Shoe upper, method for manufacturing a shoe, and system for preparing a shoe upper or components of a shoe upper

Abstract

The present invention provides a shoe upper, a method of manufacturing a shoe, and a system for preparing a shoe upper or a component of a shoe upper. A stitch is applied to the shoe or shoe component, and then the stitch is printed. The stitch may be formed from a continuous thread. After printing, a portion of the continuous thread may have a different color or appearance than other portions of the continuous thread.

Description

[0001] This application is a divisional application of an application with an application date of June 1, 2017, application number 201780034568.7, and invention name “Upper, method for manufacturing shoes, and system for preparing uppers or components of uppers”. Technical Field

[0002] The invention relates to a shoe upper, a method for manufacturing a shoe and a system for preparing a shoe upper or a component of a shoe upper. Background Art

[0003] The manufacture of footwear has traditionally been a laborious process that involves cutting out individual pieces and sewing these pieces together to form footwear. However, this manufacturing process is batch-like, meaning that a series of operations may be performed on a portion of a shoe by a first operator, and then another series of operations may be performed by a different operator at a later time. This start and stop process can create inefficiencies in the process.

[0004] If the upper is not monochromatic, sewing these sheets together can also be challenging. It is often desirable to use the color of the sewing thread to complement the appearance of the shoe. In some designs, this may mean using matching threads to minimize the appearance of the stitches, using contrasting threads to highlight the appearance of the stitches, or using selected threads to form a part of a pattern, image, or design on the shoe or otherwise highlight the pattern, image, or design. However, if the shoe is not monochromatic, the sewing thread needs to be replaced, which can be troublesome. A variety of thread types must be stocked, and if a line of stitches passes through two different colors or two different segments designed on the shoe, the thread must be replaced during manufacturing. Replacing the thread adds time, cost, and complexity to manufacturing, and can increase the number and duration of stops and starts in the process. Summary of the invention

[0005] Aspects of the present invention relate to on-seam printing that can be performed during continuous in-line manufacturing of articles of footwear.

[0006] In some aspects, the present invention relates to an upper. The upper may have a first area defined by a first color or visual pattern. The upper may have at least one second area defined by a second color or visual pattern. The second color or visual pattern may be visually distinguishable from the first color or visual pattern. The upper may have a row of stitches formed by a continuous fine line. The row of stitches may be at least partially disposed in the first area of ​​the upper and at least partially disposed in the second area of ​​the upper. The continuous fine line may match the first color or visual pattern in the first area and match the second color or visual pattern in the second area. The stitches may define a quilt pattern. The upper may be flat. The stitches may be decorative. The stitches may be at least partially structural. At least one of the first area and the second area may include a multi-color pattern.

[0007] In some aspects, the present invention relates to a method of manufacturing a shoe. The method may include sewing a flat pattern of a shoe using a continuous thread. The method may include printing at least a portion of the sewn flat pattern in at least two zones. A first zone may be defined by a first color or visual pattern, and at least one second zone may be defined by a second color or visual pattern. The second color or visual pattern may be visually distinguishable from the first color or visual pattern. The continuous thread may be at least partially sewn in the first zone and at least partially sewn in the second zone. After printing, the continuous thread may match the first color or visual pattern in the first zone and match the second color or visual pattern in the second zone. The printing may use a method selected from digital printing, flexographic printing, screen printing, rotary screen printing, pad printing, and combinations thereof. The printing may impart color or pattern only to the continuous thread. The printing may impart color or pattern to the continuous thread and to at least a portion of the flat pattern. The flat pattern may be assembled into a three-dimensional shoe. The printing or the sewing may be aligned to one or more distinguishing features of the flat pattern. The printing and the sewing may be aligned to one or more distinguishing features of the flat pattern using at least one vision system. The sewing may be performed using a quilting arm. The sewing may define quilting on at least a portion of the flat pattern. The sewing and the printing may be performed at the same manufacturing station. The sewing may be aligned to the flat pattern at the first manufacturing station using a first vision system. The printing may be aligned to the flat pattern at the second manufacturing station using a second vision system.

[0008] In some aspects, the present invention relates to a system for preparing an upper or a component of an upper. The system may include a conveyance system. The conveyance system may move a flat pattern along at least a portion of a manufacturing line. The system may include at least one vision system. The vision system may observe one or more distinguishing features of the flat pattern on the conveyance system. The system may include a sewing device. The sewing device may sew a continuous fine line to at least a portion of the flat pattern. The sewing may be aligned with one or more distinguishing features of the flat pattern. The system may include a printing device. The printing device may impart color and / or pattern to at least a portion of the continuous fine line after the continuous fine line has been sewn to the flat pattern. The sewing device may include a quilting arm. The printing device may include a digital printer, a flexographic printer, a screen printer, a rotary screen printer, or a pad printer. The printing device may impart color and / or pattern to the flat pattern and the continuous fine line.

[0009] This application provides the following:

[0010] 1) A shoe upper comprising: a first area defined by a first color or visual pattern; at least one second area defined by a second color or visual pattern visually distinguishable from the first color or visual pattern; and a row of stitches formed by a continuous fine line, wherein the row of stitches is at least partially arranged in the first area of ​​the shoe upper and at least partially arranged in the second area of ​​the shoe upper; wherein the continuous fine line matches the first color or visual pattern in the first area and matches the second color or visual pattern in the second area.

[0011] 2) The shoe upper according to 1), wherein the stitching defines a quilting pattern.

[0012] 3) The shoe upper according to 1) or 2), wherein the shoe upper is flat.

[0013] 4) The shoe upper according to any one of 1) to 3), wherein the stitching is decorative.

[0014] 5) The shoe upper according to any one of 1) to 4), wherein the stitching is at least partially structural.

[0015] 6) The shoe upper according to any one of 1) to 5), wherein at least one of the first area and the second area includes a multi-color pattern.

[0016] 7) A method for manufacturing shoes, the method comprising: using a continuous fine thread to sew a flat pattern of the shoe; printing at least a portion of the sewn flat pattern in at least two of the following areas: a first area defined by a first color or visual pattern, and at least one second area defined by a second color or visual pattern that is visually distinguishable from the first color or visual pattern; wherein the continuous fine thread is at least partially sewn in the first area and at least partially sewn in the second area, and wherein after printing, the continuous fine thread matches the first color or visual pattern in the first area and matches the second color or visual pattern in the second area.

[0017] 8) The method according to 7), wherein the printing uses a method selected from digital printing, flexographic printing, screen printing, rotary screen printing, pad printing, and combinations thereof.

[0018] 9) The method according to 7) or 8), wherein the printing imparts color or pattern only to the continuous thin lines.

[0019] 10) The method according to 7) or 8), wherein the printing imparts color or pattern to the continuous thin lines and to at least a portion of the flat pattern.

[0020] 11) The method according to any one of 7) to 10), further comprising assembling the flat pattern into a three-dimensional shoe.

[0021] 12) The method according to any one of 7) to 11), further comprising aligning the printing or the sewing to one or more distinctive features of the flat pattern.

[0022] 13) A method according to any one of 7) to 12), wherein at least one vision system is used to align the printing and the sewing to one or more distinctive features of the flat pattern.

[0023] 14) A method according to any one of 7) to 13), wherein the sewing is performed using a quilting arm.

[0024] 15) A method according to any one of 7) to 14), wherein the sewing defines quilting on at least a portion of the flat pattern.

[0025] 16) The method according to any one of 7) to 15), wherein the sewing and the printing are performed at the same manufacturing station.

[0026] 17) A method according to any one of 7) to 15), wherein the sewing is aligned to the flat pattern at a first manufacturing station using a first vision system, and the printing is aligned to the flat pattern at a second manufacturing station using a second vision system.

[0027] 18) A system for preparing an upper or a component of an upper, the system comprising: a conveying system that moves a flat pattern along at least a portion of a manufacturing line; at least one vision system that observes one or more distinguishing features of the flat pattern on the conveying system; a sewing device that aligns a continuous fine thread with the one or more distinguishing features of the flat pattern and sews it to at least a portion of the flat pattern; and a printing device that imparts color and / or pattern to at least a portion of the continuous fine thread after the continuous fine thread has been sewn to the flat pattern.

[0028] 19) A system according to 18), wherein the sewing device includes a quilting arm.

[0029] 20) A system according to 18) or 19), wherein the printing device comprises a digital printing press, a flexographic printing press, a screen printing press, a rotary screen printing press, or a pad printing press.

[0030] 21) A system according to any one of 18) to 20), wherein the printing device imparts color and / or pattern to the flat pattern and the continuous thin line.

[0031] This summary is provided to introduce a series of selected concepts in a simplified form that are further described in the detailed description below. This summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used in addition to the rest of the invention (including the drawings) to help determine the scope of the claimed subject matter. BRIEF DESCRIPTION OF THE DRAWINGS

[0032] Various illustrative aspects of the invention are described in detail below with reference to the accompanying drawings, which are incorporated herein by reference and in which:

[0033] Figure 1A is a perspective view of an exemplary shoe having a continuous thin line extending across two zones according to an aspect of the present invention;

[0034] Figure 1B According to an aspect of the invention, a portion of the continuous fine line has been visually modified Figure 1A a perspective view of the exemplary shoe shown;

[0035] Figure 2 Shows continuous in-line production on a substrate having a series of uppers according to an aspect of the present invention;

[0036] Figure 3 It is shown that according to the present invention, Figure 2 The substrate is shown passing along a series of manufacturing processing stations forming a continuous in-line manufacturing system for a shoe upper;

[0037] Figure 4 Showing a flat pattern upper formed from a substrate according to an aspect of the present invention;

[0038] Figure 5 A diagram showing a plurality of illustrative reference lines according to aspects of the present invention is shown. Figure 4 Flat pattern upper as shown;

[0039] Figure 6 It is shown that according to the present invention, the Figure 4 An exemplary overlay on a substrate material of the flat pattern upper shown;

[0040] Figure 7 Shown according to the present invention Figure 6 Another exemplary overlay coupled to the flat pattern upper is an eye stay overlay;

[0041] Figure 8 It is shown that according to the present invention, the Figure 7 midfoot panel over the eyelet panel shown;

[0042] Fig. 9 The shoe is shown as a shoe made of a decorative plate, a shoe eyelet decorative plate, a midfoot decorative plate, and a collar liner according to the present invention. Figure 8 Flat pattern upper as shown;

[0043] Fig.10 Shown according to the present invention Fig. 9 The flat pattern upper, wherein the ankle opening area, the midfoot opening area, and the nested tongue have been removed from the flat pattern upper;

[0044] Fig.11 An exemplary alignment tool according to an aspect of the present invention is shown;

[0045] Fig.12 It is shown that according to the present invention, the flat pattern upper has been Fig.10 After the heel area is joined, Fig.11 The alignment pin of the alignment tool is shown extending through a footbed-shaped opening of a flat pattern upper;

[0046] Fig.13 According to the present invention, Fig.12The upper portion shown is wrapped around an alignment tool so that the formed openings of the medial flap are mechanically engaged by the alignment pins;

[0047] Fig.14 According to an aspect of the present invention, a shoe last is inserted into a volume formed by coupling the inner waist flap with the footbed portion;

[0048] Fig.15 According to the present invention, Figures 4 to 10 The three-dimensional shoe with the flat pattern upper formed as shown;

[0049] Fig.16 A simplified cross-sectional view showing an ankle collar according to an aspect of the present invention;

[0050] Fig.17 A flow chart showing a method of making an article of footwear having a veneer from a flat pattern according to an aspect of the present invention is shown;

[0051] Fig.18 A flow chart showing a method of making an article of footwear having a veneer from a flat pattern according to an aspect of the present invention is shown;

[0052] Fig.19 A flow chart showing a method of manufacturing an article of footwear having a collar lining integrated with a flat pattern upper according to an aspect of the present invention is shown;

[0053] Fig. 20 Showing a shoe according to an aspect of the present invention; and

[0054] Fig.21 is a flow chart of an exemplary method according to aspects of the invention. DETAILED DESCRIPTION

[0055] The subject matter of various embodiments of the present invention will be specifically described herein to meet statutory requirements. However, this description itself is not intended to limit the scope of this patent. Instead, the inventors have contemplated that the claimed subject matter may also be implemented in other ways in conjunction with other current or future technologies to include steps different from those described in this document or combinations of steps similar to those described in this document.

[0056] In some aspects, the present invention relates to sewing shoes and shoe components, and the sewn shoes or shoe components. Figure 1A An exemplary shoe 10 is shown with a design 12 and a row of stitches 14. The row of stitches 14 is formed of a continuous thin line with stitches 16 outside the area of ​​the design 12 and stitches 18 within the area of ​​the design 12. The area outside the area of ​​the design 12 is referred to as area 11.

[0057] When initially sewn, the continuous thread has a uniform appearance across both the area 11 and the area of ​​the design 12. Figure 1B As shown in, the continuous fine line in a row of sutures 14 can be printed to match or complement the appearance (e.g., color, visual characteristics) of design 12. As shown in the figure, after printing, stitch 18A matches the color or visual characteristics of design 12, for example, with similar coloring, pattern or other visual characteristics. The stitch may not be printed, or it may be printed in a different manner from the manner printed at stitch 18A. In this way, after sewing, printing the fine line enables the use of continuous fine lines to match or complement the different designs or patterns on the shoe 10, without having to change the fine line (e.g., using two or more discontinuous fine lines) when sewing a row of sutures 14. In other words, printing on the fine line enables the use of continuous fine lines across at least two districts with different visual characteristics (e.g., different materials, colors, patterns) during the common sewing operation. Therefore, as provided herein, printing on the sutures can achieve a reduction in manufacturing time, complexity and / or cost. Printing on stitching can be accomplished in a variety of forms and processes, and in some aspects, as described herein, stitching and / or printing can be performed on a flat pattern upper of a shoe.

[0058] although Figure 1A Design 12 is shown as part of shoe 10 before stitching 18A is printed, but it is contemplated that in exemplary aspects, design 12 is formed by a co-printing operation that visually alters stitching 18A. Figure 1A and Figure 1B Shoe 10 is shown in a formed (non-planar) orientation, but as provided herein, it is contemplated that printing of stitching 18A (and, in some examples, design 12 or a portion of design 12) is performed while the components forming shoe 10 are in a planar configuration. However, it is also contemplated that in exemplary aspects, one or more printing operations may be performed while one or more portions of the shoe are in a non-planar configuration.

[0059] Footwear articles may include shoes, boots, sandals, etc. The term "shoe" will be used herein to refer to footwear articles in general. It should be understood that the term "shoe" is not limited to traditional style shoes, but may include boots, sports shoes, sandals, running shoes, cleats, and other footwear articles. Generally speaking, a shoe is composed of a ground contacting portion that can be referred to as a sole. The sole can be formed of various materials and / or various individual components. For example, as known in the art, the sole may include an outer sole, a midsole, and / or an inner sole. A shoe may also be composed of a foot fixing portion that effectively fixes the user's foot to the sole. The foot fixing portion may be referred to herein as a shoe upper (or simply "upper"). The shoe upper may be formed of one or more materials and / or one or more individual components. In the following, exemplary systems and techniques for forming the shoe upper will be provided in more detail.

[0060] Regardless of the materials or techniques used to form the upper and / or sole, additional shaping and forming may be used to obtain a desired three-dimensional shape (e.g., a dimensional shoe). Traditionally, a tool known as a cobbler's last serves as a shape around which the shoe may be formed to the desired size, shape, and configuration. As used herein, the term "last" will refer to a tool form around which the upper may be formed. In some aspects, the sole may be coupled (e.g., adhered, sewn) to the upper while the upper is lasted (i.e., the last is positioned within the interior volume of the upper). The last may define the contour, shape, style, and other characteristics of the resulting shoe.

[0061] Aspects herein contemplate a flat pattern that is then formed into a three-dimensional shoe. Figures 4 to 10As generally shown in , a "flat pattern" is a substantially planar collection of materials. Although different materials can be coupled to each other in a manner to form textures, bumps, embossings, protrusions, etc., the collection of materials is still substantially planar and therefore "flat" even if there are height deviations along the surface. When molded around a shoe last to form a receiving cavity in which a user's foot can be fixed, the flat pattern becomes a "three-dimensional" article. For example, a three-dimensional footwear article is an article that is molded in a manner that can be fixed to a wearer and around a portion of the wearer's body. In an exemplary embodiment, compared to a "three-dimensional" article, the "flat" pattern is not molded to accommodate a portion around the wearer's body. The concept of a flat pattern is conducive to manufacturing because many of the materials used to form the upper are rolled goods that are substantially planar (e.g., sheet-like) in their original state. Thus, the operation of constructing an upper from a collection of flat components can be automated to achieve a continuous in-line manufacturing process in a flat pattern that is later transformed into a three-dimensional article, such as by using a last or a bespoke tool.

[0062] At a high level, aspects contemplate forming the upper in a continuous in-line manufacturing process that enables each of the upper portions formed as part of the in-line manufacturing to have a variety of styles, sizes, and / or materials. It is contemplated that manufacturing may be automated such that one or more processes along the continuous line are performed by machines that are programmed to complete a series of specific tasks. Additionally or alternatively, it is contemplated that one or more processes of the manufacturing line are performed by humans. Thus, in exemplary aspects, any combination of machine and human involvement may be implemented to form the upper and possibly complete the shoe as a whole.

[0063] Continuous in-line manufacturing enables strategic implementation of engineered material properties such as tensile strength, elongation characteristics, and moisture transportation on a flat pattern in an efficient manner. The flat pattern concept allows for greater manufacturing consistency and enables the implementation of less complex machinery and logic to perform certain portions of the manufacturing process relative to the three-dimensional upper manufacturing process.

[0064] Manufacturing Systems

[0065] Figure 2 and Figure 3 Provided is an overview of continuous on-line manufacturing of a shoe upper according to aspects of the present invention. Specifically, Figure 2Continuous in-line production 100 is shown on a substrate 102 having a series of uppers 118, 120, 122, 124, and 126 according to an aspect of the present invention. In an exemplary aspect, the substrate 102 serves as a foundation on which a flat upper can be formed. In an exemplary aspect, the substrate 102 has a minimum stretch that allows for alignment of the position of the material applied thereto. For example, the system can track the position of the substrate 102 as it passes through an in-line manufacturing process. In an exemplary aspect, knowing the position of the substrate can provide guidance for what process should be performed on the substrate and where the process should be performed to produce a flat patterned upper portion. The substrate 102 can have any width and / or any length. In an exemplary aspect, the substrate 102 is a rolled article having a width sufficient to form at least one, two, three, four, five, or six flat patterns of the upper across the width. As Figure 2 , substrate 102 has a width sufficient to form at least two flat pattern uppers, as shown in groups 104 and 106. In an exemplary aspect, groups 104 and 106 represent matching uppers for forming a pair of shoes. Exemplary groups 108, 110, 112, 114, and 116 may represent left and right pairs of flat uppers, which will become paired shoes after completion. Each of the groups may represent uppers with different styles, shapes, configurations, or other deviations from the next group. For example, in an exemplary aspect, group 108 may represent women's running uppers, while group 110 may represent men's baseball cleats uppers. In addition, it is envisioned that in alternative exemplary aspects, each of the groups may represent uppers with common sizes, shapes, and styles.

[0066] The substrate 102 may be any material; however, in an exemplary aspect, the substrate 102 is a sheet material. For example, the substrate 102 may be a nonwoven fabric, which is a sheet-like structure or a web-like structure formed by entanglement of fibers / filaments through a mechanical process, a thermal process, and / or a chemical process. The nonwoven material may be a flat porous material that is neither woven nor knitted. The nonwoven material may be formed from recycled materials (e.g., residual materials generated from the on-line manufacturing process itself).

[0067] The nonwoven fabric may be a mesh material made by needle felting polyester fibers, such as industrial felt. It is contemplated that the substrate 102 in the form of a nonwoven fabric or other material (e.g., woven / knitted) may be formed from any synthetic or natural fiber. In an exemplary aspect, the fibers may be captured as part of a waste stream from the manufacturing process itself. For example, after forming an upper, the portion of the substrate 102 that does not form the upper may be included in the waste stream. In an exemplary aspect, the substrate 102 waste stream portion may be recycled to form the substrate 102 again for a subsequent manufacturing process. In an exemplary aspect, when recycling of the waste stream material is contemplated, the nonwoven substrate 102 may provide greater economic efficiency relative to a knitted structure or a woven structure, which has a specific engineered structure (e.g., interlacing, looping) that is different from the random entanglement of fibers that form the nonwoven material.

[0068] Alternatively, the substrate 102 may be formed of a woven or knitted material. For example, it is contemplated that the substrate 102 may be formed of an in-line knitted or woven material such that the substrate begins as a yarn material, fiber material, thread material, or other raw material and is then formed into a sheet-like form as part of an in-line manufacturing process. Alternatively, it is contemplated that the substrate 102 is formed into a sheet-like form by knitting or braiding before being introduced into an in-line continuous manufacturing process.

[0069] Back to Figure 2 , the substrate 102 shows a series of manufacturing processes for the connected upper groups along the direction indicated by the arrow 101. For example, the upper 118 in the group 108 is shown as having a contour in the shape of a flat pattern and a series of openings, as will be shown in FIG. Figures 4 to 10 The substrate 102 is then forwarded to another process at the group 110 having the upper 120. The upper 120 may have a trim applied thereto (e.g., Figure 6 The overlay 500 shown in the figure is used to provide the desired mechanical and / or aesthetic properties to the flat upper. The progression continues to a shoe having another overlay applied thereon (e.g., Figure 7 The in-line manufacturing on the continuous roll of substrate 102 can continue to the group 114 with the upper 124, where another overlay (e.g., Figure 8 Finally, in the exemplary in-line manufacturing sequence shown, another overlay (e.g., midfoot overlay 700) is applied to the flat pattern upper (upper 126) in group 116. Fig. 9 In this process, the stitching 128 is shown, and the Fig. 9 This is discussed in more detail.

[0070] Despite the combination Figure 2 Characteristic components and processes are shown, but it should be understood that any process (e.g., cutting, coupling, painting, printing, applying, molding, etc.) can be performed in any order at any time according to aspects of the present invention. In addition, although specific components are shown, it is contemplated that in exemplary aspects, any combination, shape, sequence, material, and / or configuration of components can be implemented.

[0071] Directional terms are used herein to provide a relative positioning of one or more features. For example, toeward or toewardly describes a direction toward the toe end of a component. Similarly, heelward or heelwardly describes a direction toward the heel end of a component. Medial and lateral are directional terms relative to a formed three-dimensional shoe worn by a user. For example, the medial side is the inner portion relative to the midline of the body toward the foot of the user when worn, and the lateral side is the outer portion relative to the midline of the body toward the foot of the user when worn.

[0072] Figure 3 It is shown that according to the present invention, the substrate 102 advances along a series of manufacturing processing stations forming a continuous online manufacturing system 200 (hereinafter referred to as system 200) for the upper. Specifically, the system 200 is composed of a conveyor system 202 and a series of processing stations 204, 206, 208, 210 and 212. The conveyor system 202 and each processing station are essentially exemplary and are only intended to illustrate the continuous online manufacturing system. It should be understood that different systems and stations can be implemented in any combination, spacing, sequence, and configuration to achieve the aspects provided herein. Exemplary processing stations may include but are not limited to printing stations, liquid application stations, heat stations, steam stations, cutting stations, punching stations, placement stations, sewing stations, bonding stations, welding stations, etc. In addition, it is envisioned that one or more stations can be combined into a common station to perform two or more operations in a common position and / or simultaneously. In addition, it is envisioned that one or more stations can be responsible for humans, so that the operation is performed by humans in the absence of machines or in connection with machines.

[0073] Figures 4 to 10A sequence of exemplary processes that can be performed by one or more stations of the system 200 in an exemplary aspect is shown. However, the specific flat pattern upper formed by the system will be different from the illustrative examples provided herein. By design, the flexibility of the system 200 enables the manufacture of different flat uppers in a variety of ways without making material changes to the system 200 configuration. Instead, it is envisioned that one or more stations can be enabled or disabled, depending on whether a specific flat pattern upper passes through it. For example, it is envisioned that a first upper can use a printing station to add printing elements on it, while the subsequent uppers formed on the same continuous substrate 102 do not use the printing station because the subsequent uppers have different styles. Similarly, it is envisioned that a first upper uses a station to perform a first task (e.g., a specific cutting pattern, a specific sewing pattern, a specific adhesion pattern, a specific printing pattern), while subsequent uppers with different styles / configurations also use the processing station, but for different tasks (e.g., different specific cutting patterns, different specific sewing patterns, different specific adhesion patterns, different specific printing patterns).

[0074] It is contemplated that one or more identifiers may be used to inform the system 200 what action should be performed on a given flat pattern upper. For example, it is contemplated that a visual recognition system may be used at one or more of the processing stations to identify a particular flat pattern upper based on a flat upper component, a tag (e.g., a barcode, a Quick Response (QR) code), or other visually detectable features. It is also contemplated that Radio Frequency Identification (RFID) technology may be implemented at one or more of the processing stations to identify the flat pattern upper. For example, it is contemplated that RFID technology may be utilized. Other technologies, such as embedded reactive fibers that respond to one or more stimuli (e.g., electromagnetic energy), are also contemplated. In addition, it is contemplated that the location of the flat pattern on the substrate may be registered so that when the substrate 102 advances to a known location / distance, the particular flat pattern upper formed on the substrate 102 is also known. In other words, in one aspect, the low elastic modulus associated with the continuous substrate can provide sufficient accuracy for knowing the location of a flat upper formed on the continuous substrate as it advances through system 200. It is also contemplated that two or more identification systems can be implemented in combination to assist in manufacturing uppers in a continuous in-line system.

[0075] like Figure 3 As shown in , it is contemplated that the system 200 may be advanced to the point where a flat pattern upper is removed from a continuous roll of substrate 102. Thus, it is contemplated that a portion of substrate 102 forms a portion of the removed upper. Figure 3A flat pattern upper outline 214 is shown removed from substrate 102. The remaining portion formed from the waste stream is shown by portion 216 of substrate 102. In an exemplary aspect, portion 216 may be recycled for use in another portion of the substrate to subsequently form an upper.

[0076] Figures 4 to 10 2 shows an exemplary formation sequence of a flat pattern upper 300 according to an aspect of the present invention. It should be noted that the flat pattern upper 300 can be a continuous substrate (e.g., Figure 2 and / or Figure 3 Thus, although in Figures 4 to 10 , an outer perimeter is shown for the substrate layer, but in reality, such a perimeter cannot be defined until the flat pattern upper 300 is removed from a larger set of substrate materials. Alternatively, it is contemplated that in an exemplary embodiment, the substrate is cut and shaped before (or during) one or more manufacturing processes are completed before the subsequent processes to be performed on the flat pattern upper 300. In this alternative contemplated solution, Figure 4 The illustrated perimeter may represent the edge of the substrate material on which the flat pattern upper 300 is formed. In addition, as previously provided, the shapes, sizes, and configurations of the components (e.g., the components forming the flat pattern upper 300) may be formed. Figure 4 The illustrated base plate) may vary, and the representations provided are illustrative in nature. For example, it is contemplated that in an exemplary aspect, the footbed portion 304 may be divided such that a portion thereof is located on the upper inner waist 311 of the upper portion 302 and another portion of the footbed portion may be located on the upper outer waist 313 of the upper portion 302. Furthermore, it is contemplated that in alternative aspects, the flat pattern upper is not formed with a coextensive footbed portion. Furthermore, although in Figure 4 A sleeve tongue extending from the upper heel end 348 is shown, but in various aspects, such a feature may be omitted without departing from the scope of the present invention. Therefore, it is contemplated that one or more features of the flat pattern upper have alternative configurations, shapes, patterns, and orientations, and are not limited to the exemplary description of the present invention.

[0077] Base plate as flat pattern upper

[0078] Specifically, go to Figure 4 , which shows a flat pattern upper 300 according to an aspect of the present invention. The flat pattern upper 300 is composed of an upper portion 302 and a co-extending footbed portion 304. The term "co-extending" as used herein means that one part is connected to another part in an integral manner. For example, the upper portion 302 and the footbed portion 304 are made of a common connecting material (e.g., Figure 2The materials forming each of the coextensive portions are integral with each other so that the portions meet together and are not subsequently joined together by, for example, welding, adhering, or sewing.

[0079] The upper portion is composed of an upper toe end 306 and an upper heel end 348, the upper toe end 306 forming a convex edge. The upper heel end 348 can be further defined by an upper inner waist heel end 308 and an upper outer waist heel end 310. The upper portion 302 is further composed of an upper inner waist side 311 and an opposite upper outer waist side 313. In the illustrated example, the upper inner waist side 311 can also be defined by an inner waist edge 326 towards the toes, an inner waist flap edge 329, and an inner waist edge 330 towards the heels. In addition, the upper portion 302 is composed of an inner waist flap 328 to be discussed in more detail below. The upper outer waist side 313 can also be defined by an outer waist edge 352 towards the toes and an outer waist edge 350 towards the heels. As will also be discussed below, in the illustrated aspect, the upper portion 302 and the footbed portion 304 are coextensive proximate at least a portion of the upper outer waist 313 .

[0080] The footbed portion 304 is comprised of a footbed toe end 312, a footbed heel end 314, a footbed outer waist 317, and a footbed inner waist 315. The footbed inner waist 315 may be further defined by a toe end apex 316, a nadir 318, and a heel end apex 320. The toe end apex 316, the nadir 318, and the heel end apex 320 define a concave edge 319 of the inner waist (the footbed inner waist 315).

[0081] Transforming the flat pattern upper 300 into a three-dimensional shoe with the proper shape and comfort can be accomplished by the meeting of the co-extending upper portion 302 and the footbed portion 304 at one or more of the heel end or the toe end. For example, an intersection point 322 is formed at the intersection of the toe-facing outer waist edge 352 and the outer waist side (footbed outer waist side 317) of the footbed portion 304. An acute angle is formed at the intersection point 322 between the upper portion 302 and the footbed portion 304. The acute angle enables the three-dimensional footwear with a curved composite surface to have an acceptable molding near the toe end (e.g., toe box) of the footwear article. In an exemplary aspect, an obtuse angle may be detrimental to transforming the flat pattern upper with the co-extending upper portion and footbed portion in the exemplary aspect into a three-dimensional footwear article. Similarly, at the heel-facing end, the flat pattern upper 300 forms an intersection point 324 at the intersection of the heel-facing outer waist edge 350 and the outer waist side (footbed outer waist side 317) near the heel end (footbed heel end 314) of the footbed portion 304. An acute angle is formed at the intersection point 324 between the upper portion 302 and the footbed portion 304. For the reasons discussed with respect to the toe-facing acute angle, in exemplary aspects, similar benefits can be achieved by an acute angle between the upper portion and the footbed portion at the heel.

[0082] If it will Figures 11 to 14 As described in the figure, according to aspects of the present invention, forming a three-dimensional shoe from a flat pattern upper 300 can utilize one or more formed openings to achieve proper alignment and registration between the upper portion and the footbed portion. It is contemplated that any number of openings with any size can be utilized in any location. Figure 4 304 and 302. An exemplary configuration of openings is shown; however, a fewer number of openings, openings arranged differently, and / or openings of different sizes may be implemented. For example, it is contemplated that a single opening located on the footbed portion 304 and a single opening located on the upper portion 302 may be used to form a flat pattern upper into a three-dimensional shoe. It is also contemplated that two openings associated with the footbed portion 304 and two openings associated with the upper portion 302 may be used to form a flat pattern upper into a three-dimensional shoe. Additionally, as shown, it is contemplated that in an exemplary aspect, three or more openings located on both the upper portion and the footbed portion may be used to form a flat pattern upper into a three-dimensional shoe.

[0083] The footbed portion 304 is shown as having a footbed first opening 334, a footbed second opening 332, and a footbed third opening 336. The upper portion 302 is shown as having an upper first opening 340, an upper second opening 338, and an upper third opening 342. Figures 11 to 14 As explained in FIG. 1 , it is contemplated that similarly named openings in the footbed portion and the upper portion are aligned to their respective correspondingly named openings so that the flat pattern upper 300 is properly aligned when formed into a three-dimensional shoe. Figure 5 and Figures 11 to 14 Such openings suitable for aligning portions of the flat pattern upper 300 are discussed in greater detail in FIG.

[0084] Another type of opening is also shown in the flat pattern upper 300. An origin 344 and a second origin 346 are shown within the upper portion 302. As will be discussed below, the origin opening provides an alignment indicator for one or more subsequent components (e.g., panels), features (e.g., adhesives, printing), cutting, and / or other processes performed on the flat pattern upper 300. For example, the origin can be a physical alignment for the panels so that a pin extends through the origin of the base and also extends through the alignment opening of the panel to ensure that the panel is properly positioned relative to the base. As will be discussed in Figure 5 , in an exemplary aspect, the starting point opening can be positioned anywhere on or near the flat pattern upper 300. However, in a particular configuration, the starting point opening is formed in the midfoot opening area (e.g., Fig.10 The starting point is positioned within the midfoot opening area 901 shown, for example, within the throat between two opposing eyebrow of the sports shoe. By positioning the starting point within the midfoot opening area, the starting point can be centrally located within the upper portion 302 and can also be removed when the midfoot opening is formed. In other words, in an exemplary aspect, positioning the starting point within a location to be removed as a waste stream after one or more operations enables the starting point to serve its intended purpose during in-line manufacturing without affecting the final three-dimensional shoe.

[0085] As discussed earlier, Figure 4 The flat pattern upper 300 shown is illustrative in nature and is not limiting with respect to the concepts provided herein. For example, alternative sizes, shapes, and orientations are contemplated within the scope of the features provided herein.

[0086] Guides

[0087] Go to Figure 5 , which shows a plurality of illustrative reference lines according to an aspect of the present invention Figure 4 The flat pattern upper 300 is shown. The reference lines illustrated are exemplary only and are not necessarily visible demarcation lines. Therefore, it is contemplated that in the online manufacturing process, the flat pattern upper 300 will not actually show any Figure 5 Instead, it can be determined according to the following discussion Figure 5 Reference lines shown.

[0088] An upper midline 402 is shown extending between the upper toe end 306 and the upper heel end 348. Specifically, it is contemplated that in exemplary aspects, the upper midline 402 extends through the apex of the upper toe end 306. It is also contemplated that the upper midline 402 extends through the upper heel end 348 at a location equidistant between an inner waist heel intersection point 420 and an outer waist heel intersection point 422. The inner waist heel intersection point 420 is formed at the intersection of the upper inner waist edge toward the heel (the inner waist edge toward the heel 330) and the upper inner waist heel end 308. The outer waist heel intersection point 422 is formed at the intersection of the outer waist edge toward the heel 350 and the upper outer waist heel end 310. Since the shape and configuration of the flat pattern upper can be variable between various styles, the inner waist heel intersection point 420 can be located at the outermost intersection between the inner waist side and the heel end of the upper portion. Similarly, since the shape and configuration of the flat pattern upper can be variable between various styles, the outer waist heel intersection point 422 can be located at the outermost intersection between the outer waist side and the heel end of the upper portion.

[0089] An inner waist reference line 404 is shown extending from an inner waist heel intersection point 420 to the intersection of the upper midline 402 and the toe end (upper toe end 306). An outer waist reference line 406 is shown extending from an outer waist heel intersection point 422 to the intersection of the upper midline 402 and the toe end (upper toe end 306).

[0090] A first reference line 408 is shown extending between the toe-end vertex 316 and the heel-end vertex 320 of the footbed portion 304. A second reference line 410 extending through the bottom point 318 and parallel to the first reference line 408 is shown.

[0091] A partial intersection line 412 is shown extending through intersection point 322 and through intersection point 324. In an exemplary aspect, partial intersection line 412 divides upper outer waist 313 from footbed outer waist 317, where the portions are coextensive in the exemplary aspect. For example, it is contemplated that in an alternative configuration of a flat upper pattern where a portion of the footbed portion is also located on upper inner waist 311, a second partial intersection line (not shown) may be formed at the intersection of the upper and inner waist footbed portions.

[0092] A third reference line 414 is shown extending perpendicular to the upper midline 402 and extending through the intersection point 322. A fourth reference line 418 is shown extending perpendicular to the upper midline 402 and passing through the bottom point 318 of the footbed portion 304. A fifth reference line 416 is shown extending perpendicular to the upper midline 402 and between the third reference line 414 and the fourth reference line 418. In an exemplary aspect, the fifth reference line 416 extends along the ball width of the flat pattern upper 300 when the flat pattern upper 300 is molded around a shoe last in an exemplary aspect.

[0093] Forming opening

[0094] As previously combined Figure 4 As described, the flat pattern upper 300 is formed of two or more openings that effectively align the upper portion 302 with the footbed portion 304 when the flat pattern upper 300 is formed into a three-dimensional shoe. The footbed portion 304 is formed of a footbed first opening 334, a footbed second opening 332, and a footbed third opening 336. The upper portion 302 is formed of an upper first opening 340, an upper second opening 338, and an upper third opening 342. As previously discussed, any number of formed openings are contemplated.

[0095] The footbed first opening 334 is located near the inner waist edge near the bottom point 318. In an exemplary aspect, the footbed first opening 334 is within 20 millimeters ("mm") of the fifth reference line 416 and within 20 millimeters of the inner waist edge of the footbed. In another exemplary aspect, the footbed first opening is within 20 millimeters of the bottom point 318. The location of the footbed first opening 334 provides acceptable alignment of the various portions of the flat pattern upper 300 because the proximity to the bottom point 318 applies tension to the flat pattern upper 300 as it is formed around the last. Additionally, it is contemplated that in an exemplary aspect, the footbed second opening 332 is located between the first reference line 408 and the second reference line 410.

[0096] In an exemplary aspect, the footbed second opening 332 is proximate to the inner waist edge of the footbed between the toe end vertex 316 and the bottom point 318. Specifically, it is contemplated that the footbed second opening 332 is less than 20 millimeters proximate to the concave edge of the footbed portion 304. In an exemplary aspect, the footbed second opening 332 is located between the third reference line 414 and the fifth reference line 416. In yet another exemplary aspect, the footbed second opening is within 20 millimeters of the third reference line 414 and / or the fifth reference line 416. The location of the footbed second opening 332 provides alignment close to the width of the sole of the three-dimensional shoe, where the last can apply tension at the vertex of the compound curve formed by the last.

[0097] In an exemplary aspect, the footbed third opening 336 is positioned between the footbed first opening 334 and the heel end of the footbed. Further, it is contemplated that the footbed third opening 336 is within 20 millimeters of the inner waist of the footbed. In additional aspects, it is contemplated that in an exemplary aspect, the footbed third opening 336 is positioned between the bottom point 318 and the heel end apex 320 near the inner waist of the footbed portion 304. It is contemplated that in an exemplary aspect, the footbed third opening 336 is positioned between the first reference line 408 and the second reference line 410.

[0098] The shaped openings on the upper portion 302 described above include the upper first opening 340, the upper second opening 338, and the upper third opening 342. However, as discussed above, it is contemplated that any number of shaped openings may be present on the flat pattern upper. Specifically, it is contemplated that there are two shaped openings on a first side (e.g., the inner waist side of the upper portion) and two corresponding shaped openings on an opposite second side (e.g., the inner waist side of the footbed portion).

[0099] The molded openings of the upper portion 302 are shown formed at Figure 4 In the shown inner waist flap piece 328. The inner waist flap piece 328 can extend along the inner waist side of the upper portion 302 so that it is expected to overlap with a portion of the shoe bed portion 304 between the toe end vertex 316 and the heel end vertex 320. By overlapping in the convex area of ​​the waist edge in the shoe bed portion, when formed into a three-dimensional shoe, the inner waist flap piece 328 is positioned under the arch area of ​​the wearer's foot. In an exemplary aspect, the overlapping of the substrate in this area can be detected by the user to the lowest degree, and when formed into a three-dimensional shoe, greater comfort is provided than when the flap piece extends to the sole or heel of the user.

[0100] The first opening 340 of the upper is located on the upper portion 302 near the inner waist edge. In an exemplary embodiment, the first opening 340 of the upper is located near the inner waist flap. Figure 4 The inner waist flap edge 329 is shown. For example, the upper first opening 340 is within 20 mm of the inner waist edge. In an exemplary aspect, the upper first opening 340 is close to the fifth reference line 416. It is envisioned that in an exemplary aspect, the upper first opening is within 20 mm of the fifth reference line 416.

[0101] In an exemplary embodiment, the second upper opening 338 is located on the upper portion 302 near the inner waist edge and between the first upper opening 340 and the upper toe end 306. Figure 4 The inner waist flap edge 329 is shown. In an exemplary aspect, the second opening 338 of the upper can be positioned between the third reference line 414 and the fifth reference line 416. In addition, it is envisioned that the second opening 338 of the upper is located at the outer edge (e.g. Figure 4 Within 20 mm of the inner waist flap edge 329 shown.

[0102] The third upper opening 342 is positioned on the upper near the inner waist edge and between the first upper opening 340 and the inner waist heel end 308 of the upper. In an exemplary aspect, the third upper opening 342 is positioned on the inner waist flap toward the heel relative to the first upper opening 340. It is also contemplated that the third upper opening 342 is positioned within 20 mm of the inner waist edge of the upper portion 302.

[0103] Positioning the various mold openings within at least 20 millimeters of the edge allows sufficient substrate material to extend between the mold openings and the edge to support the tension applied to the substrate material during the molding (e.g., lasting) process while minimizing the amount of substrate material that overlaps. It is contemplated that in exemplary aspects, greater than 20 millimeters are utilized. Furthermore, it is contemplated that in exemplary aspects, the substrate material extending between the mold openings and the edge can be removed after the upper portion 302 and the footbed portion 304 are coupled (e.g., adhered, sewn, welded).

[0104] Will be in Figures 11 to 14 304 to form a three-dimensional shoe around a shoe last or other shoe mold. Therefore, it is contemplated that the position of the upper first opening 340 and the position of the footbed first opening 334 are positioned so that when the inner waist of the upper portion 302 is approached and aligned with the inner waist of the footbed portion 304 through the first opening, the flat pattern upper 300 will be properly formed according to the shoe last. Similarly, the upper second opening 338 and the footbed second opening 332 are positioned when utilized so that when the inner waist of the upper portion 302 is approached and aligned with the inner waist of the footbed portion 304 through the second opening, the flat pattern upper 300 will be properly formed according to the shoe last. The position of the upper third opening 342 and the position of the footbed third opening 336 are similarly positioned to enable the flat pattern upper 300 to be properly formed into a three-dimensional shoe.

[0105] Although the shaped opening is shown as a circular hole extending through the substrate material, it is contemplated that it may be of any configuration. In an exemplary aspect, the shaped opening is not even a hole extending through the substrate, but is used to indicate an alignment pin (e.g., Fig.11 The first alignment pin 1002 shown will extend through the base plate, thereby at least temporarily forming an opening. Thus, the formed opening acts as an alignment tool to ensure proper positioning of the flat pattern upper parts when they are formed into a three-dimensional shoe.

[0106] starting point

[0107] As previously Figure 4 As described in , starting point 344 provides a location from which a process and / or component can be oriented to ensure proper positioning and / or alignment. Figure 6, the trim 500 is positioned on the substrate material. The position of the trim 500 is determined based on the physical alignment of the starting point 344 with the alignment opening 345 of the trim 500. A combination of two or more starting openings can be used in combination to achieve positional alignment and rotational alignment between two or more components / layers. In addition, it is contemplated that the starting point (such as the starting point 344 opening) will provide a positional guide for one or more processes to be performed. For example, through mechanical interaction with the starting point and / or through optical detection of the starting point, the robotic component can perform the processes contemplated herein (e.g., cutting, sewing, gluing, welding, positioning) on ​​one or more portions of the flat pattern upper 300.

[0108] The starting point 344 is positioned on the base plate between the upper toe end 306 and the upper heel end 348. In an exemplary aspect, the starting point 344 is positioned within 10 millimeters of the upper midline 402. In an exemplary aspect, the 10 millimeter tolerance enables the starting point 344 to be maintained in the midfoot opening area (e.g., Fig.10 Thus, in this example, the starting point 344 can provide functional assistance to the molding of the flat pattern upper 300 without detracting from the value of the finished three-dimensional shoe.

[0109] In an exemplary aspect, starting point 344 is positioned toward the heel relative to third reference line 414. Additionally, in an exemplary aspect, starting point 344 is positioned toward the toe relative to fourth reference line 418. It is contemplated that the starting point is positioned between third reference line 414 and fourth reference line 418. It is also contemplated that starting point 344 is positioned within 10 millimeters of the intersection between upper midline 402 and fifth reference line 416. Additionally, it is contemplated that starting point 344 is positioned between third reference line 414 and fourth reference line 418 in the toe-heel direction and between inner waist reference line 404 and outer waist reference line 406 in the inner waist-outer waist direction.

[0110] In an exemplary aspect, the second starting point 346 is positioned between the starting point 344 and the upper heel end 348. Further, it is contemplated that in an exemplary aspect, the second starting point is within 10 millimeters of the upper midline 402. Further, it is contemplated that in an exemplary aspect, the second starting point is positioned between the starting point 344 and the upper heel end 348 in the toe-heel direction and between the inner waist reference line 404 and the outer waist reference line 406 in the inner waist-outer waist direction. Additionally or alternatively, it is contemplated that the second starting point 346 is positioned in the midfoot opening area (e.g., Fig.10 The midfoot opening area 901 is shown.

[0111] As with the formed opening, it is contemplated that although shown as a circular hole extending through the substrate, the starting point may instead be any shape or configuration. For example, the starting point may be a visual mark through which an alignment pin extends to align one or more trim pieces. Extending the alignment pin through the substrate may at least temporarily form the opening. Alternatively, it is contemplated that visual alignment is performed based on the location of the starting point formed as a visual mark. Furthermore, it is contemplated that any number of starting points may be utilized in any configuration and in any position to achieve the aspects contemplated herein.

[0112] Trim sheets and pre-cut covered materials

[0113] Go to Figure 6 According to the present invention, the exemplary decorative piece 500 is positioned on the substrate material forming the flat pattern upper 300. The decorative piece 500 or any decorative piece can be formed of any material and can have any shape, orientation, size, and / or position. In the exemplary aspect, the decorative piece 500 or any decorative piece is formed by a knitted material. In an alternative exemplary aspect, the decorative piece 500 or any decorative piece is formed by a woven material. In another alternative exemplary aspect, the decorative piece 500 or any decorative piece is formed by a thin sheet material or a film material. In the exemplary aspect, the decorative piece can be a cushioning element, a tensile element, a plastic element, a rubber element, or any material or functional part. It is envisioned that the decorative piece 500 or any decorative piece can be formed by a synthetic material or a natural material. For example, the decorative piece can be formed by a polymer material, a cotton material, a wood material, a leather material, and any other material suitable for constructing a shoe.

[0114] As discussed previously, for purposes of illustration, the various figures represent a flat pattern upper 300 having a solid perimeter. However, if the flat pattern upper is formed from a substrate in a continuous manner, some of the perimeter elements of the substrate material may not be formed (e.g., cut out) until one or more processes (e.g., panel coupling, printing, midfoot opening cutting, sewing) have been performed on the flat pattern upper 300 substrate material. Delaying the step of separating the substrate portion of the flat pattern upper 300 from a larger substrate source allows the flat pattern upper to be processed as it passes through a continuous in-line manufacturing system (e.g., discussed previously). Figure 2 and Figure 3 ) while being held in a known relative position to a larger substrate material.

[0115] However, since some materials may be layered on other materials (such as substrates), processes such as cutting are performed before masking the material to be processed. Figure 6Portions of the base material of the flat pattern upper 300 where the base is not covered by the overlay 500 are shown with solid line perimeter markings. However, those portions of the base that are covered by the overlay and overlap of the overlay 500 are shown with dashed lines. For example, the heel-facing inner waist edge 330, the toe-facing inner waist edge 326, the toe-facing outer waist edge 352, the heel-facing outer waist edge 350, and the portions of the footbed outer waist edge extending from the intersections with the upper portion (e.g., intersections 322, 324) are shown with dashed lines.

[0116] It is contemplated that prior to placing the overlay 500 on the substrate material, a cutting process is performed to cut the substrate at the imaginary lines of the heel-facing inner waist edge 330, the toe-facing inner waist edge 326, the toe-facing outer waist edge 352, the heel-facing outer waist edge 350, and certain portions of the footbed outer waist edge. Since the flat pattern upper 300 extends through the continuous in-line manufacturing system in a substantially planar manner, cutting the covered portion of the material after the overlay is aligned may include displacing or moving the overlay, which may disrupt the alignment. Therefore, prior to placing and possibly securing the overlay, the covered portion of the underlying material (e.g., substrate) is cut to limit movement of the overlay while the overlay is aligned on the underlying material.

[0117] Briefly go to Fig.18 , which illustrates a flow chart 1700 representing a method of manufacturing a footwear article with a veneer from a flat pattern according to an aspect of the present invention. At a first block 1702, a first cut is formed in a first material having a top surface and an opposite bottom surface. The first cut extends through the top surface and the bottom surface. The first material can be any material, such as a substrate or another layer of a flat pattern upper (e.g., an additional veneer). For example, the cut can be formed through a substrate. The substrate has both a top surface and an opposite bottom surface. The first cut can be formed by any means, such as a knife, a die, a punch, a laser, a water jet, an air jet, a media jet, a hot edge, and the like known in the art. The cut can be linear, such as defining at least a portion of a perimeter (e.g., a perimeter of a footbed portion or a perimeter of an upper portion). The cut can form an opening, such as a starting point or a formed opening. In exemplary aspects, the cutouts may be positioned at an interior position of the flat pattern upper, or the cutouts may appear at a periphery of the flat pattern upper.

[0118] At block 1704, after the first cut is cut through the first material, a trim is coupled to the top surface of the first material. The trim extends above the top surface of the first material and covers the first cut on the top surface of the first material. Therefore, if the first cut is intended to be formed after the trim is positioned on the first material, at least a portion of the trim will need to be repositioned or otherwise moved to approach the first material in order to form the first cut without cutting the trim. Therefore, the portion of the first material to be cut is cut before the trim is placed on the first material, without cutting the corresponding overlapping portion of the trim. The trim can be coupled to the first material using sewing, adhering, welding, mechanical fastening, and similar methods for coupling the trim to the first material.

[0119] Can be Figure 6 The first cut is formed by forming an acute angle at the intersection point 322 and / or the intersection point 324 shown. Figure 4 , the acute angles may represent a flat pattern configuration that enables the footbed portion and the upper portion to be properly formed around a tool (e.g., a last) while avoiding unintended deformation, wrinkling, and / or puckering of the base plate. However, it is contemplated that in exemplary aspects, the overlay (e.g., Figure 6 The overlay 500 is shown to cover the sharp angles at the intersections 322 and / or 324 to form the aesthetically desirable outer surface for the finished shoe.

[0120] In an exemplary aspect, coupling the trim to the first material does not include connecting / coupling the trim and the first material at the first cut. Rather, it is contemplated that the first material can move independently of the trim at the first cut. For example, Fig.13 5 , a portion of the base plate that is pre-cut prior to applying the trim 500 extends around the last at the pre-cut portion to enable the base plate to be molded around the last. Therefore, to limit the impact on the fixation and alignment of the base plate around the last, the trim is not fixed at one or more of the pre-cut locations.

[0121] In additional aspects, it is contemplated that the method shown in flowchart 1700 optionally includes cutting a second cut extending through the first material and the trim. The second cut can be formed after block 1702. The second cut can be performed before or after block 1704. The second cut is performed at a location that will be covered by the second trim, which is at Figure 6 The decorative piece is shown on the top surface 502 (hereinafter referred to as the top surface 502) and extends on the first material of the block 1702. It is also envisioned that in this optional aspect, a second decorative piece is coupled to the decorative piece. The coupling can be any way, such as sewing, welding, adhesion, etc.

[0122] At block 1706, the first material having the first cutout is formed into a three-dimensional shoe. Fig.13 and Fig.14 In the present invention, it is contemplated that a flat patterned upper having a first cutout formed therein may be formed into a three-dimensional shoe. Forming of the three-dimensional shoe may include wrapping a substrate material having the first cutout extending therethrough around a last or other forming tool. The first cutout enables substrate to be removed from a larger substrate source (e.g., a continuous row of substrates) without cutting one or more trim pieces that extend beyond the perimeter of the substrate. Thus, while the substrate may be cut to be formed around the last, the trim pieces do not need to be cut at the same location to achieve the desired aesthetic finish, which is not constrained by the desired shaping of the underlying substrate.

[0123] Back to Figure 6 , the trim 500 is positioned on the substrate forming the flat pattern upper 300. Proper positioning of the trim relative to the flat pattern upper 300 is achieved using the starting point 344, and in this example, the second starting point 346, which are aligned with the first alignment opening 345 and the second alignment opening 347, respectively. The first alignment opening 345 extends through the trim 500 and is positioned on the trim 500 to enable proper positioning relative to the underlying material (e.g., the substrate). Similarly, the second alignment opening 347 extends through the trim 500 and is positioned on the trim 500 to enable proper positioning relative to the underlying material (e.g., the substrate).

[0124] like Figure 6 As shown in FIG. , the starting point 344 is aligned with the first alignment opening 345 . Figure 6 Also shown in the figure is a second starting point 346 aligned with a second alignment opening 347. As previously provided, the use of starting openings and alignment openings allows for mechanical alignment of two or more components during an in-line manufacturing process. However, it is contemplated that in alternative aspects, the starting openings and alignment openings may be omitted, such as when a continuous substrate (e.g., a rolled article) forms the basis of a flat patterned upper. In this example, it is contemplated that a known position of the continuous substrate provides sufficient position information to align one or more panels on the continuous substrate.

[0125] Briefly go to Fig.17 , which illustrates a flow chart 1600 showing a method of manufacturing a footwear article with a veneer from a flat pattern according to an aspect of the present invention. At block 1602, a starting point is formed, the starting point extending through an upper portion of a flat pattern upper. The starting point can be located in a midfoot opening area of ​​a shoe. As previously provided, the starting point can be formed by any suitable means, such as cutting, stamping, burning, etc.

[0126] At block 1604, the trim having the alignment opening is coupled to the upper portion (e.g., substrate material). Aligning the trim with the upper portion aligns the alignment opening with the starting point, thereby extending the common member through each of the starting point and the alignment opening. As previously provided, the trim can be coupled by any suitable means, such as sewing, adhering, welding, etc.

[0127] At block 1606, a midfoot opening region is removed from the upper portion having the origin opening. Fig.10 The illustrated midfoot opening area 901 includes an origination opening, and once the overlay is coupled to an underlying material (eg, a substrate), the origination may no longer be required and thus may be removed along with the midfoot opening area material.

[0128] At block 1608, the upper portion with the overlay coupled thereto and the midfoot opening area removed is formed into a three-dimensional shoe.

[0129] Go to Figure 7 , which shows another exemplary trim, namely, eyelet trim 600, coupled to flat pattern upper 300 according to aspects of the present invention. In this example, eyelet trim 600 is coupled to top surface 502 of trim 500. However, it is contemplated that the trim may be coupled to any other material forming flat pattern upper 300, such as the substrate itself. The eyelet trim includes alignment openings aligned with starting point 344 and second starting point 346 to achieve proper position, orientation, and rotation. In an exemplary aspect, eyelet trim 600 is formed of a durable material, such as leather or a polymer-based material (e.g., thermoplastic polyurethane). Eyelet trim 600 may serve as a reinforcement material through which one or more eyelets for a lacing structure are formed. Eyelet trim 600 demonstrates an engineered placement of functional materials on a shoe manufactured on the warp. Additionally, the location of the eyelet overlay 600 highlights the benefit of having the above provided starting point 344 in a location on the flat pattern upper 300 such that the starting point 344 can serve as a location guide for components proximate the midfoot opening area while still being removable when necessary.

[0130] Go to Figure 8 , which shows that according to the present invention, the Figure 7600. As can be appreciated, the flat pattern upper 300 can be formed of multiple layers that are positioned, secured, and aligned to form the desired resulting flat pattern upper 300. In this example, it is contemplated that the eyelet and midfoot overlays 600 and 700 have not yet been permanently secured to an underlying material (e.g., a substrate). Rather, one or more alignment pins can maintain proper alignment until a coupling process has been performed, which can couple multiple overlays simultaneously. Alternatively, it is contemplated that one overlay can be coupled to an underlying material before another overlay is applied. Thus, in this example, in an exemplary aspect, the eyelet overlay 600 can be coupled to the overlay 500 before the midfoot overlay 700 is applied.

[0131] In an exemplary aspect, the midfoot trim 700 can serve as an eyebrow finish material. As will be discussed below, the midfoot trim 700 can form a peripheral edge for the midfoot opening obtained after removal. In addition, as will be discussed in Fig. 9 , the midfoot overlay can serve as a finishing material for the overlay tongue 810 at the top edge 812 of the overlay tongue 810. Thus, the common overlay can serve multiple roles in the construction of the flat pattern upper 300.

[0132] Now go to Fig. 9 , which shows a flat pattern upper 300 composed of a trim 500, an eyelet trim (not shown), a midfoot trim 700, and a collar 800 according to an aspect of the present invention. The collar 800 is an exemplary trim. In an exemplary aspect, the collar is formed of a knitted material or a woven material to provide a comfortable surface that can contact the user's ankle. As will be described in detail in FIG. Fig.15 and Fig.16 As described in the embodiment of the present invention, the collar 800 can extend through the midfoot opening (and ankle opening) to the interior cavity of the three-dimensional shoe to form a lining of the cavity. Therefore, as will be discussed, in an exemplary aspect, the collar 800 can be inverted to transform from a flat pattern state to a three-dimensional shoe state.

[0133] In an exemplary aspect, collar 800 may also serve as a tongue lining for sleeve tongue 810. However, as provided herein, the configuration, shape, and size of flat pattern upper 300 are exemplary, and it is contemplated that aspects may omit one or more features, such as sleeve tongue 810.

[0134] In this example, collar 800 is positioned so that inner surface 802 faces away from the underlying material and outer surface 804 (not shown) is positioned so that Fig. 9 In Fig.16When formed into a three-dimensional shoe, the inner surface 802 faces the bottom surface of the flat pattern upper (e.g., the bottom surface of the base plate). When formed into a three-dimensional shoe, the outer surface 804 forms the foot contacting surface of the three-dimensional shoe, as described below. Fig.16 As shown in .

[0135] The collar 800 extends from the inner heel end 308 of the upper and the outer heel end 310 of the upper toward the toes. Fig. 9 As shown in , the collar 800 may extend across a portion of the midfoot opening area. Fig. 9 , the collar 800 may extend across a portion of the midfoot trim 700, but not all the way to the toe-facing end of the midfoot trim 700. The collar 800 may extend in a coextensive manner in the inner waist-outer waist direction across the inner waist and outer waist sides of the upper portion of the flat pattern upper. This extension width in the inner waist-outer waist direction provides enough collar material to extend downward along the inner sidewall of the inner cavity of the three-dimensional shoe at the ankle opening. This enables the collar 800 to function as a collar for a three-dimensional shoe.

[0136] The collar lining is coupled to the underlying material of the flat pattern upper 300, for example, by sewing, welding, and / or adhering. A coupling location 806 (e.g., a seam) is shown in dashed lines. The coupling location 806 couples the collar lining 800 to the flat pattern upper 300 near the ankle opening area and the midfoot opening area. In an exemplary aspect, as shown in FIG. Fig.10 As shown in , the coupling location 806 can form a seam that defines a perimeter of the ankle opening and a perimeter of a portion of the midfoot opening.

[0137] like Fig. 9 As shown in FIG, an optional overlay tongue 810 having a bottom edge 814 and a top edge 812 may also be coupled to the collar 800 along a tongue coupling 805. The tongue coupling secures a portion of the collar 800 that is intended to be removed from the ankle opening area to the overlay tongue 810 near the top edge 812. In this way, the collar may serve as a backing for the overlay tongue when integrated into a three-dimensional shoe. For example, it is contemplated that the overlay tongue 810, with a portion of the collar 800 and the midfoot overlay 700 coupled together at the top edge, may be removed from a flat pattern upper adjacent to the tongue coupling 805. In an exemplary aspect, the bottom edge 814 may be secured together with a vamp area (e.g., a toe-facing area of ​​the midfoot opening), and the top edge 812 may extend toward the ankle opening of the three-dimensional shoe.

[0138] Fig.10A flat pattern upper according to an aspect of the present invention is shown from which an ankle opening area 902, a midfoot opening area 901, and a sleeve tongue 810 have been removed. A coupling location 806 is shown as a dotted line to indicate where the collar 800 is secured to the underlying material proximate to the newly formed ankle opening area 902 extending into the midfoot opening area 901. The starting point 344' and the second starting point 346' are shown for illustration purposes since they have been removed as part of the material removed from the midfoot opening area 901 and the ankle opening area 902. As previously provided, the location of the starting point 344 and the location of the second starting point 346 can be selected so that after the materials are coupled, the starting point opening can be removed to not affect the function and / or aesthetics of the three-dimensional shoe. The ankle opening area 902 and the midfoot opening area 901 are partially defined by an outer waist opening edge 904 and an inner waist opening edge 906. It is contemplated that the outer waist opening edge 904 and the inner waist opening edge 906 are formed by a cutting operation that enables the removal of material at the ankle opening area 902. In addition, as will be described in Fig.16 As shown in FIG. 8 , in an exemplary embodiment, when the collar 800 is turned over to form a collar of a three-dimensional shoe, the outer waist opening edge 904 and the inner waist opening edge 906 may be covered.

[0139] Briefly go to Fig.19 , which illustrates a flow chart 1800 showing a method of manufacturing a footwear article having a collar lining integrated with a flat pattern upper according to an aspect of the present invention. At block 1802, a flat pattern upper portion having a top surface and an opposite bottom surface is formed. In an exemplary aspect, this forming may include providing one or more processes, such as cutting and coupling. For example, in Figures 4 to 8 An example of forming the upper portion is shown in FIG.

[0140] At block 1804, a collar is overlaid on the upper portion formed in block 1802. The collar has an inner surface and an outer surface. The collar is positioned on the upper portion so that when in a planar configuration, the collar outer surface faces the upper portion top surface.

[0141] At block 1806, the collar is secured to the upper portion to form a collar seam. As provided herein, the securing may be achieved by welding, adhering, tacking, sewing, etc. In an exemplary aspect, a computer-controlled machine (e.g., a long-arm quilting machine) may sew the collar together with other components forming the upper portion at the collar seam.

[0142] At block 1808, the collar lining and a portion of the upper portion near the collar seam are removed from the flat pattern upper. For example, material in the ankle opening area and the midfoot opening area may be removed, such as by being cut away from the rest of the upper portion. Removing the material may form the ankle opening and midfoot opening of the three-dimensional shoe to be formed. Fig. 9 As discussed, it is also contemplated that the removed material may include a sleeve tongue, which may then be processed for inclusion in a three-dimensional shoe.

[0143] At block 1810, the collar is flipped relative to the upper portion. This process may include joining the inner heel end 308 of the upper with the outer heel end 310 of the upper. Fig.12 ). In addition, the edges of the collar lining corresponding to the upper inner waist heel end 308 and the upper outer waist heel end 310 may also be joined. The joining may be achieved by several seaming techniques such as butt zigzag stitch. However, other techniques such as welding, adhesive bonding, etc. are contemplated. Fig.16 As shown in , the collar lining portion can now be turned over so that the outer surface of the collar lining is transformed into a top surface facing away from the underlying material at a position away from the coupling location (e.g., the shoe collar seam). This turning over causes the collar lining to form a lining in the three-dimensional shoe being formed. In other words, the turning over of the collar lining causes the collar lining to extend from what will become the exterior of the three-dimensional shoe to the interior cavity of the three-dimensional shoe.

[0144] At block 1812, the upper portion with the turned collar is formed into a three-dimensional shoe, such as Fig.15 The shoes shown in.

[0145] Three-dimensional shoe molding

[0146] Go to Fig.11 , which shows an exemplary alignment tool 1000 according to aspects of the present invention. Although the alignment tool 1000 is shown as having a particular size and shape, it is contemplated that the alignment tool may be any size and shape sufficient to align two or more molded openings. The alignment tool 1000 is shown as having a first alignment pin 1002, a second alignment pin 1004, and a third alignment pin 1006. The number, location, and size of the alignment pins may vary, and Fig.11 The illustrations in are not intended to be limiting.

[0147] Go to Fig.12 , which shows that according to an aspect of the present invention, alignment pins 1004, 1002, and 1006 extend through the first opening 334 of the footbed, the second opening 332 of the footbed, and the third opening 336 of the footbed, respectively. Figures 4 to 10The formed opening of the footbed portion 304 discussed in the foregoing is aligned on the alignment tool 1000 by mechanically engaging the alignment pin with the formed opening.

[0148] like Fig.12 308 and the outer waist heel end 310 of the upper have been joined as a seam 309. As discussed above, the seam 309 can be sewn, sealed, adhered, welded, etc. Although the seam 309 combines the first portion (e.g., the inner waist side) of the upper portion 302 with the second portion (e.g., the outer waist side) of the upper portion 302 in a vertical seam 309, it is contemplated that the first portion and the second portion of the upper portion 302 can be joined at any position. For example, the joining can occur at the toe end, the outer waist side, the inner waist side, and thus extend across multiple areas, etc. In addition, it is contemplated that the joining seam can extend in a non-vertical manner. For example, in an exemplary aspect, the joining seam can extend in an oblique manner from the midfoot opening area 901 and / or the ankle opening area 902 toward the outer edge (e.g., the inner waist perimeter or the outer waist perimeter) in a toe-toward direction or in a heel-toward direction.

[0149] Although the collar 800 is shown as being secured proximate to the ankle opening 902, it is contemplated that in various aspects, the collar is also secured to one or more layers (e.g., base, overlay, itself), which may or may not be secured proximate to the seam 309. In addition, as shown, Fig.12 The collar liner 800 in the embodiment has not yet been turned over to extend into the foot receiving cavity to be formed. However, it is contemplated that in an exemplary embodiment, the collar liner 800 may be formed before the seam 309 is formed, before alignment with the alignment tool 1000, and / or in the following Fig.13 The illustrated situation was previously flipped.

[0150] Fig.13 Shown according to the present invention, the upper part is wound on the alignment tool 1000 so that the molding opening of the inner waist flap piece is mechanically engaged by the alignment pin. For example, the second alignment pin 1004 extends through the first opening 334 of the shoe bed and the first opening 340 of the upper. The first alignment pin 1002 extends through the second opening 332 of the shoe bed and the second opening 338 of the upper. The 3rd alignment pin 1006 extends through the third opening 336 of the shoe bed and the third opening 342 of the upper. Based on the alignment provided by the alignment tool, the inner waist flap piece (or other parts of the upper part) is coupled with the shoe bed part. For example, welding or adhesive can be used to couple the parts together so that once the alignment tool 1000 is removed, the molding opening just remains in an acceptable relative position.

[0151] About collar lining 800 and Fig.12Similar to the discussion of , collar 800 is not shown as being flipped into the positively formed interior cavity of the three-dimensional shoe; however, collar 800 can be flipped into the interior cavity at the stage shown, and the interior cavity will serve as the foot receiving cavity of the three-dimensional shoe. In addition, Fig.13 1 and 2, and the heel end edges are shown in an unjoined manner to be joined; however, it is also contemplated that the heel end edges can be joined as shown in FIG. Fig.13 As shown in FIG. 1 , the upper portion is wrapped around the alignment tool 1000 so that the heel end edges are engaged before or after the formed openings of the inner waist flap are mechanically engaged by the alignment pins.

[0152] Fig.14 The shoe last 1300 is shown inserted into the volume formed by coupling the inner waist flap 328 with the footbed portion 304 according to an aspect of the present invention. Fig.13 In the embodiment, the inner waist flap 328 is aligned to couple with the footbed portion 304 by means of an alignment tool 1000, and the shoe last 1300 is a tool intended to be used to shape a three-dimensional footwear. It is envisioned that the shoe last 1300 effectively positions, adjusts (sets), and aligns the inverted collar 800 in the cavity occupied by the shoe last 1300, as shown. Therefore, the collar 800 is inverted so that it extends from the ankle opening and from a portion of the midfoot opening into the internal cavity occupied by the shoe last 1300. As a result of this inversion, as shown in FIG. Fig.15 As shown in FIG. 1 , the collar 800 forms the edge of the ankle opening. In an exemplary aspect, the heel end edges of the collar (or any edges to be coupled) are secured together prior to insertion into the last 1300. However, it is also contemplated that in an exemplary aspect, an adhesive or other bonding agent is applied to the collar 800 or to the interior portion of the three-dimensional shoe to maintain the collar 800 in place within the interior cavity.

[0153] It is contemplated that one or more portions of the flat pattern upper are then formed around the last 1300. For example, one or more portions may have a heat-activated agent that, when exposed to heat, increases the stiffness of the material to which the agent is applied. For example, in the toe box area of ​​the three-dimensional shoe, it is contemplated that an agent is applied and heat is introduced to cause the toe box area to be formed around the inserted last 1300. After the last 1300 is removed, the toe box area will maintain the shape guided by the last 1300 because the agent has cured and helps maintain the shape. The agent may be applied to other portions, such as the heel area, to provide similar properties in those areas to which the agent is applied.

[0154] Similarly, it is contemplated that one or more portions of the material forming the three-dimensional shoe may be coupled together while the shoe last 1300 is maintained within the internal cavity. For example, when the shoe last 1300 is present, an adhesive may be applied along a peripheral portion of one or more trims to secure the trims to one or more other materials (e.g., a substrate). This enables the three-dimensional shoe to be formed from a substantially planar flat upper into a three-dimensional shoe having a desired shape, size, and curvature. In another example, in an exemplary aspect, portions of the trim (or substrate) forming the upper portion 302 that extend around the shoe last 1300 in the toe end and / or heel end may be secured to the footbed portion 304 to substantially enclose the internal cavity housing the shoe last 1300.

[0155] In addition, it is also contemplated that the sole may be applied to the lasted upper. Thus, it is contemplated that the flat pattern upper may have the sole applied as known in the art when it is molded around the last 1300.

[0156] Fig.15 According to the present invention, Figures 4 to 10 As shown, the collar 800 extends from an outer position near the ankle opening area 902 to the inner cavity occupied by the shoe last 1300. The collar extends from an outer lower position 1402 to an apex 1400 and then folds back into the foot-receiving inner cavity of the shoe. Fig.16 Middle Edge Fig.15 The section line 15 shown provides a simplified cross section. Fig.16 The cross-section shown illustrates that the outer surface 804 of the collar lining 800 first faces the top surface 502 of the trim 500 at a coupling location 806 (proximate the outer lower location 1402). Fig.16 The cross section further shows that the outer surface 804 transitions into the top surface 502 facing away from the overlay 500, such as at the vertex 1400. This configuration enables the collar 800 to function both as a foot receiving cavity liner and as an upper edge at the ankle opening, with a finished seam coupling the collar to one or more materials that form a three-dimensional shoe exterior.

[0157] Printing on the seam

[0158] As about Figure 3As shown and described, substrate 102 may be processed at a series of processing stations 204, 206, 208, 210, and 212. In some aspects, a first processing station may add stitches to substrate 102. The stitches may be decorative, structural, or both, or different portions of the stitches may be decorative and structural. For example, the stitches may be used to join different layers or portions, or may be used to provide strength or stability to one or more portions, or may be decorative, or may join different layers or portions in a decorative stitching pattern, or may join one or more portions or provide strength or stability to the one or more portions and continue past the structural stitches to a decorative stitching pattern. In some aspects, the stitches may form a quilting pattern on at least a portion of the substrate corresponding to the upper. As shown in FIG. Figure 3 As shown in , stitches can be applied while the substrate 102 is flat. Stitches can be added at one, two, or more processing stations. For example, a first stitching pattern can be applied at a first processing station, and a second stitching pattern can be applied at a subsequent processing station. Each stitch processing station can include one or more stitching devices. At least one of the stitching devices can be a quilting arm, Figure 3 206. In some aspects, stitches are added at a single processing station. In some aspects, stitches are applied using a continuous line of fine thread. In some aspects, stitches are applied using a continuous line of fine thread at a single processing station. The transport system can move substrate 102 along at least a portion of the manufacturing line. One vision system, or two or more vision systems can observe the distinctive features of the flat pattern on substrate 102 and align stitching and / or printing to one or more distinctive features of the flat pattern.

[0159] Subsequent processing stations may add printing to substrate 102. For example, if Figure 3 The processing station 206 in the processing station 208, 210 and / or 212 can apply printing to the substrate 102. Sewing can occur at one or more processing stations, and one or more processing stations can be present between each sewing station, or between a sewing station and a printing station, or between each sewing station and between a sewing station and a printing station. The printing station may include one or more printing devices. The printing device may use methods such as digital printing, flexographic printing, screen printing, rotary screen printing, pad printing, and combinations thereof to print. Printing can be applied to the entire substrate 102, to all flat patterns on or from the substrate 102, or to continuous sewing fine lines, or to at least a portion of continuous sewing fine lines.

[0160] When printing is performed, the substrate 102 or the flat pattern may be monochromatic. Alternatively, the substrate 102 may be colored, patterned, or may have a surface design. The pattern or design may be multi-color, or multi-hue, or both. The color, pattern, or design may be inherent to the material of the substrate (e.g., woven into a woven substrate), or the substrate itself may have been dyed or printed in an earlier process step. The pattern or design, or a portion thereof, may be printed onto the substrate 102. Since printing occurs after sewing, printing may provide color, pattern, or design to the substrate 102 and to the continuous thread at the same time, thereby obtaining a continuous thread with different appearances in different parts of the substrate 102. In some aspects, printing may only impart color to the continuous thread. For example, a printing dye or ink may be selected to color the continuous thread but not the substrate 102. The result of the printing operation is to make the continuous thread have a variable appearance to match or coordinate with the substrate 102. Thus, even if the shoe includes areas of different colors and / or patterns, a decorative stitch or functional stitch visible from the exterior of the shoe may be achieved with a single continuous thin line.

[0161] In some aspects, such as Fig. 20 , shoe 1900 may have stitching in quilting pattern 1910A. Any desired stitching pattern may be used—lines, curves, or other shapes, including but not limited to abstract or irregular shapes, circles, dots, stars, flowers, clouds, or other shapes, other outlines or other designs, or combinations thereof. Design 1920 is present on upper 120 and / or overlay 500 (if an overlay is present). After sewing, sewn upper 120 is subjected to a printing process that may add design 1920 to upper 120, or may print portions of the continuous stitching lines in quilting pattern 1910B within design 1920 to match or complement the appearance of design 1920. Whether the aesthetic design is to match the continuous lines in the quilted pattern 1910B to the design 1920 (i.e., to blend in with the color) or to emphasize the lines by using a different color or hue for the lines than the underlying upper substrate, the color is imparted by the printing process so that the stitching is continuous even at the intersection 1930 between the stitching in the quilted pattern 1910B and the perimeter of the design 1920, where traditionally the stitching lines would have had a uniform appearance or would have been altered (e.g., not being a continuous line but rather a row of stitching comprising two or more different types or colors of lines) to transition between the different colors in the design 1920 and the rest of the upper 120.

[0162] Thus, the upper may have a first area defined by a first color or visual pattern, such as design 1920, and at least one second area defined by a second color or visual pattern that is visually distinguishable from the first color or visual pattern. A row of stitches may be formed from a continuous thread, such as quilting patterns 1910A and 1910B. The row of stitches may be at least partially disposed in a first area of ​​the upper and at least partially disposed in a second area of ​​the upper. The continuous thread may match the first color or visual pattern in the first area and match the second color or pattern in the second area. That is, the continuous thread may have different colors or appearances in different portions of the stitches due to printing. This is shown in FIG. Fig. 20 , which uses a standard drawing symbol pattern representing color to show that in an exemplary embodiment, a gray upper 120 and / or overlay 500 having a continuous stitch using a continuous fine line is printed gray in a quilting pattern 1910A corresponding to the upper 120 and / or overlay 500 and printed red in a quilting pattern 1910B corresponding to the design 1920, and a red design 1920. In some aspects, the printing process can impart a color, pattern, or design to both the substrate of the upper 120 (including the overlay 500, if an overlay is used) and to the continuous fine line sewn into the upper 120 and / or overlay 500.

[0163] The continuous thread may have the same, similar, or different materials relative to the upper and / or overlay 500 (if an overlay is used). As an example, the continuous thread may be an organic material (e.g., cotton), and the upper and / or overlay 500 may be formed of one or more synthetic materials, or a mixture of synthetic and organic materials. As another example, the continuous thread and the upper and / or overlay may be formed of different polymer materials. The materials may have textures, sheens, or other visual properties that are similar or different in nature. Printing may or may not change these non-color attributes. For example, after printing, the continuous thread may match the color or hue of the upper and / or overlay, but may have a different texture or sheen, and thus may have a matching color but a different overall appearance. As another example, printing may use certain substances to coat the continuous thread, the upper and / or overlay, or otherwise mask the visual properties of the continuous thread, the upper and / or overlay, so that the printing makes those materials look more or less similar in non-color attributes and / or color attributes. As an example, a matte pigment applied to both the continuous thread and the upper and / or overlay can reduce the difference in gloss between the different materials. As another example, a pigment with dimensional properties or a pigment in a carrier with dimensional properties (e.g., puffy paint) can change or mask the texture, gloss, and / or color of the continuous thread, upper, and / or overlay.

[0164] like Fig.21 As shown in , a method 2000 for manufacturing a shoe may include sewing a flat pattern of a shoe (i.e., a shoe, or a shoe component, such as an upper) using a continuous fine line (block 2010). The method may include printing at least a portion of the sewn flat pattern in at least two zones (block 2020). The first zone may be defined by a first color or visual pattern. The second zone may be defined by a second color or visual pattern that is visually distinguished from the first color or visual pattern. The continuous fine line may be at least partially sewn in the first zone and at least partially sewn in the second zone. After printing, the continuous fine line may match the first color or visual pattern in the first zone and match the second color or visual pattern in the second zone. The first zone and the second zone may be visually distinguished when the flat pattern is being sewn, or may only be visually distinguished after the printing step (e.g., when different colors or patterns are imparted at least in part by the printing process). Thus, a continuous fine line may be sewn into a first area and a second area of ​​the substrate 102 and / or the upper 120, which are partially distinguishable from a plan view or template, but are not clearly perceived as visually different areas until further processing. The printing may be performed in a single process step or operation, or may be performed in two or more process steps or operations. For example, certain design elements may be imparted in a first printing process, which may use the same or different printing materials, methods, and / or equipment as a second printing process that imparts other design elements. As another example, one color may be printed in a first step and a second color may be printed in a second step. As yet another example, the fine line may be printed in one step and the upper or the substrate of the upper may be printed in another step. In this regard, as described above, the use of a starting point and / or distinguishing features of a flat pattern may help maintain alignment or registration of printed colors and / or patterns in different processes or steps. In some aspects, portions of substrate 102 corresponding to upper 120 and / or overlay 500 may have a color or pattern that is inherent in the material and / or was previously imparted to the material independently of the continuous fine line (e.g., dyed, printed, or otherwise transferred to upper 120 and / or overlay 500). In such cases, the printing process may impart color only to the continuous fine line, for example, by printing only one row of stitching, by using a mask to prevent printing on substrate 102 except for the continuous fine line, or by using a combination of printing ink or dye and material so that the printing process affects only the continuous fine line.

[0165] As discussed above, printing, sewing, or both can be aligned to one or more distinguishing features of a flat pattern (e.g., one starting point opening or two starting point openings). At least one vision system can be used to align printing and sewing, or both to one or more distinguishing features of a flat pattern. At least one vision system can be used to align printing to a suture. If multiple printing and / or sewing processes are used, any subcombination of processes, or all printing and / or sewing processes (e.g., all printing processes, or all sewing processes, or all printing and sewing processes) can be aligned to one or more distinguishing features of a flat pattern. Sewing and printing can be performed at the same manufacturing station. Even if performed at the same manufacturing station, the printing and / or sewing process can be aligned to one or more distinguishing features of a flat pattern.

[0166] like Figure 3 As shown in , the extracted flat pattern upper outline 214 can be obtained from the substrate 102. The extracted flat pattern upper outline 214 can be extracted before or after the sewing and / or printing process. The sewn, printed and extracted flat pattern upper outline 214 can be formed into a three-dimensional upper, and can finally be formed into a three-dimensional shoe. Sewing on a flat pattern and printing on the seams can simplify the manufacture of the upper and / or shoe, and can make the production of various shoes with different patterns or designs more cost-effective (for example, because there is no need to stock a large number of different substrates and fine lines), and specifically, because the printing is performed on a flat substrate, it can allow the use of printing techniques (such as digital printing) that may be difficult to use on a three-dimensional upper and / or three-dimensional shoe.

[0167] Without departing from the spirit and scope of the present invention, the various components shown and components not shown may have many different schemes. Embodiments of the present invention have been described, where the intent is illustrative rather than restrictive. Alternative embodiments that do not depart from the scope of the present invention will become apparent to those skilled in the art. Those skilled in the art may develop alternative ways to implement the aforementioned improvements without departing from the scope of the present invention.

[0168] It should be understood that certain features and subcombinations are of utility and may be employed without reference to other features and subcombinations and are contemplated within the scope of the claims. Not all steps listed in the figures need to be performed in the particular order described.

Claims

1. A shoe assembly comprising: a first area defined by a first color or a first visual pattern; a second area defined by a second color or a second visual pattern that is visually distinguishable from the first color or the first visual pattern; as well as a row of stitches, the stitches being formed by a continuous thin line, the stitches being at least partially disposed in the first region and at least partially disposed in the second region, Wherein, after the continuous thin line has been printed, the continuous thin line includes ink that substantially matches the first color or the first visual pattern in the first zone, and includes ink that substantially matches the second color or the second visual pattern in the second zone.

2. The shoe assembly of claim 1, wherein the stitching defines a quilting pattern. The shoe assembly of claim 1 , wherein the stitching is decorative. The shoe assembly of claim 1 , wherein the stitching is at least partially structural.

5. The shoe assembly of any one of claims 1-4, wherein at least one of the first zone and the second zone comprises a multi-color pattern.

6. A method of manufacturing a shoe component, the method comprising: Using a continuous thread to sew a flat pattern, the flat pattern comprising a first area defined by a first color or a first visual pattern, and at least one second area defined by a second color or a second visual pattern visually distinguishable from the first color or the first visual pattern, wherein the continuous thread is at least partially sewn in the first area and at least partially sewn in the second area; and Printing on a portion of the continuous thin line with ink so that the continuous thin line matches the first color or the first visual pattern in the first zone and matches the second color or the second visual pattern in the second zone.

7. The method of manufacturing a shoe component according to claim 6, wherein the printing uses a method selected from the group consisting of digital printing, flexographic printing, screen printing, pad printing, and combinations thereof.

8. The method of manufacturing a shoe component according to claim 7, wherein the screen printing comprises rotary screen printing.

9. A method of manufacturing a shoe component according to claim 6 or claim 7, wherein the printing imparts a colour or pattern only to the continuous thin lines.

10. A method of manufacturing a shoe component according to claim 6 or claim 7, wherein the printing imparts a colour or pattern to the continuous thin lines and to at least a portion of the flat pattern.

11. The method of manufacturing a shoe assembly of claim 6, further comprising aligning the printing or the sewing to one or more distinctive features of the flat pattern.

12. The method of manufacturing a shoe component of claim 6, wherein at least one vision system is used to align the printing and the sewing to one or more distinctive features of the flat pattern.

13. The method of manufacturing a shoe assembly of claim 6, wherein the sewing is performed using a quilting arm.

14. The method of manufacturing a shoe assembly of claim 13, wherein the sewing defines quilting on at least a portion of the flat pattern.

15. The method of manufacturing a shoe component according to claim 6, wherein said sewing and said printing are performed at the same manufacturing station.

16. A method of manufacturing a shoe component according to any one of claims 6-8 and 11-14, wherein the sewing is registered to the flat pattern at a first manufacturing station using a first vision system and the printing is registered to the flat pattern at a second manufacturing station using a second vision system.

17. A system for preparing a shoe component according to any one of claims 1 to 5, wherein the shoe component comprises an upper or a component of an upper, the system comprising: a conveyor system that moves the flat pattern along at least a portion of a manufacturing line; at least one vision system that observes one or more distinctive features of the planar pattern; a sewing device that sews a continuous fine line to at least a portion of the planar pattern in alignment with the one or more distinctive features; as well as A printing device imparts color and / or pattern to at least a portion of the continuous thread after the continuous thread has been sewn to the flat pattern.

18. The system of claim 17, wherein the sewing device comprises a quilting arm.

19. The system of claim 17 or claim 18, wherein the printing device comprises a digital printer, a flexographic printer, a screen printer, or a pad printer.

20. The system of claim 19, wherein the screen printer comprises a rotary screen printer.

Images