Method for manufacturing layered elements with incisions
A manufacturing method may include forming incisions through an incision layer that is secured to a transfer layer. After defining the incisions, the incision layer is secured to a substrate layer, and the transfer layer is then separated from the incision layer. The manufacturing method may be applied to elements used in footwear, apparel, or a variety of other products.
1. A method comprising steps of:
providing a structure having a first layer and a second layer that are secured together and substantially parallel to each other;
forming an incision that extends through the first layer, the incision extending at least partially into the second layer;
locating the first layer adjacent to a third layer such that the first layer is substantially located between the second layer and the third layer;
securing the first layer to the third layer; and
separating the second layer from the first layer.
2. The method recited in claim 1 , wherein the step of forming the incision includes utilizing a laser.
3. The method recited in claim 1 , further including a step of placing an adhesive on a surface of the first layer that faces away from the second layer.
4. The method recited in claim 3 , wherein the step of securing includes utilizing the adhesive to join the first layer to the third layer.
5. The method recited In claim 3 , wherein the step of placing the adhesive is performed prior to the step of forming the incision.
6. The method recited in claim 1 , further including a step of selecting at least one of the first layer and the third layer to be a textile material.
7. The method recited in claim 1 , further including a step of incorporating the first layer and the third layer into an article of footwear.
8. A method comprising steps of:
providing a structure having an incision layer and a transfer layer that are secured together and substantially parallel to each other, the incision layer having a first surface and an opposite second surface, the second surface facing the transfer layer;
forming incisions that extend through the incision layer, the incisions extending at least partially into the transfer layer;
locating the first surface of the incision layer adjacent to a substrate layer;
securing the incision layer to the substrate layer; and
separating the transfer layer from the incision layer to expose the second surface.
9. The method recited in claim 8 , wherein the step of forming the incisions includes utilizing a laser.
10. The method recited in claim 8 , further including a step of placing an adhesive on the first surface.
11. The method recited in claim 10 , wherein the step of securing includes utilizing the adhesive to join the incision layer to the substrate layer.
12. The method recited In claim 10 , wherein the step of placing the adhesive is performed prior to the step of forming the incisions.
13. The method recited in claim 8 , further including a step of selecting at least one of the incision layer and the substrate layer to be a textile material.
14. The method recited in claim 8 , further including a step of incorporating the incision layer and the substrate layer into an article of footwear.
15. A method of manufacturing an upper for an article of footwear, the method comprising steps of:
providing a structure having an incision layer and a transfer layer that are secured together and substantially parallel to each other, the incision layer having a first surface and an opposite second surface, the second surface facing the transfer layer, and at least one of the incision layer and the substrate layer being a textile material;
placing an adhesive on the first surface;
forming incisions with a laser that extend through the adhesive and the incision layer;
locating the first surface of the incision layer adjacent to a substrate layer such that the adhesive is located between the incision layer and the substrate layer;
securing the incision layer to the substrate layer with the adhesive;
separating the transfer layer from the incision layer to expose the second surface; and
incorporating the incision layer, the adhesive, and the substrate layer into the upper of the article of footwear so that the second surface forms a portion of an exterior surface of the footwear.
16. The method recited in claim 15 , wherein the step of forming the incisions further includes extending at least a portion of the incisions into the transfer layer.
17. The method recited In claim 15 , wherein the step of placing the adhesive is performed following the step of forming the incisions.
18. A method of manufacturing an upper for an article of footwear, the method comprising steps of:
utilizing a laser to form a plurality of incisions in a stratified material, the stratified material having a plurality of layers that include a first layer, a second layer, and a third layer, the second layer being located between the first layer and the third layer, the incisions extending through at least the first layer and the second layer, and at least one of the second layer and a fourth layer being a textile material;
securing the stratified material to the fourth layer with the first layer;
separating the third layer from a remainder of the stratified material; and
incorporating the first layer, the second layer, and the fourth layer into the upper of the article of footwear.
19. The method recited in claim 18 , further including a step of structuring the stratified material to locate the second layer adjacent to the third layer.
20. The method recited in claim 18 , further including a step of selecting the first layer to be an adhesive material.
21. A method comprising steps of:
utilizing a laser to form a plurality of incisions through an incision layer that is secured to a transfer layer, each of the plurality of incisions being one of a cut or a slit;
securing the incision layer to a substrate layer after forming the incisions; and
separating the transfer layer from the incision layer after securing the incision layer to the substrate layer.
22. The method recited in claim 21 , wherein the step of utilizing the laser includes forming the incision to extend at least partially into the transfer layer.
23. The method recited in claim 21 , further including a step of placing an adhesive on a surface of the incision layer that faces away from the transfer layer.
24. The method recited in claim 23 , wherein the step of securing includes utilizing the adhesive to join the incision layer to the substrate layer.
25. The method recited In claim 23 , wherein the step of placing the adhesive is performed prior to the step of utilizing the laser.
26. The method recited in claim 21 , further including a step of selecting at least one of the Incision layer and the substrate layer to be a textile material.
27. The method recited in claim 21 , further including a step of incorporating the incision layer and the substrate layer into an article of footwear.
28. A method comprising steps of:
utilizing a cutting apparatus to form a plurality of incisions through an incision layer that is secured to a transfer layer, each of the plurality of incisions being one of a cut or a slit;
securing the incision layer to a substrate layer after forming the incisions; and
separating the transfer layer from the incision layer after securing the incision layer to the substrate layer.
29. The method recited in claim 28 , wherein the step of utilizing the cutting apparatus includes forming the incision to extend at least partially into the transfer layer.
30. The method recited in claim 28 , further including a step of placing an adhesive on a surface of the incision layer that faces away from the transfer layer.
31. The method recited in claim 30 , wherein the step of securing includes utilizing the adhesive to join the incision layer to the substrate layer.