TW201808135A - 鞋類物件之鞋面 - Google Patents
鞋類物件之鞋面 Download PDFInfo
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- TW201808135A TW201808135A TW106139424A TW106139424A TW201808135A TW 201808135 A TW201808135 A TW 201808135A TW 106139424 A TW106139424 A TW 106139424A TW 106139424 A TW106139424 A TW 106139424A TW 201808135 A TW201808135 A TW 201808135A
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Abstract
揭示一種鞋楦系統及一種製作該鞋楦系統之方法。該鞋楦系統包含一鞋楦構件及一外層。該外層在被加熱至高於一特性溫度時變得可變形。該方法可包含使一編織鞋類組件形成於該鞋楦系統上。該外層可藉由將鞋楦系統加熱至高於該特性溫度而與該編織鞋類組件結合。
Description
本實施例大致上係關於鞋類物件,且特定言之係關於一種用於製作鞋類物件之鞋楦系統。 鞋類物件大體上包含兩個主要元件:一鞋面及一鞋底結構。鞋面可由多種材料形成,其等被縫合或黏著接合在一起以在鞋類內形成一空間用於舒適地且牢固地收納一腳部。鞋底結構固定至鞋面之一下部分,且大致上定位在腳部與地面之間。在許多鞋類物件(包含運動鞋類款式)中,鞋底結構通常併入一內底、一中底及一外底。 可使用一鞋楦製造一鞋面。鞋楦可為一足形形式,鞋面可繞其組裝,使得鞋面具有一腳部之近似形狀。
在一態樣中,一種製作一鞋類物件之一鞋面之方法包含提供一鞋楦構件,其中該鞋楦構件具有一外表面。方法亦包含使一可熱變形材料之一外層形成至鞋楦構件之外表面上。方法亦包含使一編織鞋類組件形成至外層上。方法亦包含加熱外層,使得外層與編織鞋類組件結合以形成一複合結構。方法亦包含從複合結構移除鞋楦構件。 在另一態樣中,一種製作一鞋類物件之一鞋面之方法包含提供一鞋楦構件,其中該鞋楦構件具有一外表面。方法亦包含使一外層之一第一區域形成至鞋楦構件之外表面上,其中第一區域具有一第一厚度,且其中外層由一可熱變形材料組成。方法亦包含使外層之一第二區域形成至鞋楦構件之外表面上,其中第二區域具有與第一厚度不同之一第二厚度。方法進一步包含使一編織鞋類組件形成至外層上,且加熱外層,使得外層與編織鞋類組件結合以形成一複合結構。方法亦包含從複合結構移除鞋楦構件。 在另一態樣中,一種用於製作一鞋類物件之鞋楦系統包含具有一外表面之一鞋楦構件,其中鞋楦構件具有一足狀幾何形狀。鞋楦系統亦包含被安置在外表面上之一外層。鞋楦構件由一第一材料製成且外層由與第一材料不同之一第二材料製成。外層之第二材料具有一特性溫度,其中第二材料經組態以可在被加熱至高於特性溫度之一溫度時模製。外層具有一第一區域及一第二區域,其中第一區域具有一第一厚度,且其中第二區域具有不同於第一厚度之一第二厚度。 一般技術者在查閱以下圖式及[實施方式]之後將明白或將變得明白實施例之其他系統、方法、特徵及優點。所有此等額外系統、方法、特徵及優點旨在包含在此描述及此發明內容內,包含在實施例之範疇內且受隨附申請專利範圍保護。
圖1繪示一鞋楦系統100之一實施例之一等角視圖。鞋楦系統100可具有一腳部之近似幾何形狀,且可大致上經構形以收納用於形成一鞋類物件之鞋面之材料。在例示性實施例中,鞋楦系統100被展示為具有一大致上足形,但是在其他實施例中,鞋楦系統100可經構形為具有任何所要腳部幾何形狀。 鞋楦系統100可用於製作不同種類的鞋類的組件(例如,一鞋面)。鞋類之類型可包含但不限於:登山鞋、足球鞋、橄欖球鞋、運動鞋、跑步鞋、交叉訓練鞋、英式橄欖球鞋、籃球鞋、棒球鞋以及其他種類的鞋。此外,在一些實施例中,鞋楦系統100可用於製造各種其他種類之非運動相關鞋類,包含但不限於:拖鞋、涼鞋、高跟鞋及懶人鞋。 雖然實施例描繪經構形用於製作鞋類物件之一鞋楦系統,但是其他實施例可使用用於製造其他種類的物件之一楦系統。此等物件可包含但不限於:服裝、帽子、手套、襪子、包、護墊、運動裝備之物件以及可使用一些種類之一楦製造之任何其他種類的物件。在其他實施例中,一楦系統之幾何形狀可變化以適應任何其他種類的物件。 鞋楦系統100可進一步包含一鞋楦構件102及一外層104。特定言之,如圖1中所見,外層104可被安置在鞋楦構件102之外表面106上。如圖1之放大截面圖中所見,鞋楦構件102可包括鞋楦系統100之一核心部分或內部部分。具體地,在至少一些實施例中,鞋楦構件102可完全被外層104覆蓋。替代地,在一些其他實施例中,僅鞋楦構件102之一些部分可用外層104覆蓋,而鞋楦構件102之其他部分可暴露在鞋楦系統100之一最外表面上。 為闡釋的目的,在例示性實施例中將外層104描述為實質上透明,使得鞋楦構件102至少部分穿透外層104可見。在一些實施例中,外層104可由至少部分透明的材料製成。但是,在其他實施例(未展示)中,外層104可實質上不透明,使得鞋楦構件102甚至無法部分穿透外層104可見。 參考圖1,為參考之目的,鞋楦系統100可被劃分為前足部分10、中足部分12及後跟部分14。此等部分可大致上與一腳部之相應部分關聯,此係因為鞋楦系統100與一腳部共用一大致上類似幾何形狀。前足部分10可大致上與趾部及將趾骨與指骨連接的關節關聯。中足部分12可大致上與一腳部之足弓關聯。同樣地,後跟部分14可大致上與一腳部之腳跟(包含跟骨)關聯。此外,鞋楦系統100可包含外側16及內側18。特定言之,外側16及內側18可為鞋楦系統100之相對側。此外,外側16及內側18兩者可延伸穿過前足部分10、中足部分12及後跟部分14。 將暸解,前足部分10、中足部分12及後跟部分14僅旨在用於描述之目的且不旨在劃定鞋楦系統100之精確區域。同樣地,外側16及內側18旨在大致上表示鞋楦系統100之兩側,而非將鞋楦系統100精確劃定為兩半。此外,在實施例通篇,前足部分10、中足部分12、後跟部分14、外側16及內側18可用來指鞋楦系統100之個別組件(包含鞋楦構件102及/或外層104)之部分/側。 為一致及方便,在對應於所繪示實施例之貫穿此[實施方式]採用方向形容詞。如貫穿此[實施方式]及在申請專利範圍中使用之術語「縱向」指的是在一組件(例如,一鞋楦系統)之一長度上延伸之一方向。在一些情況中,縱向方向可從組件之一前足部分延伸至一後跟部分。此外,如貫穿此[實施方式]及在申請專利範圍中使用之術語「側向」指的是沿著一組件之一寬度延伸之一方向。換言之,側向方向可在一組件之一內側與一外側之間延伸。此外,如貫穿此[實施方式]及在申請專利範圍中使用之術語「垂直」指的是大致上垂直於側向方向及縱向方向之一方向。例如,鞋楦系統100之垂直方向可大致上從鞋楦系統100之底側110延伸至鞋楦系統100之頂側112。此外,如本文中使用,術語「外」及「內」(例如,外表面及內表面或外部分及內部分)指相關部分及/或表面。一組件之外部分或外表面可被安置為與一組件之內部分或表面相比距離一參考內部位置(例如,一中心軸、內部空間等)更遠。 在不同實施例中,鞋楦構件102之幾何形狀可變化。在一些實施例中,鞋楦構件102可具有一腳部之近似幾何形狀。可使用所屬領域之已知的用於鞋類鞋楦的任何幾何形狀。當然,在一些其他實施例中,鞋楦構件102可包含非對應於一腳部之其他幾何特徵部。此等特徵部可包含凸緣、把手、開口或其他特徵部。例如,一些實施例可包含在製造程序期間允許一鞋楦被安裝或以其他方式附接一機器、支架或夾具之幾何特徵部。 在不同實施例中,鞋楦構件102之尺寸可變化。例示性尺寸可包含共同與鞋類鞋楦關聯之尺寸,包含用於各種不同鞋大小之尺寸的範圍。在一些實施例中,例如,鞋楦構件102可與一特定腳部大小關聯,該腳部大小可與高度、長度及寬度之一給定範圍對應。 在不同實施例中,組成鞋楦構件102之材料可變化。可用作鞋楦構件102之例示性材料包含但不限於:木材、金屬、塑膠、橡膠、複合材料以及可能的其他材料。在一些實施例中,鞋楦構件102可由一熱固性聚合物製成。在其他實施例中,鞋楦構件102可由一熱塑性聚合物製成。設想在至少一些實施例中,鞋楦構件102可由已知用於列印三維物件之一材料製成,如下文進一步詳細討論。 在不同實施例中,外層104之幾何形狀可變化。在一些實施例中,外層104可包括經形成於鞋楦構件102之外表面106上之一相對較薄材料層。例如,在例示性實施例中,鞋楦構件102之前足部分10可具有如從鞋楦構件102之一中心軸132至外表面106量測之一徑向厚度130。相較之下,外層104可具有如在外層104之一內表面107與外層104之一外表面108之間量測之一厚度140。在一些實施例中,厚度130可實質上大於厚度140。換言之,鞋楦構件102之至少一些部分(例如,一前足部分)可實質上比外層104厚。在一些實施例中,厚度130可比厚度140大五至十倍。在其他實施例中,厚度140可比厚度140大十至二十倍。舉一實例,厚度130可具有3至8釐米之一值,而厚度140可為1至10毫米之數量級。 在圖1至圖17中所示之實施例中,外層104可具有一實質上恆定的厚度。但是,在其他實施例中,外層104可具有在鞋楦系統100之不同區域內變化之一厚度。在下文討論且在圖18至圖23中展示具有針對一外層之變化厚度的實施例。 鞋楦構件102及外層104的材料特性可變化。例如,在不同實施例中,鞋楦構件102及外層104之相對硬質性及/或硬度可變化。為比較之目的,鞋楦構件102之特徵可為一第一硬質性,且外層104之特徵可為一第二硬質性。在一些實施例中,第一硬質性可大於第二硬質性(例如,鞋楦構件102可比外層104更硬質)。在其他實施例中,第二硬質性可大於第一硬質性(例如,外層104可比鞋楦構件102更硬質)。在另外其他實施例中,第一硬質性可實質上等於第二硬質性(例如,鞋楦構件102及外層104可同等硬質)。在一例示性實施例中,外層104的硬質性可小於鞋楦構件102。 在不同實施例中,外層104可係由不同材料製成。在一些實施例中,外層104可係由可熱變形材料製成。如貫穿此[實施方式]及在申請專利範圍中使用的術語「可熱變形材料」指的是在被加熱時可變得柔軟、可模製或可熔融及/或流動的任何材料。可熱變形材料可包含熱固性聚合物及熱塑性聚合物。此外,可熱變形材料亦可包含由熱固性材料及熱塑性材料(諸如熱塑性彈性體(TPE))組成的材料。 可熱變形材料(例如,熱固性聚合物及熱塑性聚合物)可與一特性溫度關聯。如貫穿此[實施方式]及在申請專利範圍中使用之術語「特性溫度」指的是一材料之一或多個性質改變之一溫度。此等變化可包含或可不包含相變。在一些情況中,例如,特性溫度可與一材料之一玻璃態化關聯,在此情況中,不存在材料之相變,但是材料變為更柔軟及/或可模製。在此等情況中,特性溫度可與一材料之一玻璃態化溫度關聯。在其他情況中,特性溫度可與一相變關聯,諸如從一固態改變為一液態(即,熔融)。在此等情況中,特性溫度可與一材料之一熔融溫度關聯。 在一些實施例中,外層104可係由一或多個熱塑性材料製成。熱塑性材料在高於一特性溫度的情況下變為柔軟或可模製,且在被冷卻至低於特性溫度時恢復至一固態。可根據所使用之特定材料來判定特性溫度之值。可用作一外層之例示性熱塑性材料可包含,但不限於:丙烯酸、尼龍、聚乙烯、聚丙烯、聚苯乙烯、聚氯乙烯(PVC)及熱塑性聚氨酯(TPU)。 當由不同材料製成時,鞋楦構件102及外層104可具有不同的熔融溫度及/或玻璃態化溫度。在一些實施例中,例如,鞋楦構件102可由具有一相對較高玻璃態化溫度及/或熔融溫度之材料製成。替代地,鞋楦構件102可能無一玻璃態化溫度及/或熔融溫度,且取而代之可在高於一特性溫度的情況下劣化(例如,燃燒)。相比之下,外層104可具有一相對較低玻璃態化溫度及/或熔融溫度。因此,例如,若外層104與一特性溫度(其可為一玻璃態化溫度或一熔融溫度)關聯,則鞋楦構件102可經組態以在超過特性溫度之溫度下保持固態形式。此等預備件可允許外層104在鞋楦系統100被加熱至高於特性溫度時變為柔軟及/或熔融,而鞋楦構件102保持在一固態形式中以維持所要腳部幾何形狀。 圖2係經歷藉由一熱源180加熱之鞋楦系統100之一示意圖。熱源180可為任何種類的熱源,包含但不限於:加熱燈、電加熱器、火焰以及可能的所屬領域中已知的任何其他種類的熱源。為簡明的目的,熱源180被描繪為單個源,但是其他實施例可包含被配置為圍繞一鞋楦系統之任何構形的任何其他數目之熱源。 如圖2中所見,熱源180使鞋楦100之一部分190之溫度升高至高於一特性溫度(例如,與外層104關聯之一玻璃態化溫度及/或一熔融溫度)。在高於此特性溫度的情況下,外層104可變為柔軟及/或熔融。因此,如在放大截面圖中所見,部分190已開始在鞋楦構件102之外表面106上熔融。此外,清楚的是鞋楦構件102保持其形狀,且甚至在被加熱至高於特性溫度時仍不變形。 在不同實施例中,熱源180可經組態以在一系列溫度中操作。在一些實施例中,熱源180可將鞋楦系統100之部分(或所有)加熱至近似在攝氏100度與200度之間之範圍中之一溫度。在其他實施例中,熱源180可將鞋楦系統100之部分(或所有)加熱至近似在攝氏150度與300度之間之範圍中之一溫度。在另外其他實施例中,熱源180可將鞋楦系統100之部分(或所有)加熱至實質上大於攝氏300度之一溫度。此外,在一些其他實施例中,熱源180可將鞋楦系統100之部分(或所有)加熱至小於攝氏100度之一溫度。將暸解,可根據用於製作鞋楦系統100的材料的類型(例如,組成鞋楦構件102及外層104之材料)以及可能的其他製造考量來選擇熱源180之操作溫度。具體地,在一些情況中,可選擇熱源180的操作範圍,使得一鞋楦系統之一外層可被加熱至高於一玻璃態化溫度及/或熔點,同時保持低於其中一鞋楦構件變為柔軟、熔融及/或劣化之溫度。 實施例可包含用於使用一積層製造程序形成一鞋楦系統之預備件。在一些實施例中,一鞋楦構件及/或一外層可使用一積層製造程序建構。在一實施例中,鞋楦構件102及外層104兩者可使用一積層製造程序建構。 圖3至圖5繪示使用積層製造裝置200製造鞋楦系統100之一程序中之步驟的一示意圖。術語「積層製造」(亦被稱作「三維列印」)指的是用於透過一積層製造程序製作一三維物件之任何技術,其中在一電腦的控制下連續鋪設材料層。可使用的例示性積層製造技術包含但不限於:擠壓方法,諸如熔融沈積成形(FDM)、電子束無模製造(EBF)、直接金屬雷射燒結(DMLS)、電子束熔融(EBM)、選擇性雷射熔融(SLM)、選擇性加熱燒結(SHS)、選擇性雷射燒結(SLS)、基於石膏的3D列印、分層實體製造(laminated object manufacturing (LOM))、立體微影(SLA)及數位光處理(DLP)。在一實施例中,積層製造裝置200可為一熔融沈積成形型列印機,其經組態以列印熱塑性材料,諸如丙烯腈丁二烯苯乙烯(ABS)或聚乳酸(PLA)。 使用熔絲製造(FFF)之一列印裝置之一實例揭示於1989年10月30日申請且標題為「Apparatus and Method for Creating Three-Dimensional Objects」之Crump的美國專利第5,121,329號中,該申請案以引用的方式併入本文中,且在下文被稱作「3D物件」申請案。本揭示內容之實施例可利用3D物件申請案中揭示之任何系統、組件、裝置及方法。 積層製造裝置200可用於製作用於形成一鞋類物件之一或多個組件。例如,積層製造裝置200可用於形成一鞋類鞋楦(或簡稱「鞋楦」),其可用於形成一鞋類物件之一鞋面。此外,在至少一些實施例中,積層製造裝置200可用於形成一鞋類物件之其他組件,包含但不限於:鞋底組件(例如內底組件、中底組件及/或外底組件)、裝飾組件、套疊件(overlay)組件、鞋眼片、面板或一鞋面之其他部分,以及可能的其他組件。此等預備件可利用任何系統及/或組件,其等揭示於2014年5月9日申請且標題為「System and Method for Forming Three-Dimensional Structures」之Sterman的美國專利公開案第_______號(現美國專利申請案第14/273,726號)中,此申請案之完整內容以引用的方式併入本文中。 如圖3至圖4中所示,積層製造裝置200可包含一裝置外殼201、一致動總成202及擠壓頭205。積層製造裝置200亦可包含平台206。在一些情況中,擠壓頭205可經由致動總成202在z軸(即,垂直軸)上平移,而積層製造裝置200之平台206可在x及y方向(即,水平軸)上移動。在其他情況中,擠壓頭205可具有一固定平台上方之全三維移動(例如,x-y-z移動)。 圖3至圖4描繪如何使用積層製造裝置200形成客製化鞋楦構件102。具體地,當擠壓頭205鋪設連續材料層時形成鞋楦構件102。例如,圖3展示形成鞋楦構件102之一初始層210。在圖4中,鞋楦構件102之最後層212已形成。 在一些實施例中,亦可用積層製造程序形成外層104。如圖5中所見,一旦已形成鞋楦構件102,積層製造裝置200即可用於在鞋楦構件102上形成外層104。在圖5中所示之實施例中,外層104之一頂部部分220已形成(例如,列印)至鞋楦構件102之外表面106上。 雖然例示性實施例描繪鞋楦構件102在外層104被積層之前完全形成,但是在其他實施例中,鞋楦構件102及外層104可被製造,使得在鞋楦構件102已完全形成之前擠壓外層104之一些部分。例如,在另一實施例中,可在形成鞋楦構件102 (及外層104)之中足及/或後跟部分之前形成鞋楦構件102之前足部分及外層104之關聯前足部分。 亦將暸解,在其他實施例中,可依任何其他方式形成鞋楦系統100。例如,在圖6中所示之一替代實施例中,一鞋楦構件300可與可模製材料302 (例如,一熔融的熱塑性材料)之一容器310結合。在將鞋楦構件300之一部分304浸入可模製材料302中時,部分304可覆蓋有可模製材料302之一層320。層320可固化以在鞋楦構件300上形成一外層之一部分。雖然在此實例中僅鞋楦構件300之一部分被覆蓋,但是將暸解,此一方法可用於在鞋楦構件300之整個外部上方形成一外層。在另外其他實施例中,用於形成一外層之一材料可被噴灑至鞋楦構件300上或以其他方式用熱及/或壓力施加。 圖7至圖8繪示使用一編織裝置400使一編織鞋類組件形成至鞋楦系統100上之一方法之示意圖。例示性編織裝置可包含任何外層編織裝置、徑向編織裝置及三維編織裝置。編織裝置400可經組態以將伸張元件(例如,線)施加至一鞋楦上以在鞋楦上方形成編織線。為此目的,編織裝置400可經組態為具有複數個線軸402,該等線軸402被配置在編織裝置400之一周邊部分404上。來自線軸402之線406可朝向一中心編織區域410徑向向內饋送。 例示性方法在一鞋楦系統上提供一編織鞋類組件。如貫穿此[實施方式]及在申請專利範圍中使用的術語「編織鞋類組件」(或簡稱「編織組件」)指的是伸張線(例如,線、紗等)的任何配置,其中一些伸張線與其他伸張線編織在一起。此外,如本文中使用的編織指的是其中三根或更多根材料線交織之任何配置。 在利用用於製作一鞋面之一編織裝置的實施例中,用於製造鞋面之材料可主要由不同種類的伸張元件(或伸張線)組成,該等伸張元件可使用編織裝置形成為一鞋面。此等伸張元件可包含,但不限於:線、紗、細繩、金屬線、纜線以及可能的其他種類的伸張元件。如本文中使用,伸張元件可描述具有比對應直徑大得多的長度之大致上細長材料。換言之,伸張元件可為近似一維元件,其與可大致上為近似二維(例如,具有比其等長度及寬度小得多的厚度)的紡織品材料之片或層形成對比。例示性實施例繪示不同種類的線的使用,但是將暸解,可在其他實施例中使用與一編織裝置相容的任何其他種類的伸張元件。 可結合一編織裝置使用之例示性線或紗包含由下列材料製成之纖維,其包含但不限於:羊毛、亞麻及棉以及其他一維材料。纖維可由動物、植物、礦物及合成源形成。動物材料可包含例如毛髮、動物皮、動物皮膚、絲等。植物材料可包含例如草、燈心草、***、劍麻等。礦物材料可包含例如玄武岩纖維、玻璃纖維、金屬纖維等。合成纖維可包含例如聚酯、芳族聚醯胺、丙烯酸、碳纖維以及其他合成材料。 在圖7中,使一編織鞋類組件形成至鞋楦系統100上之程序可藉由將鞋楦系統100與編織裝置400結合而開始。在一些情況中,鞋楦系統100可與編織裝置400對準在特定定向中,使得鞋楦系統100之一所要部分與鞋楦系統100之一中心編織區域410對準。 在圖8中,鞋楦系統100可被饋送穿過編織裝置400之中心編織區域410以形成一編織鞋面之形式之一編織鞋類組件。在一些實施例中,鞋楦系統100可由一操作者手動饋送穿過編織裝置400。在其他實施例中,一連續鞋楦饋送系統可用於將鞋楦系統100饋送穿過編織裝置400。本實施例可利用用於形成一編織鞋面之任意方法及系統,其等如揭示於2014年9月24日申請且標題為「Article of Footwear with Braided Upper」之Bruce的美國專利公開案第_______號(現美國專利申請案第14/495,252號)中,該案完整內容以引用的方式併入本文中。此外,一些實施例可包含用於固持物件及/或饋送物件穿過編織裝置之額外預備件。例如,一些實施例可包含支撐平台、軌道、傳送器或可促進饋送物件穿過編織裝置之其他結構。 如圖8中所示,當鞋楦系統100被饋送穿過編織裝置400時,繞鞋楦構件102形成一編織鞋類組件500。具體地,編織鞋類組件500形成至鞋楦系統100之外層104之一外表面上。在此情況中,編織鞋類組件500包括符合鞋楦系統100之一連續編織鞋面組件,且因此具有鞋楦系統100之近似幾何形狀。 圖9至圖11繪示一編織鞋類組件之線與一外層結合之一程序中之步驟。如本文中使用,結合可指使一編織鞋類組件之線與組成一鞋楦系統之一外層之材料接合、熔合、固定或以其他方式附接。首先參考圖9,在從編織裝置400移除具有編織鞋類組件500之鞋楦系統100後,可移除編織鞋類組件500之一部分。具體地,在一些情況中,部分510可鄰近編織鞋類組件500之一踝帶部分512,其可形成一開口514,最終可穿過該開口514移除鞋楦構件102。 最初,在圖9中所示之構形中,編織鞋類組件500之線550被安置在外層104之外表面108上。為可開始結合線550與外層104,可使用熱源600加熱鞋楦系統100,如圖10及圖11中所示。為簡明的目的,在圖10及圖11中描繪兩個熱源,但是在其他實施例中,可使用任何數目的熱源。此外,熱源600可相對於鞋楦系統100定位在任何位置及/或定向。在一些情況中,熱源600可經組態為一傳送器系統上之一站,使得具有編織鞋類組件500之鞋楦系統100在離開編織裝置400後自動移近熱源600。 如圖10中所見,當外層104之溫度升高至高於一預定溫度(例如,諸如玻璃態化溫度或熔融溫度之特性溫度)時,外層104可變為柔軟。編織鞋類組件500中之張力可易於將線550拉至外層104中(即,徑向向內),該外層104現為柔軟的且能夠收納線550。接下來參考圖11,組成外層104之材料在繼續加熱的情況下變為足夠柔軟以繞線550模製。此允許外層104之材料填充在線550之間之空間中,藉此部分(或完全)圍封線550。 在編織鞋類組件500及外層104已被結合或以其他方式整合在一起後,可移除熱源600。在一些情況中,編織鞋類組件500及組成外層104之材料可被冷卻至低於預定溫度,使得組成外層104之材料再次形成實質上固體材料。在一些情況中,可使用風扇及/或其他冷卻機構促進冷卻。 如圖12中所見,在冷卻後,可從編織鞋類組件500及外層104移除鞋楦構件102。在一些實施例中,編織鞋類組件500及外層104已被結合在一起以形成一複合結構650。此外,複合結構650可呈一鞋類鞋面之形式。 如貫穿此[實施方式]及在申請專利範圍中使用之術語「複合結構」指的是由兩種或更多種材料組成之一結構。在例示性實施例中,複合結構經構形具有複數條伸張線,其等被配置在一編織構形中(即,編織鞋類組件),其中線至少部分固定至一可熱變形材料(例如,一熱塑性材料)。複合結構可具有對應於可熱變形材料及內嵌伸張線兩者之材料性質。因此,可熱變形材料在被冷卻至低於玻璃態化溫度(或熔融溫度)時,可充當一接合劑(例如,樹脂、基質及/或黏著劑),該接合劑至少部分塗佈伸張線且限制其等的相對移動。特定言之,複合結構可提供比單單編織鞋類組件更硬質的結構。 為簡明的目的,組成外層104之材料在與編織鞋類組件500結合且冷卻至一固體後可被稱作一複合結構之一基質部分。此外,組成基質部分之材料可被稱作基質材料。藉由將一編織鞋類組件之線與一基質部分結合,線可被部分固定在適當位置中,藉此減小線變為混亂之傾向及/或減小原始編織圖案隨時間而劣化之傾向。此基質部分亦可賦予改進的耐磨性、強度、支撐力及甚至緩衝作用(取決於所選擇的基質材料)。在一些情況中,將編織鞋類組件與一基質部分結合亦可幫助減小一編織鞋類組件中之非所要拉伸。更進一步,基質部分(例如,一熱塑性材料)可填充線之間的空間以減小污垢及/或碎屑穿過鞋面進入物件之傾向。換言之,在一些情況中,一基質部分可充當一編織鞋類組件之開放網狀織物結構之一密封劑。 一些實施例可進一步包含將鞋底元件接合至複合結構650之步驟。在圖13中,一例示性實施例包含一第一鞋底組件700及一第二鞋底組件702,其等已接合至複合結構650以形成一成品鞋類物件670。鞋底組件可併入一或多個鞋底元件,包含內底元件、中底元件及/或外底元件。此外,可使用黏著劑、縫合、焊接或所屬領域中已知用於結合鞋面與鞋底之任何其他方法來將鞋底組件結合至複合結構(例如,一鞋面)。 在圖13中,看見複合結構650係由(一編織鞋類組件的)線550組成,該等線550與一基質部分652結合。如已討論,基質部分652係由先前形成鞋楦系統100 (見圖1)之外層104的材料(例如,熱塑性材料)組成。在此情況中,基質部分652形成一基質,線550可係部分(或完全)內嵌在該基質內。 圖14繪示被穿著在一使用者之一腳部799上之鞋類物件670之一示意等角視圖。圖15至圖17繪示如沿著圖14中指示之一切割表面取得之一複合結構的各種可能構形。如圖15中所見,在一些實施例中,線550可係暴露於鞋類物件670之一外表面672上。在此情況中,線550可係部分但非完全內嵌於基質部分652內。此外,線550可係由基質部分652之一內表面653與腳部799分開。可藉由在線550有時間完全地穿過外層104之前冷卻外層104來達成此一構形。此構形可藉由限制線550與腳部799之間的接觸來改進腳部799的腳感。 替代地,如圖16中所示,線550可係完全圍封於基質部分652內,使得線550的部分不暴露於基質部分652之內表面653或外表面655上。可藉由使基質部分652形成為具有實質上大於線550之一直徑740之一厚度730來達成此一構形。此構形可改進腳感且減小對線550之磨損,此係因為線550被保護以防與腳部及鞋類物件670外部的物件接觸。 在圖17中所示之又一構形中,線550可係部分但非完全內嵌在基質部分652內。在此情況中,線550可被暴露於基質部分652之內表面653上,但可能不暴露於基質部分652之外表面655上。可藉由在冷卻外層104之前允許線550有時間收縮穿過外層104的整個厚度來達成此一構形。此構形可提供線550抵抗與基質部分652之外表面655上之物件之接觸之增大的耐磨性。當然,在另外其他實施例中,基質部分652可足夠薄,使得線550暴露於基質部分652之一內表面及一外表面兩者上。 實施例可包含用於變化用於一鞋類物件之一複合結構之材料特性的預備件。在一些實施例中,一鞋楦系統可經構形為具有一外層,該外層具有不同厚度的區域或區。當與一編織鞋類組件之線接合時,不同厚度之區域或區藉此可跨物件之不同區提供不同材料特性。此等材料特性可包含但不限於:硬質性、硬度、拉伸、撓性以及可能的其他材料特性。例如,具有大於一第二區域之一第二厚度之一第一厚度之一第一區域可為第一區域提供比第二區域大的硬質性。 圖18繪示用於形成一鞋楦系統800之一程序中之一步驟。參考圖18,已使用積層製造裝置900形成一鞋楦構件802。此時,積層製造裝置900之一擠壓頭905正形成鞋楦系統800之一外層804。更具體地,外層804形成有一趾部區域810及一鄰近鞋皮區域812。如圖18中所見,趾部區域810已形成為具有比鞋皮區域812大的厚度。換言之,與在鞋皮區域812中相比,更多材料已在趾部區域810中被鋪設至鞋楦系統802上。 圖19繪示由圖18中所示之積層製造程序生產之鞋楦系統800之一實施例之一示意圖。參考圖19,鞋楦系統800包含一趾部區域810以及一腳踝區域816。在本實施例中,趾部區域810及腳踝區域816兩者具有實質上大於外層804之其餘區域的厚度。具體地,趾部區域810具有一第一厚度830,腳踝區域816具有一第二厚度832,且外層804之其餘部分(例如,鞋皮區域812)具有一第三厚度834。在例示性構形中,第一厚度830大於第三厚度834。此外,第二厚度832亦大於第三厚度834。 圖20繪示可藉由使一編織鞋類組件1002形成於鞋楦系統800上方(見圖19)且施加熱以將外層804與編織鞋類組件1002接合而形成複合結構1000之一例示性構形。此外,複合結構1000可附接至鞋底組件1001以形成一鞋類物件1003。參考圖19及圖20,外層804之趾部區域810已與編織鞋類組件1002之線1004組合以形成複合結構1000之一加厚趾部區域1010。同樣地,外層804之腳踝區域816已與編織鞋類組件1002之線1004組合以形成複合結構1000之一加厚腳踝區域1012。 如圖20中所示,趾部區域1010具有一第一厚度1020,腳踝區域1012具有一第二厚度1022,且複合結構1000之其餘區域(例如,鞋皮區域1014)具有一第三厚度1024。此外,第一厚度1020大於第三厚度1024,且第二厚度1022大於第三厚度1024。與例如複合結構1000之鞋皮區域1014及其他區域相比,此配置可導致趾部區域1010及腳踝區域1012之一更硬質構形。 圖21及圖22繪示在一腳部1100伸入包含複合結構1000之一鞋類物件內的情況下複合結構1000之趾部區域1010及鞋皮區域1014之一些之特寫之示意圖。圖21表示其中複合結構1000未經受任何力之一狀態,而圖22表示其中力已被施加至複合結構1000之一狀態。 在圖22中,一第一力1202施加在趾部區域1010處。此外,一第二力1204施加在鞋皮區域1014處。為比較趾部區域1010與鞋皮區域1014之材料性質的目的,考慮在此情況中,第一力1202及第二力1204係等效的。此一力曲線可在一球同時撞擊複合結構1000之趾部區域1010及鞋皮區域1014時達成。 如藉由比較圖21及圖22所見,區域1010之相對硬質性防止趾部區域1010在施加第一力1202的情況下明顯變形。相比之下,看見鞋皮區域1014歸因於其相對較低硬質性而在第二力1204下變形。此構形因此允許針對趾部之增大保護。換言之,在一些情況中,趾部區域1010可依類似於一鞋頭蓋及/或一趾墊的方式作用以保護趾部。雖然圖21及圖22繪示趾部區域1010對鞋皮區域1014之相對硬質性,但是可暸解腳踝區域1012可同樣地經構形以依類似於趾部區域1010之方式抵抗變形。腳踝區域1012之此構形可允許腳踝區域1012提供與趾部區域1010提供給趾部類似的強度及支撐給腳踝。 圖23繪示一鞋楦系統之一外層之變化厚度之數個不同區或區域,其可導致由外層及一編織鞋類組件建構之一複合結構之厚度的相應變化。參考圖23,鞋楦系統1300包含鞋楦構件1302及外層1304。在一些實施例中,外層1304可包含一加厚底部鞋底區域1310,該加厚底部鞋底區域1310可在外層1304被併入一鞋類物件中時在一腳部下方提供額外強度、支撐力及可能的緩衝作用(例如,提供至腳部之腳底)。在一些實施例中,外層1304可包含一加厚後跟區域1312,該加厚後跟區域1312可在外層1304被併入一鞋類物件中時提供額外強度、支撐力及可能的緩衝作用給一腳部之腳跟。 變化厚度之區可能不限於具有大面積之區域。在一些情況中,變化厚度之區可形成為各種幾何形狀,包含細長形狀(例如,脊部、通道等)。例如,在一些實施例中,外層1304可包含一加厚鞋眼片區域1314,該加厚鞋眼片區域1314可促進併入外層1304之一物件中之孔眼之改進強度。特定言之,在一些情況中,孔眼可形成為外層1304之鞋眼片區域1314內的孔,且可進一步藉由一相關聯編織鞋類組件之線加固。圖23中看見鞋眼片區域1314具有限制鞋楦系統1300之一緊固區域1315之周邊之一大致上細長形狀。在一些實施例中,外層1304可例如,在趾部區域1321中併入加厚脊部區域1318 (或脊部部分)。此等脊部區域1318可包括外層1304中的增加厚度的帶或線。此等脊部可在形成一複合結構之程序期間維持其等的近似形狀,使得脊部可為一成品鞋類物件提供控球或其他功能。 雖然複合結構(包含外層)之下列實施例的特徵在於具有比結構的其餘部分厚的各種區或區域,但是其他實施例可併入厚度實質上比其餘部分小的區域。例如,設想在另一實施例中,一複合結構之大部分可具有一第一厚度,而一區域(例如,一內側區域)可具有實質上小於第一厚度之一第二厚度。較小厚度之此等區域可促進一腳部之一些區域上之增大的腳感或立體感受,此係因為此等區域可不如鞋面之其餘部分硬質且因此提供更大觸感給一穿著者。 將暸解,其他實施例可在一鞋楦構件之一外表面上使用一材料之選擇性施加區域。特定言之,一外層無需被施加遍及一鞋楦構件之整個表面,且取而代之可施加在選擇區域中。舉一實例,實施例可包含具有靠近趾部、鞋皮、腳跟及/或腳踝之單獨(例如,不同)區域之一外層。在此等情況中,僅一編織組件之一些部分或區域可與一外層結合,使得所得結構可包括分開的複合區域。例如,一實施例可包含具有內嵌在一趾部區域中之一基質部分中之編織線之一複合區域之一鞋面,但可僅在一鞋皮區域中具有編織線(即,無基質部分)。可熱變形材料之此等選擇性施加可為一所得鞋面提供可變硬質性的區域。 雖然已描述各種實施例,但該描述係意欲為例示性而非限制性且一般技術者將明白在本發明之範疇內之多得多的實施例及實施方案係可行的。因此,不應限制該等實施例,惟根據隨附申請專利範圍及其等之等效物除外。此外,可在隨附申請專利範圍之範疇內作出各種修改及變化。
10‧‧‧前足部分
12‧‧‧中足部分
14‧‧‧後跟部分
16‧‧‧外側
18‧‧‧內側
100‧‧‧鞋楦系統
102‧‧‧鞋楦構件
104‧‧‧外層
106‧‧‧外表面
107‧‧‧內表面
108‧‧‧外表面
110‧‧‧底側
112‧‧‧頂側
130‧‧‧厚度
132‧‧‧中心軸
140‧‧‧厚度
180‧‧‧熱源
190‧‧‧部分
200‧‧‧積層製造裝置
201‧‧‧裝置外殼
202‧‧‧致動總成
205‧‧‧擠壓頭
206‧‧‧平台
210‧‧‧初始層
212‧‧‧最後層
220‧‧‧頂部部分
300‧‧‧鞋楦構件
302‧‧‧可模製材料
304‧‧‧部分
310‧‧‧容器
320‧‧‧層
400‧‧‧編織裝置
402‧‧‧線軸
404‧‧‧周邊部分
406‧‧‧線
410‧‧‧中心編織區域
500‧‧‧編織鞋類組件
510‧‧‧部分
512‧‧‧踝帶部分
514‧‧‧開口
550‧‧‧線
600‧‧‧熱源
650‧‧‧複合結構
652‧‧‧基質部分
653‧‧‧內表面
655‧‧‧外表面
670‧‧‧鞋類物件
672‧‧‧外表面
700‧‧‧第一鞋底組件
702‧‧‧第二鞋底組件
730‧‧‧厚度
740‧‧‧直徑
799‧‧‧腳部
800‧‧‧鞋楦系統
802‧‧‧鞋楦構件
804‧‧‧外層
810‧‧‧趾部區域
812‧‧‧鞋皮區域
816‧‧‧腳踝區域
830‧‧‧第一厚度
832‧‧‧第二厚度
834‧‧‧第三厚度
900‧‧‧積層製造裝置
905‧‧‧擠壓頭
1000‧‧‧複合結構
1001‧‧‧鞋底組件
1002‧‧‧編織鞋類組件
1004‧‧‧線
1010‧‧‧加厚趾部區域
1012‧‧‧加厚腳踝區域
1014‧‧‧鞋皮區域
1020‧‧‧第一厚度
1022‧‧‧第二厚度
1024‧‧‧第三厚度
1202‧‧‧第一力
1204‧‧‧第二力
1300‧‧‧鞋楦系統
1302‧‧‧鞋楦構件
1304‧‧‧外層
1310‧‧‧加厚底部鞋底區域
1312‧‧‧加厚後跟區域
1314‧‧‧加厚鞋眼片區域
1315‧‧‧緊固區域
1318‧‧‧加厚脊部區域
1321‧‧‧趾部區域
12‧‧‧中足部分
14‧‧‧後跟部分
16‧‧‧外側
18‧‧‧內側
100‧‧‧鞋楦系統
102‧‧‧鞋楦構件
104‧‧‧外層
106‧‧‧外表面
107‧‧‧內表面
108‧‧‧外表面
110‧‧‧底側
112‧‧‧頂側
130‧‧‧厚度
132‧‧‧中心軸
140‧‧‧厚度
180‧‧‧熱源
190‧‧‧部分
200‧‧‧積層製造裝置
201‧‧‧裝置外殼
202‧‧‧致動總成
205‧‧‧擠壓頭
206‧‧‧平台
210‧‧‧初始層
212‧‧‧最後層
220‧‧‧頂部部分
300‧‧‧鞋楦構件
302‧‧‧可模製材料
304‧‧‧部分
310‧‧‧容器
320‧‧‧層
400‧‧‧編織裝置
402‧‧‧線軸
404‧‧‧周邊部分
406‧‧‧線
410‧‧‧中心編織區域
500‧‧‧編織鞋類組件
510‧‧‧部分
512‧‧‧踝帶部分
514‧‧‧開口
550‧‧‧線
600‧‧‧熱源
650‧‧‧複合結構
652‧‧‧基質部分
653‧‧‧內表面
655‧‧‧外表面
670‧‧‧鞋類物件
672‧‧‧外表面
700‧‧‧第一鞋底組件
702‧‧‧第二鞋底組件
730‧‧‧厚度
740‧‧‧直徑
799‧‧‧腳部
800‧‧‧鞋楦系統
802‧‧‧鞋楦構件
804‧‧‧外層
810‧‧‧趾部區域
812‧‧‧鞋皮區域
816‧‧‧腳踝區域
830‧‧‧第一厚度
832‧‧‧第二厚度
834‧‧‧第三厚度
900‧‧‧積層製造裝置
905‧‧‧擠壓頭
1000‧‧‧複合結構
1001‧‧‧鞋底組件
1002‧‧‧編織鞋類組件
1004‧‧‧線
1010‧‧‧加厚趾部區域
1012‧‧‧加厚腳踝區域
1014‧‧‧鞋皮區域
1020‧‧‧第一厚度
1022‧‧‧第二厚度
1024‧‧‧第三厚度
1202‧‧‧第一力
1204‧‧‧第二力
1300‧‧‧鞋楦系統
1302‧‧‧鞋楦構件
1304‧‧‧外層
1310‧‧‧加厚底部鞋底區域
1312‧‧‧加厚後跟區域
1314‧‧‧加厚鞋眼片區域
1315‧‧‧緊固區域
1318‧‧‧加厚脊部區域
1321‧‧‧趾部區域
參考以下圖式及描述可更好地理解實施例。圖式中之組件不一定按比例,而是重點在於繪示實施例之原理。此外,在圖式中,相同參考數字指示不同視圖中的相應部分。 圖1係包含一鞋楦構件及一外層之一鞋楦系統之一實施例之一示意圖; 圖2係經歷加熱之一鞋楦系統之一實施例之一示意圖; 圖3至圖5係根據一實施例之使用一積層製造機形成一鞋楦構件之步驟之示意圖; 圖6係將一外層施加至一鞋楦構件之另一方法之一實施例之一示意圖; 圖7至圖8係根據一實施例之使一編織鞋類組件形成至一鞋楦系統上之步驟之示意圖; 圖9係根據一實施例之在收納一編織鞋類組件後之一鞋楦系統之一示意圖,其包含移除編織鞋類組件之一部分之一步驟; 圖10至圖11係根據一實施例之被加熱以形成一複合結構之一編織鞋類組件及一外層之示意圖; 圖12係根據一實施例之從一複合結構移除一鞋楦構件之一步驟之一示意圖; 圖13係根據一實施例之包含一複合結構及鞋底組件之一成品鞋類物件之一示意圖; 圖14係根據一實施例之由一使用者穿著之一鞋類物件之一示意圖; 圖15繪示根據一第一實施例之一複合結構中之線之一可能構形; 圖16繪示根據一第二實施例之一複合結構中之線之一可能構形; 圖17繪示根據一第三實施例之一複合結構中之線之一可能構形; 圖18係根據一實施例之製作包含變化厚度之區域之一鞋楦系統之一程序中之一步驟之一示意圖; 圖19係具有一外層之一鞋楦系統之一實施例之一示意圖,該外層具有變化厚度之區域; 圖20係具有變化厚度之區域之一複合結構之一實施例之一示意圖; 圖21至圖22繪示一複合結構之不同區域對所施加力之回應之示意圖;及 圖23係包含一外層之一鞋楦系統之一實施例之一示意圖,該外層具有變化厚度之各種不同區域。
1000‧‧‧複合結構
1001‧‧‧鞋底組件
1010‧‧‧加厚趾部區域
1014‧‧‧鞋皮區域
Claims (1)
- 一種鞋類物件之鞋面,其包括: 一複合結構,其形成該鞋面之至少一部分,該複合結構包括; 一基質材料;及 一編織鞋類組件,其與該基質材料熱結合,使得該編織鞋類組件內嵌在該基質材料內; 一第一部分,其具有一第一厚度,該第一厚度包括該複合結構; 一第二部分,其具有一第二厚度,該第二厚度包括該複合結構,其中該第一厚度大於該第二厚度。
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