JP5639062B2 - Efficient and local shoe production methods - Google Patents

Description

CROSS REFERENCE TO RELATED APPLICATIONS This application is a US Provisional Patent Application No. 61/194, filed September 26, 2008, under the name “Method for Efficient and Localized Production of Shoes”. , 496 benefits.

  Shoe production is a labor intensive process that has not changed much over the last 100 years, despite mechanization advances.

That is, most shoe manufacturing processes today require a great deal of manual input. For example, one worker must cut, mold, align, and stitch the upper part of the shoe.
Although this process utilizes a large number of machines, it still requires a great deal of human intervention, which may not change between the two different upper parts. The upper part of the shoe is then handed over to another worker to add embroidery or other decorations, which also requires a great deal of human intervention. These high levels of human intervention can cause unwanted changes in the finished shoe product. Moreover, the large amount of human effort required during shoe creation has limited the ability to produce custom custom shoes at a price that many customers can afford.

  This summary selectively introduces, in a simplified form, a selection of concepts that are described in further detail in the following description. This summary is not intended to identify key features or essential features of the claims, nor is it intended to determine the scope of the claims. The present invention provides several practical applications in this technical field and is not limited to the specific type of shoe production methods described herein.

  The present invention relates to an efficient shoe manufacturing method and system for manufacturing a pair of shoes while avoiding the high costs and special maintenance often associated with highly mechanized manufacturing equipment. Reduce special human labor required for With the system and method according to the present invention, multiple models of custom shoes can be produced in a single shoe manufacturing facility. For example, if one customer orders a particular model of shoes, the next customer can order another model of shoes, and both shoes models are manufactured on the same equipment by using an overlapping workflow. can do.

  The subject matter of this invention is described in detail herein in order to meet legal requirements. However, the description itself is not intended to limit the scope of this patent. Rather, the inventor expects the claims to be implemented in other ways, including other current or future technologies, as well as different steps or combinations of steps similar to those described in this document. Shall be. In addition, the term “step” is used herein to imply different elements of the method employed, and unless otherwise stated and unless otherwise stated to the order of the individual steps. Should not be construed as implying a particular order between the various steps.

  Embodiments of the present invention provide a method for efficiently producing shoes that meet geographic location requirements. By way of example and not limitation, the production equipment for efficient production of shoes is divided into specific modules, which are related to distributed placement work, such as embroidery or midsole production, or of the shoe making process. It shall mean an area having characteristics associated with one or more aspects. In one embodiment, one or more modules are designed to optimize an individual worker's work environment, and the interaction between the workers and the machines in the worker's module is responsible for maintaining worker health. Ergonomically designed to contribute to Each module is referred to as a “module”. When a shoe part moves through a module, there can be different processes and changes with steps in the overall production of the shoe.

  A shoe product that is a finished shoe or a partially completed shoe or part of a finished shoe can only be produced after a customized order has been received. The customization order shall include custom shoe parameters associated with one or more shoes produced for any consumer. In addition, each shoe must be custom made and each shoe must be paired with a customer's request (eg, male size 9, blue, medium hardness left foot with male size 9.5, red, high hardness right foot) Can have various characteristics.

  Once the customer has ordered one or more shoes, the order is monitored through the production system so that one or more workers are notified of the characteristics specific to each order. In one method, the customized order is presented to one or more workers on one or more sheets. Each form is communicated to the appropriate worker to inform the worker what changes the shoe and / or shoe part the worker is changing. The operator then selects the desired features, such as suitable colors, from material sources in the modular production facility, or the operator selects the desired design and / or from a series of program options on the computer system. Or a pattern shall be selected. In the latter method, the operator retrieves a predetermined set of designs that can be used for printing and / or embroidery and / or etching on the material, and further programming the computer to print and / or embroidery the material. And / or to etch. In another method, the operator enters a design or program provided by the customer as a custom design for one or more shoe parts.

  In another embodiment, an operator accesses information related to a customized order through the shoe parts manufacturing facility by having customer information stored on a database accessible to the operator at the shoe parts manufacturing facility. It shall be possible. An operator shall be able to access customized order information via a computer interface at or near one or more modules in a shoe parts manufacturing facility. It is assumed that the worker can also access information about the customer via one or more barcodes. In one method, the barcode is accessible to customized order information from a database that contains all of the information needed to produce a customized order for one or more shoes. The bar code may be used to access all information about one or more shoe parts, or it may be used to access specific information about one or more shoe parts.

  For example, suppose an operator scans one barcode at each software access point along the process. In another embodiment, a bar code is associated with each feature and / or shoe component. For example, the barcode can be associated with a color that is desired to be applied to the background of the shoe component. In another embodiment, the barcode can be associated with the part and / or design desired to be reflected in the upper portion (upper). In yet another embodiment, the barcode may be associated with part selection from the marketplace. For example, one bar code displays a men's running shoe size 9 while another bar code displays a women's basketball shoe size 7. In another embodiment, the use of bar codes shall be related to or replaced with the use of number codes that provide customized order features. For example, if the bar code is damaged or the bar code reader simply does not move, the operator shall enter a few codes to reflect characteristic customer information associated with one or more shoe orders. .

The three starting points for producing one or more shoe parts are outsole production, midsole production, and upper part (upper) production. Outsole and / or midsole production begins before the customer places an order. The outsole and / or midsole can also be produced as needed after a customized order has been received for the production of one or more shoes.
The present invention is described in detail below with reference to the accompanying drawings.

It is explanatory drawing of the shoe components manufacturing equipment in manufacture of custom shoe components by the Example of this invention. 4 is a flowchart of a method for efficiently manufacturing multiple models of custom shoes in a single manufacturing facility, according to an embodiment of the present invention. 6 is a flowchart of an outsole manufacturing workflow for a running shoe in an outsole / midsole module, according to an embodiment of the present invention. 6 is a flowchart of a midsole manufacturing workflow for a running shoe in an outsole / midsole module, according to an embodiment of the present invention. Figure 5 is a flowchart of a running shoe workflow in a priming and bonding module, according to an embodiment of the present invention. 4 is a flowchart of a workflow for combining an outsole and a midsole as a midsole-outsole on a running shoe according to an embodiment of the present invention. 6 is a flowchart of a workflow for customizing an upper portion of a running shoe according to an embodiment of the present invention. 4 is a flowchart of a workflow for assembling an upper portion of a running shoe according to an embodiment of the present invention. 4 is a flowchart of a durability and quality control workflow for a running shoe, according to an embodiment of the present invention. 4 is a flowchart of an outsole manufacturing workflow for a basketball shoe in an outsole / midsole module, according to an embodiment of the present invention. 6 is a flowchart of a midsole manufacturing workflow for basketball shoes in an outsole / midsole module, according to an embodiment of the present invention. 4 is a flowchart of a workflow for basketball shoes in a priming and bonding module, according to an embodiment of the present invention. 4 is a flowchart of a workflow for combining an outsole and a midsole as a midsole-outsole in a basketball shoe according to an embodiment of the present invention. 4 is a flowchart of a workflow for customizing the upper portion of a basketball shoe according to an embodiment of the present invention. 4 is a flowchart of a workflow for assembling an upper portion of a basketball shoe according to an embodiment of the present invention. 4 is a flowchart of a durability and quality control workflow for a basketball shoe according to an embodiment of the present invention. 4 is a flowchart of an outsole manufacturing workflow for skate shoes in an outsole / midsole module, according to an embodiment of the present invention. 4 is a flowchart of a midsole manufacturing workflow for skate shoes in an outsole / midsole module, according to an embodiment of the present invention. 4 is a flowchart of a workflow for skateball shoes in a priming and bonding module, according to an embodiment of the present invention. 4 is a flowchart of a workflow for combining an outsole and a midsole as a midsole-outsole on a skate shoe according to an embodiment of the present invention. 6 is a flowchart of a workflow for customizing the upper portion of a skate shoe, according to an embodiment of the present invention. 4 is a flowchart of a workflow for assembling an upper portion of a skate shoe according to an embodiment of the present invention. 4 is a flowchart of a durability and quality control workflow for skate shoes, according to an embodiment of the present invention. It is a workflow explanatory drawing of the shoe components manufacturing equipment for custom shoe components manufacture by the example of the present invention. It is a block diagram of the module structure used for shoe production by the Example of this invention. 1 is a system block diagram for producing and assembling shoe components according to an embodiment of the present invention. FIG. 2 is a flowchart of a shoe workflow manufactured through a process according to an embodiment of the present invention.

  With reference to the normal drawing, particularly initially FIG. 1, a typical operating environment suitable for embodiments of the present invention is typically illustrated and labeled as a shoe part manufacturing facility 100. However, the shoe component manufacturing facility 100 is an example of a suitable manufacturing environment and is not intended to suggest a limitation of the scope of use or functionality of the present invention. Neither is the shoe component manufacturing facility 100 intended to be construed as complying with or requiring one or a combination of the illustrated components.

  FIG. 1 shows a floor layout of six shoe manufacturing modules organized in a process performed by an operator associated with the module. The six modules shown in FIG. 1 are outsole and midsole modules; midsole, outsole, upper part (upper) prime and adhesive module; final assembly and stockfit module; upper part customization module; It shall comprise an upper part forming and sewing module; and shoe moulding, reshoe moulding, quality control and packaging modules. The area of each module in the shoe component manufacturing facility 100 will be described with reference to the explanatory diagram of FIG.

  The outsole and midsole modules include a preform injection molding machine 102 that is used to produce phylon biscuit. The outsole and midsole module also includes a midsole marketplace 108 that stores phylon biscuits for use in forming the midsole. The outsole and midsole module also includes a press 106, particularly a Kingstead Quick Open Press manufactured by Kingstead, which is used as a phylon as a right-oriented shoe, a left-oriented shoe, or a neutral-oriented shoe. Characterize biscuits. The outsole and midsole modules also have a microwave heat source to preheat the phylon biscuits. The outsole and midsole module also includes a stabilization oven 110 that can be used to stabilize the midsole and reduce the midsole volume. The outsole and midsole module also includes a wash / dry table 112. The outsole and midsole module also includes other midsole marketplaces 104. The outsole and midsole module also includes a rubber injection molding machine 116 that is used to produce the outsole. The outsole and midsole module also includes a wash / dry area 114 that is used to clean the outsole with an alkaline or acid wash. The outsole and midsole module also includes an outsole marketplace 118.

  The midsole, outsole, upper partial prime (overcoat) and adhesive module can have a midsole marketplace 104 and an outsole marketplace 118. The midsole, outsole, upper partial prime and adhesive module also include a prime and adhesive area 120. In another embodiment, the prime and adhesive areas are two separate areas. The midsole, outsole, upper portion prime, and adhesive module also includes a chemical storage area 158 that stores chemicals associated with one or more processes in the manufacture of shoe parts and / or shoe products in the shoe part manufacturing facility 100. Shall be provided. The midsole, outsole, upper partial prime and adhesive module also include an infrared (IR) oven 122. In another method, the midsole, outsole, upper part prime and adhesive module also comprise a standard oven in which one or more shoe products activate the adhesive. It goes through.

  The final assembly and stock fit module includes an IR oven 122. The final assembly and stock fit module also includes a bladder press 124 that is used to mate the midsole and outsole together. The final assembly and stockfit module also includes a standard press 126. The final assembly and stock fit module also includes a cooling device 128 that is used to provide a midsole-outsole shoe product bond.

  The upper part customization module comprises an eco solvent printer 132 and a print desk 134 and a sublimation dye printer 136. The upper part customization module is a custom die cutting machine 138 used to modify the material used in the upper part customization, and one or more shoe parts and / or one or more shoe products in the shoe part manufacturing facility 100. A tooling area 160 comprising tools associated with one or more manufacturing processes. The upper part customization module also includes a laser 140 and a laser / embroidery desk 146 that are used to etch the material used in the upper part customization. The upper part customization module also includes a sublimation dye press 142. The upper part customization module also comprises a left embroidery machine 162 and a right embroidery machine 164. The upper part customization module also includes a tooling area 166 that includes tools for one or more shoe parts and / or one or more processes in the manufacture of one or more shoe products in the shoe part manufacturing facility 100. The upper part customization module also includes a radio frequency (RF) welder 148, which can include an RF relay area that is used to temporarily store shoe components in the shoe production process. .

  The upper part forming and sewing module includes an RF welder 148 that includes an RF relay area that is used to temporarily store shoe parts in the process of producing or modifying a shoe product. The upper part forming and sewing module also includes a marketplace 150 that can be used to temporarily store and easily obtain the customizable parts needed to complete the production of a shoe or shoe product. And The upper part forming and sewing module also includes a material repository 168, which is a material and / or shoe component associated with one or more processes in the manufacture of shoe parts and / or shoe products in the shoe part manufacturing facility 100. Stockpile. The upper part forming and sewing module also includes a final trimming die cutter 144 and a wing arm relay area 130. The upper part forming and sewing module also includes a market die cutting machine 170, a heating press 172, a cooling rack 174, a cutting press 176, a heel forming machine 178, a post-sewing 180 and a strobel sewing 182.

  The shoe mold matching, re-shoe mold matching, quality control and packaging module includes a swing arm relay area 130. The shoe mold matching, re-shoe mold matching, quality control and packaging module shall also include a shoe mold matching area 152, final quality control 154, shoe mold matching and packaging 156 and material storage 184.

  With reference to the illustration of FIG. 1, one shoe production through one or more modules of the shoe manufacturing facility 100 will be described. It should be understood that this and other configurations described herein are described by way of example only. Other configurations and elements (eg, machines, processes, methods, etc.) can be used in addition to or in place of those discussed, and some elements can be omitted entirely. Moreover, many of the elements described herein are functional entities that can be implemented in conjunction with separate or distributed elements or other elements and in any suitable combination and arrangement. .

  In some embodiments, the first step in outsole production utilizes a rubber injection molding machine 102. Different sizes and / or shapes of molds are used to produce different outsole for different shoe sizes and styles. Various types and / or colors of rubber can also be used to produce outsole with different functions and / or aesthetic properties. For example, using indicia (such as dotted lines) in the production of outsoles, using designers (eg embroiders or those who add mechanical features, or adhesives or other types of adhesives) Guides one or more persons who add textiles and decorations to one or more shoe parts. In other cases, the different colors of the shoe component have functional elements that add an easily visible color, such as bright yellow, to one or more shoe components to make the shoe wearer more noticeable. Alternatively, different slippery, different rubbers are placed along the shoe parts to reduce the extent to which mud or other external elements adhere to one or more shoes of the shoe wearer.

  The operator of the rubber injection molding machine 102 determines each size, style, color, and other numerical values of the outsole and forms them based on the outsole display initially required in the outsole marketplace 118. For example, the display includes a preset range of expected sales (use) quantities for the marketplace. The number of outsole is also listed on the inventory display receipt of decreasing size, style, color, etc. The sales (use) amount of the preset range is planned for one day or other period, for example one week or one month or one season. The operator of the rubber injection molding machine 102 alternatively or additionally determines what size outsole to form based on the amount of size outsole remaining in the outsole marketplace 118. The outsole marketplace 118 includes a number of temporary storage methods, each temporary storage method corresponding to a particular style, size, color, functional characteristics, and the like. For example, the temporary storage method includes placing a newly formed outsole of size 9 in a first-come-first-served service queue. In another embodiment, the temporary storage method allows an operator to place each newly formed outsole in a warehouse associated with one or more characteristics of the outsole (eg, a male size 9 outsole). In one warehouse and a male size 5 outsole in another warehouse). In yet another embodiment, the temporary storage method is based on placing all newly formed outsoles in a warehouse, and then, for example, visual differences between different sized outsole or different sized uneven processing indications. And selecting an outsole so that an operator can remove an appropriately sized outsole from the warehouse when needed.

  After finding a low quality size outsole remaining in the outsole marketplace 118, such as a visual inspection, the operator then decides to manufacture the size outsole. The outsole can be produced by reacting directly to an order, or can be formed by specifying the style, size, color, functional characteristics, etc. in the order.

  After the outsole is removed from the rubber injection molding machine 102 by the operator, it is placed in the cleaning / drying area 114. The wash / dry area 114 may comprise one or more wash steps that wash the shoe and remove any residue from the rubber. For example, rubber residue is caused by oil and stearic acid used during the curing process. In another embodiment, the curing process eliminates the need for cleaning / drying area 114 by eliminating the use of stearic acid during the curing process and / or reducing the amount of oil used during the curing process. be able to. This curing process can reduce or eliminate rubber residues that occur during the curing process, and can reduce or eliminate the need for one or more cleaning steps. In this manner, priming (undercoating) can be performed immediately after the outsole is formed in the rubber injection molding machine 116.

  If cleaning is required, the outsole is dried after cleaning. For example, the outsole is dried in the wash / dry area 114. In another embodiment, the outsole is dried by placing it in a fully heated, fully dehumidified area (eg, drying one or more shoes adjacent to a window). The operator removes the dried outsole from the wash / dry area 114 and places it in the outsole marketplace 118 for use.

  The outsole marketplace 118 and the midsole marketplace 104 comprise one or more temporary storage methods, the midsole is stored in a warehouse, and the warehouse is the size, style, color or other of the parts stored in this warehouse Can be arranged according to the characteristics of Outsole marketplace 118 and midsole marketplace 104 can store outsole and midsole produced based on display receipts that anticipate customized orders. Outsole marketplace 118 and midsole marketplace 104 also include outsole and midsole produced based on the receipt of specific customized orders. In other embodiments, an outsole and / or midsole produced based on a customized order receipt bypasses the outsole marketplace 118 and / or midsole marketplace 104 and moves directly to the next production step. To do. It will be apparent to those skilled in the art that still other embodiments are possible.

  Midsole production begins before the customer places an order. The midsole can also be produced as needed based on receipt of a customized order for one or more shoes. Further, the midsole can be produced as a result of a display receipt that adjusts the quality and characteristics of the midsole remaining in the midsole marketplace 104.

  To begin midsole production, a pre-weighed amount of raw, unprocessed EVA pellets is poured into a mold of a preform injection molding machine 102 heated to approximately 100 ° C. The mold temperature should be high enough that the EVA pellets will melt and match the shape of the mold, but not so high that the EVA expansion agent is activated. Production will be referred to as injection phylon biscuits, hereinafter referred to as “biscuits”, which biscuits are stored prior to activating the expansion agent forming the midsole. Different amounts of EVA pellets are associated with different shoe sizes, styles, midsole density and / or hardness. Further, the base polymer used in the injection phylon biscuit process varies based on the final hardness characteristics required by the shoe midsole. Each set of shoes includes one or more biscuits of various volumes and sizes that comprise the midsole of each shoe. The hardness of one or more biscuits in the midsole can be customized to vary in the lateral and / or longitudinal direction of the shoe. Such a feature can prevent, for example, mild pronation in shoe users, such as runners, or simply improve comfort.

  After forming the biscuits, the biscuits are removed and stored in the biscuits marketplace 108. From the biscuits marketplace 108, biscuits can be removed as needed. When a customer orders one or more shoes, for example, an operator takes out one or more biscuits according to the customer's order. In another method, an operator removes one or more biscuits from the marketplace and places them in an apparatus that exposes the one or more biscuits to a microwave radiation source. For example, one or more biscuits are housed in a Magic Chef MCB780W 1.2 kilowatt microwave device and exposed to microwave radiation at high power for 65 seconds.

  The operator then puts each biscuit into the press 106, which can be used for left foot shoes and right foot shoes or a combination of both. The operator loads the press machine 106 for left foot shoes or right foot shoes, and uses the press 106 to set each biscuit as “left” or “right”. Thereafter, the operator takes out each biscuit from the press machine 106. The press machine 106 is not limited to holding only one biscuit, but can hold a plurality of biscuits at any time. Further, the biscuits press need not be synchronized with each biscuit in the press 106, but rather can be designed to have multiple biscuits loading and pressing and unloading at any time. In yet a further embodiment, the module operator avoids the step of using the press 106, designates the shoe product as “left” or “right”, and simply turns or Biscuits can be manually formed using one or more blades. The operator can also designate each biscuit as “left” or “right” using another type of machine before placing each biscuit into the intermediate, omnidirectional press 106. The operator can also hold the biscuit in a neutral designation, and each shoe portion can be interchangeable for use with left and / or right foot shoes.

  After the press 106 receives the biscuits, the biscuits are heated to a temperature sufficient to melt the biscuits to approximately 172 ° C. This temperature is sufficient to activate the expansion agent in the biscuits. This expansion agent initiates the expansion process which degrades the polymer chains and increases the volume of the biscuits by approximately 200% to match the shape of the press. At the same time, the curing agent in the biscuit that functions at a slower reaction rate than the swelling agent can initiate cross-linking of the polymer chains and retain the shape of the reinforced biscuit.

  After forming the enlarged biscuit, the operator takes out the enlarged midsole from the press machine 106 and loads the enlarged midsole into the stabilization oven 110. When placed in the stabilization oven 110, the enlarged midsole is approximately 75 ° C. In another embodiment, the enlarged midsole is placed in a stabilization oven 110 at a temperature of 75 ° C. or higher. In one embodiment, the enlarged midsole is assumed to be the highest temperature that can be obtained in the press 106 and further conveyed in the stabilization oven 110 at the same temperature. The stabilization process in the stabilization oven 110 consists of three or more cooling stages in which the temperature is reduced from approximately 75 ° C. to approximately 45 ° C. In another embodiment, the stabilization process in stabilization oven 110 is performed over a number of steps through the use of water and / or air as the cooling solvent. In yet another embodiment, additional solvents and / or chemical solutions can be used to facilitate the cooling process in the stabilization process of stabilization oven 110. The stabilization process can reduce the volume of the enlarged midsole by approximately 20% and the midsole resulting from the stabilization process can be approximately 160% of the initial biscuit volume. In another embodiment, the stabilization process is improved to increase or decrease the rate of change seen in the volume of the enlarged midsole. In another method, any form of stabilization method is used to stabilize one or more enlarged biscuits, which method includes the step of soaking in water or other solution at a desired temperature. In another embodiment, the enlarged biscuit is stabilized through the use of an aerosol solution or aeration at the desired temperature.

  Another way to change the volume of the enlarged midsole is to manually change the midsole, eg by manually using a lathe or one or more cutting tools or a second mold. Encased in a second mold, the enlarged midsole can be contracted in volume using pressure or pressed from the enlarged midsole into a desired shape using pressure and then cut and / or unnecessary excess By cutting off the material, the volume can be reduced.

  The operator can then remove the biscuits from the stabilization oven 110 and load the biscuits onto the cleaning / drying table 112 and clean one or more midsole using an ultrasonic bath. The wash / dry table 112 shall wash the midsole using one or more wash steps. In another embodiment, the stabilization of the enlarged biscuit is combined with the wash / dry table 112. In another embodiment, the biscuits are removed from the stabilization oven and then loaded into another type of washer and / or solvent and / or cleaning liquid. In another embodiment, each biscuit removed from the stabilization oven 110 should be hand polished by one or more workers.

  The operator then removes the biscuits from the wash / dry table 112 and loads the biscuits into the drying oven. In another embodiment, the biscuits are removed from the wash / dry table 112 by exposure to a sufficiently high temperature to evaporate the desired amount of moisture from the biscuits. The midsole is dried by taking out the midsole and air drying. The operator then removes the biscuits from the drying oven and loads the biscuits into the marketplace.

  At this point in this embodiment, the midsole marketplace 104 and outsole marketplace 118 comprise a series of different types of outsole and one or more midsole as described above. When a customer orders one or more shoes, the outsole and one or more midsole associated with the customer's order are retrieved from outsole marketplace 118 and midsole marketplace 104, if available. If one or more of the customer orders midsole or outsole are not available in the midsole marketplace 104 or outsole marketplace 118, respectively, the necessary parts may be formed on an order basis.

  After the outsole and one or more midsole are removed from the outsole marketplace 118 or the midsole marketplace 104, respectively, they are primed with UV-activated primers in area 120. The primer (primer) is placed on one or more midsole within 24 hours after activation. In an alternative embodiment, primers can be placed on each outsole and midsole before entering the outsole marketplace 118 or midsole marketplace 104, respectively.

  After priming the outsole and one or more midsole, each part is housed in an infrared (IR) oven 122. After being placed in the oven, the temperature is raised to approximately 55 ° C. The primer is activated at a sufficiently high temperature. Thereafter, each part is removed from the infrared oven and the adhesive is applied at the prime and adhesive area 120. Each part is then loaded into an infrared oven 122 and heated to about 55 ° C. which activates the adhesive. Thereafter, each part is taken out from the infrared oven 122. In an alternative embodiment, each part is applied at the prime and adhesive area 120 and then loaded into a standard oven and heated. This standard oven shall be heated to a temperature at which the adhesive is activated. For example, the outsole and one or more midsole are pressed together. For example, the outsole and one or more midsole are manually bonded using a bladder press 124 and a standard press 126. In another embodiment, the outsole and midsole are loaded into a press aligner that functions to bond the outsole and one or more midsole.

  After the outsole is pressed together with its associated midsole, the outsole-midsole is placed in the cooling device 128. The cooling device 128 can reduce the outsole-midsole temperature to about 0 ° C., thereby curing the adhesive. In an alternative method, the outsole-midsole can be cooled and cured for a sufficient amount of time necessary to reduce the temperature to which the adhesive will adhere. Next, the outsole-midsole is transferred to the relay area in the swing arm post 130.

  In one embodiment, production of the upper portion begins when the customer orders one or more shoes. After the customer orders one or more shoes, the operator loads a piece of synthetic material (eg, synthetic leather, polyester, or mesh) onto the eco-solvent printer 132. The composite is white, which allows the customer to request that the composite be printed with one or more desired aesthetic elements related to the customer order. Alternatively, the composite material can be dyed to customize customer orders for one or more shoes. In another method, the operator loads a natural material (eg, cotton or natural leather) onto the eco-solvent printer 132. In another method, the desired color of the composite is loaded into the eco solvent printer 132. By loading the composite material of the desired color, the step of dyeing the composite material can be reduced or omitted.

  The operator then loads the eco-solvent printer 132 and the sublimation dye printer 136 with a composite material that imprints and / or dyes and / or marks customer-customized parameters on the eco-solvent printer 132. Thereafter, the eco solvent printer 132 prints toward the sublimation dye printer 136. Next, the eco solvent printer 132 performs printing. The eco-solvent printer 132 then cuts the customized synthetic material from the original piece of synthetic material. In another method, the customized composite can be cut by using scissors or a blade blade or using a press.

  After cutting the customized composite, the operator loads the customized composite into the laser 140. Thereafter, the operator inputs the specification specified by the customer, and if applicable, starts the laser etching operation.

  The operator then removes the customized composite and loads it into the sublimation dye press machine 142. The sublimation dye press machine 142 can be used to imprint a design, such as a Nike swoosh. The operator removes the laser cut upper part from the sublimation dye press machine 142 and loads the upper part into the embroidery machine 146. The operator then starts the embroidery machine 146 and customizes the upper portion by embroidering the desired design using the desired set of colors. Thereafter, the operator removes the customized upper part from the embroidery machine 146 and feeds it to the high frequency welder 148.

  At this point in the process, the upper portion and the outsole-midsole are collected by the operator. The operator also collects the remaining shoe parts kit from the market place 150. In one embodiment, the remaining shoe parts comprise a “kit” and the operator collects the remaining parts needed for a men's size 9 running shoe, for example. In another embodiment, one or more workers may retrieve one or more remaining shoe parts from the kit parts marketplace. After collecting the shoe parts, the operator uses the high frequency welder 148 to join the parts.

  After assembling the upper portion, the operator uses the final trimming die cutter 144 to make one or more final cuts to define the shape of the upper portion. In another embodiment, the upper portion cuts using visual judgment and / or expertise to determine where and / or at what angle and / or how much to cut. Thereafter, the upper part is sewn to the outsole-midsole by the swing arm 130. In another embodiment, the upper portion is sewn using visual judgment and / or expertise to determine where and / or at what angle and / or how much to cut. Thereafter, the subassembly is transferred to the shoe mold matching area 152.

  FIG. 2 illustrates a method 200 for efficiently manufacturing multiple models of custom shoes in a single manufacturing facility, such as the one described above. In accordance with the present invention, a first customer places an order for a first model of shoes and one or more customization parameters specific to this customer order. The second customer places an order for the second model shoe and one or more customization parameters specific to the customer order. By utilizing the system and method according to the present invention, both the first and second customer shoes can be efficiently manufactured in the same facility at an affordable cost and in an affordable time. By utilizing the system and method according to the present invention, the physical footprint of manufacturing equipment capable of producing multiple models of shoes can also be reduced.

  Again, it should be understood that the books and other configurations and workflows described herein are shown by way of example only. Other configurations and elements (eg, processes, methods, etc.) can be used in addition to or in place of those shown and described, and some elements can be omitted entirely.

  In step 205, the shoe model options are presented to the customer. The shoe model options presented at step 205 include, for example, a running shoe model, a basketball shoe model, and a skate shoe model. Of course, other shoe models, both competitive and non-competitive, may alternatively or additionally be included in the available shoe model options presented in step 205. Step 205 can optionally comprise all available shoe model options that can be produced locally, for example at a shoe manufacturing facility connected or not connected to the network. In addition, the shoe model option is locally available in a shoe manufacturing facility that is connected or not connected to the network, along with a shoe model that cannot be locally produced in a shoe manufacturing facility that is connected or not connected to the network. There can be a shoe model that can be produced. An indication of whether a particular shoe model can optionally be produced locally at a manufacturing facility connected to or not connected to the network shall also be optionally presented. Step 205 presents, for example, information describing available shoe model options to the customer on a computer using a graphic user interface, along with a local manufacturing availability indication for each particular model. Can be included.

  In step 210, the customer's shoe model selection is received. For example, step 210 comprises receiving a user selection of a shoe model presented from within a graphic user interface. The customer, for example, selects a check box for a basketball shoe model to indicate that he wants to order basketball shoes.

  In step 215, functional options for the selected shoe model may be presented to the customer. Similar to step 205, step 215 can be performed, for example, in a graphic user interface operating on a computer. Function options shall include parameters such as shoe size. Other types of options to select in step 215 shall include outsole hardness options, support options, motion control options, outsole fabric options, outsole material options, and the like. It should be understood that step 215 does not necessarily have to be presented after step 205 and step 210, and in many cases the available functional options will depend on the selected shoe model. For example, functional options related to foot motion control are related to running shoes and can therefore be made available for customer selection after the customer has selected a running shoe model, while motion control options are basketball shoes. Does not need to be enabled for the basketball shoe model. Additionally, similar to step 205, local manufacturing information specific to each function option can be displayed. For example, some functional options can be used for shoes produced locally at a manufacturing facility that is connected or not connected to the network, while other functional options are only available at non-local manufacturing facilities. One skilled in the art will readily recognize that there are any number of other types of functional options that are relatively specific to one or more particular model types of shoes.

  In step 220, a customer feature option selection is received. Similar to step 210, step 220 is performed, for example, in a graphic user interface executing on a computer. For example, step 220 includes receiving a user selection of a particular functional option, such as midsole hardness, within the graphic user interface. For example, the customer selects a check column regarding the display of the midsole hardness, and displays that he / she desires a midsole of a shoe having the midsole as a specific hardness.

  In step 225, the aesthetic and / or functional options of the selected shoe model are presented to the customer. Step 225 can be performed on a computer using a graphic user interface, similar to steps 205 and 215. The aesthetic options presented at step 225 depend at least in part on the model options selected by the customer and / or the functional options selected by the customer. However, aesthetic options can exist completely or partially independent of model and / or function options, in which case step 225 can be performed before or simultaneously with steps 205 and / or 215. . For example, the choices for shoe colors shall not depend on the shoe model or functional choice. On the other hand, the choice regarding the color of the specific functional element depends on, for example, whether the functional element is selected as part of the shoe model selection or as a functional option. Also, similar to step 205, local manufacturing information specific to each aesthetic option can be displayed. For example, some aesthetic options may be used for shoes manufactured locally at a manufacturing facility that is connected or not connected to the network, while other aesthetic options are only available for non-local manufacturing facilities.

  In step 230, an aesthetic choice selection is received from the customer. Step 230 can be performed, for example, by clicking a check box appropriate for each selected aesthetic option, for example, by receiving a customer selection using a pointing device in a graphic user interface on a computer.

  In step 235, the customer's local manufacturing options are presented. Similar to step 205, step 235 can be performed, for example, in a graphic user interface on a computer. The local manufacturing options presented in step 235 can be, for example, options for local manufacturing at a networked or non-connected manufacturing facility, options for manufacturing at a specific local or non-local facility, or manufacturing location And an option that does not indicate preference. It should be understood that the options presented in this step are affected by the shoe model customer selection at step 210, the functional shoe option customer selection at step 220, and / or the aesthetic option customer selection at step 230. For example, if the customer selects a shoe model in step 210 that cannot be locally manufactured at a manufacturing facility that is connected or not connected to the network, step 215 does not present such a manufacturing option to the user. Also, by way of example, if a customer selects a functional option in step 220 and / or an aesthetic option in step 230 that cannot incorporate shoes at a particular manufacturing location, such manufacturing location may include a manufacturing option list in step 235. Shall not be included. Step 235 is, for example, presenting a list of options to the user, the options including all locations where a specific model of shoes with specific selection functions and aesthetic options can be manufactured. including.

  In step 240, the customer's location manufacturing selection is received. Similar to step 210, step 240 can be performed, for example, in a graphical user interface operating on a computer. For example, step 240 comprises receiving a user selection of a manufacturing facility presented from within a graphical user interface. For example, the customer may select a check box for a local manufacturing facility to indicate that the shoe desires local production at a manufacturing facility that is connected or not connected to the network.

  In step 245, the receiving options for the selected shoe model are presented to the customer. For example, step 245 is the step of presenting a list of options to the user, the option of receiving shoes at the store where the order was received, the option of receiving shoes from a manufacturing facility connected or disconnected from the network, different locations And an option for delivering shoes to a customer's store and an option for delivering shoes to a customer's residence. One skilled in the art will appreciate that the options presented in this step can be adjusted to reflect the customer's manufacturing location selection during step 240. For example, if the user selects local manufacture for the order in step 240, step 245 shall present the user with the option to receive shoes from a store or network connected or nearby manufacturing facility. . On the other hand, for example, when the customer selects shoes that cannot be locally manufactured in step 240, the option presented in step 245 does not include the option of receiving shoes at the nearest manufacturing facility.

  In step 250, a customer receipt selection is received. Similar to step 210, step 250 can be performed, for example, in a graphical user interface operating on a computer. Step 250 comprises, for example, receiving a user selection of receipt options from within a graphic user interface. For example, a customer may select from a drop-down list to indicate that his shoes are desired to be received at the store where he ordered. Alternatively, step 250 comprises receiving an indication that the user wishes to deliver his order to his residence. In another embodiment, step 250 comprises receiving an indication that the user wishes to deliver his order to another receiving location.

  In step 255, the workflow begins in the facility specified by the user in step 240 and assembles the outsole according to the shoe model option selected by the customer. The workflow shall also incorporate functional choices and / or aesthetic choices selected by the customer. For example, in step 210, if the customer selects a basketball shoe model, the basketball shoe workflow begins in the outsole manufacturing area. Although the specific basketball shoe workflow for a particular basketball shoe can vary to some extent and the customer's specific features and / or aesthetic options are incorporated into the final basketball shoe, the workflow is still the same as the basketball shoe workflow. It should be understood that it can be viewed (as opposed to the workflow of skate shoes). Alternatively, if the customer selects a running shoe model in step 210, for example, the running shoe workflow shall begin assembling the outsole according to the running shoe model.

  It should first be understood that step 255 does not necessarily have to incorporate a different workflow for each shoe model, as some shoe models show a certain amount of overlap in some parts manufacturing areas. For example, the workflow for an outsole for skate shoes can be similar to the workflow for an outsole for basketball shoes, with only one outsole workflow for producing both basketball and skate shoe outsole. To require. However, this does not necessarily mean that each part of these shoes can share the workflow as well, that is, the basketball outsole workflow encompasses the workflow of the skate shoe outsole and both shoe models One outsole workflow can be used, while each shoe workflow, for example, must significantly branch into its respective midsole production to maintain a separate midsole workflow . Different shoe model workflows can thus be performed in various parts manufacturing areas by varying the degree of overlap. By overlapping, branching and converging these workflows, it is possible to efficiently produce multiple models of shoes in one manufacturing facility, and at the same time reduce the physical footprint of the manufacturing facility.

  It should be finally understood that step 255 does not necessarily have to start with a specific selection by a specific customer. For example, the stock of outsole with various characteristics can be maintained at a predetermined level. The three different colored outsole can be formed, for example, in sizes that can be used for each of the three different models of shoes that can be used in the facility. The outsole is then used from inventory based on customer orders. When an outsole of a given model, size, and color begins to run out of stock, the operator can begin the workflow for that model and assemble additional outsole that meets those parameters. In this way, step 255 is performed in a manner that depends on the shoe model, functional options, and / or aesthetic options selected by the customer, while not having to be initiated directly by the customer's selection. Furthermore, step 255 is different, for example by starting a workflow for outsole that is normally used with an inventory system and starting a workflow that produces less commonly used outsole only in response to an order that requires them. Perform in different ways for different types of outsole.

  In step 260, a workflow for midsole production is initiated according to the shoe model, ie, functional and / or aesthetic options are also incorporated according to the customer selected options. First, it should be noted that, as in step 255, each shoe model does not necessarily have its own specific workflow, but shares a workflow with another shoe model. Second, similar to step 255, the workflow for a particular shoe model may be altered to some extent to allow a user-selected function and / or aesthetic customization to be incorporated into the shoe model. Third, and similar to step 255, step 260 does not need to begin in response to a specific customer ordering a shoe, but instead uses an inventory system to create a midsole with the desired characteristics. A workflow for production can be started. Finally, as in step 255, for example, start a workflow for a regular use midsole with an inventory system, and start a workflow that produces less commonly used midsoles only on orders that require them. Thus, the step of initiating the midsole production workflow is performed differently for different types of midsole.

  In step 265, a workflow is initiated to prepare for laminating the outsole and midsole according to the selected shoe model, and the shoe model shall also incorporate the functional and aesthetic options desired by the customer. Step 265 includes, for example, removing one or more outsole suitable for customer order from the outsole marketplace, removing one or more midsole suitable for customer order from the midsole marketplace, Cutting the edges of the outsole, placing the removed midsole and outsole in an infrared oven, priming the removed midsole and outsole, and placing the removed midsole and outsole in an infrared oven Re-entering. Note that, like steps 255 and 260, each shoe model does not necessarily have its own unique workflow in step 265, and can share a workflow with other shoe models. Also, similar to steps 255 and 260, the workflow for a particular shoe model may be altered to some extent to allow the user-selected function and / or aesthetic customization to be incorporated into the shoe model.

  Any and / or all workflows in any and / or all sections, including those utilized in steps 255 and 260, preferably take the same amount of time to complete and complete the finished parts simultaneously. Is possible. For example, the workflows from steps 255 and 260 produce parts that arrive at the same time so that they can be prepared in step 265 without having to delay the start of the workflow of step 265 waiting for the arrival of the required parts. .

For example, if the customer selects a basketball shoe model, step 255 is the step of initiating a basketball shoe workflow, which includes (1) injection molding a rubber outsole, approximately in mechanical work time. A step of approximately 15 seconds with 220 seconds and human working time,
(2) removing the flash part (protruding part) and relaying the outsole into the final outsole marketplace, taking about 5 seconds of human work time;
(3) The step of removing the outsole from the final market place, which takes about 5 seconds in human work time,
(4) A step of washing the outsole with alkali, which takes about 50 seconds in mechanical work time,
(5) acid-washing the outsole, which takes approximately 50 seconds in mechanical work time;
(6) drying the outsole, taking about 90 seconds of mechanical work time;
(7) removing the outsole from the drying oven, taking approximately 2 seconds of human work time, and (8) relaying the outsole into the outsole marketplace, the human work time Step for about 3 seconds,
Shall be included. That is, the basketball shoe outsole production workflow in this embodiment takes approximately 350 seconds. In this embodiment, this is the situation, but preferably the workflow utilized in step 260 is similar so that parts arrive at the same time and step 265 proceeds without undue delay over approximately 350 seconds. can do.

Furthermore, it should be noted that an arbitrary workflow can overlap with another workflow not only in space but also in time. For example, the basketball midsole production workflow at step 260 is:
(1) A step of injection-molding a biscuit, which takes about 30 seconds for the machine work time;
(2) putting the biscuits into the biscuits marketplace, which takes about 10 seconds in human work time
(3) heating and pressing the biscuits, taking about 420 seconds for mechanical work time and about 20 seconds for human work time;
(4) loading the biscuits into the stabilization oven, taking about 5 seconds of human work time;
(5) heating the biscuits to produce a midsole that takes approximately 3600 seconds of mechanical work time;
(6) removing the biscuits from the stabilization oven, taking about 5 seconds of human work time;
(7) washing the midsole with water, which takes about 600 seconds in mechanical work time;
(8) drying the midsole and relaying it to the midsole relay marketplace, taking about 300 seconds for mechanical work time and about 5 seconds for human work time;
(9) removing the midsole from the midsole relay marketplace, taking about 2 seconds of human work time, and (10) relaying the midsole for assembly, A step of about 3 seconds of time,
Shall be included.

  Using the workflow of this embodiment without time overlap, one midsole can be produced approximately every 5000 seconds. However, for example, step (5) takes approximately 3600 seconds in this embodiment, but stabilization can be performed by a load stabilization oven comprising a unit that can subject multiple midsoles to the stabilization process at once. it can. Thus, for example, the first basketball midsole workflow can be started and steps (1), (2), (3) and (4) can be performed on the first biscuit. In step (5), the first biscuit needs to be held in the stabilization oven for approximately 3600 seconds to become the first midsole. During this time, the first biscuit is in the stabilization oven, but for basketball or other shoes, a second midsole workflow is started, for example from step (1) of this specific workflow, and further, for example, this specific workflow I.e., proceeding to a step in the specific workflow of loading the second biscuit into the stabilization oven. In this embodiment, at this point in time, the two individual workflows are advanced, each going to the stabilization step, and simultaneously performing the stabilization step. Thus, two or more different biscuits, whether different models of shoes, can be placed in the stabilization oven at different stages of stabilization at any time. Any number of workflows can be started with varying stages of progression and can be duplicated in this way. Upon completion of the first workflow stabilization step (5), the first midsole can be removed from the stabilization oven and the started first basketball midsole workflow can be resumed at step (6).

  In another embodiment of a temporally overlapping workflow, referring again to the basketball midsole workflow embodiment described above, after loading the first biscuit into the stabilization oven in step (5), the second workflow Begin to produce basketball shoes outsole. This second workflow can be completed and a third basketball outsole workflow can be initiated and completed. One skilled in the art will appreciate that any number of workflows can be initiated while maintaining the first midsole workflow from the above embodiment in step (5). At any time, the midsole workflow of the first embodiment can be resumed at step (6) to complete the first midsole.

  It should be noted that these workflows can be duplicated in an advantageous manner as will be apparent to those skilled in the art. In this embodiment, each workflow is adjusted to overlap so that the new midsole appears in a time comparable to the time it takes to produce other shoe parts in this or other shoe parts manufacturing area. Like that. This advantageously allows, for example, various parts to arrive at the same time and go through a combined workflow. In this embodiment, for example, through the use of workflows that overlap in time, one midsole is produced approximately every 350 seconds and the time taken to execute the outsole workflow from the example used in step 255 To match. These two workflows can take the same amount of time to produce two parts to be combined using the combined workflow without undue delay. It should be noted that the use of time-overlapping workflows can be applied to any step using wow flow, such as steps 255 and 260, as will be apparent to those skilled in the art.

  In step 270, the one or more customization workflows for the upper portion for a particular shoe model begin according to the shoe model, and the shoe model may incorporate customer-selected functional and / or aesthetic options. it can. Note again that, like steps 255, 260, and 265, each shoe model does not necessarily have its own specific workflow, and the workflow can be shared with another shoe model. Also, similar to steps 255, 260, and 265, the specific shoe model workflow is altered to some extent to allow the user-selected function and / or aesthetic customization to be incorporated into the shoe model. Similar to steps 255, 260, and 265, step 270 can be performed regardless of the specific order by the customer, but in practice, step 270 is performed in response to the specific customer order, depending on the customization applied to the upper portion of the shoe. There is a high possibility of becoming. For example, step 270 initiates a workflow to assemble the upper portion for a running shoe having a red color. Similarly, step 270 initiates a workflow to assemble the upper portion of other types of shoe models, such as basketball shoes or skate shoes, and these workflows further include additional ankle support, side vents, and Various functional features, such as other similar functional options, can be incorporated with various aesthetic options such as specific colors, embroidery patterns, emblems, and the like.

In another embodiment, step 270 initiates a basketball shoe upper part customization workflow, the step comprising:
(1) printing eco-solvent customization, which takes about 120 seconds for mechanical work time and about 30 seconds for human work time;
(2) cutting the lining of the toe leather and the quarter of the toe leather, which takes about 30 seconds in human work time;
(3) Laser customization step, which takes about 120 seconds for mechanical work time and about 30 seconds for human work time,
(4) Embroidery customization step, which takes about 120 seconds for mechanical work time and about 30 seconds for human work time;
(5) Conveying the parts and heating and pressing them, which takes about 5 seconds in human work time, and (6) inspecting the marketplace and cutting the parts if necessary. , A step of about 6 seconds in human work time,
With. That is, the basketball workflow in this embodiment takes about 491 seconds. This process, similar to steps 255, 260, and 265, allows the upper part to produce other parts in this or other compartments utilized for different workflows by changing the degree of workflow time overlap. Note that the production can be done in a time as short as the production time. For example, by using workflows that overlap in time, any customized upper part of any model type can be produced approximately every 350 seconds.

As another embodiment, and to further illustrate how workflows overlap spatially, step 270 comprises initiating a running shoe upper portion customization workflow in response to receiving the customer's model selection input. And This workflow is, for example,
(1) printing eco-solvent customization, which takes about 120 seconds for mechanical work time and about 30 seconds for human work time;
(2) cutting the lining of the toe leather and the quarter of the toe leather, which takes about 30 seconds in human work time;
(3) printing the sublimation dye customization, taking about 120 seconds for mechanical work time and about 20 seconds for human work time;
(4) Pressing the sublimation dye customization, which takes about 12 seconds for mechanical work time and about 10 seconds for human work time (5) Laser customization step, about mechanical work time Taking approximately 30 seconds with 120 seconds and human working time,
(6) Embroidery customization step, which takes about 120 seconds for mechanical work time and about 30 seconds for human work time;
(7) transferring the parts to the high frequency welder market place and heating and pressing, taking about 5 seconds in human work time; and (8) inspecting the high frequency welder market place and if necessary parts And a step of taking about 6 seconds in human work time. That is, in this embodiment, the customized running shoe upper part can be assembled in approximately 613 seconds. This process, similar to the previous steps used in the workflow, allows the upper part of the running shoe to move other parts in this or other compartments used for different workflows by changing the degree of time overlap of the workflow. Note that it will be possible to produce in as little time as it takes to produce. For example, using the time-overlapping workflow, the upper part of the customized running shoe of any model type can be produced approximately every 350 seconds. In these embodiments, it will be appreciated by those skilled in the art how to customize this upper running shoe workflow to overlap with similar machines, technologies, and work areas involved in the basketball shoe customization workflow illustrated above. It will be obvious.

  In step 275, one or more workflows for further manufacturing the upper portion for a particular shoe model can be initiated according to the shoe model, and the customer selected functional options and / or aesthetic options. Incorporate. Note again that, as with steps 255, 260, 265, and 270, each shoe model does not necessarily have its own unique workflow, and the workflow can be shared with another shoe model. Also, similar to steps 255, 260, 265, and 270, the specific shoe model workflow may be altered to some extent to allow the user-selected function and / or aesthetic customization to be incorporated into the shoe model. Similar to steps 255, 260, 265, and 270, step 275 can be performed regardless of the specific order by the customer, but in practice, step 275 can be performed on a specific customer order, depending on the customization applied to the upper portion of the shoe, or More specifically, there is a high possibility that the process will be executed according to the upper part produced in step 270. For example, step 275 initiates a workflow to sew an upper portion for a running shoe according to a user selection, which can be produced and customized according to the user selection at step 270.

In one embodiment, step 275 comprises initiating a basketball shoe upper part formation and sewing workflow, the workflow comprising: (1) collecting parts from the marketplace, approximately 15 human work hours. Step for seconds,
(2) assembling the upper part portion, which takes about 20 seconds for mechanical work time and about 30 seconds for human work time;
(3) activating the heating press, which takes approximately 10 seconds for mechanical work time and approximately 2 seconds for human work time;
(4) loading the parts into the cooling rack, taking about 60 seconds for mechanical work time and about 1 second for human work time (5) cutting the final trimming, A step that takes about 15 seconds in working time,
(6) a heel formation step that takes approximately 180 seconds for mechanical work time and approximately 20 seconds for human work time;
(7) Post-sewing step, which takes about 30 seconds in human work time,
(8) Strobel sewing step, which takes about 40 seconds in human work time, and (9) Transfers the upper part to the shoe mold matching process, which takes about 5 seconds in human work time. Step,
Shall be provided. That is, the basketball upper part formation and sewing workflow in this embodiment takes approximately 428 seconds. The process in the embodiment described above, like steps 255, 260, 265, and 270, allows the upper portion to be in this or other areas utilized for different workflows by changing the degree of workflow time overlap. It should be noted that it can be produced in a time as short as the time for producing other parts. For example, in step (6), the machine waits until the heel is sewn, but the operator can initiate another workflow for the same or another model of shoes. For example, when the worker reaches step (6) in this second workflow, the first upper part can complete step (6) and then the operator can execute step (6) on the second upper part. Suppose that steps (7), (8) and (9) can be continued in the first upper part while the machine continues to step (6) in the second upper part. As will be apparent to those skilled in the art, any of these or other steps of a given workflow can be advantageously overlapped.

As another example, and to further illustrate how workflows overlap spatially, step 275 shall comprise initiating a running shoe upper part high frequency welding and sewing workflow. This workflow is, for example,
(1) collecting parts from the high frequency welding marketplace, taking about 15 seconds in human work time;
(2) assembling the upper part portion, which takes about 20 seconds for mechanical work time and about 30 seconds for human work time;
(3) activating the high frequency welding cycle, which takes approximately 10 seconds for mechanical work time and approximately 10 seconds for human work time;
(4) cutting the final trimming, which takes about 15 seconds in human work time;
(5) a step of sewing the upper part to the shoe sole, which takes about 60 seconds in human work time, and (6) a step of transferring to the final quality control area, which takes about 5 in human work time. Step for seconds,
Shall be provided. The workflow in this embodiment takes approximately 145 seconds. This process, like the previous steps used in the workflow, allows the upper part to produce other parts in this or other areas utilized for different workflows by changing the degree of workflow time overlap. Note that production can be done in a time shorter than that of For example, a customized running shoe upper portion of any model type can be produced approximately every 350 seconds using a time-overlapping workflow. In these embodiments, how this high-frequency welding and sewing workflow for the upper part of the running shoe overlaps with similar machines, techniques, and work areas involved in the basketball shoe formation and sewing workflow illustrated above. Will be apparent to those skilled in the art.

  In step 280, a workflow can be initiated and the outsole, midsole, and upper portion can be laminated together to form a selected shoe model according to the selected shoe model, and the customer can select the desired functional and aesthetic options. Can also be incorporated. Step 280 includes, for example, fitting a suitable outsole, a suitable midsole, and a specially customized upper portion to form a shoe as ordered by the customer. Note that, as with steps 255, 260, 265, 270, and 275, each shoe model does not necessarily have its own unique workflow in step 280, and the workflow can be shared with other shoe models. . Also, similar to steps 255, 260, 265, 270, and 275, the specific shoe model workflow is altered to some extent to allow the user-selected function and / or aesthetic customization to be incorporated into the shoe model.

In another embodiment, step 280 includes (1) applying adhesive to the upper portion produced in step 275, the midsole produced in step 260, and the outsole produced in step 255, A step that takes approximately 75 seconds in working time,
(2) placing the part into the oven, taking about 120 seconds of mechanical work time;
(3) A step of manually combining parts, which takes about 75 seconds in human work time,
(4) pressing the part, taking about 30 seconds in mechanical working time and about 10 seconds in human working time; and (5) cooling the part, in mechanical working time. A step of about 60 seconds and a human work time of about 5 seconds,
Shall be provided. That is, the workflow of this embodiment takes about 460 seconds. As is known to those skilled in the art, as with other steps used in this embodiment, multiple workflows can be duplicated in time to reduce the time taken to complete step 280.

  In step 285, the workflow should be initiated to quality control, thread lace, and shoe mold the customized combined shoe parts, and also incorporate the functional and aesthetic options desired by the customer. Note that, like steps 255, 260, 265, 270, 275, and 280, each shoe model does not necessarily have its own unique workflow in step 280, and the workflow can be shared with other shoe models. I want to be. Also, similar to steps 255, 260, 265, 270, 275, and 280, the workflow for a particular shoe model can be altered to some extent to allow the user-selected functionality and / or aesthetic customization to be incorporated into the shoe model. .

In some embodiments, step 285 includes (1) quality control inspection and shoe-molding of the combined shoe parts, taking about 90 seconds for mechanical work time and about 90 seconds for human work time;
(2) Quality control inspection and re-shoe matching of the combined shoe parts, taking about 30 seconds of human work time;
(3) passing the shoelaces through the combined shoe parts, taking about 60 seconds of human work time, and (4) packaging the shoes, which basically takes less time,
Shall be provided. That is, the workflow in this embodiment takes about 270 seconds. As is known to those skilled in the art, as with other steps using the workflow in this embodiment, multiple workflows can be duplicated in time to vary the time taken to complete step 285.

  In step 290, the customized shoes are delivered to the customer according to the receiving option selected by the customer from step 245. Step 290 further includes customer inspection and approval, payment, etc. Although step 290 can be performed at a location that is geographically remote from where all or part of the other steps in method 200 are performed, the desired characteristics of method 200 are that the locality of the shoe is relative to the customer order. It should be understood that manufacturing is possible. Such local manufacturing can reflect local needs and preferences over remote manufacturing, and can reduce inventory and shipping costs. Thus, step 290, like the remaining steps of method 200, is actually performed geographically in the same large facility.

  Turning now to FIG. 3, an exemplary method of forming an outsole for a running shoe is indicated generally by the reference numeral 300. In step 305, a rubber outsole is injection molded by an injection molding process. In an exemplary injection molded rubber process, the rubber is injected into a mold that forms the outsole. In another method, the outsole is carved and / or cut out from the rubber mass. In step 310, the outsole is cured. In another method, the outsole is cured using stearic acid and oil. This combination results in rubber blooming and undesirable rubber residues on the outsole.

  In step 315, the flash (overhang) portion is removed from the outsole. One method of removing the outsole flush includes cutting and / or removing and / or cutting off excess excess rubber. Another method of flash removal involves wiping or picking the rubber outsole by hand. In step 320, the outsole relays to the outsole pre-clean marketplace. In an alternative method, the number and characteristics (eg, size, shape, color, etc.) of the outsole placed in the marketplace can be based on demand forecasts. In step 325, an order is received. An exemplary method for receiving an order includes receiving the order manually. In yet another method, an order can be received by uploading order details through a web interface. In the alternative, steps 305-320 are not performed until an order is received. In this alternative, the outsole is produced as needed, rather than receiving a predicted marketplace demand. At step 330, the outsole is removed from the outsole pre-clean marketplace.

  In step 335, the outsole is washed. In some methods, the outsole is washed with an alkaline solution. In another method, the outsole should proceed directly from step 315 of removing flush from the outsole to step 335 of cleaning the outsole. In step 340, the outsole is washed. In some methods, the outsole is washed with an acid solution. Washing steps 335 and / or 340 provide a means for removing excess rubber residue generated in the curing process of step 310. In another method, the curing process is performed without the use of stearic acid, thereby reducing or reducing the resulting rubber residue. In this way, the washing steps 335 and / or 340 can reduce or eliminate time and / or material. In step 345, the outsole is dried in an oven. In another embodiment, the outsole shall be dried using a method that can generate heat to dry the outsole to a desired dryness within a desired period of time. In step 350, the outsole is removed from the oven. In another method, the outsole is removed from another heating device used to remove moisture from the outsole mold. In step 355, the outsole relays to the outsole broadcast marketplace. Alternatively, if there is little or no rubber excess generated from the curing process 315, the outsole should proceed directly from the curing process 315 to relay to the outsole relay marketplace 355. Alternatively, if the rubber residue is minimal, the outsole should proceed directly from the curing process 315 to a cleaning step 335 where the outsole is wiped with a material such as a cloth to remove excess rubber. In the former embodiment, the outsole either proceeds directly from the curing process 315 to the cleaning step 335 or proceeds from the curing process 315 to the outsole marketplace 320 before removal from the outsole marketplace 330. . When receiving an order prior to outsole production (e.g., producing outsole on demand), the outsole can skip the time spent in outsole marketplaces 320-330.

  With reference to FIG. 4, an exemplary method of forming a midsole for a running shoe is indicated generally by the reference numeral 400. In step 402, a predetermined volume of EVA pellets is loaded into an injection mold. In the alternative, the choice of polymer type to be injected at step 402 can be correlated to the desired hardness associated with the resulting midsole customer order. EVA pellets can be processed in the same mold under the same conditions, ie by introducing EVA pellets with longer polymer chains, the hardness is increased compared to EVA pellets with shorter polymer chains. The longer polymer chains cannot degrade to the same extent as the shorter polymer chains under the same reaction conditions. In step 404, the injection mold is heated to 100 ° C. to form a predetermined volume of EVA pellets in the form of biscuits. In another embodiment, the EVA pellets are heated to a temperature that is hot enough to form the EVA pellets during biscuit formation but not sufficient to activate the expansion agent in the phylon. In yet another embodiment, the reaction conditions of the mold can be varied to affect the degree to which a given polymer will decompose, thereby obtaining a variety of different hardnesses. In step 406, the biscuit is then removed from the injection mold. In step 410, the biscuit then relays into the biscuit marketplace. In step 415, an order is received. An exemplary method for receiving an order includes receiving the order manually. In yet another method, an order can be received by uploading order details through a web interface.

  In step 420, the biscuit is removed from the biscuit marketplace. In step 430, the biscuit hot press is then loaded. In another method, for example, when an order is received prior to biscuit formation, the biscuit should proceed directly from the step of removing from the injection mold 406 to the step of loading into the hot press 430. In another method, a right hot press machine and a left hot press machine are provided for right foot shoe biscuits and left foot shoe biscuits, respectively. In yet another method, the right heat press and the left heat press can be operated simultaneously. In step 434, the biscuits are heated to 172 ° C. In another embodiment, the biscuits are heated to a sufficiently high temperature to activate the expansion agent. In step 438, the biscuits are removed from the hot press. In step 440, the biscuits are loaded into a stabilization oven. Within the stabilization oven, the biscuits cool to a low temperature where the biscuits can be sized as a midsole. In step 444, the biscuits are placed in a pneumatic stabilization oven and the temperature is reduced to 75 ° C. The process of passing air through biscuits in a stabilizing oven is performed using one or more air knife centrifugal blowers. In steps 448-452, the biscuits shall be reduced in temperature over three stages. In step 448, the temperature of the biscuit is reduced from 75 ° C to 65 ° C. In step 452, the biscuit temperature is reduced from 65 ° C to 55 ° C. In step 454, the biscuit temperature is reduced from 55 ° C to 45 ° C. In another method, the cooling stages 448-452 are performed in more than two stages. In another alternative, the step 444 of lowering the biscuit temperature to 75 ° C. can be adjusted to a higher or lower temperature. In another method, one or more biscuits are stabilized using a series of water baths that range in temperature from 90 ° C to 45 ° C. The biscuit temperature is reduced from 90 ° C. to 75 ° C. and then from 75 ° C. to 45 ° C., and the time in each bath is evenly distributed.

  In step 458, the midsole is removed from the stabilization oven. At step 460, the midsole is loaded into one or more ultrasonic baths. In step 464 in the ultrasonic bath, the midsole is cleaned. In another method, step 458 is omitted, and the midsole can be cleaned while it is still in the double stabilized oven ultrasonic bath apparatus. In step 468, the midsole is removed from the ultrasonic bath. In step 470, the midsole is loaded into one or more drying ovens. In step 474, the midsole is dried. In step 478, the midsole is removed from one or more drying ovens. At step 480, the midsole is loaded into the midsole transit marketplace.

  Turning now to FIG. 5, an exemplary method of applying primer and adhesive on a running shoe is indicated generally by the reference numeral 500. In step 504, a customer order is received. A customer order shall include a specification of features associated with one or more desired running shoes, such as size or style or color. In step 506, outsole that matches the characteristics determined in the customer order is retrieved from the outsole broadcast marketplace. At step 508, a midsole that matches the characteristics determined in the customer order is removed from the midsole broadcast marketplace. In step 510, the midsole and outsole are primed. In step 520, the primed midsole and primed outsole are placed in an infrared (hereinafter “IR”) oven. In step 530, the midsole and outsole are removed from the IR oven. In step 540, adhesive is applied to the midsole and outsole. In step 550, the midsole and outsole are placed in an IR oven.

  Referring now to FIG. 6, an exemplary method for combining the outsole and midsole into a midsole-outsole on a running shoe is indicated generally by the reference numeral 600. In step 610, the outsole and midsole are removed from the IR oven. In step 620, the outsole and midsole are bonded together to form a midsole-outsole. At step 630, the midsole-outsole is loaded into a stockfit press. In step 634, the midsole-outsole is heated. With heat, the adhesive can bond the midsole-outsole component more permanently. At step 638, the midsole-outsole is removed from the stockfit press. In step 640, the midsole-outsole is loaded into the cooling device. The midsole-outsole can be cooled to approximately 0 ° C. by the cooling device to solidify the adhesive. In another method, the midsole-outsole is placed in one or more temperature areas where the midsole-outsole is allowed to cool for longer periods of time. In another method, in step 644, the midsole-outsole temperature is decreased. In another method, the press is stopped and the midsole-outsole is left in the press and allowed to cool until the heat is dissipated. In yet another method, the press connects to both heating and cooling components, allowing shoe products such as midsole-outsole to be heated and cooled in one place. In doing so, having a dual heating and cooling press saves space and creates a shift during the period in which the shoe product parts move between the heating press and the cooling device. Alternatively, the risk of peeling off can be eliminated. In step 648, the midsole-outsole is removed from the cooling device. In step 650, the midsole-outsole is transferred to the swing arm post relay area.

  Referring to FIG. 7, an exemplary method for customizing the upper portion for a running shoe is indicated generally by the reference numeral 700. In step 702, an order is received. An exemplary method for receiving an order includes receiving the order manually. In yet another method, orders are received by uploading order details through a web interface. In step 704, the material associated with the upper part order (eg, synthetic leather or mesh or polyester, etc.) is loaded into the eco-solvent printer. In step 706, the eco-solvent printer and the sublimation dye printer are loaded with materials related to the order, such as the desired color. In step 708, the desired design and / or pattern is printed on the desired material used for the upper portion using a sublimation dye printer. In step 710, the desired design and / or pattern is printed on the desired material used for the upper portion using an eco-solvent printer. In step 715, the customized composite is cut from the desired composite according to the specifications characterizing the order. In step 720, the customized composite is loaded into the laser device. In step 724, the laser device is loaded with the design specifications associated with the order. In step 728, the laser etches the customized design on the customized composite.

  In step 730, the dye sublimation press is loaded. In step 735, the customized composite is removed from the laser device. At step 740, the right embroidery machine is loaded with the customized composite. In step 742, the left embroidery machine is loaded with the customized composite material. In step 744, the design specifications associated with the order are loaded into the embroidery machine. In step 746, the left and right parts are embroidered using the left embroidery machine and the right embroidery machine, respectively. In step 750, the left part and the right part are removed from the embroidery machine. In step 760, the customized part is delivered to a high frequency (hereinafter "RF") welding relay area.

  Some decoration techniques disclosed above may not be applicable to each shoe model, and therefore some steps disclosed above may be omitted. For example, assume that all shoe models do not require embroidery or laser etching. Further, different parts of the upper portion can be advanced through different steps, in different orders, and at different times.

  With reference to FIG. 8, an exemplary method for assembling the upper portion for a running shoe is indicated generally by the reference numeral 800. In step 805, the customized part for the upper part is removed from the RF welding relay area. In step 810, the set of parts is removed from the marketplace with the necessary parts associated with the customer order. In step 820, the upper portion is assembled from the customized parts. In step 825, the RF welding cycle is activated to join the assembled upper portion formed of the customized part. In step 830, the final trimming is cut to the upper portion to determine the final shape of the upper portion. In step 840, the midsole-outsole is removed from the swingarm relay area. In step 850, the upper portion is sewn to the midsole-outsole.

  Referring to FIG. 9, an exemplary method for shoe sizing and quality control for running shoes is indicated by the reference numeral 900, plug-in. In step 910, the shoe part is removed from the swing arm area. In step 920, a quality control inspection is performed and the upper part is shoe-shaped. In step 930, a quality control inspection is performed on the shoe-matched upper part, and then the upper part is re-shoe-matched. In step 940, a quality control inspection is performed and a shoelace is passed through the upper portion. In step 950, a quality control inspection is performed and the shoe is packaged.

  Referring now to FIG. 10, an exemplary method for forming a basketball shoe outsole is indicated generally by the reference numeral 1000. In step 1005, an injection molded rubber outsole is formed using an injection molding process. In an exemplary injection molded rubber process, rubber is injected into a mold that forms the outsole. In another method, the outsole is engraved and / or cut out from the rubber mass. In step 1010, the outsole is cured. In one alternative, the outsole is cured using stearic acid and oil. This combination results in rubber blooming and undesired rubber residues on the outsole.

  In step 1015, the flash portion (the protruding portion) is removed from the outsole. One method of removing the outsole flush includes cutting and / or removing and / or cutting off excess excess rubber. Another method of flash removal involves wiping or picking the rubber outsole by hand. In step 1020, the outsole relays to the outsole pre-clean marketplace. In an alternative method, the number and characteristics (eg, size, shape, color, etc.) of the outsole placed in the marketplace can be based on demand forecasts. In step 1025, an order is received. An exemplary method for receiving an order includes receiving the order manually. In yet another method, an order can be received by uploading order details through a web interface. In the alternative, steps 1005-1020 are not performed until an order is received. In this alternative, the outsole is produced as needed, rather than receiving a predicted marketplace demand. In step 1030, the outsole is removed from the outsole pre-clean marketplace.

  In step 1035, the outsole is washed. In some methods, the outsole is washed with an alkaline solution. In another method, the outsole should proceed directly from step 1015 to remove flush from the outsole to step 1035 to clean the outsole. In step 1040, the outsole is washed. In some methods, the outsole is washed with an acidic solution. The cleaning steps 1035 and / or 1040 are a means for removing excess rubber residue formed in the curing process of step 1010. In another method, the curing process is performed without the use of stearic acid, thereby reducing or reducing the resulting rubber residue. In this manner, the cleaning steps 1035 and / or 1040 can reduce or eliminate time and / or material. In step 1045, the outsole is dried in an oven. In another method, the outsole shall be dried using a method that can generate heat to dry the outsole to a desired dryness within a desired period of time. In step 1050, the outsole is removed from the oven. In another method, the outsole is removed from another heating device used to remove moisture from the outsole mold. In step 1055, the outsole relays to the outsole broadcast marketplace. Alternatively, if there is little or no rubber excess generated from the curing process 1015, the outsole should proceed directly from the curing process 1015 to relay to the outsole relay marketplace 1055. Alternatively, if rubber residue is minimal, the outsole should proceed directly from the curing process 1015 to a cleaning step 1035 where the outsole is wiped with a material such as a cloth to remove excess rubber. In the former embodiment, the outsole either proceeds directly from the curing process 1015 to the cleaning step 1035 or proceeds from the curing process 1015 to the outsole marketplace 1020 prior to removal from the outsole marketplace 1030. . When an order is received prior to outsole production (eg, when the outsole is produced as needed), the outsole can skip the time spent in the outsole marketplace 1020-1030.

  Referring to FIG. 11, an exemplary method of forming a basketball shoe midsole is indicated generally by the reference numeral 1100. In step 1102, a predetermined volume of EVA pellets is loaded into an injection mold. In the alternative, the choice of polymer type to be injected at step 1102 can be correlated to the desired hardness associated with the resulting midsole customer order. EVA pellets can be processed in the same mold under the same conditions, ie by introducing EVA pellets with longer polymer chains, the hardness is increased compared to EVA pellets with shorter polymer chains. The longer polymer chains cannot degrade to the same extent as the shorter polymer chains under the same reaction conditions. In step 1104, the injection mold is heated to 100 ° C. to form a predetermined volume of EVA pellets in the form of biscuits. In another embodiment, the EVA pellets are heated to a temperature that is hot enough to form the EVA pellets during biscuit formation, but not sufficient to activate the expansion agent in the phylon. In yet another embodiment, the reaction conditions of the mold can be varied to affect the degree to which a given polymer will decompose, thereby obtaining a variety of different hardnesses. In step 1106, the biscuit is then removed from the injection mold. In step 1110, the biscuit is then relayed to the biscuit marketplace. In step 1115, an order is received. An exemplary method for receiving an order includes receiving the order manually. In yet another method, an order can be received by uploading order details through a web interface.

  In step 1120, the biscuit is removed from the biscuit marketplace. In step 1130, the biscuits are then loaded into the hot press. In another method, for example, when an order is received prior to biscuit formation, the biscuit should go directly from the step of removing from the injection mold 1106 to the step of loading into the hot press 1130. In another method, a right hot press machine and a left hot press machine are provided for right foot shoe biscuits and left foot shoe biscuits, respectively. In yet another method, the right heat press and the left heat press can be operated simultaneously. In step 1134, the biscuits are heated to 172 ° C. In another embodiment, the biscuits are heated to a sufficiently high temperature to activate the expansion agent. In step 1138, the biscuit is removed from the hot press. In step 1140, the biscuits are loaded into a stabilization oven. In the stabilization oven, the biscuits are cooled to a low temperature where the biscuits are the desired size as a midsole. In step 1144, the biscuits are placed in a pneumatic stabilization oven and the temperature is reduced to 75 ° C. The process of passing air through biscuits in a stabilizing oven is performed using one or more air knife centrifugal blowers. In steps 1148 to 1152, the biscuit is assumed to reduce the temperature over three stages. In step 1148, the temperature of the biscuit is reduced from 75 ° C to 65 ° C. In step 1152, the biscuit temperature is reduced from 65 ° C to 55 ° C. In step 1154, the biscuit temperature is reduced from 55 ° C to 45 ° C. In another method, the cooling stages 1148-1152 are performed in more than two stages. In another method, the step 1144 of lowering the biscuit temperature to 75 ° C. can be adjusted to a higher or lower temperature.

  In step 1158, the midsole is removed from the stabilization oven. In step 1160, the midsole is loaded into one or more ultrasonic baths. In step 1164 in the ultrasonic bath, the midsole is cleaned. In an alternative method, step 1158 is omitted, and the midsole can be cleaned while it is still present in the double stabilized oven ultrasonic bath apparatus. In step 1168, the midsole is removed from the ultrasonic bath. In step 1170, the midsole is loaded into one or more drying ovens. In step 1174, the midsole is dried. In step 1178, the midsole is removed from one or more drying ovens. In step 1180, the midsole is loaded into the midsole transit marketplace.

  Turning now to FIG. 12, an exemplary method of applying primer and adhesive on a basketball shoe is indicated generally by the reference numeral 1200. In step 1204, a customer order is received. The customer order shall include a specification of features associated with one or more desired basketball shoes, such as size or style or color. In step 1206, an outsole that matches the characteristics determined in the customer order is removed from the outsole relay marketplace. In step 1208, a midsole that matches the characteristics determined in the customer order is removed from the midsole transit marketplace. In step 1210, the midsole and outsole are primed. In step 1220, the primed midsole and primed outsole are placed in an IR oven. At step 1230, the midsole and outsole are removed from the IR oven. In step 1240, adhesive is applied to the midsole and outsole. In step 1250, the midsole and outsole are placed in an IR oven.

  Turning now to FIG. 13, an exemplary method for combining an outsole and a midsole into a midsole-outsole on a basketball shoe is indicated generally by the reference numeral 1300. In step 1310, the outsole and midsole are removed from the IR oven. In step 1320, the outsole and midsole are bonded together to form a midsole-outsole. At step 1330, the midsole-outsole is loaded into a stockfit press. In step 1334, the midsole-outsole is heated. With heat, the adhesive can bond the midsole-outsole component more permanently. At step 1338, the midsole-outsole is removed from the stock fit press. In step 1340, the midsole-outsole is loaded into the cooling device. The midsole-outsole can be cooled to approximately 0 ° C. using a cooling device to solidify the adhesive. In another method, the midsole-outsole is placed in one or more temperature areas where the midsole-outsole is allowed to cool for longer periods of time. In another method, in step 1344, the midsole-outsole temperature is decreased. In another method, the press is stopped and the midsole-outsole is left in the press and allowed to cool until the heat is dissipated. In yet another method, the press connects to both heating and cooling components so that shoe products, such as midsole-outsole, can be heated and cooled in one place. In doing so, having a dual heating and cooling press can save space and produce slippage or flaking during the movement of shoe product parts between the heating press and the cooling device. It is also possible to eliminate the risk of doing. At step 1348, the midsole-outsole is removed from the cooling device. In step 1350, the midsole-outsole is transferred to the swing arm post relay area.

  With reference to FIG. 14, an exemplary method for customizing an upper portion for a basketball shoe is indicated generally by the reference numeral 1400. In step 1402, an order is received. An exemplary method for receiving an order includes receiving the order manually. In yet another method, orders are received by uploading order details through a web interface. In step 1404, the material associated with the upper part order (eg, synthetic leather or mesh or polyester, etc.) is loaded into the eco-solvent printer. In step 1406, the eco-solvent printer and the sublimation dye printer are loaded with materials related to the order, such as the desired color. In step 1408, the desired design and / or pattern is printed on the desired material used for the upper portion using a sublimation dye printer. In step 1410, the desired design and / or pattern is printed on the desired material used for the upper portion using an eco-solvent printer. In step 1415, the customized composite is cut from the desired material according to the specification characterizing the order. In step 1420, the customized composite is loaded into the laser device. In step 1424, the laser is loaded with the design specifications associated with the order. In step 1428, the laser etches the customized design on the customized composite.

  In step 1430, a sublimation dye press is loaded. In step 1435, the customized composite is removed from the laser. In step 1440, the customized composite material is loaded into the right embroidery machine. In step 1442, the left embroidery machine is loaded with the customized composite material. In step 1444, the embroidery machine is loaded with design specifications associated with the order. In step 1446, the left and right parts are embroidered using the left embroidery machine and the right embroidery machine, respectively. In step 1450, the left part and the right part are removed from the embroidery machine. In step 1460, the customized parts are transferred to the hot press marketplace. In step 1470, the upper portion is inspected for excess material and cut if necessary.

  Some decoration techniques disclosed above may not be applicable to each shoe model, and therefore some steps disclosed above may be omitted. For example, assume that all shoe models do not require embroidery or laser etching. Further, different parts of the upper portion can be advanced through different steps, in different orders, and at different times.

  With reference to FIG. 15, an exemplary method for forming and sewing an upper portion for a basketball shoe is indicated generally by the reference numeral 1500. In step 1505, the customized part for the upper part is removed from the hot press marketplace. In step 1510, the set of parts is retrieved from the marketplace with the necessary parts associated with the customer order. In step 1520, the upper portion is assembled from the customized parts. In step 1530, the assembled upper part is loaded into a hot press. In step 1534, the heated press is operated to heat the assembled upper part. The ultimate temperature is sufficiently high so that the adhesive used for joining the components is activated. In step 1538, the part is removed from the hot press. In step 1540, the parts are placed in a cooling rack. In step 1548, the part is removed from the cooling rack. In step 1550, the heel is formed by sewing. In the alternative, the heel is formed by a different joining method. In step 1560, the part is sewn back. In step 1570, the part is stitched. In step 1580, the part is transferred to the shoe lining area.

  Referring to FIG. 16, an exemplary method for shoe matching and quality control for basketball shoes is indicated generally by the reference numeral 1600. In step 1610, the shoe component is removed from the shoe mold matching area. In step 1620, a quality control inspection is performed and the upper part is shoe-shaped. In step 1630, a quality control inspection is performed on the shoe-matched upper part, and then the upper part is re-shoe-matched. In step 1640, a quality control inspection is performed and a shoelace is passed through the upper portion. In step 1650, a quality control inspection is performed and the shoe is packaged.

  Referring now to FIG. 17, an exemplary method for forming a skate shoe outsole is indicated generally by the reference numeral 1700. In step 1705, an injection molded rubber outsole is formed by an injection molding process. In an exemplary injection molded rubber process, rubber is injected into a mold that forms the outsole. In another method, the outsole is engraved and / or cut out from the rubber mass. In step 1710, the outsole is cured. In one alternative, the outsole is cured with stearic acid and oil. This combination results in rubber blooming and undesired rubber residues on the outsole.

  In step 1715, the flash is removed from the outsole. One method of removing the outsole flush includes cutting and / or removing and / or cutting off excess excess rubber. Another method of flash removal involves wiping or picking the rubber outsole by hand. In step 1720, the outsole relays to the outsole pre-clean marketplace. In an alternative method, the number and characteristics (e.g., size, shape, color, etc.) of outsole to enter the marketplace can be based on demand forecasts. In step 1725, an order is received. An exemplary method for receiving an order includes receiving the order manually. In yet another method, an order can be received by uploading order details through a web interface. In the alternative, steps 1705-1720 are not performed until an order is received. In this alternative, the outsole is produced as needed, rather than receiving a predicted marketplace demand. At step 1730, the outsole is removed from the outsole pre-clean marketplace.

  In step 1735, the outsole is washed. In some methods, the outsole is washed with an alkaline solution. In another method, the outsole should proceed directly from step 1015 to remove the flash from the outsole to step 1735 to clean the outsole. In step 1740, the outsole is washed. In some methods, the outsole is washed with an acid solution. Washing steps 1735 and / or 1740 provide a means for removing excess rubber residue formed in the curing process of step 1710. In another method, the curing process is performed without stearic acid, thereby reducing or reducing the resulting rubber residue. In this way, the cleaning steps 1735 and / or 1740 can reduce or eliminate time and / or material. In step 1745, the outsole is dried in an oven. In another method, the outsole should be dried by a method that can generate heat that causes the outsole to dry to a desired degree of dryness within a desired period of time. In step 1750, the outsole is removed from the oven. In another method, the outsole is removed from another heating device used to remove moisture from the outsole mold. In step 1755, the outsole is relayed to the outsole broadcast marketplace. Alternatively, if there is little or no rubber excess generated from the curing process 1715, the outsole should proceed directly from the curing process 1715 to relay to the outsole relay marketplace 1755. Alternatively, if rubber residue is minimal, the outsole should proceed directly from the curing process 1715 to a cleaning step 1735 where the outsole is wiped with a material such as a cloth to remove excess rubber. In the former embodiment, the outsole either proceeds directly from the curing process 1715 to the cleaning step 1735 or proceeds from the curing process 1715 to the outsole marketplace 1720 prior to removal from the outsole marketplace 1730. . When an order is received prior to outsole production (eg, when outsole is produced on demand), the outsole can skip the time spent in the outsole marketplaces 1720-1730.

  Referring to FIG. 18, an exemplary method of forming a skate midsole is indicated generally by the reference numeral 1800. In step 1802, a predetermined volume of EVA pellets is loaded into an injection mold. In the alternative, the selection of the polymer type to be injected at step 1802 can be correlated to the desired hardness associated with the resulting midsole customer order. EVA pellets can be processed in the same mold under the same conditions, ie increasing the hardness compared to EVA pellets with shorter polymer chains by introducing EVA pellets with longer polymer chains. Longer polymer chains cannot degrade to the same extent as shorter polymer chains under the same reaction conditions. In step 1804, the injection mold is heated to 170 ° C. to form a predetermined volume of EVA pellets in the form of biscuits. In another embodiment, the EVA pellets are heated to a temperature that is hot enough to form the biscuit, but not hot enough to activate the expansion agent in the phylon. In yet another embodiment, the reaction conditions of the mold can be varied to affect the degree to which a given polymer will decompose, thereby obtaining a variety of different hardnesses. In step 1806, the biscuit is then removed from the injection mold. In step 1810, the biscuit is then relayed to the biscuit marketplace. In step 1815, an order is received. An exemplary method for receiving an order includes receiving the order manually. In yet another method, an order can be received by uploading order details through a web interface.

  In step 1820, the biscuit is removed from the biscuit marketplace. In step 1830, the biscuit hot press is then loaded. In another method, for example, when an order is received prior to biscuit formation, the biscuit should proceed directly from the step of removing from the injection mold 1806 to the step of loading into the hot press 1830. In another method, a right hot press machine and a left hot press machine are provided for right foot shoe biscuits and left foot shoe biscuits, respectively. In yet another method, the right heat press and the left heat press can be operated simultaneously. In step 1834, the biscuits are then heated to 172 ° C. In another embodiment, the biscuits are heated to a temperature high enough to activate the expansion agent. In step 1838, the biscuit is removed from the hot press. In step 1840, the biscuits are loaded into the stabilization oven. In the stabilization oven, the biscuits cool to a low temperature that allows the biscuits to be the desired size as a midsole. In step 1844, the biscuit is lowered to a temperature of 75 ° C. In steps 1848 to 1852, the temperature of the biscuit is decreased over three stages. In step 1848, the temperature of the biscuit is reduced from 75 ° C to 65 ° C. In step 1852, the biscuit temperature is reduced from 65 ° C to 55 ° C. In step 1854, the biscuit temperature is reduced from 55 ° C to 45 ° C. In another method, cooling stages 1848-1852 are performed in more than two stages. In another method, the step 1844 of lowering the biscuit temperature to 75 ° C. can be adjusted to a higher or lower temperature.

  At step 1858, the midsole is removed from the stabilization oven. In step 1860, the midsole is loaded into one or more ultrasonic baths. In step 1864, the midsole is cleaned in an ultrasonic bath. In an alternative method, step 1858 is omitted, and the midsole can be cleaned while it is still present in the double stabilized oven ultrasonic bath apparatus. In step 1868, the midsole is removed from the ultrasonic bath. At step 1870, the midsole is loaded into one or more drying ovens. In step 1874, the midsole is dried. At step 1878, the midsole is removed from one or more drying ovens. At step 1880, the midsole is loaded into the midsole transit marketplace.

  Referring now to FIG. 19, an exemplary method for applying primer and adhesive to skate shoes is indicated generally by the reference numeral 1900. In step 1904, a customer order is received. The customer order shall include a specification of features associated with one or more desired basketball shoes, such as size or style or color. At step 1906, outsole that matches the characteristics determined in the customer order is retrieved from the outsole broadcast marketplace. At step 1908, a midsole that matches the characteristics determined in the customer order is removed from the midsole broadcast marketplace. In step 1910, the midsole and outsole are primed. In step 1920, the primed midsole and primed outsole are placed in an IR oven. In step 1930, the midsole and outsole are removed from the IR oven. In step 1940, adhesive is applied to the midsole and outsole. In step 1950, the midsole and outsole are placed in an IR oven.

  Referring now to FIG. 20, an exemplary method of combining an outsole and a midsole into a midsole-outsole in a skate shoe is indicated generally by the reference numeral 2000. In step 2010, the outsole and midsole are removed from the IR oven. In step 2020, the outsole and midsole are bonded together to form a midsole-outsole. At step 2030, the midsole-outsole is loaded into a stockfit press. In step 2034, the midsole-outsole is heated. With heat, the adhesive can bond the midsole-outsole component more permanently. In step 2038, the midsole-outsole is removed from the stock fit press. In step 2040, the midsole-outsole is loaded into the cooling device. The midsole-outsole can be cooled to approximately 0 ° C. by the cooling device to solidify the adhesive. In another method, the midsole-outsole is placed in one or more temperature areas where the midsole-outsole is allowed to cool for longer periods of time. In another method, in step 2044, the midsole-outsole temperature is decreased. In another method, the press is stopped and the midsole-outsole is left in the press and allowed to cool until the heat is dissipated. In yet another method, the press connects to both heating and cooling components, allowing shoe products such as midsole-outsole to be heated and cooled in one place. In doing so, a dual heating and cooling press can be provided to save space and shift the shoe product parts during the time they move between the heating press and the cooling device. Alternatively, the risk of peeling off can be eliminated. In step 2048, the midsole-outsole is removed from the cooling device. In step 2050, the midsole-outsole is transferred to the swing arm post relay area.

  Referring to FIG. 21, an exemplary method for customizing the upper portion of a skate shoe is indicated generally by the reference numeral 2100. In step 2102, an order is received. An exemplary method for receiving an order includes receiving the order manually. In yet another method, orders are received by uploading order details through a web interface. In step 2104, the material associated with the upper part order (eg, synthetic leather or mesh or polyester, etc.) is loaded into the eco-solvent printer. In step 2106, the eco-solvent printer and the sublimation dye printer are loaded with materials related to the order, such as the desired color. In step 2108, the desired design and / or pattern is printed on the desired material used for the upper portion using a sublimation dye printer. In step 2110, the desired design and / or pattern is printed on the desired material used for the upper portion using an eco solvent printer. In step 2115, the customized composite is cut from the desired material according to the specifications characterizing the order. In step 2120, the customized composite is loaded into the laser device. In step 2124, the laser device is loaded with the design specifications associated with the order. In step 2128, the laser etches the customized design on the customized composite.

  In step 2130, a sublimation dye press is loaded. In step 2135, the customized composite is removed from the laser device. In step 2140, the customized composite material is loaded into the right embroidery machine. In step 2142, the left embroidery machine is loaded with the customized composite material. In step 2144, the embroidery machine is loaded with the design specifications associated with the order. In step 2146, the left and right parts are embroidered using the left embroidery machine and the right embroidery machine, respectively. In step 2150, the left part and the right part are removed from the embroidery machine. In step 2160, the customized parts are transferred to the hot press marketplace. In step 2170, the upper portion is inspected for excess material and cut if necessary.

  Some decoration techniques disclosed above may not be applicable to each shoe model, and therefore some steps disclosed above may be omitted. For example, assume that all shoe models do not require embroidery or laser etching. Further, different parts of the upper portion can be advanced through different steps, in different orders, and at different times.

  With reference to FIG. 22, an exemplary method for forming and sewing an upper portion for a skate shoe is indicated generally by the reference numeral 2200. In step 2205, the customized part for the upper part is removed from the hot press marketplace. In step 2210, the set of parts is retrieved from the marketplace with the necessary parts associated with the customer order. In step 2220, the upper portion is assembled from the customized parts. In step 2230, the assembled upper part is loaded into a hot press. In step 2234, the hot press is operated to heat the assembled upper part. The ultimate temperature is sufficiently high so that the adhesive used for joining the components is activated. In step 2238, the part is removed from the hot press. In step 2240, the parts are placed in a cooling rack. In step 2248, the part is removed from the cooling rack. In step 2250, the heel is formed by sewing. In the alternative, the heel is formed by a different joining method. In step 2260, the part is sewn back. In step 2270, the part is stitched. In step 2280, the part is transferred to the shoe lining area.

  Referring to FIG. 23, an exemplary method for shoe matching and quality control for skate shoes is indicated generally by the reference numeral 2300. In step 2310, the shoe component is removed from the shoe mold matching area. In step 2320, a quality control inspection is performed and the upper part is shoe-shaped. In step 2330, a quality control inspection is performed on the shoe-matched upper portion and then the upper portion is re-shoe-matched. In step 2340, a quality control inspection is performed and a shoelace is passed through the upper portion. In step 2350, a quality control inspection is performed and the shoe is packaged.

  Referring now to FIG. 24, a workflow block diagram 2400 of a shoe part manufacturing facility for custom shoe part manufacturing is shown in accordance with an embodiment of the present invention. The workflow block diagram 2400 represents the physical configuration of the factory floor, but can also be considered a general workflow method. A large number of modules can be used to efficiently manufacture shoes according to the present invention. Each module is operated by at least one operator 2401. Although these modules are variable, as in the embodiment of FIG. 24, a cutting and kitting module 2402, a customization module 2404, a forming and sewing module 2406, a midsole and outsole manufacturing module 2410, and a stock fit and assembly module 2408.

  The cutting and kitting module 2402 cuts the shoe upper part from the stock of the upper part raw material. The at least one upper part raw material is a customizable intermediate product. Then, the cut shoe upper part material is combined as a kit. In an embodiment, the kit includes all of the upper part elements necessary to form the entire shoe upper part. Then store the kit temporarily.

  First, in the cutting and kitting module 2402, parts required for manufacturing the shoe upper portion are cut out, and parts to be relayed as a kit that can be used for assembling and customizing the shoes are prepared. The material used in the cutting and kitting module 2402 is stored in the material warehouse 2413. The raw materials used to form the shoe parts are supplied by a supplier who applies or does not apply hot melt lamination to the raw materials. The lamination process is aimed at assembling shoe parts, and the shoe parts are bonded by lamination. Alternatively, if the material for the shoe component does not yet have a hot melt lamination as supplied by the vendor, apply the hot melt lamination to the raw material. In an embodiment, the raw material taken out from the warehouse 2413 has a hot melt lamination applied to the material by a hot melt lamination press machine 2412. However, if the material supplied by the supplier has already been applied with hot melt lamination, the hot melt lamination press machine 2412 is not required in the block diagram 2400.

  After the material is taken out from the material warehouse 2413, the material is changed to a shoe part by using a part cutting machine 2414. Part cutting machine 2414 is an automatic cutting machine that utilizes blades, lasers, and / or any other cutting method or tool to fabricate the upper shoe portion into one or more manufacturing parts. Equipped with automatic cutting machine. When used in an automatic cutting machine, such as that used in a part cutting machine 2414, the fabric is held where suction, fasteners, etc. are used. The material used in the manufacture of the upper part of the shoe is an intermediate product, which can be easily customized through printing, dyeing, embroidery, etc. The cut parts are stored in parts marketplace 2416. After storing the cut parts in the marketplace, combine the cut parts as a kit. In some embodiments, the kit is an upper part that includes the upper part necessary to assemble the upper part for one shoe or the upper part for a pair of shoes. In one embodiment, warehouse 2413 and marketplace 2416 comprise vertical carousels. Based on the shoe design to be manufactured, one size shoe or any number of shoe sizes can be assembled using the kit of upper part parts. For example, in some shoe designs, a single kit can be used to manufacture and assemble shoes having men's size 8, 9, or 10.

  The upper part kit is supplied from cut parts stored in the marketplace 2416 as needed when the shoe order is processed. The cutting and kitting module 2402 can then address the shortage of specific parts of the marketplace 2416 by cutting and kitting the required type of upper part material.

After selecting the kit from the parts marketplace 2416, the kit is customized in the customization module 2404. In an alternative embodiment, customization module 2404 retrieves the temporarily stored kit from cutting and kitting module 2402. The customization module 2404 then places the kit's shoe upper partials on top of each other and places them on the flat frame assembly as multiple layers. The customization module 2404 then customizes at least a portion of the shoe upper part by decorating the shoe upper part.

  In an embodiment, the customization module 2404 comprises a plurality of discrete stations, but one shoe upper portion need not necessarily be advanced at each station of the customization module 2404. For example, after transferring the kit to the desk 2418, an operator, such as the operator 2401, uploads a print file for the customized order. The print file is associated with the order customization entered by the customer at customer input receiver 2422. In an embodiment, the print file is sent to an eco-solvent printer 2420 and / or a sublimation dye digital printer station. In the embodiment, an eco solvent printer 2420 is used to print an image to be applied from the kit to the shoe upper part. Further, a sublimation dye digital printer station 2422 sublimates the design and / or image onto the upper portion of the shoe.

  The upper part customization also utilizes a lamination heating press 2424 to laminate the design (design) onto the shoe upper part part. Similarly, the sublimation dye pattern printed by 2424 is applied using a sublimation dye heating press 2426. Additionally, customized trimming operations can be performed at station 2428, which can use a first trimming die cutter to change the material used in the upper portion customization. Further, laser customization, such as customized cutting and / or etching, is performed at the laser customization station 2430. Additionally, multiple embroidery stations 2432 are used to apply embroidery customization to the shoe upper portion. In the embodiment, the shoe parts are embroidered after they are once loaded into the embroidery machine. After embroidery of one or more shoe parts, the shoe parts are removed from the embroidery machine. In the embodiment, it is preferable to use four embroidery stations 2432 as shown in FIG. 24, but the number of embroidery stations may be one or more. Desk 2434 can also be used to customize the upper portion of the shoe.

  After customization of the upper part, the forming and sewing module 2406 forms the upper part. Forming and sewing module 2406 receives the customized shoe upper part. The upper part of the custom shoe is placed on a flat frame and holds this part in place. The frame is loaded into a solid state (SS) RF press 2436 and RF welded to the upper shoe part. Additionally and / or alternatively, the flat frame is loaded into a hot press 2438. A hot press machine 2438 is used to form the upper portion from the heat activated component. Whichever press machine 2436 and / or press machine 2438 is used, the upper part of the shoe is joined using the press machine. Once the shoe parts are joined by press 2436 and / or press 2438, the joined shoe parts are cut using shuttle cutter 2440. Shuttle cutter 2440 removes excess material from the bonded shoe parts. After shuttle cutter 2440 removes excess material, the combined shoe parts are removed from the flat frame. In addition, the desired sewing can be performed to form the upper portion at the sewing station, for example, flat sewing station 2442, zigzag sewing station 2444, back sewing station 2448, and heel sewing station 2454, all of which are It shall be used for sewing shoe parts in the form of the upper part of the shoe. Additionally, a hot melt sprayer 2446 can be used to hold the shoe in place as the shoe component is affixed to other shoe components and / or the shoe upper portion to form the shoe upper portion. .

  Toe forming component 2450 is used to form the toe of the upper portion. A heel forming component 2452 is used to form the heel of the upper portion. The strobing component 2456 is used to affix the strobing to the upper portion of the shoe for lasting. Toe adjustment component 2458 is used to adjust the upper shoe portion and / or shoe component as part of shoe matching. For example, in the toe adjustment component 2458, the shoe upper portion and / or shoe component is exposed to steam to soften the shoe component. In addition, the shoe-matching component 2460 is used after attaching the strobebell to shoe-match the upper shoe portion before applying the midsole and / or outsole. In this way, module 2406 forms the customized shoe upper part component as a three-dimensional shoe upper part. Further, the module 2406 applies a strobe bell to the upper portion of the formed shoe. Additionally, module 2406 shoe molds the formed shoe upper portion and strobing.

  The midsole and outsole component 2410 produces a shoe midsole and shoe outsole for use simultaneously with the shoe-matched upper portion for shoe assembly. The midsole and outsole can be formed in a variety of ways and from a variety of materials. The midsole can be formed from phylon material and the outsole can be formed from latex rubber. Feasible systems and processes for use with the midsole and outsole module 2410 are described elsewhere herein. The midsole and / or outsole is supplied to the stock fit and assembly module 2408 using a marketplace system, or supplied on a per order basis.

  Stock fit and assembly module 2408 receives shoe molds and formed shoes from forming and sewing module 2406. Additionally, module 2408 receives shoe midsole and shoe outsole from midsole and outsole module 2410. Thereafter, the module 2408 combines the shoe midsole, the shoe outsole, and the shoe mold, and assembles the formed shoe upper portion and the strobing into a shoe.

  In an embodiment, the midsole, outsole, and / or shoe-molded shoe upper portion is received by the vent table 2462. In the ventilation table 2462, the adhesive is applied to the bottom side of the midsole and the top side of the outsole. The midsole-outsole combination is then placed in an IR oven, such as IR oven 2462. Adhesives in the shoe midsole and shoe outsole are activated in the IR oven 2462. Thereafter, the shoe midsole and shoe outsole are set in a bladder press machine station 2466 where the midsole and outsole are pressed together to form a seal. In the embodiment, a block press machine 2468 is used to press the midsole and the outsole together to form a seal portion.

  After pressing the midsole and outsole together, the midsole-outsole is transferred to a bite marking machine 2470 to mark for adhesive. In particular, the midsole-outsole has a shoe upper portion that is placed in the midsole-outsole and determines the degree of adhesive coverage required. Thereafter, an adhesive is applied to the midsole-outsole and the shoe upper portion at the ventilation table 2472. After the adhesive is applied to the shoe upper part and midsole-outsole according to the bite line, the shoe upper part and midsole-outsole are placed in an IR oven 2474. In IR oven 2474, the adhesive applied to the shoe upper portion and midsole-outsole is activated. Thereafter, the upper portion of the shoe and the midsole-outsole are pressed together by a block press machine 2468. Once the shoe is formed by pressing the shoe upper portion and the midsole-outsole together, the shoe is set in the cooling device 2476. After the shoes are set, the shoes are re-shoe-matched at the re-shoe-matching station 2478. In addition, the shoes are quality controlled and packaged at table 2480.

  Referring now to FIG. 25, there is shown a block diagram 2500 of a modular configuration utilized for shoe production according to the present invention. As shown in the embodiment of FIG. 25, the shoe uses one cutting and kitting module 2530 and one outsole and midsole module 2540, coupled in two modules, customized, formed and bonded, As well as performing stock fitting and assembly. Customization, forming and bonding, and stock fitting and assembly operations are performed in the first section 2510 and / or the second section 2520. The first section 2510 includes a first customization module 2512, a first forming and laminating module 2514, and a first stock fit and assembly module 2516. The first customization module 2512 receives a completed kit for the shoe upper portion from the cutting and kitting module 2530. After the customization module 2512 performs the necessary customization on the shoe upper portion, the customization module 2512 delivers the customized shoe upper portion to the first forming and laminating module 2514. The first forming and laminating module 2514 forms the shoe upper portion and then delivers the formed shoe upper portion to the first stock fit and assembly module 2516. The first stock fit and assembly module 2516 receives the formed shoe upper portion from the first forming and laminating module 2514 and further receives the outsole and midsole from the outsole and midsole module 2540. The first stock fit and assembly module 2516 assembles and completes the shoes and then delivers the completed shoes to a finished product row 2518.

Similarly, the second section 2520 includes a second customization module 2522, a second forming and laminating module 2524, and a second stock fit and assembly module 2526. The second customization module 2522 receives a kit for manufacturing the shoe upper portion from the cutting and kitting module 2530. Thereafter, the second customization module 2522 performs the necessary customization for the upper portion of the shoe. The second customization module then further passes the customized shoe upper portion to the second forming and laminating module 2524 to form the desired shoe upper portion. Thereafter, the second forming and laminating module 2524 delivers the upper portion of the forming shoe to the second stock fit and assembly module 2526. The second stock fit and assembly module 2526 receives the forming shoe upper portion from the second forming and laminating module 2524 and further receives the outsole and midsole from the outsole and midsole module 2540. Stock fit and assembly module 2526 delivers the completed shoe to finished product row 2528. The finished product column 2518 and the finished product column 2528 shall be combined into one finished product column to further display the point at which the customer will receive one or a pair of customized shoes. All the modules shown in FIG. 25 can be juxtaposed in one location. However, the first section 2510 and the first finished product row 2518 are separated from the second section 2520 and the second finished product row 2528, from the cutting and kitting module 2530, and / or from the outsole and midsole module 2540. Install. Similarly, the second section 2520 and the second finished product row are spaced apart from the first section 2510 and the first finished product row 2518, from the cutting and kitting module 2530, and from the outsole and midsole module 2540. . It is advantageous to use one cutting and kitting module 2530 and / or one outsole and midsole module 2540 for two or more modules for customization, forming and bonding, and stock fitting and assembly. The shoe production rate of a series of modules can be maximized.

  FIG. 26 illustrates a system 2600 for producing and assembling shoe parts according to an embodiment of the present invention. System 2600 includes a customer input receiver 2640. The receiver 2640 receives customer input, for example regarding customer shoe customization. For example, the customer enters an order for red shoes into the receiver 2640. System 2600 further includes a marketplace 2610 for storing shoe parts. In an embodiment, marketplace 2610 is provided as a temporary repository for the first shoe component. The first shoe part is produced in the first module 2620. The first module 2620 comprises a first shoe part manufacturing module that produces at least one first shoe part based on receiving an indication 2612 from the marketplace 2610 to produce the first shoe part. When the threshold amount of the first shoe component stored in the marketplace 2610 decreases below a predetermined threshold amount, the display 2612 transmits from the marketplace 2610 to the first module 2620. In embodiments, the one or more first shoe components comprise a shoe upper portion component, a midsole, and / or an outsole.

  The system 2600 also includes a second module 2630 that produces one or more second shoe parts in response to receiving customer input 2642 from the customer input receiver 2640. In an embodiment, the customized parts are produced by the second module 2630 and the second shoe parts are produced by changing the shoe parts supplied from the marketplace 2610 to the second module 2630. The shoe parts supplied from the market place 2610 to the second module 2630 include the first shoe parts produced by the first module 2620.

  After producing one or more first parts and one or more second parts, the one or more first parts and one or more second parts are assembled in a third module 2650. One or more first parts 2614 are transferred from the marketplace 2610 to the third module 2650. Additionally and / or alternatively, one or more first parts 2624 are transferred from the first module 2620 to the third module 2650. In addition, one or more second parts 2632 are transferred from the second module 2630 to the third module 2650. After assembling the one or more first parts and the one or more second parts in the third module 2650, the one or more finished shoes 2652 are transferred to the finished product row 2660.

  FIG. 27 shows a flowchart 2700 of a shoe manufacturing workflow through the process. This process comprises steps performed within a shoe manufacturing module, such as a cutting and kitting module 2710, a customization module 2720, a forming module 2730, an outsole and midsole module 2740, and a stock fit and assembly module 2750. In the cutting and kitting module 2710, the plurality of raw materials required for the upper portion of the multilayer shoe is provided at step 2712. Further, in step 2714, the raw material in module 2710 is cut out as a part of the upper part of the multilayer shoe. Additionally, in module 2710, the parts needed to form one multi-layer shoe upper portion are placed in the kit of step 2716.

  The customization module 2720 receives the kit at step 2722. Again at step 2724 in the customization module 2720, the shoe upper part is assembled in multiple layers. This multilayer is aligned on a flat frame. Further, in step 2426, the multi-layer upper part is customized by decorating at least one multi-layer shoe upper part. The customization of step 2426 performed by the customization module 2420 is performed while the multi-layer shoe upper part is on the flat frame.

  In the forming module 2730, while the multi-layer shoe upper part is on the frame, in step 2732 the multi-layer upper part is combined to form one integrated shoe upper part. In step 2734, excess upper portion material is cut from the shoe upper portion. Further, at step 2736, the combined shoe upper portion is removed from the frame. Thereafter, the formed shoe upper portion is formed as a three-dimensional shoe upper portion in step 2738. In forming module 2730, the strobe is sewn to the upper portion of the forming shoe at step 2739.

  In the outsole and midsole module 2740, a shoe midsole is formed at step 2742. Further, in the outsole and midsole module 2740, a shoe outsole is formed at step 2744. At stock fit and assembly module 2750, the shoe midsole is attached to the shoe upper portion at step 2752. At stock fit and assembly module 2750, a shoe outsole is attached to the shoe upper portion at step 2754.

  Although the invention has been described with reference to particular embodiments, they are intended in all respects to be illustrative and not limiting. Alternative embodiments will be apparent to those skilled in the art, and the present invention will be relevant without departing from its scope. As will be appreciated by those skilled in the art, different models of shoes may, for example, utilize different specific processes, materials, or modules and still fall within the scope of the claims of the present invention.

  From the foregoing description, it should be understood that the present invention is well adapted to achieve all of the above objectives and goals, as well as other advantages of providing systems and methods. It should be understood that certain features and subcombinations are useful and can be used without reference to other features and subcombinations. This can be envisaged in the claims and can even be within the scope.

Claims (20)

In a system for producing and assembling shoe parts, the system includes a receiving module for receiving customer input;
A marketplace forming at least one temporary storage for the first shoe component;
When the first shoe component has decreased below a predetermined threshold amount in the at least one temporary depository of the marketplace for temporarily storing the contents of said first shoe components, the marketplace notification of this reduction grounds based on the received from, producing at least one first shoe components, a first shoe component manufacturing module,
A second shoe part manufacturing module that produces one or more second shoe parts based on receipt of the customer input;
Producing shoe products assembled before Symbol least one of said first shoe components and the one or more second shoe components, a third component production module,
Equipped with a,
A system capable of changing the degree of temporal overlap between the workflow of the first shoe part manufacturing module and the workflow of the second shoe part manufacturing module.   The system of claim 1, wherein the one or more first shoe parts are processed after the first shoe parts are removed from the temporary storage.   The system of claim 1, wherein the first shoe component manufacturing module produces an outsole.   The system of claim 1, wherein the first shoe component manufacturing module manufactures a midsole.   The system of claim 1, wherein the second shoe part manufacturing module produces a customized upper partial shoe part. The system of claim 1, mosquitoes static Mize shoe components is characterized to be treated prior to bonding to said first shoe components system. The system of claim 1, mosquitoes static Mize shoe components is characterized in that it consists of two or more customized shoe components coupled together system. The system of claim 1, wherein the second shoe part manufacturing module comprises a number of customization sub-modules. In a processing facility for modular production of composite customized shoe parts, the processing facility includes:
Cutting upper shoe part parts from an inventory of upper part raw materials, wherein at least one of said upper part raw materials is a customizable intermediate product, and thereafter a kit of said cutting shoe upper part material to form the entire shoe upper part Cutting out as a kit including all of the upper subelements necessary for the above, and further storing the kit temporarily, the cutting and kitting module,
Removing the temporary storage kit from the cutting and kitting module, laminating the shoe upper part of the kit as a plurality of layers in a flat framed assembly, and further decorating the shoe upper part by decorating the shoe upper part A customization module for customizing at least one part of the parts;
Receive the customized shoe upper part components, the customized form shoe upper portion parts as a three-dimensional shoe upper part, a pre-Symbol forming shoe upper portions are combined shoe, the forming and stitching module,
A midsole and outsole manufacturing module for manufacturing a shoe midsole and a shoe outsole;
A stock fit and assembly module, wherein the aligned shoe, also receives the shoe upper portion formed from the forming and stitching module, receiving the shoe midsole and the shoe outsole from the midsole and outsole module, further, the shoe midsole, the shoe outsole, and then combined the shoe, also assembled shoe upper portion formed on the shoe, and the stock fit and assembly module,
Equipped with a,
A processing facility capable of varying the degree of temporal overlap between the workflow of the cutting and kitting module, the customization module and the forming and sewing module and the workflow of the midsole and outsole manufacturing module.   10. The processing facility according to claim 9, wherein the cutting and kitting module includes a material storage component that holds the upper partial raw material, a parts cutting machine, and a marketplace that holds the kit after assembly. Characteristic processing equipment.   10. The processing facility according to claim 9, wherein the customization module includes a hot melt lamination press, an eco solvent printer, a digital sublimation dye printer station, and an embroidery station. 10. The processing facility according to claim 9, wherein the forming and sewing module comprises a high frequency press for bonding the layers of the shoe upper portion, a cutting press for cutting the bonded shoe upper portion from an excess upper portion material, and the shoe upper portion. characterized in that the toe formed components which form part of the one or earlier, and heel forming component that forms the shoe upper part of either transient, a structure having a processing facility. 10. The processing facility of claim 9, wherein the forming and sewing module comprises a heated press for bonding the layers of the shoe upper portion, a cutting press for cutting the bonded shoe upper portion from excess upper portion material, and the shoe upper portion. one or toes forming component to form a first, and a heel formation component for forming the shoe upper part of either transient, characterized by being configured to have the processing facility. In the processing facility of claim 9, wherein the stock fit and assembly modules are assembled by applying at least one adhesive, the shoe outsole, the shoe midsole, and the type-up and formed shoe upper part, Processing equipment, characterized by shoes. 15. The processing facility of claim 14, wherein the stockfit and assembly module further applies at least one adhesive between the mold and forming shoe upper portion and the shoe midsole, and further includes at least one adhesive. After applying between the shoe midsole and the shoe outsole, the shoe outsole, the shoe midsole, and a press machine that applies pressure to the upper part of the mold taking and forming shoe Characteristic processing equipment. In shoe manufactured through a process, the process comprising,
Within the cutting and kitting module, supply a plurality of raw materials required for the upper part of the multilayer shoe, cut out the raw material as the part of the upper part of the multilayer shoe, and the parts necessary to form the upper part of the multilayer shoe Including as a kit,
Within the customization module, the kit is received, the shoe upper part is assembled in a multi-layer on a flat frame, and a decoration is applied to the multi-layer while the multi-layer shoe upper part is on the flat frame. Customizing the multi-layer upper part by applying to at least one layer of the shoe upper part;
Within the forming module, while the multi-layer shoe upper part is present in the frame, the multi-layer upper part is joined to form one integrated shoe upper part, from the excess upper part material by cutting out the shoe upper part, taken out the coupling shoe upper portion from the frame, the steps that form a shoe upper part bound as a three-dimensional shoe upper part,
Forming a shoe midsole and forming a shoe outsole within the outsole and midsole module;
In stock fit and assembly module, a step wherein the shoe mounting the midsole to the shoe upper part, also to form a finished shoe is attached to the shoe outsole to the shoe upper part,
Equipped with a,
Manufactured via the process, the degree of temporal overlap between the incorporating step, the customizing step and the forming step and the step of forming the shoe midsole and the shoe outsole can be varied. shoes.   17. A shoe according to claim 16, wherein the upper joint part is cut from the excess upper part material using a press.   17. A shoe according to claim 16, wherein the kit of shoe upper part parts each comprises the parts necessary to form a shoe upper part for a shoe having a predetermined size.   The shoe according to claim 16, wherein the multilayer upper part is joined by a hot press.   17. A shoe according to claim 16, wherein the multi-layer upper part is joined by high frequency welding.

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