PROCESS FOR MANUFACTURING SHOE UPPERS

Abstract

A method for manufacturing shoe uppers is provided. The method for manufacturing shoe uppers comprises the steps of obtaining shoe upper materials, forming the shoe uppers, processing the shoe uppers, and printing the shoe uppers in turn. Thus, a multi-layer composite shoe fabric is produced, which is then processed to form the required shoe uppers. Thus, different heating temperatures and times are set for hot melting and adhesion of a thermoplastic elastomer to a shoe fabric made from different materials to meet different user requirements. In addition, production efficiency is improved and production capacity is increased by combining an upper mold (21) with a plurality of lower molds (22). This method is more efficient than those currently used.Figure for abstract: Fig. 3.

Description

Title of the invention: METHOD OF MANUFACTURE OF SHOE UPPERS

[0001] CONTEXT OF THE INVENTION Field of invention

[0002] The present invention relates to a method for manufacturing shoe uppers, particularly a method for manufacturing shoe uppers in which a different temperature and heating time are set for hot melting and adhesion of a thermoplastic elastomer to a shoe fabric made from different materials. In addition, production efficiency is improved and production capacity is increased. The method is more convenient and efficient than those currently used.

[0003] Description of the related prior art

[0004] In the modern footwear industry, a shoe consists of a plurality of components, including but not limited to the upper, sole, heel, insole, last, accessories, etc., which are manufactured respectively by different departments or production lines, and the shoe is manufactured through processes including, in turn, material preparation, template making, cutting, sewing, molding, sole attachment, assembly, inspection, and packaging.

[0005] The conventional footwear industry is characterized by intensive labor, many types of raw materials used, and complicated manufacturing processes. Especially for the manufacture of shoe uppers, manufacturers must check the toughness of the materials, whether the connection is firm or not, whether the use of adhesives is correct or not, and whether reinforcement is used to reinforce certain areas. Then, the shoe upper is produced after the inner material (lining) and the reinforcement are properly combined with each other and after the sewing process. There is an old saying in the footwear industry that manufacturing shoes is much more difficult than manufacturing clothes, not only because of higher requirements for product quality, but also because of the difficulties encountered during the manufacturing processes.Although artificial intelligence has been applied to some production lines, it is not applicable to all production lines. Currently, the footwear industry still relies heavily on manual operation in most processes.

[0006] There is therefore room for improvement and it is necessary to propose a new process for manufacturing shoe uppers. Summary of the invention

[0007] Therefore, a main objective of the present invention is to provide a method for manufacturing shoe uppers in which different temperatures and heating times are set for hot melting and adhering a thermoplastic elastomer to a shoe fabric made from different materials to meet different user requirements. In addition, production efficiency is improved and production capacity is increased by combining an upper mold with a plurality of lower molds. Furthermore, the present method not only improves production efficiency and production capacity, but also features reduced labor cost, fewer processes, and easy operation in use. Thus, various types of shoe uppers for different purposes and occasions are produced and more convenient to use.

[0008] In order to achieve the above objective, a method of manufacturing shoe uppers according to the present invention comprises the following steps: A.obtaining materials for shoe uppers: starting a laser cutting machine and inserting a winding bar of the laser cutting machine with a roll of shoe fabric and thermoplastic elastomer (TPE); then arranging a material conveyor on the winding bar for supplying the shoe fabric and thermoplastic elastomer to a laser cutting platform; inputting a graphic file with arranged upper patterns into a control computer of the laser cutting machine, so that a laser head of the laser cutting machine cuts an inner diameter and an outer diameter of the shoe fabric and thermoplastic elastomer; then sending the cut shoe fabric and thermoplastic elastomer to a finished product area by a conveyor belt while the residual waste is conveyed to a scrap area by another conveyor belt; . B. Forming shoe uppers: activating a shoe upper forming machine having an upper mold and several lower molds and placing a shoe upper template on the lower mold; then setting the heating temperature and time of the upper mold and those of the lower mold while the heat of the lower mold is transferred to the shoe upper template during the heating process; operating an air compressor, placing the shoe fabric and thermoplastic elastomer available in the finished product area on the shoe upper template after confirming that the temperature of the lower mold has reached the set temperature, and cover with a silicone vacuum barrier to prevent air from entering outside; then a lower mold vacuum pump starts working to remove the residual air in the lower mold so that the shoe fabric and thermoplastic elastomer are held on the shoe upper template evenly and stably;moving the lower mold under the upper mold and transporting the upper mold downward so that it is aligned and connected with the lower mold so that the upper and lower molds continue to heat the shoe fabric and the thermoplastic elastomer until the set heating time has elapsed so that the shoe fabric and the thermoplastic elastomer are fused and in a state of adhesion to each other at the set heating temperature to form a multi-layer composite shoe fabric having arranged upper patterns; then the upper mold is automatically lifted and the lower mold is automatically returned to its original position so that the heat dissipation is ready for demolding; during the heat dissipation of the lower mold, another lower mold is automatically moved to repeat the above-mentioned steps;cooling the silicone vacuum barrier after dissipating the heat of the lower mold, and then lifting the silicone vacuum barrier to continuously cool the multi-layer composite shoe fabric; ; performing demolding by slowly pulling the multi-layer composite shoe fabric upwards so as to release it from the shoe upper template after cooling; then delivering the already bonded and formed multi-layer composite shoe fabric to a laser machine, to implement the next step after demolding; C. Shoe upper processing: Activate the laser machine to carry out the following processes: arrange breathing holes and / or cut burrs and / or cut unnecessary waste, and then deliver the finished multi-layer composite shoe fabric to a printing machine, for the next step; D. Shoe upper printing: Start the printing machine and place the multi-layer composite shoe fabric on a printing table of the printing machine for printing, and then remove the multi-layer composite shoe fabric after printing to obtain a finished product.

[0009] Thus, a multi-layer composite fabric for footwear is produced and further processed to form the required shoe uppers.

[0010] According to another aspect of the invention, the shoe fabric is selected from the group consisting of canvas, leather, breathable mesh fabric, reflective fabric and a combination thereof.

[0011] According to another aspect of the invention, the shoe upper forming machine is a machine which performs low temperature microporous sintering and vacuum thermal transfer printing.

[0012] According to another aspect of the invention, the shoe upper template on the lower mold can be replaced by other shoe upper templates with different upper patterns.

[0013] According to another aspect of the invention, a thermometer is used to check whether the temperature of the lower mold has reached, in step B, the set temperature.

[0014] According to another aspect of the invention, the shoe fabric and the thermoplastic elastomer are, in step B, placed on the shoe upper template by a method of aligning positioning points.

[0015] According to another aspect of the invention, a high pressure compressed air blower is used in step B to cool the silicone vacuum barrier.

[0016] According to another aspect of the invention, a high pressure compressed air blower is, in step B, moved in circles to cool the multi-layer composite shoe fabric continuously. Brief description of the drawings

[0017] The structure and technical means adopted by the present invention to achieve the above and other objectives may be better understood by referring to the following detailed description of the preferred embodiments and the accompanying drawings, in which:

[0018] [Fig-1] [Fig.l] is a flowchart showing a manufacturing process of a embodiment according to the present invention;

[0019] [Fig.2] [Fig.2] is a schematic drawing showing a laser cutting machine according to one embodiment of the present invention;

[0020] [Fig.3] [Fig.3] is a schematic drawing of a shoe upper molding machine according to one embodiment of the present invention;

[0021] [Fig.4] [Fig.4] is a schematic drawing is a perspective view of a shoe produced according to an embodiment of the present invention.

[0022] DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

[0023] In order to understand the technical content, objectives and functions of the present invention more clearly and completely, reference should be made to the following detailed descriptions, figures and reference signs.

[0024] With reference to [Fig. 1], it appears that a method of manufacturing shoe uppers according to the present invention mainly comprises the following steps.

[0025] A. Obtaining materials for shoe uppers: See [Fig.2]: Operating a laser cutting machine 1 which includes a winding bar 11, a material conveyor 12, a laser cutting platform 13 and a laser head 14. The winding bar 11 is inserted into a roll of shoe fabric and thermoplastic elastomer (TPE). The shoe fabric may be canvas, leather, breathable mesh fabric, reflective fabric, or combinations thereof. Then, the material conveyor 12 is arranged on the winding bar 11 for supplying the shoe fabric and thermoplastic elastomer to the laser cutting platform 13.At least one graphic file with arranged upper patterns is input into a control computer of the laser cutting machine 1 so that the laser head 14 of the laser cutting machine 1 cuts through an inner diameter and an outer diameter of the shoe fabric and the thermoplastic elastomer. The cut shoe fabric and the thermoplastic elastomer are sent to a finished product area by a conveyor belt while the residual waste is delivered to a scrap area by another conveyor belt. Thus, the manual operation time is significantly reduced and the production capacity is increased.

[0026] B. Forming shoe uppers: activating a shoe upper forming machine 2 which is a machine that performs low-temperature microporous sintering, and vacuum heat transfer printing, as shown in [Fig. 3]. The shoe upper forming machine 2 consists of an upper mold 21 and a plurality of lower molds 22. A shoe upper template is placed on the lower mold 22 and can be replaced by other shoe upper templates with different upper designs. In order to meet the functional needs of users, at least one of the shoe fabrics including canvas, leather, breathable mesh fabric, reflective fabric, etc. and the thermoplastic elastomer are thermally fused and adhered to each other so as to form an integrated multi-layer composite shoe fabric 3.The multi-layer composite shoe fabric 3, for different purposes, has different material properties so that the temperature and time required for fusion and adhesion are different. The heating temperature and time of the upper mold 21 and those of the lower mold 22 are set respectively according to the combinations of the materials used. During the heating process, the heat of the lower mold 22 is transferred to the shoe upper template. Start an air compressor and use a thermometer to check whether . the temperature of the lower mold 22 has reached the set temperature. After confirming that the temperature of the lower mold 22 has reached the set temperature, at least one shoe fabric which is selected from canvas, leather, breathable mesh fabric and reflective fabric, as well as the thermoplastic elastomer already available on the surface of the finished product, is placed on the shoe upper template by a positioning point alignment method, and then covered with a vacuum barrier 23 made of silicone so as to keep air out. Then, a vacuum pump of the lower mold 22 starts to operate so as to remove the residual air in the lower mold 22. Thus, the shoe fabric and the thermoplastic elastomer are held on the shoe template in a flexible and stable manner.Next, the lower mold 22 is moved under the upper mold 21, and then the upper mold 21 is lifted so as to be aligned and connected to the lower mold 22. The upper and lower molds 21, 22 continue to heat the shoe fabric and the thermoplastic elastomer until the set time, so that the shoe fabric and the thermoplastic elastomer are fused and adhered to each other at the set temperature to form the multi-layer composite shoe fabric 3, with the upper patterns that have been arranged. Next, the upper mold 21 is automatically lifted and the lower mold 22 is automatically returned to its initial position to dissipate heat and be ready for demolding. During the heat dissipation time of the lower mold 22, another lower mold 22 is automatically moved to repeat the above-mentioned steps.Production efficiency is thus improved by utilizing the heat dissipation and demolding time. Therefore, production capacity is increased by up to 80% without increasing the costs of hiring additional operators and purchasing machines. After the heat dissipation time of the lower mold 22 has elapsed, use a high-pressure air gun to cool the silicone vacuum barrier 23. Lift the silicone vacuum barrier 23 and move the high-pressure air gun in circles to cool the multi-layer composite shoe fabric 3 continuously. After cooling is completed, demolding is performed. Slowly pull the multi-layer composite shoe fabric 3 upwards to detach it from the shoe upper template.After demolding, supply the already glued and formed 3-layer composite shoe fabric to a laser machine to implement the next step.

[0027] C. Shoe upper processing: Activate the laser machine to perform operations such as making breathing holes, trimming burrs, cutting unnecessary waste, etc. and then supply the finished multi-layer composite 3 shoe fabric to a printing machine for the next step.

[0028] D. Printing of shoe uppers: starting the printing machine and placing the multi-layer composite shoe fabric 3 on a printing table of the printing machine to perform printing. After printing, removing the multi-layer composite shoe fabric 3 to obtain the finished product.

[0029] With reference to [Fig.4], it appears that a shoe A is manufactured using the multi-layer composite shoe fabric 3 obtained by the respective steps mentioned above.

[0030] In summary, the present method of manufacturing shoe uppers has the following advantages over currently available techniques:

[0031] 1. Without increasing the process steps and labor, the manufacturing of The single-material shoe upper is replaced by the production of versatile multi-layer composite shoe fabric. This achieves the optical utilization of today's production equipment for many different purposes and makes it possible to meet the various user requirements in the market. At the same time, the product yield rate is improved, production capacity is increased, and labor costs are reduced.

[0032] 2. The present method not only enables various fabrics to be cut and prepared of shoes made from canvas, leather, breathable mesh fabric, reflective fabric, etc. for different purposes, but also to automatically sort finished products and waste so as to significantly reduce manual operation time and effectively increase production capacity.

[0033] 3. The demolding interval can be effectively utilized by using a single mold. upper in combination with a plurality of lower molds. Thus, both efficiency and production capacity are improved.

[0034] 4. Due to the combination of an upper mold and a plurality of molds lowers, the various lower molds as well as the multi-layer composite shoe fabric made from combinations of various materials are used to form the shoe uppers in turn. At the same time, the multi-layer composite shoe fabric made from combinations of various materials is produced.

[0035] 5. During the processes, the multi-layer composite shoe fabric, at different purposes, has different material properties so that the temperature and time required to fuse and achieve adhesion are different. Thus, the heating temperature and time (parameters) of the upper mold and lower molds are set respectively according to the combinations of the materials for the multi-layer composite shoe fabric. These parameters are set and recorded in the control computer of the laser cutting machine of modularized manner so that users only need to directly press predefined memory modules for different material combinations during operation. Thus, human errors in setting related parameters can be avoided so that unnecessary materials consumed and waste generated in the production line are significantly reduced and unnecessary expenses are reduced. In addition, the yield rate is improved and the production capacity and gross margin are increased.

[0036] Other advantages and modifications will readily become apparent to those skilled in the art. Accordingly, the invention in its broader aspects is not limited to the specific details, and representative devices shown and described herein. Accordingly, various modifications may be made without departing from the spirit or scope of the general inventive concept as defined by the appended claims and their equivalent.

Claims

1. Claims Method for manufacturing shoe uppers, characterized in that it comprises the following steps: A.: starting a laser cutting machine (1) and inserting a winding bar (11) of the laser cutting machine (1) into a roll of shoe fabric and thermoplastic elastomer (TPE); then, arranging a material conveyor (12) on the winding bar (11), for supplying the shoe fabric and the thermoplastic elastomer to a laser cutting platform (13); inputting into a control computer of the laser cutting machine (1) a graphic file with arranged upper patterns, so that a laser head (14) of the laser cutting machine (1) cuts an inner diameter and an outer diameter of the shoe fabric and the thermoplastic elastomer; then send the cut shoe fabric and thermoplastic elastomer to a finished product area by a conveyor belt while the residual waste is conveyed to a scrap area by another conveyor belt;B.: activating a shoe upper forming machine (2) provided with an upper mold (21) and several lower molds (22) and placing a shoe upper template on the lower mold; then setting the heating temperature and time of the upper mold (21) and those of the lower mold while the heat of the lower mold is transferred to the shoe upper template during the heating process; operating an air compressor, placing the shoe fabric and thermoplastic elastomer available in the finished product area on the shoe upper template after confirming that the temperature of the lower mold has reached the set temperature, and covering with a vacuum barrier (23) made of silicone to prevent air from entering outside;then a vacuum pump of the lower mold starts working to remove the residual air in the lower mold so that the shoe fabric and the thermoplastic elastomer are held on the shoe upper template evenly and stably; moving the lower mold under the upper mold (21) and transporting the upper mold (21) to the;

2. bottom so that it is aligned and connected to the lower mold so that the upper and lower molds continue to heat the shoe fabric and the thermoplastic elastomer until the set heating time has elapsed so that the shoe fabric and the thermoplastic elastomer are fused and in a state of adhesion to each other at the set heating temperature to form a multi-layer composite shoe fabric having arranged upper patterns; then the upper mold (21) is automatically lifted and the lower mold is automatically returned to its original position so that the heat dissipation is ready for demolding; during the heat dissipation of the lower mold, another lower mold is automatically moved to repeat the above-mentioned steps;cooling the silicone vacuum barrier after dissipating the heat of the lower mold, and then lifting the silicone vacuum barrier to continuously cool the multi-layer composite shoe fabric (3); performing demolding by slowly pulling up the multi-layer composite shoe fabric (3) so as to release it from the shoe upper template after cooling; and then delivering the already bonded and formed multi-layer composite shoe fabric (3) to a laser machine to perform the next step after demolding; C.: Activate the laser machine to carry out the following processes: make breathing holes and / or cut burrs and / or cut unnecessary waste, and then deliver the finished multi-layer composite shoe fabric (3) to a printing machine, for the next step; D.: Starting the printing machine and placing the multi-layer composite shoe fabric (3) on a printing table of the printing machine to do printing, and then removing the multi-layer composite shoe fabric (3) after printing, to obtain a finished product. The method of claim 1, characterized in that the shoe fabric is selected from the group consisting of canvas, leather, breathable mesh fabric, reflective fabric and a combination thereof.

3. Method according to claim 1, characterized in that a thermometer is used to check whether the temperature of the lower mold (22) has reached, in step B, the set temperature.

4. A method according to claim 1, characterized in that the shoe fabric and the thermoplastic elastomer are, in step B, placed on the shoe upper template by a method of aligning the positioning points.

5. Method according to any one of claims 1 to 4, characterized in that a high pressure compressed air blower is, in step B, used to cool the silicone vacuum barrier (23).

6. Method according to claim 1, characterized in that a high-pressure compressed air blower is, in step B, moved in circles to cool the multi-layer composite shoe fabric (3) continuously.

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