two-dimensional method, the article of wear comprises a generally flat shape with three-dimensional features molded into the first material layer.

First claim

That which is claimed is:

1 . A method of two-dimensionally forming an article of wear comprising:
positioning a first side of a first material layer adjacent a one-sided mold comprising cut-out locations; positioning a second material layer adjacent a second side of the first material layer; applying a vacuum to the first side of the first material layer so that the first material layer is molded to the cut-out locations within the one-sided mold; and bonding the second material layer to the first material layer in areas outside the cut-out locations of the one-sided mold.

2 . The method of claim 1 , wherein the method further comprises applying heat to the first material layer and the second material layer while applying the vacuum to the first side of the first material layer.

3 . The method of claim 1 , wherein the method further comprises pre-heating at least the first material layer prior to positioning the first side of the first material layer adjacent the one-sided mold.

4 . The method of claim 1 , wherein the method further comprises cutting the article of wear out of the first material layer and the second material layer.

5 . The method of claim 4 , wherein the method further comprises separating the cut article of wear from the first material layer and the second material layer.

6 . The method of claim 1 , wherein the first material layer is a non-breathable film, and the second material layer is a breathable material.

7 . The method of claim 6 , wherein the article of wear comprises a formed plate having air pockets sandwiched between the first material layer and the second material layer.

8 . The method of claim 7 , the method further comprising coupling sides of the formed plate to an upper so that the second material layer is facing a wearer's foot to provide breathability and wicking to the wearer's foot.

9 . The method of claim 7 , the method further comprising coupling sides of the formed plate to an upper so that the first material layer is facing a wearer's foot to provide a waterproof upper.

10 . The method of claim 1 , wherein applying the vacuum to the first side of the first material layer does not cause the second material layer to become molded to the cut-out locations within the one-sided mold.

11 . The method of claim 1 , wherein the article of wear comprises a generally flat shape with three-dimensional features molded into the first material layer.

12 . The method of claim 11 , wherein the three-dimensional features comprise one or more of embossing, de-bossing, and texture features.

13 . A system for vacuum forming articles of wear comprising:
a frame supporting a vacuum table comprising a one-sided mold; a seal frame coupled to the frame and positioned above the vacuum table, wherein the seal frame is configured to surround the one-sided mold; and a heating element slidingly coupled to the frame above the seal frame.

14 . The system of claim 13 , further comprising a roller coupled to a pair of tracks positioned in opposing sides of the seal frame.

15 . The system of claim 13 , further comprising one or more heating elements positioned adjacent the vacuum table.

16 . The system of claim 13 , further comprising a cutting tool mounted to the frame above the vacuum table.

17 . The system of claim 13 , further comprising a retrieval device slidingly coupled to the frame.

18 . The system of claim 17 , further comprising a plurality of telescoping arms positioned on the retrieval device.

19 . An article of wear comprising a generally flat shape formed by:
a first material layer formed of non-breathable material, wherein the first material layer comprises three-dimensional features; and a second material layer formed of breathable material, wherein the second material layer forms a locking layer with the first material layer that maintains a shape of the three-dimensional features when the article of wear is transitioned from the generally flat shape to a three-dimensional structure.

20 . The article of wear of claim 19 , wherein the second material layer maintains the shape of the three-dimensional features when the article of wear is transitioned from the generally flat shape to the three-dimensional structure by having a low amount of stretch or no stretch.

Assignees

• Adidas Ag

Inventors

• Iovu Tiberiu

Classifications

• B29C51/10 Primary

  Forming by pressure difference, e.g. vacuum · CPC title

• A43B23/0235

  Different layers of different material · CPC title

• B29L2031/50

  Footwear, e.g. shoes or parts thereof · CPC title

• B29C2791/006

  Using vacuum · CPC title

• B29L2031/48

  Wearing apparel · CPC title