JP2012504068A - How to produce efficient and localized shoes - Google Patents

Abstract

A method and system for efficient shoe manufacturing that reduces the specialized labor required to manufacture shoes while avoiding the high cost and special maintenance requirements often associated with highly automated manufacturing facilities Provides a method and system that can. Systems and methods in accordance with the present invention can be used to produce multiple models of customized shoes on a single shoe manufacturing facility, using workflow duplication, thereby reducing the physical footprint of the manufacturing facility. Additionally, embodiments of the present invention provide methods and systems for efficiently producing shoes, meeting the needs of specific geographical locations, thereby eliminating the need to bring in shoes produced elsewhere. can do.

Description

This application claims the benefit of US Provisional Patent Application No. 61/194, filed Sep. 26, 2008, entitled "Method for Efficient and Localized Production of Shoes". Claim the benefits of 496.

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

That is, most shoe manufacturing processes today require a great deal of manual input. For example, one worker must cut, shape, align and sew the upper portion of the shoe.
Although this process utilizes a large number of machines, it still requires a great deal of manual intervention, which can cause changes between the two different upper parts. The upper part of the shoe is then passed on to another worker and embroidered or otherwise decorated, but this also requires a great deal of manual intervention. These high levels of manual intervention cause unwanted changes in the finished shoe product. In addition, the large amount of human effort required during shoe making has limited the ability to produce custom custom shoes at prices that many customers can tolerate.

  This summary selectively introduces, in a simplified form, a selection of concepts that will be described in more 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 the art and is not limited to the method of producing the particular type of shoes 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 frequently associated with highly mechanized manufacturing facilities. Reduce the special human effort required for Systems and methods in accordance with the present invention can be used to produce multiple models of custom shoes on a single shoe manufacturing facility. For example, even if one customer orders shoes of a particular model, the next customer can order shoes of another model, and the models of both shoes are manufactured at the same facility by utilizing an overlapping workflow. can do.

  The contents of the present invention are described in detail herein in order to meet the requirements of the law. However, the description itself is not intended to limit the scope of this patent. Rather, the inventor expects that the content of the claims will be implemented in other ways, including different steps or combinations of steps similar to those described herein, as well as other current or future technologies. It shall be Further, the term "step" is used herein to imply different elements of the method employed, and this term is used herein unless and until the order of the individual steps is explicitly stated. And should not be construed as implying any particular order between the various steps.

  Embodiments of the present invention provide a method of efficiently producing shoes that meet geographic location requirements. By way of example and not limitation, production equipment for efficient production of shoes is divided into specific modules, which are associated with distributed placement operations, such as embroidery or midsole production, or of the shoe making process By an area is meant that it has the characteristics associated with one or more aspects. In one embodiment, one or more modules are designed to optimize the working environment of an individual worker, and the interaction between the worker and the machine within the worker's module helps maintain worker health Ergonomically designed to contribute to Each module is called a "module". As the shoe component moves through the module, there may be different processes and variations that comprise steps in the overall manufacture of the shoe.

  Shoe products, which may be finished shoes or partially finished shoes or parts of finished shoes, can only be produced after receiving a customized order. A customized order shall include custom shoe parameters associated with one or more shoes produced for any consumer. In addition, each shoe is custom-made and each shoe is paired with each customer's request (eg male size 9, blue, medium hardness, left foot, male size 9.5, red, high hardness, right foot) Have various features according to the

  Once a customer places an order for one or more shoes, the order is monitored through the production system to notify one or more workers of features specific to each order. In one method, a customized order may be presented to one or more workers in one or more sheets. Each form should be communicated to the appropriate worker to let the worker know what changes to the shoe and / or shoe parts they are changing. The operator then selects the desired features, such as suitable colors, from the material source within the modularized production facility, or the operator selects the desired design and / or from a series of program options on the computer system. Or select the pattern. In the latter method, the operator searches a predetermined design set that can be used for printing and / or embroidery and / or etching on the material, and further programs the computer to print and / or embroider the design on the material. And / or etching. In another method, the operator enters the design or program offered by the customer as a custom design for one or more shoe parts.

  In another embodiment, the worker accesses the information related to the customized order through the shoe component manufacturing facility by having customer information stored on the worker accessible database at the shoe component manufacturing facility. Shall be able to The operator shall be able to access customized order information via the computer interface at or near one or more modules in the shoe component manufacturing facility. Workers should also have access to information about the customer via one or more barcodes. In one method, the bar code may access the customized order information from a database containing all of the information necessary for customized order production of one or more shoes. The barcode may be used to access all information on one or more shoe parts, or it may be used to access specific information on one or more shoe parts.

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

The three starting points for producing one or more shoe parts are outsole production, midsole production, and upper part production. Outsole and / or midsole production starts before the customer places an order. The outsole and / or midsole may also be produced as needed after receiving a customized order for production of one or more shoes.
The invention will be described in detail below with reference to the accompanying drawings.

FIG. 5 is an illustration of a shoe component manufacturing facility in the manufacture of custom shoe components according to an embodiment of the present invention. FIG. 5 is a flow chart of a method of efficiently manufacturing multiple models of custom shoes in a single manufacturing facility, according to an embodiment of the present invention. FIG. 7 is a flowchart of an outsole manufacturing workflow of a running shoe in an outsole / midsole module according to an embodiment of the present invention. FIG. 7 is a flowchart of a midsole manufacturing workflow of a running shoe in an outsole / midsole module, according to an embodiment of the present invention. FIG. 5 is a flow chart of a running shoe workflow in a priming and bonding module according to an embodiment of the present invention. FIG. 5 is a flow chart of a workflow for combining the outsole and midsole as a midsole-outsole on a running shoe according to an embodiment of the present invention. FIG. 5 is a flow chart of a workflow for customizing the upper portion of a running shoe according to an embodiment of the present invention. FIG. 5 is a flow chart of a workflow for assembling the upper portion of the running shoe according to an embodiment of the present invention. FIG. 5 is a flowchart of a durability and quality control workflow for a running shoe, according to an embodiment of the present invention. FIG. 5 is a flow chart of an outsole manufacturing workflow for a basketball shoe in an outsole / midsole module according to an embodiment of the present invention. FIG. 7 is a flowchart of a midsole manufacturing workflow for a basketball shoe in an outsole / midsole module, according to an embodiment of the present invention. FIG. 5 is a flow chart of a workflow for a basketball shoe in a priming and bonding module according to an embodiment of the present invention. FIG. 5 is a flowchart of a workflow for combining the outsole and midsole as a midsole-outsole in a basketball shoe, according to an embodiment of the present invention. FIG. 5 is a flow chart of a workflow for customizing the upper portion of a basketball shoe, according to an embodiment of the present invention. FIG. 5 is a flow chart of a workflow for assembling the upper portion of a basketball shoe, according to an embodiment of the present invention. FIG. 5 is a flow chart of a durability and quality control workflow for a basketball shoe, according to an embodiment of the present invention. FIG. 7 is a flowchart of an outsole manufacturing workflow for skate shoes in an outsole / midsole module according to an embodiment of the present invention. FIG. 7 is a flow chart of a midsole manufacturing workflow for skate shoes in an outsole / midsole module according to an embodiment of the present invention. FIG. 5 is a flow chart of a workflow for a skateball shoe in a priming and bonding module according to an embodiment of the present invention. FIG. 7 is a flow chart of a workflow for combining the outsole and midsole as a midsole-outsole on a skate shoe, according to an embodiment of the present invention. FIG. 5 is a flow chart of a workflow for customizing the upper portion of a skate shoe, according to an embodiment of the present invention. FIG. 5 is a flow chart of a workflow for assembling the upper portion of a skate shoe, according to an embodiment of the present invention. FIG. 5 is a flow chart of a durability and quality control workflow for skate shoes, according to an embodiment of the present invention. FIG. 5 is a workflow illustration of a shoe component manufacturing facility for custom shoe component manufacturing according to an embodiment of the present invention. FIG. 5 is a block diagram of a modular configuration for use in shoe production, according to an embodiment of the present invention. FIG. 1 is a system block diagram for producing and assembling a shoe component, according to an embodiment of the present invention. 5 is a flowchart of the workflow of a shoe manufactured through a process according to an embodiment of the present invention.

  Referring to the drawings and in particular to FIG. 1 initially, a typical operating environment suitable for embodiments of the present invention is shown and described generally as a shoe component manufacturing facility 100. However, shoe component manufacturing facility 100 is an example of a suitable manufacturing environment and is not intended to suggest a limitation on the scope of use or functionality of the present invention. Also, it is not intended that the shoe component manufacturing facility 100 be interpreted as adhering to or requiring one or a combination of the illustrated components.

  FIG. 1 shows a floor arrangement of six shoe manufacturing modules organized in a process performed by a worker associated with the module. The six modules shown in FIG. 1 are: outsole and midsole module; midsole, outsole, prime of upper part (upper) and adhesive module of the upper part; final assembly and stock fit module; upper part customization module; An upper part forming and sewing module; and a lasting, reshaping, quality control and packaging module. The area of each module in the shoe component manufacturing facility 100 will be described with reference to the explanatory view of FIG.

  The outsole and midsole module comprises a pre-formed (preform) injection molding machine 102 used to produce phylon biscuits. The outsole and midsole module also includes a midsole marketplace 108 which stores phylon biscuits for use in forming the midsole. The outsole and midsole module also comprises a press 106, in particular a Kingstead Quick Open Press made by Kingstead, using it as a right pointing shoe, a left pointing shoe or a phylon as a neutral pointing shoe Characterize biscuits. The outsole and midsole modules also include microwave heat sources to preheat phylon biscuits. The outsole and midsole module also includes a stabilizing oven 110, which can be used to stabilize the midsole and to reduce the midsole volume. The outsole and midsole module also includes a wash / dry table 112. The outsole and midsole modules also include other midsole marketplaces 104. The outsole and midsole module also comprises a rubber injection molding machine 116 used to produce the outsole. The outsole and midsole module also comprises a wash / dry area 114 used to wash the outsole with an alkaline or acid wash. The outsole and midsole module also comprises an outsole marketplace 118.

  The midsole, outsole, upper partial prime (top coat) and adhesion module can have a midsole marketplace 104 and an outsole marketplace 118. The midsole, outsole, upper part prime and adhesion module also comprises prime and adhesion areas 120. In another embodiment, the prime and bond areas are two separate areas. The midsole, outsole, upper part prime and adhesive module is also a chemical storage area 158 for storing chemicals associated with one or more processes in the manufacture of shoe components and / or shoe products in the shoe component manufacturing facility 100. Shall be provided. The midsole, outsole, upper part prime and bonding module also comprises an infrared (IR) oven 122. In another method, the midsole, outsole, upper part prime and adhesive module also comprises a standard oven in which one or more shoe products are made to activate the adhesive, the manufacturing process Through.

  The final assembly and stock fit module is equipped with an IR oven 122. The final assembly and stock fit module also includes a bladder press 124 used to bring the midsole and outsole together. The final assembly and stock fit module also comprises a standard press 126. The final assembly and stock fit module also includes a cooling device 128 used to provide adhesion of the midsole-outsole shoe product.

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

  The upper part forming and sewing module comprises an RF welder 148, which comprises an RF relay area used to temporarily store shoe parts in the process of producing or modifying a shoe product. The upper part forming and sewing module also comprises a marketplace 150, with which the customizable parts needed to complete the production of shoes or shoe products are temporarily stored and readily available. I assume. The upper part forming and sewing module also comprises a material store 168, which is a material and / or shoe component related to the shoe component in the shoe component manufacturing facility 100 and / or one or more processes in the manufacture of a shoe product. Stockpile. The upper part forming and sewing module also comprises a final trimming die 144 and a wing arm relay area 130. The upper part forming and sewing module also comprises a market die cutting machine 170, a heating press 172, a cooling rack 174, a cutting press 176, a heel forming machine 178, a back stitch 180 and a strobel stitch 182.

  The lasting, reshaping, quality control and packaging module comprises a swing arm relay area 130. The form-fit, re-form-fit, quality control and packaging module also comprises a form-fit area 152, final quality control 154, form-fit and packaging 156 and material storage 184.

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

  In one embodiment, the first step in outsole production utilizes a rubber injection molding machine 102. Different outsoles are produced for different shoe sizes and styles using molds of different sizes and / or shapes. Various types and / or colors of rubber can also be used to produce an outsole with different functionality and / or aesthetic properties. For example, in the production of an outsole, using markings (such as dotted lines), for example, a person who embroiders or who adds mechanical features, or using an adhesive or another type of adhesive Guide people who add textiles and decorations to one or more shoe parts. In other cases, the different colors of the shoe component have functional elements such as adding a readily visible color, such as bright yellow, to one or more shoe components to make the shoe wearer more noticeable. Other, different slippery, different rubbers are placed along the shoe parts to reduce the amount of dirt or other external elements sticking to the shoe wearer's shoe or shoes.

  The operator of the rubber injection molding machine 102 determines the size, style, color, and other values of the outsole to initially form based on the outsole display required by the outsole marketplace 118. For example, the display includes a preset range of expected sales (use) amounts for that marketplace. The number of outsoles will also be stated on the display receipts of decreasing stock size, style, color, etc. The amount of sale (use) of the preset range is planned for one day or another period, for example one week or one month or one season. The operator of the rubber injection molding machine 102 may alternatively or additionally determine which 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 corresponding to a particular style, size, color, functional characteristics, etc. For example, the temporary storage method comprises placing a newly formed outsole of size 9 on a first-come, first-served service queue. In another embodiment, the temporary storage method causes the operator to place each newly formed outsole in a warehouse associated with one or more properties of the outsole (e.g., a male size 9 outsole) In one warehouse, the male size 5 outsole is put into another warehouse) step. In yet another embodiment, the temporary storage method places all the newly formed outsoles in a warehouse and then further based on, for example, visual differences between differently sized outsoles or differently sized textured displays Selecting the outsole to allow the worker to take out the appropriately sized outsole from the warehouse when needed.

  Having located the low quality outsole that remains in the outsole marketplace 118, such as, for example, visual inspection, the operator then decides to manufacture the outsole of that size. The outsole can be produced in direct response to the order, or can be specified and specified in style, size, color, functional characteristics, etc.

  After the outsole is removed from the rubber injection molding machine 102 by the operator, it is placed in the wash / dry area 114. The wash / dry area 114 can comprise one or more wash steps that wash the shoe to remove any debris from the rubber. For example, rubber residue is generated by oil and stearic acid used during the curing process. In another embodiment, the curing process eliminates the need for the 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 residue generated during the curing process, and can reduce or eliminate the need for one or more cleaning steps. In this way, the outsole can be primed immediately after being formed in the rubber injection molding machine 116.

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

  Outsole Marketplace 118 and Midsole Marketplace 104 consist of one or more temporary storage methods, the midsole is stored in the warehouse, the warehouse is the size, style, color or other of the parts stored in this warehouse It can be arranged according to the characteristics of The outsole marketplace 118 and the midsole marketplace 104 can store outsoles and midsoles produced based on display receipts that anticipate customized orders. The outsole marketplace 118 and the midsole marketplace 104 also include outsoles and midsoles produced based on the receipt of certain customized orders. In other embodiments, outsoles and / or midsoles produced based on customized order receipts move directly to the next production step, bypassing outsole marketplace 118 and / or midsole marketplace 104. Do. It will be apparent to one skilled in the art that additional embodiments are possible.

  Midsole production starts before the customer places an order. The midsole may also be produced on an as-needed basis on receipt of a customized order of one or more shoes. Additionally, the midsole can be produced as a result of the display receipt adjusting 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 are injected into the mold of a preform injection molding machine 102 heated to approximately 100 ° C. The temperature of the mold should be high enough to melt the EVA pellets to conform to the shape of the mold, but not so high that the expander of EVA is activated. Production refers to injection phylon biscuit, hereinafter referred to as "biscuit", which is stored prior to activating the expansion agent forming the midsole. Different amounts of EVA pellets are associated with different shoe sizes, styles, density and / or hardness of the midsole portion. In addition, the base polymer used in the injection phylon biscuit process differs based on the final hardness properties required by the midsole of the shoe. Each set of shoes includes one or more biscuits of various volumes and sizes that make up 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 features can, for example, prevent mild pronation in the shoe user, for example a runner, or simply improve comfort.

  After the biscuits are formed, the biscuits are removed and stored in biscuit marketplace 108. From the biscuit marketplace 108, biscuits can be removed as needed. When a customer orders one or more shoes, for example, the worker takes out one or more biscuits according to the customer's order. In another method, a worker removes one or more biscuits from the marketplace and places the one or more biscuits in an apparatus that exposes them to a microwave radiation source. For example, one or more biscuits may be housed in a 1.2 kW microwave device from Magic Chef MCB 780 W and exposed to microwave radiation at high power for 65 seconds.

  The operator then places each biscuit into press 106, which may be for the left foot shoe and the right foot shoe, or a combination of both. The operator loads the press 106 for the left foot shoe or the right foot shoe and uses the press 106 to set each biscuit as "left" or "right". The operator then removes each biscuit from the press 106. The press 106 is not limited to holding only one biscuit, and may be capable of holding a plurality of biscuits at any time. Furthermore, the biscuit press does not have to be synchronized with each biscuit in the press 106, but rather can be designed to have multiple biscuit loading and pressing at any time. In still further embodiments, the operator of the module bypasses the step of using the press 106 to designate the shoe product as "left" or "right" oriented, and simply, a lathe or ladle or The biscuit can be shaped manually using one or more blades. The operator may also designate each biscuit to be "left" or "right" oriented using another type of machine prior to placing each biscuit in the intermediate, non-directional press 106. The operator can also keep the biscuits in neutral designation and be interchangeable so that each shoe portion can be used for left and / or right foot shoes.

  After the press 106 contains the biscuits, the biscuits are heated to a temperature approximately 172 ° C. sufficient to melt the biscuits. This temperature is sufficient to activate the expansion agent in the biscuit. This expansion agent initiates the expansion process, degrading the polymer chains and increasing the volume of biscuits by about 200% to match the shape of the press. At the same time, curing agents within the biscuit that function at a slower reaction rate than the expansion agent can initiate crosslinking of the polymer chains to maintain the shape of the reinforced biscuit.

  After forming the bloated biscuit, the operator removes the bloated midsole from the press 106 and loads the bloated midsole into the stabilizing oven 110. When placed in the stabilization oven 110, the hypertrophic midsole is approximately 75 ° C. In another embodiment, the hypertrophic midsole is placed in the stabilizing oven 110 at a temperature above or below 75 ° C. In one embodiment, the enlarged midsole is at the maximum temperature obtained in the press 106 and is also conveyed at the same temperature into the stabilizing oven 110. The stabilization process in stabilization oven 110 consists of three or more cooling stages, which reduce the temperature from approximately 75 ° C. to approximately 45 ° C. In another embodiment, the stabilization process in stabilization oven 110 is performed over multiple steps through the use of water and / or air as a 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 hypertrophic midsole by approximately 20% so that the midsole obtained from the stabilization process is approximately 160% of the initial biscuit volume. In another embodiment, the stabilization process is modified to increase or decrease the rate of change seen in the volume of the hypertrophic midsole. Another method is to stabilize one or more hypertrophic biscuits using any form of stabilization method, which comprises immersing in water or other solution at the desired temperature. In another embodiment, the hypertrophic biscuit is stabilized at the desired temperature through the use of an aerosol solution or aeration.

  Another way to change the volume of the hypertrophic midsole is to manually change the midsole, for example manually by using a lathe or one or more cutting tools or using a second mold. Can be stored in the second mold, the hypertrophy midsole shrinks in volume using pressure or is pressed from the hypertrophy midsole into the desired shape using pressure and then cut and / or unwanted 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 on the washing / drying table 112 and use the ultrasonic bath to wash one or more midsoles. The wash / dry table 112 should wash the midsole using one or more wash steps. In another embodiment, the stabilization of the hypertrophic biscuits is combined with the wash / dry table 112. In another embodiment, the biscuit is removed from the stabilization oven and then loaded into another type of washer and / or solvent and / or rinse. In another embodiment, each biscuit removed from the stabilization oven 110 is hand polished by one or more workers.

  Next, the worker removes the biscuit from the washing / drying table 112 and loads the biscuit into the drying oven. In another embodiment, the biscuits are removed from the washing / drying table 112 by exposing them to a sufficiently high temperature to evaporate the desired amount of water from the biscuits. Drying of the midsole is carried out by removing the midsole and air drying. The operator then removes the biscuit from the drying oven and loads the biscuit into the marketplace.

  At this point in this embodiment, midsole marketplace 104 and outsole marketplace 118 are configured with the series of different types of outsoles and one or more midsoles described above. When a customer orders one or more shoes, the outsole and one or more midsoles associated with the customer's order are retrieved from the outsole marketplace 118 and the midsole marketplace 104, respectively. Where one or more of the customer orders or midsoles or outsoles are not available at midsole marketplace 104 or outsole marketplace 118, respectively, the required parts can be made on an order basis.

  After removing the outsole and one or more midsoles from outsole marketplace 118 or midsole marketplace 104, respectively, they are primed with a UV activation primer at area 120. The primer (primer) is placed on one or more midsoles within 24 hours after activation. In an alternative embodiment, primers can be placed on each outsole and midsole prior to placement in outsole marketplace 118 or midsole marketplace 104, respectively.

  After priming the outsole and one or more midsoles, each component is housed in an infrared (IR) oven 122. After placing in the oven, the temperature is raised to approximately 55 ° C. Activate the primers at a sufficiently high temperature. The parts are then removed from the infra-red oven and an adhesive is applied at the prime and bond area 120. The parts are then loaded into an infrared oven 122 and heated to about 55 ° C. to activate the adhesive. Thereafter, each part is removed from the infrared oven 122. In an alternative embodiment, each part is coated with prime and bond 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 midsoles are pressed together. For example, the outsole and one or more midsoles are manually laminated 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 midsoles together.

  After pressing the outsole with its associated midsole, the outsole-midsole is placed in the refrigerator 128. The cooling device 128 can lower the temperature of the outsole-midsole to about 0 ° C., thereby curing the adhesive. In the alternative, the outsole-midsole can be allowed to cool and cure for a sufficient time necessary to reduce the temperature to which the adhesive bonds. Next, the outsole-midsole is transferred to the relay area at 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, mesh, etc.) onto eco-solvent printer 132. The composite is white, which allows the customer to request that the composite be printed with one or more desired aesthetics of the customer order. Alternatively, the synthetic material can be dyed to customize one or more shoe customer orders. In another method, the worker loads natural material (eg cotton or natural leather) onto eco-solvent printer 132. In another method, the desired color of the synthetic material is loaded into the eco-solvent printer 132. By loading the desired color of the synthetic material, the step of dyeing the synthetic material can be reduced or omitted.

  The worker then loads the eco-solvent printer 132 and the sublimation dye printer 136 with a composite material that imprints and / or stains and / or marks customer-customized parameters on the eco-solvent printer 132. The eco-solvent printer 132 then prints to the sublimation dye printer 136. Next, the eco-solvent printer 132 prints. The eco-solvent printer 132 then cuts out the customized synthetic from the original piece of synthetic material. In another method, the customized composite can be cut by use of a ladle or knife blade or use of a press.

  After cutting the customized composite, the operator loads the customized composite into laser 140. The operator then enters the customer specified specifications and, if applicable, starts the laser etching operation.

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

  At this point in the process, the upper part and the outsole-midsole are recovered by the worker. The operator also recovers the residual shoe component kit from the marketplace 150. In one embodiment, the residual shoe component is comprised of a "kit" and the worker recovers the residual component needed for a men's size 9 running shoe, for example. In another embodiment, one or more workers can retrieve one or more remaining shoe parts from the kit parts marketplace. After collecting the shoe parts, the worker uses the high frequency welder 148 to join the parts.

  After assembling the upper portion, the operator uses the final trimming die 144 to make one or more final cuts to define the shape of the upper portion. In another embodiment, the upper part cuts using the visual judgment and / or expertise to see 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. The subassembly is then transferred to the lasting area 152.

  FIG. 2 illustrates a method 200 for efficiently manufacturing multiple models of custom shoes in a single manufacturing facility, such as the equipment described above. According to the present invention, the first customer places an order for shoes of the first model and one or more customization parameters specific to this customer order. The second customer places an order for shoes of the second model and one or more customization parameters specific to this customer order. By utilizing the system and method according to the present invention, both the first and second customer's shoes can be efficiently manufactured within the same facility at affordable cost and time. By utilizing the system and method according to the invention, the physical footprint of a production facility 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 illustration only. Other configurations and elements (eg, processes, methods, etc.) may also be used in addition to or in place of those illustrated and described, and some elements may be completely omitted.

  At step 205, the customer is presented with a choice of shoe models. The shoe model options presented in 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 may optionally comprise all available shoe model options that can be locally produced, for example, at a shoe manufacturing facility connected or not connected to a network. In addition, the shoe model options are local to the shoe manufacturing facility connected or not connected to the network, as well as the shoe models which can not be locally manufactured on the shoe manufacturing equipment connected or not connected to the network. It can be equipped with a shoe model that can be produced. An indication of whether the particular shoe model can optionally be locally manufactured at a manufacturing facility connected or not connected to the network can optionally also be presented. Step 205, for example, presenting information describing available shoe model options to the customer on a computer using a graphical user interface, with a local manufacturing availability indication of each particular model. Can be included.

  At step 210, a customer's shoe model selection is received. For example, step 210 comprises receiving a user selection of the presented shoe model from within the graphical user interface. The customer, for example, selects the check box on the basketball shoe model to indicate that he / she desires to order a basketball shoe.

  At step 215, the functional options of the selected shoe model may be presented to the customer. Similar to step 205, step 215 can be performed, for example, in a graphical user interface operating on a computer. The functional options shall include parameters such as shoe size. Other types of options selected in step 215 include outsole hardness options, support options, motion control options, outsole fabric options, outsole material options, and the like. It is to be understood that step 215 does not necessarily have to be presented after step 205 and step 210, and in many cases the functional options available depend on the chosen shoe model. For example, the functional options associated with the motion control of the foot relate to the running shoes, and thus can be made available for customer selection after the customer has selected a running shoe model, while the motion control options are basketball shoes Regardless, it does not need to be available for basketball shoe models. Additionally, as in step 205, on-site manufacturing information specific to each feature option can be displayed. For example, certain functional options may be used for locally manufactured shoes at a manufacturing facility connected or not connected to a network, while other functional options may only be used at non-local manufacturing facilities. Those skilled in the art will readily recognize that there are also any number of other types of functional options that are relatively specific to one or more specific model types of shoes.

  At step 220, the customer's feature choice selection is received. Similar to step 210, step 220 is performed, for example, within a graphic user interface executing on a computer. For example, step 220 includes receiving, within the graphical user interface, a user selection of a particular functional option, such as midsole hardness. For example, the customer may select the check box for the indication of midsole hardness to indicate that they want the midsole of a shoe with a particular hardness for the midsole.

  At step 225, the customer is presented with the aesthetic and / or functional options of the selected shoe model. Step 225, like steps 205 and 215, may be performed using a graphic user interface on a computer. The aesthetic options presented in step 225 depend, at least in part, on the customer selected model options and / or the customer selected functional options. However, the aesthetic options may exist completely or partially independently of the model and / or functional options, in which case step 225 may be performed before or simultaneously with steps 205 and / or 215. . For example, the choice regarding shoe color shall not depend on the shoe model or functional choice. On the contrary, the choice regarding the color of a specific functional element shall depend, for example, on whether the functional element is selected as a part of shoe model selection or a functional option. Also, as in step 205, local manufacturing information specific to each aesthetic option can be displayed. For example, one aesthetic option may be available for locally manufactured shoes at a networked or non-networked manufacturing facility, while another aesthetic option may only be used for non-local manufacturing facilities.

  At step 230, the aesthetic option selection shall be received from the customer. Step 230 may be performed, for example, by clicking on a check box appropriate to each selected aesthetic option, for example, by receiving a customer selection using a pointing device in a graphic user interface on a computer.

  At 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 may 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 a manufacturing location And the option which does not show a preference. It should be understood that the options presented in this step are influenced by customer selection of the shoe model in step 210, customer selection of functional shoe options in step 220, and / or customer selection of aesthetic options in step 230. For example, if the customer selects a shoe model of step 210 that can not be locally manufactured at a manufacturing facility connected or not connected to the network, step 215 does not present such manufacturing options to the user. Also, by way of example, if the customer selects a functional option in step 220 and / or an aesthetic option in step 230 where the shoe can not be incorporated at a particular manufacturing location, such manufacturing location is a list of manufacturing options in step 235 Shall not be included in Step 235 is, for example, presenting the user with a list of options, which shall include all locations where it is possible to produce a particular model of shoe with a particular selection function and aesthetic choice. including.

  At step 240, the customer's location production 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 the presented manufacturing facility from within the graphical user interface. For example, the customer may select the check box for the local manufacturing facility to indicate that he / she wishes to locally manufacture the shoes at the manufacturing facility connected or not connected to the network.

  At step 245, the customer is presented with the receipt options for the selected shoe model. For example, step 245 is the step of presenting the option list to the user, the option of receiving the shoes at the store where the order has been received, the option of receiving shoes from a manufacturing facility connected or not connected to the network, different places The option to have the store deliver the shoes and the option to have the customer deliver the shoes to the residence of the customer. Those skilled in the art will appreciate that the options presented in this step can be adjusted to reflect the customer's choice of manufacturing location during step 240. For example, if the user selects on-site manufacturing for ordering in step 240, step 245 shall present the user the option to receive shoes from a store or network connected or near manufacturing facility . On the other hand, if, for example, the customer selects shoes that can not be locally manufactured at step 240, then the options presented at step 245 do not include the option of receiving shoes at the nearest manufacturing facility.

  At step 250, the customer's 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 from a graphical user interface and receiving a user selection of an option. For example, the customer may select from a drop down list to indicate that his shoes are desired to be received at the store where the order was placed. Alternatively, step 250 comprises receiving an indication that the user desires to deliver his order to his residence. In another embodiment, step 250 may comprise receiving an indication that the user desires to deliver his order to another store location for receipt.

  At step 255, the workflow starts in the facility specified by the user at step 240 and assembles the outsole according to the customer selected shoe model options. The workflow shall also incorporate the customer selected functional options and / or aesthetic options. For example, at step 210, if the customer selects a basketball shoe model, a workflow for basketball shoes is initiated at 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 with the basketball shoe workflow It should be understood that it allows to be considered (as opposed to the skate shoes workflow). Alternatively, if the customer selects a running shoe model at step 210, for example, the running shoe workflow may 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 component manufacturing areas. For example, the workflow for an outsole for skate shoes can be sufficiently similar to the workflow for an outsole for basketball shoes, and only one outsole workflow for the production of outsoles for both basketball and skate shoes To make However, this does not necessarily mean that each part of these shoes can share the workflow as well, that is, the workflow for the basketball outsole covers the workflow for the skate shoes, both shoe models While it is possible to use a common outsole workflow, for example, the workflow for each shoe needs to be significantly branched to each midsole production to maintain separate midsole workflows . Different shoe model workflows can be performed in different parts manufacturing areas by varying the degree of overlap in this way. The duplication, bifurcation and convergence of these workflows allow efficient production of multiple models of shoes in one manufacturing facility while at the same time reducing the physical footprint of the manufacturing facility.

  Finally, it should be understood that step 255 need not necessarily begin with a particular selection by a particular customer. For example, inventory of outsoles having various features can be maintained at a predetermined level. The three different colored outsoles can, for example, be formed in usable sizes for each of three different models of equipment usable shoes. The outsole is then used from stock based on the customer order. Whenever an outsole of a given model, size, and color begins to run out of stock, the operator can start the workflow of that model and assemble additional outsoles that meet those parameters. In this manner, step 255 may be performed in a manner depending on the customer selected shoe models, functional options, and / or aesthetic options, while not necessarily having to be initiated directly by those customers. Furthermore, step 255 differs by, for example, starting a workflow for outsoles that are normally used using an inventory system, and starting a workflow that produces outsoles that are less commonly used only according to the orders that require them. Perform in different ways for different types of outsoles.

  At step 260, a workflow for midsole production is initiated according to the shoe model, ie, features and / or aesthetic options should also be incorporated according to customer selected options. First, note 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 varied to some extent to allow the user selected features and / or aesthetic customization to be incorporated into the shoe model. Third, and similar to step 255, step 260 does not have to start in response to a given shoe order by a particular customer, but instead optionally utilizes an inventory system to have a midsole with the desired features You can start the workflow for production. Finally, as in step 255, for example, start a workflow for midsoles that you normally use with an inventory system, and start a workflow that only produces midsoles that you do not normally use in response to orders that require them The steps of starting the midsole production workflow are performed differently for different types of midsoles.

  At step 265, a workflow is initiated to prepare the outsole and midsole to be bonded together according to the selected shoe model, which also incorporates the functional and aesthetic options desired by the customer. Step 265, for example, removing one or more outsoles suitable for the customer order from the outsole marketplace, removing one or more midsoles suitable for the customer order from the midsole marketplace, the removed midsole And shaving the edge of the outsole, placing the removed midsole and outsole in an infrared oven, priming the removed midsole and outsole, and removing the midsole and outsole into the infrared oven Including the step of reinserting. Note that, similar to steps 255 and 260, each shoe model does not necessarily have to have its own unique workflow at step 265, but can share workflows with other shoe models. Also, similar to steps 255 and 260, the workflow for a particular shoe model may be varied to some extent to allow user selected features and / or aesthetic customization to be incorporated into the shoe model.

  Preferably, 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 Make it possible. For example, the workflow from steps 255 and 260 may produce parts that arrive simultaneously and allow them to prepare in step 265 without delaying 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, then step 255 is the step of starting the basketball shoe workflow, which is (1) injection molding the rubber outsole, approximately at mechanical work time 220 seconds and approximately 15 seconds of human working time
(2) removing the flash portion (protruding portion) and relaying the outsole into the final outsole marketplace, taking approximately 5 seconds of human working time;
(3) removing the outsole from the final marketplace, wherein approximately 5 seconds of human working time is applied;
(4) alkaline cleaning the outsole, wherein approximately 50 seconds of mechanical working time is applied;
(5) A step of acid-washing the outsole, wherein approximately 50 seconds of mechanical working time is applied;
(6) drying the outsole, wherein approximately 90 seconds of mechanical working time is applied;
(7) removing the outsole from the drying oven, applying approximately 2 seconds of human working time, and (8) relaying the outsole into the outsole marketplace, human working time Step for approximately 3 seconds,
Shall be included. That is, the basketball shoe outsole production workflow in this embodiment takes approximately 350 seconds. Although this situation is such in this embodiment, preferably the workflow utilized in step 260 similarly takes approximately 350 seconds so that the parts arrive simultaneously and step 265 proceeds without excessive delay. can do.

Furthermore, it should be noted that any workflow can overlap with another workflow not only spatially but also temporally. For example, the basketball midsole production workflow at step 260
(1) A step of injection molding a biscuit, wherein approximately 30 seconds are applied to machine working time,
(2) placing biscuits in the biscuit market place, and applying approximately 10 seconds of human working time;
(3) A step of heating and pressing the biscuit, wherein approximately 420 seconds of mechanical working time and approximately 20 seconds of human working time are applied;
(4) loading the biscuits into the stabilization oven, and applying approximately 5 seconds of human working time;
(5) A step of heating the biscuit to produce a midsole, and applying approximately 3600 seconds in mechanical working time.
(6) removing the biscuits from the stabilizing oven and applying approximately 5 seconds of human working time;
(7) Washing the midsole with water for about 600 seconds at mechanical working time;
(8) drying the midsole and relaying it to the midsole relay market place, applying approximately 300 seconds for mechanical working time and approximately 5 seconds for human working time;
(9) removing the midsole from the midsole relay market place, applying approximately 2 seconds to the human working time, and (10) relaying the midsole for assembly, the human working Take approximately 3 seconds to step
Shall be included.

  Using the workflow of this example with no temporal overlap, one midsole can be produced approximately every 5000 seconds. However, although, for example, step (5) takes approximately 3600 seconds in this embodiment, the stabilization may be carried out by a loading stabilization oven, comprising a unit capable of subjecting multiple midsoles to the stabilization process at once it can. Thus, for example, the workflow of the first basketball midsole may be initiated and steps (1), (2), (3) and (4) may 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, this 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 particular workflow, and also, for example, this particular workflow That is, the second biscuit can be advanced to a step in a specific workflow to load into the stabilization oven. At this point in this embodiment, two separate workflows are advanced, one each to a stabilization step, and one to simultaneously perform a stabilization step. Thus, whether or not different models of shoes, two or more different biscuits can always be introduced into the stabilization oven at different stages of stabilization. Any number of workflows can be initiated by changing the stages of progression and can be duplicated in this manner. At the completion of the first workflow stabilization step (5), the first midsole can be removed from the stabilization oven and the first basketball midsole workflow initiated can be resumed at step (6).

  In another embodiment of the temporally overlapping workflow, referring again to the above-described embodiment of the basketball midsole workflow, after loading the first biscuit into the stabilizing oven at step (5), the second workflow is performed. You can start producing basketball shoes outsoles. This second workflow can be completed and a third basketball outsole workflow can be started and completed. One skilled in the art will appreciate that the first midsole workflow from the above embodiments can be started with any number of workflows, while maintaining 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 is apparent to the person skilled in the art. In this embodiment, each workflow is adjusted to overlap so that a new midsole emerges in about the same amount of time it takes to produce other shoe parts in this or other shoe part manufacturing area Let's do it. This advantageously allows, for example, the various parts to arrive simultaneously and go through a combined workflow. In this embodiment, for example, through the use of temporally overlapping workflows, one midsole is produced approximately every 350 seconds and the time taken to perform the outsole workflow from the embodiment used in step 255 Match with. These two workflows can take the same amount of time to produce the two parts to be combined using the combined workflow without excessive delay. It should be noted that the use of temporally overlapping workflows can be applied to any of the steps using wow flow, such as steps 255 and 260, as will be apparent to those skilled in the art.

  At step 270, one or more customization workflows of the upper portion for a particular shoe model may be initiated according to the shoe model, and the shoe model may incorporate customer selected functional and / or aesthetic options. it can. Note again that as with steps 255, 260 and 265, each shoe model does not necessarily have its own specific workflow, and that the workflow can be shared with another shoe model. Also, similar to steps 255, 260 and 265, the workflow for a particular shoe model may be varied to some extent to allow the user to select features 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 the step 270 can be performed in response to a specific customer order, depending on the customization applied to the upper shoe portion. It is likely to come to 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 portions 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 along with various aesthetic options such as specific colors, embroidery patterns, emblems and the like.

In another embodiment, step 270 is the step of initiating a basketball shoe upper part customization workflow, which step comprises:
(1) printing the eco-solvent customization, wherein approximately 120 seconds of mechanical working time and approximately 30 seconds of human working time are applied;
(2) A step of cutting the lining of the point leather and the quarter of the point leather, and taking about 30 seconds in human working time,
(3) A laser customization step of applying approximately 120 seconds in mechanical working time and approximately 30 seconds in human working time;
(4) An embroidery customization step of applying approximately 120 seconds in mechanical working time and approximately 30 seconds in human working time;
(5) transporting and heat-pressing the part, applying approximately 5 seconds in human working time, and (6) inspecting the market place and cutting the part if necessary. Step taking approximately 6 seconds in human working time,
And That is, the basketball workflow in this embodiment takes approximately 491 seconds. This process, similar to steps 255, 260 and 265, changes the degree of temporal overlap of the workflow so that the upper part produces other parts in this or other compartments which are utilized for different workflows Note, to be able to produce in as little time as it is for. For example, using a workflow that overlaps in time, any model type, customized upper part can be produced approximately every 350 seconds.

In another embodiment, and to further illustrate how the workflows spatially overlap, step 270 comprises initiating a running shoe upper portion customization workflow in response to receiving a customer's model selection input I assume. This workflow, for example,
(1) printing the eco-solvent customization, wherein approximately 120 seconds of mechanical working time and approximately 30 seconds of human working time are applied;
(2) A step of cutting the lining of the point leather and the quarter of the point leather, and taking about 30 seconds in human working time,
(3) printing sublimation dye customization, wherein approximately 120 seconds of mechanical working time and approximately 20 seconds of human working time are applied;
(4) pressing the sublimation dye customization, applying approximately 12 seconds in mechanical working time and approximately 10 seconds in human working time (5) laser customizing step, approximately mechanical working time 120 seconds and approximately 30 seconds of human working time
(6) An embroidery customization step of applying approximately 120 seconds in mechanical working time and approximately 30 seconds in human working time;
(7) transferring the parts to the high frequency welder market place and applying heat to press, applying about 5 seconds in human working time, and (8) inspecting the high frequency welder market place, and if necessary, parts And approximately 6 seconds in human working time. That is, in this embodiment, the customized running shoe upper portion can be assembled in approximately 613 seconds. This process changes the degree of temporal overlap of the workflow as well as the steps before utilizing it in the workflow, so that the running shoe upper part can use other parts in this or other compartments to utilize for different workflows. It should be noted that production can be made in as little time as production time. For example, using a temporally overlapping workflow, any model type upper portion of the customized running shoe can be produced approximately every 350 seconds. In these embodiments, it is understood by those skilled in the art how this workflow for customizing the upper part of the running shoe overlaps with similar machines, techniques, and work areas involved in the basketball shoes customization workflow illustrated above by way of example. It will be clear to you.

  At step 275, one or more workflows to further manufacture 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. It shall be incorporated. Again, as with steps 255, 260, 265, and 270, it is again noted that each shoe model does not necessarily have its own unique workflow, and that the workflow can be shared with another shoe model. Also, similar to steps 255, 260, 265, and 270, the workflow for a particular shoe model may be varied to some extent to allow the user selected features 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 particular order by the customer, but in fact, depending on the customization applied to the shoe upper portion, the particular customer order, or More specifically, depending on the upper portion produced at step 270, it is likely to be performed. For example, step 275 may initiate a workflow to sew the upper portion for running shoes according to user selection, which upper portion may be produced and customized according to 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 in human work time Second step,
(2) assembling the upper portion, wherein approximately 20 seconds of mechanical working time and approximately 30 seconds of human working time are applied;
(3) activating the heating press, wherein approximately 10 seconds of mechanical working time and approximately 2 seconds of human working time are applied;
(4) loading the part into the cooling rack, applying approximately 60 seconds in mechanical working time and approximately 1 second in human working time (5) cutting the final trimming, which is human Step for approximately 15 seconds in working time,
(6) A heel forming step, wherein approximately 180 seconds of mechanical working time and approximately 20 seconds of human working time are applied;
(7) A post-sewing step that takes approximately 30 seconds in human working time,
(8) Strobber sewing step: approximately 40 seconds in human working time, and (9) transferring the upper portion to the lasting step, approximately 5 seconds in human working time Step,
And shall be provided. That is, the basketball upper part formation and sewing workflow in this embodiment takes approximately 428 seconds. The process in the above embodiment, similar to steps 255, 260, 265 and 270, changes the degree of temporal overlap of workflows so that the upper part can be used in this or other areas to utilize for different workflows. It should be noted that production can be made in as little time as it is to produce other parts. For example, in step (6), the machine waits until the heels are sewn, but the operator can start 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 may complete step (6) and then the worker may perform step (6) on the second upper part The steps (7), (8) and (9) can be continued in the first upper part, while the machine continues the step (6) in the second upper part. As those skilled in the art will appreciate, any of these steps or other steps of a given workflow can be advantageously overlapped.

As another example, and to further illustrate how the workflows spatially overlap, step 275 may include initiating a running shoe upper portion high frequency welding and sewing workflow. This workflow, for example,
(1) collecting the parts from the high frequency welding market place, and applying approximately 15 seconds in human working time;
(2) assembling the upper portion, wherein approximately 20 seconds of mechanical working time and approximately 30 seconds of human working time are applied;
(3) activating the high frequency welding cycle, wherein approximately 10 seconds of mechanical working time and approximately 10 seconds of human working time are applied;
(4) cutting the final trimming, wherein approximately 15 seconds of human working time is applied;
(5) sewing the upper portion to the sole, applying approximately 60 seconds in human working time, and (6) transferring to the final quality control area, approximately 5 human working time. Second step,
And shall be provided. The workflow for this embodiment takes approximately 145 seconds. This process is similar to the previous steps used in the workflow, but by changing the degree of temporal overlap of the workflow, the upper part is to produce other parts in this or other areas to be used for different workflows It should be noted that, in a shorter time, as much as the time of, to be able to produce. For example, a customized running shoe upper portion of any model type can be produced approximately every 350 seconds using a workflow that overlaps in time. In these embodiments, how does this high frequency welding and sewing workflow of the upper portion of the running shoe overlap with similar machines, techniques, and work areas involved in the basketball shoe forming and sewing workflow illustrated above by way of example Will be apparent to those skilled in the art.

  At step 280, the 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 desired functional options and aesthetic options Can also be incorporated. Step 280 includes, for example, fitting an appropriate outsole, an appropriate 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 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 workflow for the particular shoe model may be varied to some extent to allow the user selected features and / or aesthetic customization to be incorporated into the shoe model.

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

  At step 285, a workflow may be initiated to quality control customized laced shoe parts, lace laces, and shave molds, and may also incorporate customer desired functional and aesthetic options. Similar to steps 255, 260, 265, 270, 275, and 280, note that each shoe model does not necessarily have its own workflow in step 280, and can share the workflow 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 varied to some extent to allow the user selected features and / or aesthetic customization to be incorporated into the shoe model .

In one embodiment, step 285 is (1) a step of quality control inspection and form-fitting of the coupled shoe component, wherein approximately 90 seconds of mechanical working time and approximately 90 seconds of human working time are applied.
(2) A step of quality control inspection and reshaping of the coupled shoe parts, which takes approximately 30 seconds of human working time,
(3) a step of putting a lace over the coupled shoe part, which is approximately 60 seconds in human working time, and (4) a step of basically packaging the shoe, which is not time-consuming.
And shall be provided. That is, the workflow in this embodiment takes approximately 270 seconds. As known to those skilled in the art, as with the other steps using workflows in this embodiment, multiple workflows can be overlapped in time to vary the time taken to complete step 285.

  At step 290, the customized shoes are delivered to the customer according to the customer selected delivery options from step 245. Step 290 further includes customer inspection and approval, payment, and so on. Step 290 may be performed at a geographically remote location from where it performs all or part of the other steps in method 200, but the desired characteristics of method 200 are local to the shoe for the customer order. It should be understood that it is possible to manufacture. Such localized manufacturing can reflect localized needs and preferences over remote location manufacturing, and can reduce inventory and shipping costs. Thus, step 290 is assumed to be performed geographically in the same large facility, as the remaining steps of method 200.

  Referring now to FIG. 3, an exemplary method of forming an outsole for a running shoe is generally indicated at 300. In step 305, the 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 engraved and / or cut out of a rubber mass. At step 310, the outsole is cured. In another method, the outsole is cured with stearic acid and an oil. This combination results in rubber blooming and results in undesirable rubber residue on the outsole.

  At step 315, the flash portion is removed from the outsole. One method of removing the outsole flush involves cutting and / or removing and / or trimming away unwanted excess rubber. Another method of flash removal is to wipe off the rubber outsole or to pick it off by hand. At step 320, the outsole relays to the outsole prewash marketplace. In the alternative, the number and characteristics (e.g., size, shape, color, etc.) of outsoles placed in the marketplace can be based on demand forecasts. At step 325, an order is received. An exemplary method for receiving an order includes manually receiving the order. In yet another method, orders can be received by uploading order details through a web interface. In the alternative, steps 305-320 do not execute until the order is received. In this alternative, the outsole is produced on an as-needed basis, rather than in response to the anticipated market place demand. At step 330, the outsole is removed from the outsole prewash marketplace.

  At step 335, the outsole is cleaned. In one method, the outsole is washed with an alkaline solution. In another method, the outsole proceeds directly from the step 315 of removing the flush from the outsole to the step 335 of cleaning the outsole. At step 340, the outsole is cleaned. In one method, the outsole is washed with an acid solution. Cleaning steps 335 and / or 340 provide a means to remove excess rubber residue produced in the curing process of step 310. In another method, the curing process is performed without stearic acid, thereby reducing or reducing the resulting rubber residue. In this manner, the cleaning steps 335 and / or 340 can reduce or eliminate time and / or material. At step 345, the outsole is dried in an oven. In another embodiment, the outsole is to be dried using a method that can generate heat to dry the outsole to a desired degree of dryness within a desired period of time. At step 350, the outsole is removed from the oven. In another method, the outsole is removed from the separate heating device used to remove water from the outsole mold. In step 355, the outsole relays to the outsole relay marketplace. In another method, if there is little or no rubber excess generated from the curing process 315, the outsole will proceed directly from the curing process 315 to the outsole relay marketplace 355. In the alternative, if the rubber debris is minimal, the outsole will proceed directly from the curing process 315 to a cleaning step 335 which wipes the outsole with a cloth-like material 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 to the outsole marketplace 320 before removing it from the outsole marketplace 330 from the curing process 315 . When receiving an order prior to outsole production (e.g., when outsoles are produced as needed), the outsole can skip the time spent consuming outsole marketplaces 320-330.

  Referring to FIG. 4, an exemplary method of forming a midsole for a running shoe is indicated generally by the reference numeral 400. At step 402, a predetermined volume of EVA pellets is loaded into an injection mold. In the alternative, the choice of polymer species to inject 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 identical conditions, ie increasing the hardness compared to EVA pellets with shorter polymer chains by introducing EVA pellets with longer polymer chains It can be because longer polymer chains can not be degraded to the same extent as shorter polymer chains under identical 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 EVA pellets during biscuit formation, but not enough to activate the expansion agent in the phylon. In yet another embodiment, the reaction conditions of the mold may be varied to affect the extent to which a given polymer degrades, thereby providing a variety of different hardnesses. At step 406, the biscuit is then removed from the injection mold. At step 410, the biscuits are then relayed into the biscuit marketplace. At step 415, an order is received. An exemplary method for receiving an order includes manually receiving the order. In yet another method, orders can be received by uploading order details through a web interface.

  At step 420, the biscuits are removed from the biscuit marketplace. At step 430, it is then loaded into the biscuit heating press. In another method, for example, when receiving an order 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 heated press 430. In another method, a right heating press and a left heating press are provided for the right foot shoe biscuit and the left foot shoe biscuit respectively. In yet another method, the right and left heating presses can be operated simultaneously. In step 434, the biscuit is heated to 172 ° C. In another embodiment, the biscuit is heated to a temperature sufficiently high to activate the expansion agent. At step 438, the biscuits are removed from the heated press. In step 440, the biscuits are loaded into the stabilization oven. In the stabilization oven, the biscuits cool to a low temperature where they can be sized as the midsole. In step 444, the biscuit is placed in a pneumatic stabilization oven and the temperature is reduced to 75 ° C. The process of passing air through the biscuits in the stabilization oven is carried out using one or more air knife centrifugal blowers. In steps 448-452, the biscuit is allowed to cool in 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 three or more stages. In another alternative, the step of reducing 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 with temperatures ranging from 90 ° C to 45 ° C. The biscuit temperature is reduced from 90 ° C. to 75 ° C. and then to 75 ° C. to 45 ° C., and the time in each bath is evenly distributed.

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

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

  Referring now to FIG. 6, an exemplary method of combining the outsole and midsole into a midsole-outsole on a running shoe is indicated generally by the reference numeral 600. At step 610, the outsole and midsole are removed from the IR oven. At step 620, the outsole and midsole are laminated to form a midsole-outsole. At step 630, the midsole-outsole is loaded into a stockfit press. At step 634, the midsole-outsole is heated. The heat allows the adhesive to more permanently bond the midsole-outsole component. At step 638, the midsole-outsole is removed from the stock fit press. At step 640, the midsole-outsole is loaded into the cooling system. The cooling system allows the midsole-outsole to cool to approximately 0 ° C. to solidify the adhesive. In the alternative, the midsole-outsole is placed in one or more temperature areas, in which the midsole-outsole is left to cool for a longer period of time. In another method, in step 644, the temperature of the midsole-outsole is reduced. In another method, the press is stopped and the midsole-outsole is left in the press to cool until the heat dissipates. In yet another method, the press is connected to both the heating component and the cooling component so that the shoe product can be heated and cooled in one place, such as a midsole-outsole. In doing so, by having dual heating and cooling presses, space savings can be saved, and parts of the shoe products can be displaced during the time they move between the heating press and the cooling device. Alternatively, the risk of peeling can be eliminated. At step 648, the midsole-outsole is removed from the cooling system. At 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 of the running shoe is indicated generally by the reference numeral 700. At step 702, an order is received. An exemplary method for receiving an order includes manually receiving the order. In yet another method, the order is received by uploading the details of the order through the web interface. In step 704, materials associated with the order of the upper portion (eg, synthetic leather or mesh or polyester, etc.) are loaded into the eco-solvent printer. At step 706, the eco-solvent printer and sublimation dye printer are loaded with materials associated with the order, such as the desired color. At step 708, a sublimation dye printer is used to print the desired design and / or pattern on the desired material for use in the upper portion. At step 710, an eco-solvent printer is used to print the desired design and / or pattern on the desired material for the upper portion. At step 715, the customized synthetic is cut from the desired synthetic according to the specifications that characterize the order. At step 720, the customized composite is loaded into the laser device. At step 724, the laser is loaded with the design specifications associated with the order. At step 728, the laser etches the customized design onto the customized composite.

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

  Some of the decorative techniques disclosed above are not applicable to each shoe model, so some of the steps disclosed above can be omitted. For example, all shoe models do not require embroidery or laser etching. Furthermore, different parts of the upper part can be advanced in different orders, at different times and through different steps.

  Referring to FIG. 8, an exemplary method for assembling the upper portion for running shoes is indicated generally by the reference numeral 800. At step 805, the customized part for the upper part is removed from the RF welding relay area. At step 810, the complete set is retrieved from the marketplace comprising the necessary parts associated with the customer order. At step 820, the upper portion is assembled from the customized part. At step 825, the RF welding cycle is operated to combine the assembled upper portion formed of the customized part. At step 830, the final trimming is cut to the upper portion to determine the final shape of the upper portion. At step 840, the midsole-outsole is removed from the swing arm relay area. At step 850, the upper portion is sewn to the midsole-outsole.

  Referring to FIG. 9, an exemplary method for form matching and quality control for a running shoe is indicated by the reference numeral 900 as a plug. At step 910, the shoe component is removed from the swing arm area. At step 920, a quality control check is performed to form-form the upper portion. In step 930, a quality control check is performed on the upper portion of the lasting, and then the upper portion is re-shaped. At step 940, a quality control check is performed and the upper portion is laced. At step 950, a quality control inspection is performed and the shoes are packaged.

  Referring now to FIG. 10, an exemplary method for forming an outsole for a basketball shoe is generally indicated at 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 sculpted and / or cut out of a rubber mass. At step 1010, the outsole is cured. In one alternative, the outsole is cured using stearic acid and an oil. This combination results in rubber blooming and results in undesirable rubber residue on the outsole.

  At step 1015, the flash portion (protruding portion) is removed from the outsole. One method of removing the outsole flush involves cutting and / or removing and / or trimming away unwanted excess rubber. Another method of flash removal is to wipe off the rubber outsole or to pick it off by hand. At step 1020, the outsole relays to the outsole prewash marketplace. In the alternative, the number and characteristics (e.g., size, shape, color, etc.) of outsoles placed in the marketplace can be based on demand forecasts. At step 1025, an order is received. An exemplary method for receiving an order includes manually receiving the order. In yet another method, orders can be received by uploading order details through a web interface. In the alternative, steps 1005-1020 will not execute until an order is received. In this alternative, the outsole is produced on an as-needed basis, rather than in response to the anticipated market place demand. At step 1030, the outsole is removed from the outsole prewash marketplace.

  At step 1035, wash the outsole. In one method, the outsole is washed with an alkaline solution. In another method, the outsole proceeds directly from the step 1015 of removing the flush from the outsole to the step 1035 of cleaning the outsole. Clean the outsole at step 1040. In one method, the outsole is washed with an acidic solution. Cleaning steps 1035 and / or 1040 provide a means of removing excess rubber residue formed in the curing process of step 1010. In another method, the curing process is performed without stearic acid, thereby reducing or reducing the resulting rubber residue. In this manner, the washing steps 1035 and / or 1040 can reduce or eliminate time and / or material. At step 1045, the outsole is dried in an oven. In the alternative, the outsole should be dried using a method that can generate the heat that dries the outsole to the desired degree of dryness within the desired period of time. At step 1050, the outsole is removed from the oven. In another method, the outsole is removed from the separate heating device used to remove water from the outsole mold. At step 1055, the outsole relays to the outsole relay marketplace. In another method, if there is little or no rubber excess produced from the curing process 1015, the outsole will proceed directly from the curing process 1015 to relay to the outsole relay marketplace 1055. In the alternative, if the rubber debris is minimal, the outsole will proceed directly from the curing process 1015 to a cleaning step 1035 where the outsole is wiped with a cloth-like material 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 receiving an order prior to outsole production (e.g., producing outsoles as needed), the outsole can skip the time spent consuming outsole marketplaces 1020-1030.

  Referring to FIG. 11, an exemplary method of forming a midsole for a basketball shoe is generally indicated at 1100. At step 1102, a predetermined volume of EVA pellets is loaded into an injection mold. Alternatively, the choice of polymer type to inject in 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 identical conditions, ie increasing the hardness compared to EVA pellets with shorter polymer chains by introducing EVA pellets with longer polymer chains It can be because longer polymer chains can not be degraded to the same extent as shorter polymer chains under identical 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 EVA pellets during biscuit formation, but not enough to activate the expansion agent in the phylon. In yet another embodiment, the reaction conditions of the mold may be varied to affect the extent to which a given polymer degrades, thereby providing a variety of different hardnesses. The biscuit is then removed from the injection mold in step 1106. At step 1110, the biscuits are then relayed to the biscuit marketplace. At step 1115, an order is received. An exemplary method for receiving an order includes manually receiving the order. In yet another method, orders can be received by uploading order details through a web interface.

  At step 1120, the biscuit is removed from the biscuit marketplace. At step 1130, the biscuit is then loaded into a heated press. In another method, for example, when receiving an order prior to biscuit formation, the biscuit should proceed directly from the step of removing from the injection mold 1106 to the step of loading into the heated press 1130. In another method, a right heating press and a left heating press are provided for the right foot shoe biscuit and the left foot shoe biscuit respectively. In yet another method, the right and left heating presses can be operated simultaneously. In step 1134, the biscuit is heated to 172 ° C. In another embodiment, the biscuit is heated to a temperature sufficiently high to activate the expansion agent. At step 1138, the biscuit is removed from the heated press. In step 1140, the biscuit is loaded into a stabilization oven. In a stabilizing oven, the biscuit is cooled to a low temperature where the biscuit is the desired size as a midsole. In step 1144, the biscuit is placed in a pneumatic stabilization oven and the temperature is lowered to 75 ° C. The process of passing air through the biscuits in the stabilization oven is carried out using one or more air knife centrifugal blowers. In steps 1148-1152, the biscuits are allowed to cool in 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 three or more stages. Alternatively, the stage of step 1144 of reducing the biscuit temperature to 75 ° C. can be adjusted to a higher or lower temperature.

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

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

  Referring now to FIG. 13, an exemplary method of combining the outsole and midsole into a midsole-outsole on a basketball shoe is indicated generally by the reference numeral 1300. At step 1310, the outsole and midsole are removed from the IR oven. At step 1320, the outsole and midsole are laminated to form a midsole-outsole. In step 1330, the midsole-outsole is loaded into a stockfit press. At step 1334, the midsole-outsole is heated. The heat allows the adhesive to more permanently bond the midsole-outsole component. At step 1338, the midsole-outsole is removed from the stock fit press. At step 1340, the midsole-outsole is loaded into the cooling system. A chiller can be used to cool the midsole-outsole to approximately 0 ° C. to solidify the adhesive. In the alternative, the midsole-outsole is placed in one or more temperature areas, in which the midsole-outsole is left to cool for a longer period of time. In the alternative, at step 1344 the temperature of the midsole-outsole is reduced. In another method, the press is stopped and the midsole-outsole is left in the press to cool until the heat dissipates. In yet another method, the press is connected to both the heating component and the cooling component so that the shoe product can be heated and cooled in one place, such as a midsole-outsole. In this case, by having dual heating and cooling presses, space can be saved, and the parts of the shoe product may be dislodged or scraped during the period of movement between the heating press and the cooling device. It is possible to eliminate the risk of At step 1348, the midsole-outsole is removed from the cooling system. At step 1350, the midsole-outsole is transferred to the swing arm post relay area.

  Referring to FIG. 14, an exemplary method for customizing an upper portion for a basketball shoe is generally indicated at 1400. At step 1402, an order is received. An exemplary method for receiving an order includes manually receiving the order. In yet another method, the order is received by uploading the details of the order through the web interface. At 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. At step 1406, the eco-solvent printer and sublimation dye printer are loaded with materials associated with the order, such as the desired color. At step 1408, a sublimation dye printer is used to print the desired design and / or pattern on the desired material for the upper portion. In step 1410, the eco-solvent printer is used to print the desired design and / or pattern on the desired material for use in the upper portion. At step 1415, the customized synthetic is cut from the desired material according to the specifications that characterize the order. At step 1420, the customized composite is loaded into the laser device. At step 1424, the laser is loaded with the design specifications associated with the order. At step 1428, the laser etches the customized design onto the customized composite.

  At step 1430, the sublimation dye press is loaded. At step 1435, the customized composite is removed from the laser. At step 1440, the right embroidery machine is loaded with the customized synthetic material. At step 1442, the left embroidery machine is loaded with the customized synthetic material. At 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. At step 1450, the left and right parts are removed from the embroidery machine. At step 1460, the customized part is transferred to the heated press marketplace. In step 1470, the upper portion is inspected for excess material and cut if necessary.

  Some of the decorative techniques disclosed above are not applicable to each shoe model, so some of the steps disclosed above can be omitted. For example, all shoe models do not require embroidery or laser etching. Furthermore, different parts of the upper part can be advanced in different orders, at different times and through different steps.

  Referring to FIG. 15, an exemplary method for forming and sewing an upper portion for a basketball shoe is generally indicated at 1500. At step 1505, the customized part for the upper portion is removed from the heated press marketplace. At step 1510, the set of parts is retrieved from the marketplace comprising the necessary parts associated with the customer order. At step 1520, the upper portion is assembled from the customized part. At step 1530, the assembled upper part is loaded into the heating press. At step 1534, the heat press is operated to heat the assembled upper part. The temperature reached is high enough to activate the adhesive used to bond the parts. At step 1538, the part is removed from the heat press. At step 1540, the component is placed in a cooling rack. At step 1548, the part is removed from the cooling rack. At step 1550, the heel is formed by sewing. In the alternative, the heel is formed by another bonding method. In step 1560, the part is backstitched. In step 1570, the parts are stitched. In step 1580, the part is transferred to a lasting area.

  Referring to FIG. 16, an exemplary method for chassis alignment and quality control for a basketball shoe is indicated generally by the reference numeral 1600. At step 1610, the shoe component is removed from the lasting area. At step 1620, a quality control check is performed to form-form the upper portion. At step 1630, a quality control check is performed on the upper portion of the last, which is then re-shaped. At step 1640, a quality control check is performed and the upper portion is laced. At step 1650, a quality control check is performed and the shoes are packaged.

  Referring now to FIG. 17, an exemplary method for forming an outsole for skate shoes is generally indicated at 1700. In step 1705, an injection molded rubber outsole is formed in 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 sculpted and / or cut out of a rubber mass. At step 1710, the outsole is cured. In one alternative, the outsole is cured with stearic acid and an oil. This combination results in rubber blooming and results in undesirable rubber residue on the outsole.

  At step 1715, the flash is removed from the outsole. One method of removing the outsole flush involves cutting and / or removing and / or trimming away unwanted excess rubber. Another method of flash removal is to wipe off the rubber outsole or to pick it off by hand. At step 1720, the outsole relays to the outsole prewash marketplace. In an alternative method, the number and characteristics (e.g., size, shape, color, etc.) of outsoles placed in the marketplace can be based on demand forecasts. At step 1725, an order is received. An exemplary method for receiving an order includes manually receiving the order. In yet another method, orders can be received by uploading order details through a web interface. In the alternative, steps 1705-1720 do not execute until an order is received. In this alternative, the outsole is produced on an as-needed basis, rather than in response to the anticipated market place demand. At step 1730, the outsole is removed from the outsole prewash marketplace.

  At step 1735, wash the outsole. In one method, the outsole is washed with an alkaline solution. In another method, the outsole may proceed directly from the step 1015 of removing the flush from the outsole to the step 1735 of cleaning the outsole. At step 1740 the outsole is cleaned. In one method, the outsole is washed with an acid solution. The cleaning steps 1735 and / or 1740 provide a means to remove 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 manner, the washing steps 1735 and / or 1740 can reduce or eliminate time and / or material. At step 1745, the outsole is dried in an oven. In another method, the outsole is to be dried by a method that can generate heat that dries the outsole to a desired degree of dryness within a desired period of time. At step 1750, the outsole is removed from the oven. In another method, the outsole is removed from the separate heating device used to remove water from the outsole mold. At step 1755, the outsole is relayed to the outsole relay marketplace. In another method, if there is little or no rubber excess resulting from the curing process 1715, the outsole will proceed directly from the curing process 1715 to the outsole relay marketplace 1755. In the alternative, if the rubber debris is minimal, the outsole should proceed directly from the curing process 1715 to a cleaning step 1735 where the outsole is wiped with a cloth-like material 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 receiving an order prior to outsole production (e.g., producing outsoles as needed), the outsole can skip the time spent consuming outsole marketplaces 1720-1730.

  Referring to FIG. 18, an exemplary method of forming a midsole for skate shoes is generally indicated at 1800. At step 1802, a predetermined volume of EVA pellets is loaded into an injection mold. In the alternative, the choice of polymer type to inject 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 identical conditions, ie increasing the hardness by introducing EVA pellets with longer polymer chains as compared to EVA pellets incorporating shorter polymer chains This is because longer polymer chains can not be degraded to the same extent as shorter polymer chains under identical 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 biscuits, but not enough to activate the expansion agent in the phylon. In yet another embodiment, the reaction conditions of the mold may be varied to affect the extent to which a given polymer degrades, thereby providing a variety of different hardnesses. At step 1806, the biscuit is then removed from the injection mold. At step 1810, the biscuit is then relayed to the biscuit marketplace. At step 1815, an order is received. An exemplary method for receiving an order includes manually receiving the order. In yet another method, orders can be received by uploading order details through a web interface.

  At step 1820, the biscuit is removed from the biscuit marketplace. At step 1830, it is then loaded into the biscuit heating press. In another method, for example, when receiving an order prior to biscuit formation, the biscuit should proceed directly from removing it from the injection mold 1806 to loading it into the heated press 1830. In another method, a right heating press and a left heating press are provided for the right foot shoe biscuit and the left foot shoe biscuit respectively. In yet another method, the right and left heating presses can be operated simultaneously. In step 1834, the biscuit is then heated to 172 ° C. In another embodiment, the biscuit is heated to a temperature sufficiently high to activate the expansion agent. At step 1838, the biscuit is removed from the heat press. At step 1840, the biscuit is loaded into a stabilizing oven. In the stabilization oven, the biscuits cool to a low temperature where they can be sized as the midsole. In step 1844, the biscuit is reduced to a temperature of 75 ° C. In steps 1848-1852, the biscuits are allowed to cool in 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, the cooling stages 1848-1852 are performed in three or more stages. Alternatively, the stage of step 1844 of reducing 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. At step 1860, the midsole is loaded into one or more ultrasonic baths. The midsole is washed at step 1864 in an ultrasonic bath. In the alternative, step 1858 can be omitted and the midsole can be cleaned while it is still present in the dual stabilization oven ultrasonic bath apparatus. At step 1868, the midsole is removed from the ultrasonic bath. At step 1870, the midsole is loaded into one or more drying ovens. Dry the midsole in step 1874. At step 1878, the midsole is removed from the 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 of applying a primer and adhesive to a skate shoe is generally indicated by the reference numeral 1900. At step 1904, a customer order is received. The customer order shall include specifications of features associated with one or more desired basketball shoes, such as size or style or color. At step 1906, outsoles that match the features determined in the customer order are retrieved from the outsole relay marketplace. At step 1908, a midsole conforming to the features determined in the customer order is retrieved from the midsole transit marketplace. At step 1910, the midsole and outsole are primed. At step 1920, primed midsole and primed outsole are placed in an IR oven. At step 1930, the midsole and outsole are removed from the IR oven. At step 1940, an adhesive is applied to the midsole and outsole. In step 1950, place the midsole and outsole in an IR oven.

  Referring now to FIG. 20, an exemplary method of combining the outsole and midsole into a midsole-outsole in a skate shoe is indicated generally by the reference numeral 2000. At step 2010, the outsole and midsole are removed from the IR oven. In step 2020, the outsole and midsole are laminated to form a midsole-outsole. At step 2030, the midsole-outsole is loaded into a stockfit press. At step 2034, the midsole-outsole is heated. The heat allows the adhesive to more permanently bond the midsole-outsole component. At step 2038, the midsole-outsole is removed from the stock fit press. At step 2040, the midsole-outsole is loaded into the cooling device. The cooling system allows the midsole-outsole to cool to approximately 0 ° C. to solidify the adhesive. In another method, the midsole-outsole is to be contained within one or more temperature areas, in which the midsole-outsole is left to cool for a longer period of time. In another method, at step 2044, the temperature of the midsole-outsole is reduced. In another method, the press is stopped and the midsole-outsole is left in the press to cool until the heat dissipates. In yet another method, the press is connected to both the heating component and the cooling component so that the shoe product can be heated and cooled in one place, such as a midsole-outsole. In doing so, by providing dual heating and cooling presses, space savings can be saved, and parts of the shoe products can be displaced during the time they are moved between the heating press and the cooling device. Alternatively, the risk of peeling can be eliminated. At step 2048, the midsole-outsole is removed from the cooling system. At 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 for skate shoes is generally indicated at 2100. At step 2102, an order is received. An exemplary method for receiving an order includes manually receiving the order. In yet another method, the order is received by uploading the details of the order through the web interface. In step 2104, materials associated with the order of the upper portion (eg, synthetic leather or mesh or polyester, etc.) are loaded into the eco-solvent printer. At step 2106, the eco-solvent printer and sublimation dye printer are loaded with materials associated with the order, such as the desired color. At step 2108, a sublimation dye printer is used to print the desired design and / or pattern on the desired material for the upper portion. At step 2110, the eco-solvent printer is used to print the desired design and / or pattern on the desired material for use in the upper portion. At step 2115, a customized synthetic is cut from the desired material according to the specifications that characterize the order. At step 2120, the customized composite is loaded into the laser device. At step 2124, the laser device is loaded with the design specifications associated with the order. At step 2128, the laser etches the customized design onto the customized composite.

  In step 2130, the sublimation dye press is loaded. At step 2135, the customized composite is removed from the laser. At step 2140, the right embroidery machine is loaded with the customized synthetic material. At step 2142, the left embroidery machine is loaded with the customized synthetic material. At step 2144, the embroidery machine is loaded with 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 and right parts are removed from the embroidery machine. At step 2160, the customized part is transferred to the heated press marketplace. In step 2170, the upper portion is inspected for excess material and cut if necessary.

  Some of the decorative techniques disclosed above are not applicable to each shoe model, so some of the steps disclosed above can be omitted. For example, all shoe models do not require embroidery or laser etching. Furthermore, different parts of the upper part can be advanced in different orders, at different times and through different steps.

  Referring to FIG. 22, an exemplary method for forming and sewing an upper portion for skate shoes is generally indicated at 2200. At step 2205, the customized part for the upper part is removed from the heated press market place. At step 2210, the complete set is retrieved from the marketplace comprising the necessary parts associated with the customer order. At step 2220, the upper portion is assembled from the customized part. At step 2230, the assembled upper part is loaded into the heating press. At step 2234, the heating press is operated to heat the assembled upper part. The temperature reached is high enough to activate the adhesive used to bond the parts. At step 2238, the part is removed from the heat press. In step 2240, place the parts in the cooling rack. At step 2248, the part is removed from the cooling rack. At step 2250, a heel is formed by sewing. In the alternative, the heel is formed by another bonding method. In step 2260, the part is sewn back. In step 2270, the parts are stitched. In step 2280, the part is transferred to the lasting area.

  Referring to FIG. 23, an exemplary method for shoe-styling and quality control for skate shoes is generally indicated at 2300. At step 2310, the shoe component is removed from the lasting area. In step 2320, a quality control check is performed to make the upper portion consistent. At step 2330, a quality control check is performed on the upper portion of the last, which has been reshaped. At step 2340, a quality control check is performed and the upper part is laced. At step 2350, a quality control check is performed and the shoes are packaged.

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

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

  First, in the cutting and kitting module 2402, parts necessary for manufacturing the shoe upper part are cut out, and parts to be relayed as a kit that can be used for assembling and customizing the shoes are prepared. Materials used in the cutting and kitting module 2402 are stored in the material warehouse 2413. The raw material used to form the shoe component is supplied by the vendor who does or does not apply the hot melt lamination to the raw material. The lamination process aims at the assembly of shoe parts, and bonds the shoe parts by lamination. Alternatively, if the material for the shoe component does not yet have a hot melt lamination as supplied by the vendor, the hot melt lamination is applied to the raw material. In one embodiment, the raw material removed from the warehouse 2413 comprises a hot melt lamination applied to the material with a hot melt lamination press 2412. However, if the material supplied by the vendor has already been coated with hot melt lamination, then hot melt lamination press 2412 is not required in block diagram 2400.

  After the material is removed from the material store 2413, the part cutter 2414 is used to change the material into shoe parts. The part cutting machine 2414 is an automatic cutting machine that is used to assemble the shoe upper portion into one or more manufacturing parts using a blade, a laser, and / or any other cutting method or tool. Equipped with an automatic cutting machine. When used on an automatic cutting machine, such as used in parts cutter 2414, the dough is held in place using suction, fasteners, and the like. The material used in the manufacture of the shoe upper part is an intermediate, which can be easily customized through printing, dyeing, embroidery, etc. The cut parts are stored in the parts marketplace 2416. After the cut parts are stored in the marketplace, the cut parts are combined as a kit. In one embodiment, the kit is an upper part and comprises the upper part necessary to assemble the upper part of the shoe or the upper part of the shoe. In one embodiment, warehouse 2413 and marketplace 2416 include vertical carousels. Based on the shoe design to be manufactured, a kit of upper part parts can be used to assemble one size shoe or any multiple size shoes. For example, in some shoe designs, one kit can be used to manufacture and assemble shoes having men's sizes 8, 9, or 10.

  The upper part kit is supplied from the 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 lack of certain parts of the marketplace 2416 by cutting and kitting the required types of upper part material.

After selecting a kit from parts marketplace 2416, the kit is customized in 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 stacks the shoe upper parts of the kit and places them in multiple layers on the flat frame assembly. The customization module 2404 then customizes at least a portion of the shoe upper portion by decorating the shoe upper portion.

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

  The upper portion customization also utilizes the lamination heat press 2424 to laminate the design onto the shoe upper portion. Similarly, the sublimation dye pattern printed at 2424 is applied using a sublimation dye heating press 2426. Additionally, a customization trimming operation may be performed at station 2428, which may use the first trimming diecutter to change the material used in the upper portion customization. Additionally, laser customization, such as customization cutting and / or etching, may be performed at laser customization station 2430. Additionally, multiple embroidery stations 2432 may be used to apply embroidery customization to the shoe upper portion. In an embodiment, the shoe parts are embroidered once they have been 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, although it is preferable to use four embroidery stations 2432 as shown in FIG. 24, the number of embroidery stations can be one or more. The 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. The forming and sewing module 2406 receives the customized shoe upper part. The custom shoe upper part is placed on a flat frame and holds this part in place. The frame is loaded into a solid state (SS) RF press 2436 to RF weld the parts of the shoe upper portion. Additionally and / or alternatively, the flat frame is loaded into the heated press 2438. A heat press 2438 is used to form the upper portion from the heat activated component. Whether press 2436 and / or press 2438 is used, the press is used to join the parts of the shoe upper portion. Once the shoe parts are joined with press 2436 and / or press 2438, the joined shoe parts are cut using shuttle cutter 2440. The shuttle cutter 2440 removes excess material from the bonded shoe parts. After the shuttle cutter 2440 removes excess material, the bonded shoe component is removed from the flat frame. Furthermore, the desired sewing can be performed to form the upper part at the sewing station, for example the flat sewing station 2442, the zigzag sewing station 2444, the back sewing station 2448, and the tack sewing station 2454, all The shoe parts shall be used to sew in the form of the shoe upper part. Additionally, the hot melt sprayer 2446 can be used to attach shoe components to other shoe components and / or shoe upper portions to hold the components in place while forming the shoe upper portion. .

  Toe forming component 2450 is used to form the toe of the upper portion. The heel forming component 2452 is used to form the upper portion heel. Using a Strobel sewing component 2456, the Strobel is affixed to the upper portion of the shoe for lasting. The toe adjustment component 2458 is used to adjust the shoe upper portion and / or the shoe parts as part of the lasting. For example, in the toe adjustment component 2458, the shoe upper portion and / or shoe components are exposed to steam to soften the shoe components. In addition, the lasting component 2460 is used after attaching the cross-robel for lasting the upper portion of the shoe prior to applying the midsole and / or the outsole. In this manner, module 2406 forms the customized shoe upper portion as a three-dimensional shoe upper portion. In addition, the module 2406 sticks the strovel on the formed shoe upper part. In addition, the module 2406 provides a form-fit match between the formed shoe upper portion and the strovel.

  The midsole and outsole component 2410 manufactures a shoe midsole and shoe outsole for simultaneous use with a last-shaped upper portion for shoe assembly. Midsoles and outsoles can be formed in various ways and from various materials. The midsole may be formed of phylon material and the outsole may be formed of latex rubber. Executable systems and processes for use with midsole and outsole module 2410 are described elsewhere herein. The midsole and / or outsole may be supplied to the stock fit and assembly module 2408 using a marketplace system or on a per-order basis.

  The stock fit and assembly module 2408 receives a form-fitting and formed shoe from the forming and sewing module 2406. Additionally, module 2408 receives a shoe midsole and a shoe outsole from midsole and outsole module 2410. The module 2408 then assembles the shoe midsole, the shoe outsole, and the shoe upper portion as well as the shoe upper portion as well as the shoe strap.

  In embodiments, the midsole, outsole, and / or last-shaped shoe upper portion may be received by the ventilation table 2462. In venting 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 an IR oven 2462. Adhesives in the shoe midsole and shoe outsole activate in the IR oven 2462. The shoe midsole and shoe outsole are then set at the bladder press station 2466 where the midsole and outsole are pressed together to form a seal. In an embodiment, a block press 2468 is used to press the midsole and outsole together to form a seal.

  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 disposed in the midsole-outsole to determine the degree of adhesive coverage required. Adhesive is then applied to the midsole-outsole and shoe upper portion at venting table 2472. After the adhesive is applied to the shoe upper and midsole-outsole according to the bite line, the shoe upper and midsole-outsole are placed in an IR oven 2474. In the IR oven 2474, activate the adhesive applied to the shoe upper and midsole-outsole. The shoe upper and midsole-outsole are then pressed together with a block press 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 setting the shoes, the shoes are restyled at the resealing station 2478. In addition, the shoes are quality control inspected 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 is customized, shaped and bonded together in two modules, using one cutting and kitting module 2530 and one outsole and midsole module 2540, And manufactured by performing stock fit and assembly. Customization, formation and lamination, and stock fitting and assembly operations are performed in the first section 2510 and / or the second section 2520. The first section 2510 comprises a first customization module 2512, a first formation and lamination module 2514, and a first stock fit and assembly module 2516. The first customization module 2512 receives the complete kit for the shoe upper portion from the cutting and kitting module 2530. After the customization module 2512 performs the necessary customization of 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 formation and lamination 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 shoe and then delivers the finished shoe to the finished product row 2518.

Similarly, the second section 2520 comprises a second customization module 2522, a second formation and lamination module 2524, and a second stock fit and assembly module 2526. The second customization module 2522 receives a kit for shoe upper part manufacture from the cutting and kitting module 2530. The second customization module 2522 then performs the necessary customization on the shoe upper part. The second customization module then further passes over the customized shoe upper portion to the second forming and laminating module 2524 to form the desired shoe upper portion. The second forming and laminating module 2524 then delivers the forming shoe upper portion to the second stock fit and assembling module 2526. The second stock fit and assembly module 2526 receives the formed shoe upper portion from the second formation and lamination module 2524 and further receives the outsole and midsole from the outsole and midsole module 2540. The stock fit and assembly module 2526 delivers the finished shoe to the finished product row 2528. Finished product row 2518 and finished product row 2528 should be combined into one finished product row to further indicate where the customer will receive one or a pair of customized shoes. All modules shown in FIG. 25 can be juxtaposed in one location. However, the first section 2510 and the first complete product row 2518 are separate from the second section 2520 and the second complete 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 complete product row are installed away from the first section 2510 and the first complete 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, formation and lamination, and stock fitting and assembly. , Can maximize the shoe production rate of a series of modules.

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

  System 2600 also includes a second module 2630, which is responsive to receipt of customer input 2642 from customer input receiver 2640 to produce one or more second shoe components. In an embodiment, the customized parts are produced by the second module 2630 and the second shoe parts are produced by modifying the shoe parts supplied from the marketplace 2610 to the second module 2630. The shoe component supplied from the marketplace 2610 to the second module 2630 comprises the first shoe component produced by the first module 2620.

  After producing the one or more first parts and the one or more second parts, the one or more first parts and the one or more second parts are assembled in a third module 2650. One or more first parts 2614 may be transferred from marketplace 2610 to a 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. Further, 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 transfer to the finished product row 2660.

  FIG. 27 shows a flowchart 2700 of a shoe manufacturing workflow throughout the process. This process comprises performing 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 multi-layer shoe upper portion are provided at step 2712. Further, in step 2714, the raw material in the module 2710 is cut out as a part of the multilayer shoe upper portion. Additionally, in module 2710, the parts necessary to form one multi-layer shoe upper portion are included in the kit of step 2716.

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

  In forming module 2730, while the multi-layer shoe upper part is on the frame, in step 2732 the multi-layer upper part combines to form one integral shoe upper part. In step 2734, excess upper portion material is cut from the shoe upper portion. In addition, in step 2736, the bonded shoe upper portion is removed from the frame. The formed shoe upper portion is then formed as a three-dimensional shoe upper portion in step 2738. In forming module 2730, a strovel is sewn to the forming shoe upper portion in 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. In the stock fit and assembly module 2750, attach the shoe midsole to the shoe upper portion at step 2752. In the stock fit and assembly module 2750, attach the shoe outsole to the shoe upper in step 2754.

  Although the present invention has been described in connection with specific embodiments, they are intended in all respects to be illustrative rather than restrictive. Alternate embodiments will be apparent to those skilled in the art, and the present invention relates without departing from its scope. As will be appreciated by one skilled in the art, different models of shoes may utilize, for example, different specific processes, materials, or modules, and still fall within the scope of the present invention.

  From the above description, it should be understood that the present invention is well adapted to achieve all the above objects and goals, as well as other advantages of the system and method. It should be understood that certain features and secondary bonds are useful and can be used without reference to other features and secondary bonds. This may be contemplated by the claims and may even be within the scope thereof.

Claims (20)

In a system for producing and assembling shoe parts, the system comprises a receiving module for receiving customer input;
A marketplace that provides at least one temporary repository of first shoe parts;
The contents of the first shoe part are temporarily stored, and when the first shoe part is reduced to a predetermined threshold amount or less at the at least one temporary storage place of the marketplace, this reduction event is used as the market place. Producing at least one first shoe component based on receiving an indication from the first and second shoe component manufacturing modules;
A second shoe component manufacturing module producing one or more second shoe components based on receipt of the customer input; and the one or more first shoe components and the one or more second shoe components And a third part manufacturing module, which assembles to produce a shoe product,
System with   The system of claim 1, wherein the one or more first shoe components are processed after removing the first shoe component from the temporary repository.   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 component manufacturing module produces a customized upper partial shoe component.   The system of claim 1, wherein the customized shoe component is treated prior to bonding to the first shoe component.   The system of claim 1, wherein the customized shoe component comprises two or more interconnected customized shoe components.   The system of claim 1, wherein the second shoe manufacturing module comprises a number of customization submodules. In a processing facility for modularized production of complex customized shoe parts, the processing facility comprises:
Cutting the shoe upper part from the stock of the upper part raw material, at least one of said upper part raw material being a customizable intermediate, and then a kit of said cutting shoe upper part material to form the entire shoe upper part A cutting and kitting module, which is cut out as a kit including all of the upper partial elements necessary for the operation, and the kit is temporarily stored.
Remove the temporary storage kit from the cutting and kitting module, laminate the shoe upper component of the kit as multiple layers in a flat framed assembly and further decorate the shoe upper component. A customization module for customizing at least one part of the parts;
Receiving the customized shoe upper part, forming the customized shoe upper part as a three-dimensional shoe upper part, attaching a street bell to the formed shoe upper part, and further shaping the shoe upper part and the trowel together , Forming and sewing modules,
A midsole and outsole manufacturing module, and a stock fit and assembly module for manufacturing a shoe midsole and shoe outsole, the shoe upper portion and the trowel being formed and sewn to and formed from the last. Received from the module, the shoe midsole and the shoe outsole from the midsole and the outsole module, and further the shoe midsole, the shoe outsole, and the shoe-shaped fitted and formed shoe upper portion and the strobel Assemble the shoe into a stock fit and assembly module,
Processing equipment comprising:   10. The processing facility according to claim 9, wherein the cutting and kitting module comprises a material storage component for holding the upper part raw material, a parts cutting machine, and a marketplace for holding the kit after assembly. Processing equipment to be characterized.   A processing facility according to claim 9, wherein the customization module comprises 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 part; a cutting press for cutting the bonding shoe upper part from excess upper part material; A toe forming component forming the toe of the portion, a heel forming component forming the heel of the shoe upper portion, and a strow bell sewing component for stitching a strow bell to the shaping shoe upper portion And processing equipment.   10. The processing facility according to claim 9, wherein the forming and sewing module comprises: a heating press for bonding the layers of the shoe upper part; a cutting press for cutting the bonding shoe upper part from excess upper part material; A toe forming component forming the toe, a heel forming component forming the heel of the shoe upper portion, and a strover sewing component for sewing a strobbell to the molding shoe upper portion are characterized. , Processing equipment.   10. The processing facility of claim 9, wherein the stock fit and assembly module applies at least one adhesive to the shoe outsole, the shoe midsole, and the molded and formed shoe upper portion and the strobbell. Processing equipment, characterized in that it is assembled into shoes.   15. The processing facility according to claim 14, wherein the stock fit and assembly module further applies at least one adhesive between the molded and formed shoe upper portion and the strobello and the shoe midsole, and at least one further. A press for applying pressure to the shoe outsole, the shoe midsole, and the molded and formed shoe upper portion and the strovel after applying an adhesive between the shoe midsole and the shoe outsole; The processing equipment characterized by having it. In shoes manufactured through the process, the steps of the process are:
In the cutting and kitting module, supply the multiple raw materials required for the multilayer shoe upper part, cut out the raw materials as the parts of the multilayer shoe upper part, and the parts needed to form the multilayer shoe upper part Incorporating as a kit;
In the customization module, receive the kit, assemble the shoe upper parts in a multilayer on a flat frame, and also decorate the multilayer while the multilayer shoe upper part is on the flat frame Customizing the multi-layer upper part by applying it to at least one layer of a 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 integral shoe upper part and the excess upper part material from the material Removing the coupled shoe upper portion from the frame by cutting out the shoe upper portion, forming the joined shoe upper portion as a three-dimensional shoe upper portion, and sewing a strovel to the formed shoe upper portion;
Forming a shoe midsole and forming a shoe outsole in the outsole and midsole module, and attaching the shoe midsole to the shoe upper portion in the stock fit and assembly module; and the shoe Attaching an outsole to the shoe upper portion to form a finished shoe;
A shoe manufactured through the process, comprising:   The shoe according to claim 16, characterized in that the bonding upper 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 parts comprises the parts necessary to form a shoe upper part for a shoe having a predetermined size.   Shoe according to claim 16, characterized in that the multilayer upper part parts are joined by means of a heating press.   Shoe according to claim 16, characterized in that the multilayer upper parts are joined by means of high frequency welding.

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