Patent Description:
Thermoforming an article can include heating the article to, or above, a specific temperature and then cooling the article to, or below, a specific temperature. In certain processes, during this heating and cooling, the article may be formed into a particular shape or structure.

<CIT> describes a process and a system for thermoforming articles of wear including utilizing a negative pressure generation system to seal an article in a forming material.

According to an aspect, the problem to be solved by the claimed invention relates to providing an improved method and system for preparing an article for thermoforming.

The claimed invention solving the above problem is defined by the subject-matter of the independent claims. Additional embodiments are defined by the dependent claims.

Illustrative aspects useful for the understanding of the claimed invention are described in detail below with reference to the attached drawing figures, which are incorporated by reference herein and wherein:.

The subject matter of aspects useful for the understanding of the claimed invention is described with specificity herein to meet statutory requirements. However, the description itself is not intended to limit the scope of this patent. Rather, the inventors have contemplated that the claimed subject matter might also be embodied in other ways, to include different steps or combinations of steps similar to the ones described in this document, in conjunction with other present or future technologies.

Aspects herein are directed to methods and systems for thermoforming articles and/or for preparing articles for thermoforming. Certain thermoforming systems can include heating an article and then cooling the article, while the article is formed into a desired shape. Certain current thermoforming systems may only provide inefficient or uneven exposure of the article to the various temperatures required in the heating and/or cooling processes of thermoforming. Further, certain current thermoforming processes can result in defects to the thermoformed article, e.g., by misalignment or creasing of a material utilized to aid in shaping or forming the thermoformed article, which may result in creases or other defects on the surface of the thermoformed article.

The systems and methods disclosed herein can alleviate one or more of the above-mentioned problems. For instance, a system is disclosed for preparing an article for thermoforming and the subsequent thermoforming of the article. At a high level, the system and methods disclosed herein can aid in inserting an article into a shaped compression material. In such aspects, vacuum or negative pressure can be applied to such a shaped compression material to apply a compressive force to all or a portion of the article during the thermoforming process. In certain aspects a compressive material or vacuum bag can be utilized that is shaped similar to the article and/or is substantially similar in size to the article, which can limit creases and other defects forming on the surface of the thermoformed article. However, the insertion of the lasted upper into the compression material can be manually difficult due to the minimal size and/or shape difference between the lasted upper and the compression material.

The system and methods described herein allow for efficient and aligned insertion of the article into a compression material, e.g., a shaped compression material. For example, in one aspect, the compression material can be placed in a vessel and negative pressure or vacuum pressure can be applied to expand the compression material to the dimensions of the vessel thereby allowing for ease of insertion of the article into the compression material. In aspects, an identifier on the vessel and/or the compression material can guide the article for proper aligned insertion into the compression material. In such an aspect, once the article is inserted into the expanded compression material, ambient atmospheric pressure (or a pressure above the negative pressure applied previously) can be applied to cause the compression material to shift from the expanded configuration to a more neutral configuration, with the article inserted therein. In aspects, vacuum pressure can then be applied so that the compression material can compress onto the article to allow for thermoforming.

Further, in certain aspects, systems and methods disclosed herein can provide for efficient and even exposure to the temperatures that may be required for each of the thermoforming process steps. For example, in aspects, the system and methods disclosed herein can introduce and rotate an article within a heating station so that each side of an article is exposed to the thermal elements present within a heating station, which can allow for more even heating of the article. Further, in aspects, the article can be exposed to vacuum pressure so that a compression material applies a compressive force to the article while being introduced and rotated within the heating station. Further, in certain aspects, the article can also be introduced and rotated within a cooling station, to allow for efficient cooling of the heated article. In such aspects, the cooling station may include a liquid, and the rotation of the heated article may facilitate more rapid conduction of the heat to the liquid from the upper to thereby cool down the upper more efficiently. In such aspects, the article can be exposed to vacuum pressure so that a compression material applies a compressive force to the article while being introduced and rotated within the cooling station. In various aspects, the vacuum pressure may be a continuous draw while the article is exposed to the heating and cooling stations, or can be a single initial draw prior to exposure to the heating and/or cooling stations, and the compression material can be sealed so as to maintain the compressive force on the article throughout the thermoforming process.

Accordingly, in one aspect a method for preparing an article for thermoforming is provided. The method can include inserting a compression material into a vessel, where the compression material can be present in a first position or configuration in the vessel. In this aspect, at least a portion of the compression material can form an interior portion adapted to receive an article. In aspects, the method can also include exposing an area between an outer surface of the compression material and an inner surface of the vessel to a pressure less than atmospheric pressure to shift the compression material from the first position to an expanded position, where, in the expanded position, at least a portion of the compression material is closer to the inner surface of the vessel than compared to the first position. In aspects, the method can also include inserting at least a portion of the article into the interior portion of the compression material while the compression material is in the expanded position. In aspects, the article can be present on a forming material. In various aspects, the method can also include exposing the area between the outer surface of the compression material and the inner surface of the vessel to a pressure at about atmospheric pressure so that the compression material shifts from the expanded position to a second position, where in the second position, at least a portion of the article is in the interior portion of the compression material and at least a portion of the compression material is closer to the article than when the article was inserted into the compression material in the expanded position.

In another aspect, a system for preparing an article for thermoforming is provided. The system can include a vessel. In aspects, the vessel can have an interior volume defined at least by a bottom portion and at least one sidewall extending up from the bottom portion to a top portion. In aspects, the vessel can include a port. In aspects, the system can also include a negative pressure generation system, which can be coupled to the port of the vessel. The system can further include, in aspects, a compression material, which can be positioned inside the interior volume of the vessel, where at least a portion of the compression material forms an interior portion adapted to receive an article. In aspects, the negative pressure generation system and the port are cooperatively adapted to expose an area between an outer surface of the compression material and an inner surface of the at least one sidewall to a pressure less than atmospheric pressure so that the compression material expands.

In yet another aspect, a method for thermoforming an article is provided. The method can include receiving a compression material having an article positioned inside the compression material. In aspects, the method can also include exposing an area between an inner surface of the compression material and an outer surface of the article to a pressure less than atmospheric pressure so that the compression material applies a compressive force onto the outer surface of the article. In aspects, the method can also include introducing the article to one or more heating stations and rotating the article within the one or more heating stations. Further, in aspects, the method can include introducing the article to a cooling station and rotating the article within the cooling station.

In yet another aspect, a system for thermoforming an article is provided. The system can include one or more heating stations. In aspects, each of the one or more heating stations can include a heating chamber. In various aspects, the system can also include a cooling station that includes a cooling chamber. In certain aspects, the system can also include an article movement mechanism. In aspects, the article movement mechanism can include at least one coupling member adapted to couple an article to the article movement mechanism. In aspects, the article movement mechanism can be adapted to rotate the article inside the heating chamber, the cooling chamber, or both.

Turning now to the figures, <FIG> depicts a system <NUM> for thermoforming articles. It should be understood, that while the system <NUM> depicts a portion of an article of footwear, e.g., an upper <NUM>, being exposed to the system <NUM>, other types of articles or other portions of an article of footwear can be utilized in the system <NUM> described herein. In the aspect depicted in <FIG>, the system <NUM> includes a heating station <NUM>, a cooling station <NUM>, a dryer <NUM>, a loading/unloading station <NUM>, and an article movement mechanism <NUM>.

As can be seen in <FIG>, the article movement mechanism <NUM> is coupled to the upper <NUM> for delivery to the various stations and areas of the system <NUM>. In the aspect depicted in <FIG>, the article movement mechanism <NUM> is coupled to one article, the upper <NUM>, via a coupling member <NUM> at one end of a radially extending member <NUM>. The coupling of an article to the article movement mechanism <NUM> is discussed further below.

It should be understood that the article movement mechanism <NUM> can be coupled to any number of articles. For example, in one aspect, the article movement mechanism <NUM> can include more than one radially extending member, with each member coupled to an article. In such an aspect, the system <NUM> can expose a plurality of articles to a portion of the thermoforming system simultaneously, e.g., with each article being exposed to one station or chamber at a time. Further, in such an aspect, each article can be exposed to each station or chamber for substantially the same amount of time.

As can be seen in the aspect of <FIG>, the system <NUM> is configured such that each station or chamber is circumferentially positioned with the article movement mechanism <NUM> at the center. In such an aspect, this circumferential design can provide a reduced footprint in a processing area as well as increased productivity, as article movement and/or additional operator contact with an article are reduced. Although not depicted in the figures, the system <NUM> may include an enclosure for housing the entire system <NUM> or a portion thereof. For instance, in one aspect, the system <NUM> can include an enclosure that encloses the heating station <NUM>, the cooling station <NUM>, the dryer <NUM>, and the loading/unloading station <NUM>.

In the aspect depicted in <FIG>, the heating station <NUM> includes a plurality of heating chambers <NUM>. In such an aspect, the plurality of heating chambers <NUM> can include five heating chambers <NUM>, <NUM>, <NUM>, <NUM>, and <NUM>. In various aspects, by having individual heating chambers, the upper <NUM> or another article, may be exposed to different heating temperatures or environments in each individual heating chamber. For instance, in one aspect, the upper <NUM> may be exposed to a ramping up of temperature throughout the heating station <NUM> such that the upper <NUM> is exposed to increasing temperatures at each heating chamber, which may provide for more effective melting of the thermoformable or thermoplastic materials or portion of the upper <NUM>. It should be understood that while the heating station <NUM> depicted in <FIG> includes five heating chambers, any number of heating chambers can be utilized and are contemplated herein.

In aspects, in order to expose the upper <NUM> or other article to the heating station <NUM>, e.g., by introducing the upper <NUM> into the heating chamber <NUM>, the article movement mechanism <NUM> can rotate about an axis, e.g., an axis <NUM>, and then lower the upper <NUM> through an opening <NUM> in the top portion <NUM> of a first heating chamber <NUM> of the heating station <NUM>. In such an aspect, the article movement mechanism <NUM> can include any mechanism for moving the upper <NUM>, and/or the radially extending member <NUM> up away from the heating chamber <NUM> and down towards the heating chamber <NUM>. Further, in aspects, as discussed further below, the article movement mechanism <NUM> is adapted to rotate the upper <NUM> or other article, while the upper <NUM> is within the heating chamber <NUM>, or any of the other heater chambers <NUM>, <NUM>, <NUM>, or <NUM>.

One specific example of a heating chamber, heating chamber <NUM>, is depicted in <FIG>. As can be seen in <FIG>, the upper <NUM> is positioned in an interior portion <NUM> of the heating chamber <NUM>, e.g., by the vertical shifting of the radially extending member <NUM> down towards the heating chamber <NUM>. In the aspect depicted in <FIG>, when the upper <NUM> or other article is positioned within the heating chamber <NUM>, the coupling member <NUM> can at least partly or fully cover the opening <NUM> of the top portion <NUM>, which may aid in retaining the thermal energy in the interior portion <NUM>. In alternative aspects, the coupling member <NUM> may not cover the opening <NUM> of the top portion <NUM>.

In the aspect depicted in <FIG>, the heating chamber <NUM> can include one or more thermal elements <NUM>. In this aspect, the thermal element <NUM> is positioned on a sidewall <NUM> of the heating chamber <NUM>. It should be understood that other positions for thermal elements within the heating chamber <NUM> are also contemplated for use in the system <NUM> described herein. It should also be understood that more than one thermal element can be utilized in the heating chamber <NUM> and that one thermal element <NUM> is depicted as just one example. Further, the thermal element <NUM> in <FIG> is depicted schematically and such depiction is not intended to be limiting on the type and/or shape of thermal elements that can be utilized in the system <NUM> disclosed herein. For example, in one aspect, the thermal element <NUM> can be an Infrared (IR) lamp. In the same or alternative aspects, the thermal element <NUM> can include a heated fluid, such as air. In an aspect not depicted in the figures, the thermal element <NUM> can include an IR lamp or other thermal source adjacent a fan for distribution of the thermal energy emitted from the IR lamp or other thermal source.

In certain aspects, the heating station <NUM> and/or the heating chamber <NUM> is adapted to expose an article, such as the upper <NUM>, to a temperature sufficient to cause at least a portion of a material of the article to melt and/or deform. For example, in one aspect, the heating station <NUM> and/or the heating chamber <NUM> is adapted to expose an article, such as the upper <NUM>, to a temperature above the melting temperature of a thermoplastic material of the upper <NUM> or other article. In the same or alternative aspects, the heating station <NUM> and/or the heating chamber <NUM> is adapted to expose an article, such as the upper <NUM>, to a temperature in the range of about <NUM> to about <NUM>, about <NUM> to about <NUM>, or about <NUM> to about <NUM>.

As discussed above, in certain aspects, the system <NUM> can provide for rotation of the upper <NUM> while positioned within the heating chamber <NUM>. For example, as depicted in <FIG>, at least a portion of the article movement mechanism <NUM> can rotate about an axis <NUM> so that the upper <NUM> can be more evenly heated in the heating chamber <NUM>. For instance, in one aspect, the coupling member <NUM> can rotate about the axis <NUM> relative to the radially extending member <NUM> to facilitate the rotation of the upper <NUM> in the interior portion <NUM> of the heating chamber <NUM>, which can provide direct exposure of each side of the article <NUM> to the thermal element <NUM>. The article movement mechanism <NUM> is discussed in more detail below.

It should be understood that while the heating chamber <NUM> is discussed in detail above, the description of any or all of the features of the heating chamber <NUM> are applicable to the other heating chambers, e.g., one or more of the heating chambers <NUM>, <NUM>, <NUM>, and <NUM>.

As discussed above, the heating station <NUM> can include a plurality of heating chambers <NUM>. In such an aspect, the plurality of heating chambers <NUM> can be utilized to ramp up the temperature that the upper <NUM> is exposed to in a sequential manner. For instance, in one aspect, the upper <NUM> is exposed to an increased temperature at each subsequent heating chamber. In such aspects, the upper <NUM> can be exposed to a temperature that is at least about <NUM> higher, at least about <NUM> higher, or at least about <NUM> higher at an immediate subsequent heating chamber compared to the prior heating chamber. For example, in one aspect, the upper <NUM> can be exposed to a temperature at the heating chamber <NUM> that is about <NUM> higher or about <NUM> higher than a temperature that the upper <NUM> was exposed to in the heating chamber <NUM>.

In certain aspects, after the upper <NUM> is exposed to the heating station <NUM>, e.g., to one or more heating chambers of the plurality of heating chambers <NUM>, the upper <NUM> is exposed to a cooling station, e.g., a cooling station <NUM>. <FIG> depicts one example of a cooling station <NUM>. As can be seen in the aspect depicted in <FIG>, the cooling station <NUM> includes a cooling chamber <NUM> and a secondary cooling source <NUM>. In certain aspects, the article movement mechanism <NUM>, e.g., by rotation of the radially extending member <NUM>, can transfer the upper <NUM> from the heating station <NUM> to the cooling station <NUM>.

In certain aspects, the cooling station <NUM> can expose the upper <NUM> to a cooled fluid, e.g., a cooled liquid. For example, as can be seen in <FIG>, the cooling station <NUM> can include a liquid <NUM> in an interior portion <NUM> of the cooling chamber <NUM>. In such aspects, the liquid <NUM> can be cooled to facilitate a rapid decrease in temperature of the heated upper <NUM>. In certain aspects, the liquid <NUM> can be maintained at a specific temperature by circulation of the liquid <NUM> between the cooling chamber <NUM> and the secondary cooling source <NUM>, which can in aspects, cool the liquid <NUM>. The secondary cooling source <NUM> can cool the liquid <NUM> using conventional liquid cooling techniques. In certain aspects, such as that depicted in <FIG>, liquid <NUM> from the cooling chamber <NUM>, which may in aspects have been warmed up due to contact with the heated upper <NUM>, can travel to the secondary cooling source <NUM> via the conduit <NUM>. Further, in such aspects, the cooled liquid <NUM> can travel back to the cooling chamber <NUM> via the conduit <NUM>. It should be understood that other configurations for maintaining the fluid <NUM> at a specific temperature can be utilized and are contemplated for use in the system described herein.

In aspects, the cooling station <NUM> can expose the upper <NUM> to a temperature in the range of about <NUM> to about <NUM>, about <NUM> to about <NUM>, about <NUM> ° to about <NUM>, or a temperature of about <NUM>, or about <NUM>. In certain aspects, the fluid <NUM> can comprise water or one or more other aqueous solvents. In the same or alternative aspects, the fluid <NUM> can comprise glycol or one or more other coolant liquids.

In certain aspects, the circulation of the liquid <NUM> can provide agitation or circulation within the cooling chamber <NUM> so that heat from the heated upper <NUM> is effectively transferred from the upper <NUM> to the liquid <NUM>. In the same or alternative aspects, the upper <NUM> can rotate about an axis <NUM> to provide agitation of the liquid <NUM>, e.g., the coupling member <NUM> can rotate about the axis <NUM> relative to the radially extending member <NUM> to facilitate the rotation of the upper <NUM> in the interior portion <NUM> of the cooling chamber <NUM>. The article movement mechanism <NUM> is discussed in more detail below.

In certain aspects, not depicted in the figures, the upper <NUM> can be exposed to more than one cooling chamber <NUM>. For instance, in one aspect, the system <NUM> can include an additional cooling chamber so that the upper is first exposed to the cooling chamber <NUM> and then subsequently exposed to a second cooling chamber. In such an aspect, the second cooling chamber can include any or all of the features of the cooling chamber <NUM> discussed above.

As discussed further below, the upper <NUM> can be positioned inside of a compression material. In such an aspect, the compression material can be water- or liquid-impermeable so that when the upper <NUM> is submerged in the liquid <NUM> the upper <NUM> does not absorb or otherwise attract the liquid <NUM> thereto, or come into contact with the liquid <NUM>. Further, in such an aspect, after the upper <NUM> is removed from the cooling chamber <NUM>, the compression material may harbor liquid <NUM> on its outer surface, which may be removed by the dryer <NUM>.

<FIG> depicts one example of a dryer <NUM>. In certain aspects, the upper <NUM> can optionally be transferred to the dryer <NUM> after exposure to the cooling station <NUM>, e.g., via the by rotation of the radially extending member <NUM> from adjacent the cooling station <NUM> to the dryer <NUM>. It should be understood that the dryer <NUM> depicted in <FIG> is just one example dryer <NUM> and that other drying mechanisms are contemplated for use in the present system <NUM>. The dryer <NUM> depicted in <FIG> includes one or more air nozzles <NUM> for providing a stream of air to the upper <NUM> in order to remove at least a portion of the liquid <NUM> that may be present thereon, or on the compression material. In one aspect, the stream of air can be room temperature, e.g., air that is approximately <NUM>.

In certain aspects, the upper <NUM> can vertically shift, e.g., via the vertical shifting of the radially extending member <NUM>, while the air nozzles <NUM> provide a stream of air over all or a portion of the upper <NUM>. In certain aspects, the dryer <NUM> can optionally include a reservoir <NUM> for collecting the fluid <NUM> removed from the upper <NUM> or the compression material positioned on the upper <NUM>.

In one aspect, the upper <NUM> may rotate about the vertical axis <NUM>, via the rotation of the coupling member <NUM>, as discussed herein. In alternative aspects, the upper <NUM> may not be rotated about the vertical axis <NUM> while the upper <NUM> is exposed to the stream of air from the air nozzles <NUM>.

In certain aspects, once the upper <NUM> is exposed to the dryer <NUM> or the cooling station <NUM>, the upper <NUM> may be transferred to the loading/unloading station <NUM> for removal from the system <NUM> and/or for further processing. In such an aspect, the upper <NUM> can be transferred to the loading/unloading station <NUM> via rotation of the radially extending member <NUM>.

As discussed above, in aspects, the system <NUM> can expose the upper <NUM> or other article to a heating station <NUM>, a cooling station <NUM>, and a dryer <NUM>. In certain aspects, in operation, the upper <NUM> is loaded into the system <NUM>, e.g., at the loading/unloading station <NUM>, by coupling the upper <NUM> to the article movement mechanism <NUM>. The coupling of an article to the article movement mechanism <NUM> is discussed in more detail below. Further in aspects, once the upper <NUM> is coupled to the article movement mechanism <NUM>, the article movement mechanism <NUM> can rotate about an axis, e.g., an axis <NUM>, and then lower the upper <NUM> through an opening <NUM> in the top portion <NUM> of a first heating chamber <NUM> of the heating station <NUM>. In such an aspect, the article movement mechanism <NUM> can include any mechanism for moving the upper <NUM>, and/or the radially extending member <NUM> up away from the heating chamber <NUM> and down towards the heating chamber <NUM>. Further, in aspects, the article <NUM>, via the article movement mechanism <NUM>, may be exposed to the heating chamber <NUM>, then exposed to the heating chamber <NUM>, then to the heating chamber <NUM>, and then to the heating chamber <NUM> (or to any number of heating chambers suitable for a particular system configuration or process). Further, in certain aspects, the upper <NUM> is then transferred to the cooling station <NUM> for cooling the heated upper <NUM>. Optionally, the upper <NUM> is then transferred to the dryer <NUM> for removing at least a portion of the liquid <NUM> present thereon, or on the compression material. Further, in such aspects, the upper <NUM> may be transferred back to the loading/unloading station <NUM> for removal from the system <NUM>.

As discussed above, in certain aspects, the article movement mechanism <NUM> can be utilized to transfer the upper <NUM> from one station to the next station. Further, as discussed above, the article movement mechanism <NUM> can include a plurality of radially extending members with each member coupled to an upper. In such an aspect, the article movement mechanism <NUM> can transfer each upper attached to each of a plurality of radially extending members to a subsequent processing station substantially at the same time. Stated differently, in one aspect the plurality of radially extending members can be fixedly coupled to a central portion <NUM> that rotates, thereby causing each of the plurality of radially extending members and the articles coupled thereto to rotate. In such an aspect, each article or upper is exposed to each station for a substantially similar amount of processing time. For example, the upper <NUM> may be exposed to a single cooling station <NUM> for about <NUM> seconds, while the upper <NUM> is exposed to each of the five heating chambers for <NUM> seconds each, so that the upper <NUM> is exposed to the heating station <NUM> for about <NUM> seconds. In aspects, where there may be six heating chambers, the upper <NUM> may be exposed to the heating station for about <NUM> seconds, while being exposed to the cooling station for <NUM> seconds (or <NUM> seconds in the aspect where there are two cooling chambers). It should be understood that the <NUM> second per station or per step time mentioned above is only one example for timing of exposure to the various stations or steps discussed above. In alternative aspects, the upper <NUM> or other article can be exposed to each station or step from about <NUM> seconds, about <NUM> seconds, about <NUM> seconds, about <NUM> seconds, or about <NUM> seconds.

As discussed above, one example article for use with the system <NUM> disclosed herein can be an upper <NUM> for an article of footwear. <FIG> depict the various components of the upper <NUM> and the assembly of the upper <NUM> components on a last <NUM>. It should be understood that, in certain aspects, the upper <NUM> and the components of the upper <NUM> mentioned below may be assembled in other manners not depicted in the figures. For instance, in one aspect, the components of the upper <NUM> may be assembled off the last <NUM> and, once assembled, may then be applied to the last <NUM>.

<FIG> depicts a liner <NUM> being placed on the last <NUM>. In certain aspects, the last <NUM> can be formed of a rigid material that is capable of withstanding the temperatures and other processing parameters discussed herein with respect to the system <NUM>. In various aspects, the liner <NUM> can include a heel portion <NUM>, a forefoot portion <NUM>, and a ground-facing portion <NUM>.

In certain aspects, the liner <NUM> can be formed from any type of material. In certain aspects, the liner <NUM> can include a knit textile, a braided textile, a woven textile, and a non-woven textile, a film, a sheet, or a molded article, such as an injection molded article, a foamed material, or a combination thereof. In the same or alternative aspects, the liner <NUM> can include natural materials, synthetic materials, or a combination of natural and synthetic materials. In one aspect, the liner <NUM> can include a non-woven textile. In various aspects, the liner <NUM> may include multiple pieces of one or more materials that are secured together, e.g., by bonding or stitching. In one or more aspects, the liner <NUM> can optionally include a plurality of eyestays <NUM>. In aspects, the liner <NUM> is positioned on the last <NUM> by inserting the last <NUM> into a void <NUM> of the liner <NUM>.

<FIG> depicts a chassis <NUM> that is positioned on the ground-facing portion <NUM> of the liner <NUM> positioned on the last <NUM>. In one aspect, the chassis <NUM> can be formed of any type of material as long as such a material can provide support and stability to the upper <NUM> and the article of footwear formed therefrom. In one aspect, the chassis <NUM> can include a material that may fuse with other portions of the upper throughout the thermoforming process. In such an aspect, the chassis can include a thermoplastic material that has a melting temperature, a Vicat softening temperature, a heat deflection temperature, or any combination thereof, in the range of about <NUM>° C to about <NUM>° C, or from about <NUM>° C to about <NUM>° C. The melting temperature can be determined according to the test method detailed in ASTM D7138 - <NUM>. The Vicat softening temperature can be determined according to the test method detailed in ASTM D1525-<NUM>, preferably using Load A and Rate A. The heat deflection temperature can be determined according to the test method detailed in ASTM D648-<NUM>, using a <NUM> MPa applied stress. In aspects, all or a portion of the chassis <NUM> can be made from such a material or the chassis <NUM> can be coated with such a material for fusing to another portion or portions of the upper <NUM>, such as the liner <NUM> and/or the bootie <NUM> discussed further below. In one aspect, an adhesive, such as a hot melt adhesive, may be utilized to secure at least a portion of the chassis <NUM> to the liner <NUM>.

<FIG> depicts a heel counter <NUM> placed on the heel portion <NUM> of the liner <NUM>. In certain aspects, the heel counter <NUM> can provide stability to the heel region of the upper. In certain aspects, an adhesive, such as a hot melt adhesive, can be utilized to secure at least a portion of the heel counter <NUM> to the liner <NUM>. In aspects, the heel counter <NUM> can be formed from any material as long as such a material can provide heel support upon exposure to the system <NUM> and processes described herein.

In aspects, the heel counter <NUM> can include one or more of the fusable materials discussed above with reference to the chassis <NUM>. In such an aspect, upon exposure to the system <NUM> and/or processes described herein, at least a portion of the heel counter <NUM> may melt or deform and fuse or bond to another component of the upper <NUM>, such as the liner <NUM> and/or the bootie <NUM>.

<FIG> depicts the bootie <NUM> being placed on the liner <NUM>, chassis <NUM>, and the heel counter <NUM> positioned on the last <NUM>. The bootie <NUM> of <FIG> includes a ground-facing portion <NUM>, a heel portion <NUM>, a forefoot portion <NUM>, and a plurality of eyestays <NUM>. In certain aspects, the bootie <NUM> may not include the eyestays <NUM>. In one aspect, the bootie <NUM> may be sock-like in that it can, by itself, substantially cover a forefoot region, a heel region, a ground-facing region of a wearer's foot.

In aspects, the bootie <NUM> can include a woven, braided, knit, or non-woven textile. In aspects, such a textile may include one or more yarns or fibers comprising a yarn or fiber composition that includes a thermoplastic material. In such aspects, the thermoplastic material and/or the yarn or fiber composition can exhibit a melting temperature (or melting point), Vicat softening temperature, heat deflection temperature, or a combination thereof, that is from about <NUM>° C to about <NUM>° C, or from about <NUM>° C to about <NUM>° C. In one aspect, the thermoplastic material and/or the yarn or fiber composition can exhibit a melting temperature, Vicat softening temperature, heat deflection temperature, or a combination thereof, that is about <NUM>° C or less, about <NUM>° C or less, or about <NUM>° C or less. In the same or alternative aspects, the bootie <NUM> can include one or more materials that will not melt or deform under the processing conditions disclosed herein. In such an aspect, in the case of such a thermoplastic material, such material can exhibit a melting temperature greater than about <NUM>, greater than about <NUM>, or greater than about <NUM>. Further, in such aspects, another material that may be present in the article, such as a material other than a thermoplastic material, may not degrade below a temperature of about <NUM>, about <NUM>, or about <NUM>.

In aspects, the eyestays <NUM> on the bootie <NUM> can align with the eyestays <NUM> present on the liner <NUM>. In various aspects, an alignment mechanism can be utilized to achieve alignment of the eyestays <NUM> with the eyestays <NUM>.

Turning now to <FIG> a film <NUM> is depicted that has been placed on the outside of the bootie <NUM> present on the last <NUM>. In certain aspects, the film <NUM> can include a ground-facing portion <NUM>, a heel portion <NUM>, and a toe-covering portion <NUM>. In certain aspects, through exposure to the system <NUM> and the thermoforming processes disclosed herein, the film <NUM> can include a thermoplastic material that can melt and cool to form a film on the upper <NUM> to provide support, stability, and/or a moisture barrier, for example. In certain aspects, the thermoplastic material can exhibit the melting temperature, heat deflection temperature, Vicat sofetening temperature, or a combination thereof, in the range of <NUM>° C to about <NUM>° C, or from about <NUM>° C to about <NUM>° C, or about <NUM>° C or less, about <NUM>° C or less, or about <NUM>° C or less. It should be understood that the film <NUM> depicted in <FIG> is one example and other films of films having varying coverage of varying portions of the upper <NUM> can be utilized depending upon the desired properties.

<FIG> depicts the assembled upper <NUM> discussed above with reference to <FIG> positioned on the last <NUM>. As discussed above, the upper <NUM> can include materials that may melt and flow upon exposure to the system <NUM> and thermoforming processes disclosed herein. Further as discussed above, in certain aspects, one or more of the upper <NUM> components may include a material that is to fuse or bond to another material or component of the upper <NUM> upon exposure to the system <NUM> and thermoforming processes disclosed herein. In one or more of these aspects, it may be desirable to provide a compressive force to the upper <NUM> to facilitate the fusing or bonding, to restrict the flow of the melted thermoplastic material, and/or to aid in forming the upper <NUM> or portion thereof to the forming material, e.g., the last <NUM>. In such aspects, a compression bootie can be utilized to provide such a compressive force to an outer surface <NUM> of the upper <NUM>.

<FIG> depicts one example compression bootie <NUM> that is being applied onto the upper <NUM> positioned on the last <NUM>. As can be seen in <FIG>, the compression bootie <NUM> can be sock-like in that includes a ground-facing portion <NUM>, a heel portion <NUM>, and a forefoot potion <NUM>. In one or more aspects, the compression bootie <NUM> can be formed or comprise an elastomeric material in order to provide a compressive force on the outer surface <NUM> of the upper <NUM>. In certain aspects, the compression bootie <NUM> can be formed from any elastomeric material as long as the elastomeric material exhibits a melting temperature or degradation temperature that is at least <NUM> greater, or at least <NUM> or greater, than the processing temperatures described above with reference to the heating station <NUM>. In one aspect, the compression bootie <NUM> can include polysiloxane.

<FIG> depicts the lasted upper <NUM> with the compression bootie <NUM> positioned over the lasted upper <NUM>. The partial cross-section in <FIG> shows the arrangement of the various components of the upper <NUM> discussed above with reference to <FIG>. As can be seen in <FIG>, the liner <NUM> is in contact with the last <NUM>, with the chassis <NUM> and heel counter contacting the liner <NUM> and the bootie <NUM>, and the film <NUM> is positioned between the bootie <NUM> and the compression bootie <NUM>. <FIG> provides a close up view of the heel region of the lasted upper <NUM> of <FIG>.

As discussed above, in certain aspects, the compression bootie <NUM> can apply a compressive force onto the upper <NUM> pressing the upper <NUM> against the rigid last <NUM>. In such an aspect, this compressive force can aid in restricting the flow of the film <NUM> upon melting so that it cools and hardens in the desired position on the upper <NUM>. Further, in aspects, this compressive force may facilitate the bonding of one or more of the upper <NUM> components, e.g., the heel counter <NUM> fusing or bonding to the bootie <NUM> and/or the liner <NUM>.

In certain aspects, an additional increased level of compressive force on the upper <NUM> may be desired, in addition the compressive force applied by the compression bootie <NUM>. In such aspects, the lasted upper <NUM> covered with the compression bootie <NUM> may have a compression material compressed onto the outer surface of the compression bootie <NUM> to apply this additional level of compressive force to the lasted upper <NUM>. In certain aspects, the compression material can be a vacuum bag. The compression material can be formed of any material as long as such a material will not melt or deform throughout exposure to the system <NUM> and processes disclosed herein. In one aspect, the compression material may be utilized directly on the upper <NUM> in the absence of the compression bootie <NUM>.

In one or more aspects, the vacuum bag or compression material can be at least partly shaped similar to the forming material and/or article that is to be thermoformed. For example, <FIG> depicts a compression material <NUM> that includes a portion <NUM> that is at least partly or substantially shaped like a last <NUM> and/or the upper <NUM>, at least in that the portion <NUM> generally includes a bootie shape having a ground-facing portion <NUM>, a heel potion <NUM>, and a forefoot portion <NUM>.

In certain aspects, it may be desirable that the portion <NUM> of the compression material <NUM> is similar or slightly larger in size to that of the lasted upper <NUM> inserted therein. However, in such an aspect it may be difficult to efficiently insert a lasted upper <NUM> into a similarly-sized compression material <NUM>. In such an aspect, a system or mechanism may be utilized to facilitate the assembling of the compression material <NUM> on the lasted upper <NUM>.

<FIG> depict a compression assembly system <NUM> that can be utilized to facilitate inserting a lasted upper <NUM> into a similarly sized and/or similarly shaped compression material <NUM>. As can be seen in <FIG>, the compression assembly system <NUM> can include the compression material <NUM> and a negative pressure vessel <NUM>. It should be understood that the compression assembly system <NUM> is just one example system to facilitate assembling a compression material <NUM> onto a lasted upper <NUM>, or other article, and that other system components or designs are also contemplated by the present disclosure.

As can be seen in <FIG>, the compression material <NUM> has been inserted into the interior portion <NUM> of the negative pressure vessel <NUM>. As discussed above, since the compression material <NUM> may be similarly sized or similarly shaped to the lasted upper <NUM>, the neutral configuration or position of the compression material <NUM> in <FIG> may make it difficult to efficiently insert the lasted upper <NUM> into an interior portion <NUM> of the compression material <NUM>. In such an aspect, the compression material <NUM> can be shifted to an expanded configuration to expand the interior portion <NUM> to allow for more efficient insertion of the lasted upper <NUM>. For example, as seen in <FIG>, the negative pressure vessel <NUM> can include a port <NUM>, which can provide negative pressure, or vacuum pressure, to the volume 921a between the outer surface <NUM> of the compression material <NUM> and the inner surface <NUM> of the negative pressure vessel <NUM>. In such an aspect, at least a portion of the compression material <NUM> can couple to, or otherwise provide or form a seal, at a top portion 922a and 922b of the negative pressure vessel <NUM> to allow for the drawing of the vacuum pressure in the volume 921a. In certain aspects not depicted in the figures, the port <NUM> can be coupled to a negative pressure generation device to provide the vacuum pressure to the volume 921a.

As can be seen in <FIG>, upon exposing the volume 921a between the outer surface <NUM> of the compression material <NUM> and the inner surface <NUM> of the negative pressure vessel <NUM> to negative or vacuum pressure, the compression material <NUM> can shift into an expanded configuration, such that at least a portion of the compression material <NUM> is closer to the sidewalls 924a and 924b of the negative pressure vessel <NUM> than in the neutral configuration of the compression material depicted in <FIG>. In one aspect, upon exposing the volume 921a between the outer surface <NUM> of the compression material <NUM> and the inner surface <NUM> of the negative pressure vessel <NUM> to negative or vacuum pressure, the compression material <NUM> can form to the dimensions of the negative pressure vessel <NUM>.

In certain aspects, in this expanded configuration of the compression material <NUM>, such as that depicted in <FIG>, an upper <NUM> positioned on a last <NUM> can be more easily inserted into the interior portion <NUM> of the compression material <NUM>. In an aspect not depicted in the figures, an identifier on the compression material <NUM>, the negative pressure vessel; <NUM>, or both, may be provided to identify the orientation at which the upper <NUM> should be placed in the compression material for the proper fit. In aspects, the port <NUM> can provide a continuous draw of vacuum pressure or exposure of vacuum pressure to the volume 921a while the lasted upper <NUM> is being inserted into the interior portion <NUM>. In alternative aspects, the port <NUM> can provide an initial, non-continuous, draw of vacuum pressure or exposure of vacuum pressure to the volume 921a and is then sealed to maintain the compression material in the expanded configuration while the lasted upper <NUM> is being inserted into the interior portion <NUM>.

In certain aspects, once the lasted upper <NUM> is inserted into the interior portion <NUM> of the compression material <NUM>, the port <NUM> may cease to provide the negative or vacuum pressure to the volume 921a, or a seal is removed, so that the compression material <NUM> may shift from the expanded configuration depicted in <FIG> to a closed configuration or position depicted in <FIG>. In one aspect, the port <NUM> may supply a pressure at or about atmospheric pressure to the volume 921a, which can cause the compression material <NUM> to shift away from the sidewalls 924a and 924b and towards the lasted upper <NUM>. Further, in such an aspect, the compression material <NUM> can be de-coupled from the top portions 922a and 922b and removed for further processing, such as compressing the compression material <NUM> onto the lasted upper <NUM> and exposing the lasted upper <NUM> to the system <NUM> and/or the thermoforming processes described herein.

In certain aspects, once the lasted upper <NUM> is inserted into the compression material <NUM>, the lasted upper <NUM> can be coupled to the article movement mechanism <NUM>. A close up view of one example article movement mechanism <NUM> that includes the radially extending member <NUM> and coupling member <NUM> are depicted in <FIG> also depicts one example of how the lasted upper <NUM> can be coupled to the article movement mechanism <NUM>.

In certain aspects, a portion 910a of the compression material <NUM> that extends beyond the lasted upper <NUM> can be coupled to the article movement mechanism <NUM>. As can be seen in the aspect depicted in <FIG>, the portion 910a of the compression material <NUM> can extend through the coupling member <NUM> with a top portion <NUM> utilized to seal off the interior portion <NUM> of the compression material <NUM>. In an aspect not depicted in the figures, a port within the coupling member <NUM> of the article movement mechanism <NUM> can provide vacuum or negative pressure to the interior portion <NUM> of the compression material <NUM> in order to cause the compression material <NUM> to apply a compressive force onto the lasted upper <NUM>. In such an aspect, a negative pressure generation device <NUM>, depicted in <FIG>, can be coupled to the article movement mechanism <NUM>. The negative pressure generation device <NUM> can be any type of vacuum pressure device and can be coupled to the article movement mechanism <NUM> using any couple mechanism, with a particular device or coupling mechanism chosen for a particular design or purpose.

In one aspect, the interior portion <NUM> of the compression material <NUM> can be exposed to vacuum or negative pressure in a continuous manner as the upper <NUM> is transferred between stations or chambers of the system <NUM> described above. In such an aspect, the article movement mechanism <NUM> can provide this continuous negative pressure via the negative pressure generation system <NUM>.

In alternative aspects, the interior portion <NUM> of the compression material <NUM> can be exposed to vacuum or negative pressure at an initial single step, in order to compress the compression material <NUM> onto the lasted upper <NUM> and then the coupling member <NUM> can seal off the interior portion <NUM> of the compression material <NUM>, e.g., via the top portion <NUM> or other member, in order to maintain the vacuum pressure within the interior portion <NUM>. In such an aspect, the article movement mechanism <NUM> can provide this initial single exposure of negative pressure via the negative pressure generation system <NUM>. In one aspect, another negative pressure source, other than the negative pressure generation system <NUM>, can be utilized to provide the vacuum pressure to the interior portion <NUM>, and the compression material <NUM> can be sealed either by the coupling member <NUM> or through another sealing mechanism.

As discussed above, in certain aspects, the upper <NUM> can rotate when positioned within the heating station <NUM>, e.g., within the heating chamber <NUM>, and/or when positioned within the cooling citation <NUM>, e.g., within the cooling chamber <NUM>. Further, as discussed above, in such an aspect, the article movement mechanism <NUM> can rotate the upper <NUM>. As can be seen in <FIG>, the coupling member <NUM> can rotate, relative to the radially extending member <NUM>, about the vertical axis <NUM>. In one aspect, in order to have a continuous draw of the vacuum pressure in the interior <NUM> of the compression material <NUM>, the vacuum can be drawn through an axis of rotation, e.g., the axis <NUM>, from which the compression material <NUM> and the lasted upper <NUM> rotate.

Further, as can be seen in <FIG>, the coupling member <NUM> can include a downward-extending hook <NUM> that is coupled to at least another portion of the coupling member <NUM>. In such an aspect, as the coupling member <NUM> rotates, the hook <NUM> can also rotate. In such an aspect, a portion of the lasted upper <NUM> can interface with or removably couple to the hook <NUM> to allow for the rotation of the upper <NUM> as the coupling member <NUM> and hook <NUM> rotate. In certain aspects, the hook <NUM> can also provide for the efficient loading and unloading of the lasted upper <NUM>, in combination with ease of removal of the compression material <NUM> from the coupling member <NUM>, e.g., by release of the top portion <NUM> of the coupling member <NUM>.

In certain aspects, as discussed above, the compression material <NUM> may be similarly sized and/or similarly shaped to the last <NUM> and/or the upper <NUM>. After exposure to the thermoforming process, in certain aspects, it may be desirable to utilize assistance in order to facilitate the removal of the compression material <NUM> from the upper <NUM>. In such an aspect, an air stream may be blown into the interior <NUM> of the compression material <NUM> to aid in the release of the compression material <NUM> from the surface of the upper <NUM>, or to enlarge the interior <NUM> to make removal of the upper <NUM> easier. In one aspect, a port associated with the article movement mechanism <NUM> can provide such an air stream. In alternative aspects, the air stream may be supplied by another air nozzle or port not associated with the article movement mechanism <NUM> or other components of the system <NUM> discussed above.

<FIG> depicts a flow diagram of a method <NUM> for preparing an article for thermoforming. The method <NUM> can include the step <NUM> of inserting a compression material into a vessel. In aspects, the compression material can include any or all of the features, properties, and parameters of the compression material <NUM> discussed above with reference to <FIG>. In certain aspects, the vessel can include any or all of the features, properties, and parameters of the negative pressure vessel <NUM> discussed above with reference to <FIG>. In aspects, the compression material is present in a first position in the vessel. In one aspect, the first position can be similar to the position or configuration of the compression material <NUM> depicted in <FIG>. In aspects, the compression material can include an interior portion adapted to receive an article.

The method <NUM> can include a step <NUM> of exposing an area between an outer surface of the compression material and an inner surface of the vessel to a pressure less than atmospheric pressure. In such an aspect, this pressure, less than atmospheric pressure, can shift the compression material from the first position to an expanded position. In such an aspect, in the expanded position, at least a portion of the compression material can be closer to the inner surface of the vessel than that compared to the first position. In one or more aspects, in the expanded position, the compression material can exhibit at least a portion of the dimensions of the vessel, such as that depicted in <FIG>.

The method <NUM> can also include the step <NUM> inserting at least a portion of an article inside an interior portion of the compression material. As discussed above, in certain aspects, the article can include an upper positioned on a last. In such aspects, the upper can include any or all of the features, properties, and parameters of the upper <NUM> discuss above with reference to <FIG>. In aspects, the entire upper, or a portion of the upper, can be positioned inside the compression material.

The method <NUM> can include the step <NUM> of exposing the area between the outer surface of the compression material and the inner surface of the vessel to a pressure at about atmospheric pressure so that the compression material shifts from the expanded position to a second position. In such an aspect, in the second position, at least a portion of the article is in the interior of the compression material and the compression material is closer to the article than when the article was inserted into the compression material in the expanded position. For instance, in one aspect, the second position of the compression material can be similar to that depicted in <FIG>, where the compression material has moved away from the sidewalls of the vessel and is positioned adjacent to the article.

<FIG> depicts a flow diagram of a method <NUM> for thermoforming an article. The method <NUM> can include the step <NUM> of receiving a compression material having an article positioned inside the compression material. In aspects, the compression material can include any or all of the features, properties, and parameters of the compression material <NUM> discussed above with reference to <FIG>. In certain aspects, the article can include a lasted upper, such as the lasted upper <NUM> discussed above with reference to <FIG>.

The method <NUM> can include the step <NUM> of exposing an area between an inner surface of the compression material and an outer surface of the article to a pressure less than atmospheric pressure. In such an aspect, the compression material can apply a compressive force onto the outer surface of the article. In certain aspects, the article movement mechanism <NUM> and the negative pressure generation system <NUM> can be utilized to provide the negative pressure and expose the area to a pressure less than atmospheric pressure.

The method <NUM> can include the step <NUM> of introducing the article to one or more heating stations. In aspects, the one or more heating stations can include any or all of the features, properties, and parameters of the heating station <NUM> discussed above with reference to <FIG> and <FIG>. The method <NUM> can also include the step <NUM> of rotating the article within each of the one or more heating stations. In such aspects, the article movement mechanism <NUM> discussed above with reference to <FIG>, <FIG>, and <FIG> can be utilized to couple the article thereto and to rotate the article within each of the one or more heating stations.

The method <NUM> can also include the step <NUM> of introducing the article to a cooling station. In aspects, the cooling station can include any or all of the features, properties, and parameters of the cooling station <NUM> discussed above with reference to <FIG> and <FIG>. In one aspect, the article movement mechanism <NUM> discussed above with reference to <FIG>, <FIG>, and <FIG> can be utilized to transfer the article from the one or more heating stations to the cooling station. The method <NUM> can also include the step <NUM> of rotating the article within the cooling station. In such an aspect, the article movement mechanism <NUM> discussed above with reference to <FIG>, <FIG>, and <NUM> can be utilized to rotate the article within the cooling station.

Claim 1:
A method for preparing an article for thermoforming, the method comprising:
inserting a compression material (<NUM>) into a vessel (<NUM>), the compression material present in a first position in the vessel (<NUM>), wherein at least a portion of the compression material (<NUM>) forms an interior portion adapted to receive an article (<NUM>);
exposing an area between an outer surface of the compression material (<NUM>) and an inner surface of the vessel (<NUM>) to a pressure less than atmospheric pressure to shift the compression material (<NUM>) from the first position to an expanded position, wherein in the expanded position, at least a portion of the compression material (<NUM>) is closer to the inner surface of the vessel (<NUM>) than compared to the first position;
inserting at least a portion of the article (<NUM>) into the interior portion of the compression material (<NUM>) while the compression material (<NUM>) is in the expanded position, wherein the article (<NUM>) is present on a forming material; and
exposing the area between the outer surface of the compression material (<NUM>) and the inner surface of the vessel (<NUM>) to a pressure at about atmospheric pressure so that the compression material shifts from the expanded position to a second position, wherein in the second position, the at least a portion of the article (<NUM>) is in the interior portion of the compression material (<NUM>) and the at least a portion of the compression material is closer to the article than when the article was inserted into the compression material in the expanded position.