Thermoplastic polyurethane infused mesh
Embodiments of the present invention relate to a thermoplastic polyurethane (“TPU”) infused mesh material that is molded to form at least a portion of a shoe. The TPU infused mesh may be formed as an upper, a portion of sole or other components of a shoe. The TPU infused mesh is formed, in an exemplary embodiment, through the application of liquid TPU to a surface of a spacer mesh. The liquid TPU infused spacer mesh is then cured, cut to a pattern, and heat molded to form a desired portion of the shoe. The heat molded TPU mesh is coupled to other portions of the shoe (e.g., sole) to form an article footwear in an exemplary embodiment.
1. A method of manufacturing a thermoplastic polyurethane (TPU) infused material for use in construction of a shoe, the method comprising:
infusing TPU through an external surface, an interior surface, and a variable lattice structure extending between the exterior surface and the interior surface of a flexible spacer mesh forming a TPU infused material that is effective to form a breathable portion of a shoe;
curing the TPU infused material;
cutting the TPU infused material into a pattern useable in construction of the shoe; and
heat molding the pattern of TPU infused material to form a three-dimensionally shaped molded portion.
2. The method of claim 1 , wherein the TPU is applied through a submersion of the material in a liquid TPU.
3. The method of claim 1 , wherein the TPU is applied by spraying the material with a liquid TPU.
4. The method of claim 1 , wherein the TPU is in a liquid form that is applied to the material by a rolling process.
5. The method of claim 1 , wherein the TPU is in a liquid form when applied to the material.
6. The method of claim 1 , wherein the TPU is in a flexible film state when applied to the material.
7. The method of claim 1 , wherein the TPU is at a temperature below a melting temperature of the spacer mesh material.
8. The method of claim 1 , wherein the TPU is a water-dispersed TPU.
9. The method of claim 1 , wherein the TPU is a solvent-dispersed TPU.
10. The method of claim 1 , wherein the TPU infused material is a substantially flat sheet.
11. The method of claim 1 , wherein the TPU is cured at room temperature.
12. The method of claim 1 , wherein the TPU is cured utilizing an oven.
13. The method of claim 1 , wherein the molded portion forms at least a portion of an upper of the shoe.
14. A method of manufacturing a thermoplastic polyurethane (TPU) infused spacer mesh having an exterior surface, an opposite interior surface, and a variable lattice structure extending between the exterior surface and the interior surface, the infused spacer mesh for use in construction of a shoe, the method comprising:
infusing the spacer mesh exterior surface, interior surface, and variable lattice structure with TPU forming an infused spacer mesh that is effective to form a breathable portion of a shoe;
curing the TPU infused spacer mesh material;
cutting the TPU infused spacer mesh material into a pattern useable in construction of the shoe; and
heat molding the pattern of TPU infused spacer mesh material to form a three-dimensionally shaped molded portion.