Molded footwear upper with knit texture
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.
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.