WO2017095342A1

WO2017095342A1 - Single piece shoe-upper and manufacturing method

Info

Publication number: WO2017095342A1
Application number: PCT/TR2016/000171
Authority: WO
Inventors: Fazıl AYDIN
Original assignee: Ayfa Ayakkabicilik Sanayi̇ Ve Diş Ti̇caret Ltd. Şti̇
Priority date: 2015-12-04
Filing date: 2016-11-25
Publication date: 2017-06-08

Abstract

The present invention which relates to the shoe-upper which is manufactured as a single piece through injection (plastic injection) of thermoplastics (top material) such as PVC (Polyvinyl Chloride), TPU (Thermoplastic Polyurethane) etc. on the genuine leather, artificial leather and all types of textile and woven product (base material) placed in prefabricated moulds and blocks and the manufacturing method with respect to the mentioned shoe-upper is generally composed of; the shoe-upper mould (1) enabling the manufacture of a single piece shoe- upper (5) in the desired color, texture, effect, design and material through plastic injection application; the mould shoe-upper gap (1.1) providing the manufacturing of a single piece shoe-upper (5) in the desired color, texture, effect, design and material, in the shoe-upper mould (1); color surface (1.1.1) providing the formation of the colored parts (5.1) on the shoe-upper (5) surface; texture surface (1.1.2) providing the formation of the texture parts (5.2) on the shoe-upper (5) surface; bright surface (1.1.3) providing the formation of polished parts (5.3) on the shoe-upper (5) surface; design surface (1.1.4) providing the formation of design parts (5.4) on the shoe-upper (5) surface; base material (3) of genuine leather, artificial leather and/or any type of textile and woven product placed in the shoe-upper mould (l) before the plastic injection application; shoe-upper top material (4) of thermoplastic material such as PVC (Polyvinyl Chloride), TPU (Thermoplastic Polyurethane) etc., which is injected into the shoe-upper mould (1) by plastic injection application and which welds with the base material (3) by filling the shoe-upper mould gap (1.1); injection holes (1.2) providing the injection of the melted shoe-upper top material (4.1) into the shoe-upper mould (1); injection channels (1.4) providing the melted shoe-upper top material (4.1) from the injection end (6) to reach the injection holes (1.2).

Description

SINGLE PIECE SHOE-UPPER AND MANUFACTURING METHOD

The present invention is related to the shoe-upper which is manufactured as a single piece through injection (plastic injection) of thermoplastics (top material) such as PVC (Polyvinyl Chloride), TPU (Thermoplastic Polyurethane) etc. on the real leather, artificial leather and all types of textile and woven product (base material) placed in prefabricated moulds and blocks and the manufacturing method with respect to the mentioned shoe-upper. A shoe is generally composed of two main parts. These parts are named as shoe-upper and shoe sole. Shoe-upper is defined as the upper part of the shoe except the shoe sole. This part which covers the user's foot is the most significant part of the shoe manufacturing process due to its form and structure. In the state of the art, shoe-uppers are manufactured through joining of the parts of different shapes by using various methods (sewing, gluing etc.) In the state of the art; the parts forming the shoe-upper (toe cap, vamp, top line, inner lining, outer lining, facing, back strap, holes etc.) are cut one by one from different materials (genuine leather, artificial leather, textile products, rubber, various plastics etc.). the shoe- upper parts cut in various shapes are joined in a manner to form the upper part of the shoe by the methods such as sewing, gluing etc.. The shoe-upper manufacturing in the mentioned manner and processing of the shoe-upper surface (application of figures, color, embossments, effects, design etc.) is called shoe-upper processing in shoe sector. Shoe-upper processing costs constitute about one-fourth of all the costs of the shoe that the consumers pay. There may be defects in the shoe-upper pieces during cutting performed manually. Moreover; the shoe-upper pieces joined by the methods such as sewing, gluing etc. can break off from the joints during the usage. This state reduces the durability of the shoes.

Specifically, the upper parts of the sports shoes are composed of many different sections. There are colors, designs, embossments, strips, supports etc. on the upper parts of the sports shoes. The design and structure of the shoe-upper may be different as based on the branch of the sports where the sports shoes shall be used (football, basketball, jogging etc.). This state causes increases in the cost of shoe-upper processing and shoe-upper labor costs in the manufacturing of the sports shoes.

In order to overcome the disadvantages mentioned above; improvements for reduction of the number of shoe-upper pieces were made in the state of the art. The most important one of such improvements was the method in which the shoe-upper pieces are obtained by plastic casting and/or injection. Plastic injection is the manufacturing method in which the plastic raw material melted with the help of heat is injected into a mould and shaped, then cooled and taken out of the mould. Plastic injection is generally used in the shoe sector, in the manufacturing of the soles of the shoes. In the state of the art, there is a patent document no KR201 10039103 with the title Integrally formed shoe uppers with shoe parts and manufacturing method thereof. In this document, manufacturing of seamless shoe-uppers (shoe-upper parts) through injection moulding is described. In this method however, the shoe-upper parts with different characteristics (material characteristics, color, texture, etc.) are manufactured manually one by one (through injection moulding and cutting). These shoe-upper parts; are glued on the base material and on each other in layers by synthetic resin and this way, the mentioned shoe-uppers are obtained. In the mentioned method; the shoe-upper parts are manufactured in layers. This way; the costs are lower and the manufacturing processes are shorter when compared to the traditional methods (cutting, sewing, gluing etc.). However, in this method described in the document no KR201 10039103; it is not possible to have shoe-uppers with diversity of the textures, colors, materials, figures etc on them, in a single mould and in a single time (without the j oining procedures) .

In the state of the art; there is no development or method enabling the manufacture of the shoe-uppers with different textures, colors, materials, figures etc. on their surfaces, through a single process. Due to this reason, it is not possible to manufacture in a single time and as a single piece, the shoe-uppers with different materials, textures, colors, figures on the surface, by using the present techniques.

The present invention which relates to the shoe-upper which is manufactured as a single piece through injection (plastic injection) of thermoplastics (top material) such as PVC (Polyvinyl Chloride), TPU (Thermoplastic Polyurethane) etc. on the genuine leather, artificial leather and all types of textile and woven product (base material) placed in prefabricated moulds and blocks and the manufacturing method with respect to the mentioned shoe-upper completely overcomes the disadvantages mentioned above and it is characterized by; ability to use genuine leather, artificial leather or any textile product as the base material; use of thermoplastics such as PVC (Polyvinyl Chloride), TPU (Thermoplastic Polyurethane) as the shoe-upper top material; furthering of the thermoplastics used as shoe-upper top material by plastic injection method on the base material and welding with the base material; this way, ability to manufacture a show-upper as a single piece, which is composed of different materials; placement of the base material on the prefabricated moulds; preparation of the moulds as based on the structural and visual characteristics of the shoe-upper targeted; application of the arrangement enabling texture, figure, design, effect, color etc. on the shoe- upper gap in the moulds; moreover, pouring jointly the materials of different types and/or colors by arrangement of the feeders on the moulds and welding them on the base material; this way, achieving a shoe-upper with various designs, figures, textures, colors etc. on the surface, as a single piece from a single mould in a single time; and as a result, manufacturing of shoe-uppers with any look appropriate for any purpose with this method; reduction of shoe- upper processing costs by the present invention; reduction of shoe-upper manufacturing time; manufacturing of stitch-free, glue-free, seamless shoe-uppers by the present invention method; accordingly, manufacturing of robust and economic shoe-uppers by the present invention method. The present invention related to shoe-upper manufactured from a single mould as a single piece without application of any joining procedure such as gluing, sewing etc. and with the desired designs, colors, effects and texture on the surface and the manufacturing method of the mentioned shoe-upper. The mentioned shoe-upper can be manufactured as a single piece from various materials. There is no joining application such as sewing, gluing etc. on the mentioned shoe-upper. It is obtained from various materials, as a single piece from a single mould. The desired designs, colors, effects and textures on the external and/or internal surface of the mentioned shoe- upper are ready as the shoe-upper comes out of the mould.

This way, the present shoe-upper manufacturing method; enables the manufacturing of the shoe-uppers as a single piece, appropriate for the desired purpose, at the desired visual and structural design. In the mentioned method, the shoe-uppers are manufactured within the moulds by plastic injection application. The negative of the shoe-upper form is prepared in the mould as the shoe-upper gap. For example; the embossments and rises designed on the shoe-upper surface are processed as carvings and indents in the mould gap. During the preparation of the mould shoe-upper gap; the form of all the materials to be welded on the base material and all the surfaces to be processed are taken into consideration. In the mould gap; there may be design embossments and/or indents, parts with color and/or polish and/or sections forming textures. This way; the shoe-upper with different textures, colors, designs etc. on the surface can be obtained as a single piece. In the mentioned method; the shoe-upper top material/s are welded by plastic injection application into the base material/s surface/s placed in the mould. The melted top material/s injected into the mould with the plastic injection application proceed over the base material surface and fill in the mould gap. The processing (design, embossment, indent, color, polish, texture etc.) applied in the mould gap naturally appear in the top material filling the mould gap.

As the base material; genuine leather, artificial leather and/or any textile product can be used. As shoe-upper top material; thermoplastics such as PVC (Polyvinyl Chloride), TPU (Thermoplastic Polyurethane) etc. are used. Thermoplastics in melted form are injected into the shoe-upper mould by plastic injection method. The thermoplastics injected reach the shoe- upper mould through the injection holes on the mould. The thermoplastics reaching the shoe- upper mould fill the mould gap and further over the base material. The thermoplastics fill the mould gap and form the shoe-upper top material. The base material and shoe-upper top material weld in the mould (if required, a force of 200 - 250 tons is applied on the mould) and become a single piece shoe-upper. Top material in a melted state, which is injected to the mould with plastic injection, reaches the injection holes through the channels opened on the mould. The mentioned injection channels distribute the melted thermoplastic material and provide that it reaches the mould gap from different points of the mould. This way, the top material fills the mould gap smoothly. Injection channels following separate ways independent of each other can be opened for the filling of the mould gap by different top materials jointly. The present invention is explained in detail through sampling with the attached drawings; such drawings are as;

Figure 1 is the interior part view of the shoe-upper mould.

Figure 2 is the interior parts view of the shoe-upper mould and the mould cover.

Figure 3 is the view of the open shoe-upper mould in which base material is placed.

Figure 4 is the view of the shoe-upper mould in which the base material is placed, while closing.

Figure 5 is the view of the closed state of the shoe-upper mould.

Figure 6 is the view of the shoe-upper mould when melted thermoplastic is being injected into the injection channels.

Figure 7 is the view of the single piece shoe-upper when being taken out of the mould.

Figure 8 is the general view of the single piece shoe-upper.

LEGEND

NO NAME OF THE PART

1 Shoe-upper mould

1.1 Shoe-upper mould gap

1.1.1 Color surface

1.1.2 Texture surface

1.1.3 Bright surface

1.1.4 Design surface

1.2 Injection holes

1.3 Mould guide

1.4 Inj ection channels

2 Mould cover 2.1 Guide hole

3 Base material

4 Shoe-upper top material

4.1 Melted shoe-upper top material

5 Shoe-upper

5.1 Colored part

5.2 Texture part

5.3 Polished part

5.4 Design part

5.5 Injection mould excess

6 Injection end

The present invention which relates to the shoe-upper which is manufactured as a single piece through injection (plastic injection) of thermoplastics (top material) such as PVC (Polyvinyl Chloride), TPU (Thermoplastic Polyurethane) etc. on the genuine leather, artificial leather and all types of textile and woven product (base material) placed in prefabricated moulds and blocks and the manufacturing method with respect to the mentioned shoe-upper is generally composed of; the shoe-upper mould(l) enabling the manufacture of a single piece shoe- upper^) in the desired color, texture, effect, design and material through plastic injection application; the mould shoe-upper gap(l .l) providing the manufacturing of a single piece shoe-upper(5) in the desired color, texture, effect, design and material, in the shoe-upper mould(l); color surface( 1.1.1) providing the formation of the colored parts(5.1) on the shoe- upper^) surface; texture surface(1.1.2) providing the formation of the texture parts(5.2) on the shoe-upper(5) surface; bright surface(1.1.3) providing the formation of polished parts(5.3) on the shoe-upper(5) surface; design surface(1.1.4) providing the formation of design parts(5.4) on the shoe-upper(5) surface; base material(3) of genuine leather, artificial leather and/or any type of textile and woven product placed in the shoe-upper mould(l) before the plastic injection application; shoe-upper top material(4) of thermoplastic material such as PVC (Polyvinyl Chloride), TPU (Thermoplastic Polyurethane) etc., which is injected into the shoe-upper mould(l) by plastic injection application and which welds with the base material(3) by filling the shoe-upper mould gap(l.l); injection holes(1.2) providing the injection of the melted shoe-upper top material(4.1) into the shoe-upper mould(l); injection channels(1.4) providing the melted shoe-upper top material(4.1) from the injection end(6) to reach the injection holes(l .2).

For the single piece shoe-upper(5) manufacturing; at least two different type of materials are welded into each other by plastic injection. These materials are named as base material(3) and shoe-upper top material(4). The base materials(3) can be genuine leather, artificial leather and/or all types of textile and woven product. The shoe-upper top material(4) is composed of thermoplastic materials such as PVC (Polyvinyl Chloride), TPU (Thermoplastic Polyurethane) etc.. The shoe-upper top material(4) composed of thermoplastic material are injected into a shoe-upper mould(l) by plastic injection application. The melted shoe-upper top material(4.1) injected fills the shoe-upper mould gap(l.l) in the shoe-upper mould(l) and is shaped and is welded into the base material(3) which is placed in the shoe-upper mould(l) before the plastic injection application.

The shoe-upper mould(l) is prepared as the first stage in the shoe-upper(5) manufacturing with the mentioned method. The shoe-upper mould gap(l.l) is processed by consideration of the shoe-upper(5) form and design that is desired to be obtained from the shoe-upper mould(l). The colored parts(5.1) and/or the texture parts(5.2) and/or the polished parts(5.3) and/or the design parts(5.4) which are desired to appear on the shoe-upper(5) are determined and the shoe-upper mould gap(l.l) is prepared within this context. There are color surfaces( 1.1.1) and/or texture surfaces(1.1.2) and/or bright surfaces(1.1.3) and/or design surfaces(1.1.4) and/or indents and/or rises on the shoe-upper mould gap(l.l) according to the design and form characteristics of the shoe-upper(5).

During the plastic injection process; the shoe-upper mould(l) is closed by a mould cover(2). While the shoe-upper mould(l) is closed by the mould cover(2); the mould guides(1.3), which face each other are seated into the guide holes(2.1). This way, the shoe-upper mould(l) and the mould cover(2) completely fit in. Before closing the mould cover(2); the base material(3) is placed in the shoe-upper mould(l). The injection holes(1.2) extending from the external surface of the shoe-upper mould(l) into the interior are opened for the melted shoe-upper top material(4.1) to reach the covered shoe-upper mould(l), into the shoe-upper mould gap(l.l). The injection holes(1.2) provide the melted shoe-upper top material(4.1) to reach the shoe- upper mould gap(l.l) and fill the shoe-upper mould gap(l.l) from different points. The number and placement of the injection holes(l .2) are arranged in a way to provide the melted shoe-upper top material(4.1) to fill the shoe-upper mould gap(l.l) in the most balanced manner.

The melted shoe-upper top material(4.1) come out of the injection ends(6) and reach the injection holes(1.2) by means of the injection channels(l .4). The injection channels(1.4) open to the top surface of the shoe-upper mould(l) as based on the characteristics of the material and the mould. If various different materials are to be used as the shoe-upper top material(4); the injection channels(l .4) forming ways independent of each other can be opened.

As a general sampling, the invention method is composed of the following steps:

Preparation of the shoe-upper mould(l);

- Processing of the shoe-upper mould gap(l.l) on one surface of the shoe-upper mould(l), according to the form and design of the shoe-upper(5) which is desired to be obtained;

- Processing of the color surfaces( 1.1.1) on the relevant parts of the shoe-upper mould gap(l.l) in order to obtain colored parts(5.1) on the shoe-upper(5) surface;

- Processing of the texture surfaces(l .1.2) on the relevant parts of the shoe-upper mould gap(l.l) in order to obtain texture parts(5.2) on the shoe-upper(5) surface;

- Processing of the bright surfaces(1.1.3) on the relevant parts of the shoe-upper mould gap(l.l) in order to obtain polished parts(5.3) on the shoe-upper(5) surface;

Processing of the design surfaces(1.1.4) on the relevant parts of the shoe-upper mould gap(l.l) in order to obtain design parts(5.4) on the shoe-upper(5) surface;

Processing of rises and indents in the relevant sections in the shoe-upper mould gap(l .1) in order to obtain indents and rises on the shoe-upper(5) surface

Opening the injection holes(1.2) that extend to the shoe-upper mould gap(l.l) from the other surface of the shoe-upper mould(l);

Opening the injection channels(1.4) that reach the injection holes(1.2), the other surface of the shoe-upper mould(l);

- Placement of the base material(3) in the shoe-upper mould(l);

- Closing of the shoe-upper mould(l), in which the base material(3) is placed, by the mould cover(2); Placement of the closed shoe-upper mould(l) in front of the injection end/s(6) for the plastic injection; In the mentioned placement process, aligning the injection end/s(6) with the injection channels(1.4);

- Flow of the melted shoe-upper top material(4.1) out of the injection ends(6) through the injection channels(1.4) and reaching the injection holes(1.2);

- Injection of the melted shoe-upper top material(4.1), which reaches the injection holes(1.2), into the shoe-upper mould(l);

- Filling of the shoe-upper mould gap(l.l) by the melted shoe-upper top material(4.1) which is injected into the shoe-upper mould(l);

- Furthering of the melted shoe-upper top material(4.1), which fills the shoe-upper mould gap(l.l), on the base material(3) and welding of the base material(3) with the melted shoe-upper top material(4.1);

Shaping of the melted shoe-upper top material(4.1), which welded with the base material(3) and cooled down and solidified, in the shoe-upper mould gap(l.l) and becoming the shoe-upper top material(4);

Meanwhile, appearance of the color surface(l .l.l) processed on the shoe-upper mould gap(l.l) and/or the texture surface(1.1.2) and/or the bright surface(1.1.3) and/or the design surface(1.1.4) and/or the indent and/or rises as the colored parts(5.1) and/or the texture parts(5.2) and/or the polished parts(5.3) and/or the design parts(5.4) and/or the indents and/or rises on the shoe-upper top material(4);

- Accordingly; formation of the shoe-upper(5) by the shoe-upper top material(4) together with the base material(3), which is welded with the base material(3) shaped and characterized.

When the melted shoe-upper top material(4.1), which had flown into the shoe-upper mould(l) through the injection holes(1.2) cools and solidifies; it may leave injection mould excess(5.5) as fine rises on the shoe-upper top material(4). The mentioned injection mould excess(5.5) can easily be cut and removed.

Claims

1- The present invention relates to the shoe-upper manufactured as a single piece, with all the features designed for a shoe and the manufacturing method for the mentioned shoe-upper, and it is characterized by having the following process steps;

Preparation of the shoe-upper mould(l );

- Placement of the base material(3) in the shoe-upper mould(l);

- Closing of the shoe-upper mould(l), in which the base material(3) is placed, by the mould cover(2);

Placement of the closed shoe-upper mould(l) in front of the injection end/s(6) for the plastic injection; In the mentioned placement process, aligning the injection end/s(6) with the injection channels(l .4);

Filling of the shoe-upper mould gap(l.l) by the melted shoe-upper top material(4.1) which is injected into the shoe-upper mould(l);

- Furthering of the melted shoe-upper top material(4.1), which fills the shoe-upper mould gap(l .l), on the base material(3) and welding of the base material(3) with the melted shoe-upper top material(4.1);

Shaping of the melted shoe-upper top material(4.1), which welded with the base material(3) and cooled down and solidified, in the shoe-upper mould gap(l.l) and becoming the shoe-upper top material(4) by acquiring the design characteristics which are processed in the shoe-upper mould gap(l .l);

Accordingly; formation of the shoe-upper(5) by the shoe-upper top material(4) together with the base material(3), which is welded with the base material(3) shaped and characterized. 2- It is the manufacturing method for the shoe-upper mentioned in Claim 1 and it is characterized by; the step of processing of the shoe-upper mould gap(l.l) on one surface of the shoe-upper mould(l), according to the form and design of the shoe-upper(5) which is desired to be obtained, which is characterized as; - Processing of the color surfaces( 1.1.1) on the relevant parts of the shoe-upper mould gap(l.l) in order to obtain colored parts(5.1) on the shoe-upper(5) surface.

3- It is the manufacturing method for the shoe-upper mentioned in Claim 1 and it is characterized by; the step of processing of the shoe-upper mould gap(l.l) on one surface of the shoe-upper mould(l), according to the form and design of the shoe-upper(5) which is desired to be obtained, which is characterized;

Processing of the texture surfaces(1.1.2) on the relevant parts of the shoe-upper mould gap(l.l) in order to obtain texture parts(5.2) on the shoe-upper(5) surface;

4- It is the manufacturing method for the shoe-upper mentioned in Claim 1 and it is characterized by; the step of processing of the shoe-upper mould gap(l.l) on one surface of the shoe-upper mould(l), according to the form and design of the shoe-upper(5) which is desired to be obtained, which is characterized;

5- It is the manufacturing method for the shoe-upper mentioned in Claim 1 and it is characterized by; the step of processing of the shoe-upper mould gap(l.l) on one surface of the shoe-upper mould(l), according to the form and design of the shoe-upper(5) which is desired to be obtained, which is characterized;

Processing of the design surfaces(1.1.4) on the relevant parts of the shoe-upper mould gap(l.l) in order to obtain design parts(5.4) on the shoe-upper(5) surface; 6- It is the manufacturing method for the shoe-upper mentioned in Claim 1 and it is characterized by; the step of processing of the shoe-upper mould gap(l.l) on one surface of the shoe-upper mould(l), according to the form and design of the shoe-upper(5) which is desired to be obtained, which is characterized; - Processing of the indents and rises on the relevant parts of the shoe-upper mould gap(l.l) in order to obtain indents and rises on the shoe-upper(5) surface;

7- It is the manufacturing method for the shoe-upper mentioned in Claim 1 and it is characterized by; the step of the procedure of shaping of the melted shoe-upper top material(4.1), which welded with the base material(3) and cooled down and solidified, in the shoe-upper mould gap(l .l) and becoming the shoe-upper top material(4) by acquiring the design characteristics which are processed in the shoe-upper mould gap(l.l), which is characterized as; appearance of the color surface( 1.1.1) processed on the shoe-upper mould gap(l .l) and/or the texture surface(1.1.2) and/or the bright surface(1.1.3) and/or the design surface(1.1.4) and/or the indent and/or rises as the colored parts(5.1) and/or the texture parts(5.2) and/or the polished parts(5.3) and/or the design parts(5.4) and/or the indents and/or rises on the shoe-upper top material(4).

8- It is the shoe-upper manufactured as a single piece, with all the features designed for a shoe and the manufacturing method for the mentioned shoe-upper, and it is characterized by having the following process steps;

The shoe-upper mould(l) enabling the manufacture of a single piece shoe-upper(5) The mould shoe-upper gap(l .l) providing the manufacturing of a single piece shoe- upper(5) in the desired color, texture, effect, design and material, in the shoe-upper mould(l);

- The base material(3) placed in the shoe-upper mould(l) before the plastic injection application;

The shoe-upper top material(4) which is injected into the shoe-upper mould(l) and which welds with the base material(3) by filling the shoe-upper mould gap(l .1 ). 9- It is the invention mentioned in Claim 1 or Claim 8 and it is characterized by; the base material(3) which is composed of genuine leather, artificial leather and/or any type of textile and woven product.

10- It is the invention mentioned in Claim 1 or Claim 8 and it is characterized by; shoe-upper top material(4) composed of thermoplastic material are injected into a shoe-upper mould(l) by plastic injection application.