IP Library Granted Patent US 12,097,677
Granted Patent B2
US 12,097,677 · App. 17/013,132 · Granted Sep 24, 2024

Molded footwear upper with knit texture

Inventor: Stefano Ferniani (Padua, IT)
Assignee: Crocs, Inc.
B29D35/126A43B17/003A43B23/0215B29C33/0033B29C45/00B29D35/146B29K2023/083B29K2075/00
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Quick Facts
Patent No.
US 12,097,677
App. No.
17/013,132
Granted
Sep 24, 2024
Kind
B2
Abstract

A method of manufacturing a shoe component may include injecting a material into a mold cavity to create a thin sheet of molded material formed as a single piece with molded holes extending through the molded material and formed as part of the injection molding process. The thin sheet of molded material may be in a shape that can be secured together to form a shoe upper including a vamp, a medial portion, and a lateral portion. The method may include removing, from the mold cavity, the sheet of molded material, folding the sheet of molded material, optionally cementing a first portion of the sheet of molded material to a second portion of the sheet of molded material, and cementing a third portion of the sheet of molded material to a sole to form a shoe. The completed shoe may also include an insole, a tongue, and laces.

Claims (30)

1. A method comprising:

injecting a material into a mold cavity to create a single sheet of molded material with a thickness less than 5 millimeters and molded holes extending between an inner surface of the molded material and an outer surface of the molded material, wherein the single sheet of molded material is in a shape that can be secured together to form a shoe upper; wherein the single sheet of molded material comprises a vamp, a medial portion, and a lateral portion, wherein the vamp includes at least some of the molded holes in the form of a number of small holes that increase breathability, and wherein the vamp adjacent to the number of small holes is closed;

removing, from the mold cavity, the single sheet of molded material;

folding the single sheet of molded material; and

cementing a portion of the single sheet of molded material to a sole to form a shoe.

2. The method of claim 1 , wherein the material is a thermoplastic polyurethane (TPU) material.

3. The method of claim 1 , wherein the material is an ethylene vinyl acetate (EVA) material.

4. The method of claim 1 , wherein the material has a melt-temperature range between 205 degrees Celsius and 225 degrees Celsius.

5. The method of claim 4 , wherein the material has a short-term maximum temperature of 255 degrees Celsius.

6. The method of claim 1 , comprising:

scanning a textile with a high-precision scanner; and

etching, using a laser, a texture of the textile to a mold for the mold cavity.

7. The method of claim 6 , wherein the texture of the textile is a negative of a texture of the single sheet of molded material.

8. The method of claim 6 , wherein the the thickness of single sheet of molded material is less than 5 millimeters and at least 0.04 millimeters.

9. The method of claim 1 , wherein a first point of the single sheet of molded material has a first thickness, and a second point of the single sheet of molded material has a second thickness different from the first thickness.

10. The method of claim 1 , wherein an average thickness of the single sheet of molded material is less than 1.5 millimeters.

11. The method of claim 1 , wherein the single sheet of molded material comprises a plurality of different areas, each with a different texture.

12. The method of claim 1 , comprising:

inserting an insole into the shoe.

13. The method of claim 12 , wherein the insole is a foam insole.

14. The method of claim 12 , wherein inserting the insole into the shoe comprises inserting the insole into the shoe such that after the insole is inserted into the shoe, at least a portion of the molded material is between at least a portion of the insole and at least a portion of the sole of the shoe.

15. The method of claim 12 , wherein inserting the insole into the shoe comprises inserting the insole into the shoe such that after the insole is inserted into the shoe, at least a portion of the insole is in direct contact with at least a portion of the sole of the shoe.

16. The method of claim 1 , wherein the single sheet of molded material is used to form an entire upper portion of the shoe.

17. The method of claim 1 , wherein the shoe upper comprises a heel portion and a toe portion.

18. The method of claim 1 , comprising:

attaching a tongue to the molded material by sewing the tongue to the molded material.

19. The method of claim 18 , wherein the tongue is made at least partially of a knitted material.

20. The method of claim 1 , comprising:

cementing a second portion of the single sheet of molded material to a third portion of the single sheet of molded material.

21. The method of claim 1 , wherein the single sheet of molded material is a continuous textured single sheet of molded material.

Assignments (2)
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Aug 11, 2022
From: FERNIANI, STEFANO
To: CROCS, INC.
Reel/Frame 060781/0917 →
SECURITY AGREEMENT Recorded Feb 17, 2022
From: CROCS, INC.; JIBBITZ, INC.
To: PNC BANK, NATIONAL ASSOCIATION
Reel/Frame 059173/0536 →
Continuity (2)
Provisional Application 62897066 · Sep 6, 2019
Related Publication 20210070002A1 · Mar 11, 2021