Edward G Norton

US Patent:

6558784, May 6, 2003

Filed:

Feb 28, 2000

Appl. No.:

09/514419

Inventors:

Edward J. Norton - Boxford MA
Zenon O. Smotrycz - Reading MA

Assignee:

ADC Composites, LLC - Reading MA

International Classification:

B32B 326

US Classification:

4283044, 4283084, 4285428, 424224, 424373, 36 45, 36 465, 36 49, 36 55, 36 87, 12146 C, 264244, 264257

Abstract:

A method of manufacturing a multi-layer, composite footwear upper having a three-dimensional geometry includes the steps of forming a substantially planar composite sheet from two or more layers, heating the composite sheet, and compression molding the composite sheet into the three-dimensional geometry of the footwear upper. The composite sheet is formed by laminating a first layer of thermoplastic foam to a second layer of thermoplastic urethane (TPU), preferably in the form of a TPU film. A third layer of mesh fabric can be interposed between the first and second layers. The composite sheet is compressed after heating in a mold cavity to achieve the desired three-dimensional geometry. The composite sheet can be compression molded into separate sections which are assembled after molding to form the footwear upper. Alternatively, the composite sheet can be compression molded into a seamless, unitary footwear upper that requires minimal, if any, assembly for completion. The multi-layer composite upper can be applied to a sole to form performance footwear suitable for use in a wide range of conditions.

US Patent:

6670029, Dec 30, 2003

Filed:

Sep 7, 2001

Appl. No.:

09/948984

Inventors:

Edward J. Norton - Boxford MA
Zenon O. Smotrycz - Reading MA

Assignee:

ADC Composites, LLC - Reading MA

International Classification:

B32B 326

US Classification:

4283084, 4283186, 442 30, 36 465, 36 49, 36 87, 264244, 264257, 12145, 12146 C

Abstract:

A method of manufacturing a multi-layer, composite footwear upper having a three-dimensional geometry includes the steps of forming a substantially planar composite sheet from two or more layers, heating the composite sheet, and compression molding the composite sheet into the three-dimensional geometry of the footwear upper. The composite sheet is formed by laminating a first layer of thermoplastic foam to a second layer of thermoplastic urethane (TPU), preferably in the form of a TPU film. A third layer of mesh fabric can be interposed between the first and second layers. The composite sheet is compressed after heating in a mold cavity to achieve the desired three-dimensional geometry. The composite sheet can be compression molded into separate sections which are assembled after molding to form the footwear upper. Alternatively, the composite sheet can be compression molded into a seamless, unitary footwear upper that requires minimal, if any, assembly for completion. The multi-layer composite upper can be applied to a sole to form performance footwear suitable for use in a wide range of conditions.

US Patent:

20020071946, Jun 13, 2002

Filed:

Sep 7, 2001

Appl. No.:

09/948992

Inventors:

Edward Norton - Boxford MA, US
Zenon Smotrycz - Reading MA, US

International Classification:

B32B003/26

US Classification:

428/304400

Abstract:

A method of manufacturing a multi-layer, composite footwear upper having a three-dimensional geometry includes forming a substantially planar composite sheet from two or more layers, heating the composite sheet, and shaping the composite sheet into the three-dimensional geometry of the footwear upper. The composite sheet can be formed by laminating a first layer of thermoplastic foam to a second layer of thermoplastic urethane (TPU). A third layer of mesh fabric can be interposed between the first and second layers. The composite sheet can be shaped by compression molding in a mold cavity or by lasting to achieve the desired three-dimensional geometry.

US Patent:

45611408, Dec 31, 1985

Filed:

Jun 5, 1984

Appl. No.:

6/617388

Inventors:

Kenneth W. Graham - Wakefield MA
Edward J. Norton - Boxford MA
Shuhei Kurata - Fukuoka, JP

Assignee:

New Balance Athletic Shoe, Inc. - Lawrence MA

International Classification:

A43B 1304
A43B 1314
A43B 1318
A43B 2132

US Classification:

12146BR

Abstract:

The manufacture of a sole unit for footwear, such as an athletic shoe including an integral midsole/wedge or a separable wedge for use with a midsole. The integral midsole/wedge unit and the separable wedge comprise a shell and a core at least partially encapsulated within the shell. In the manufacture the core is supported in a mold by a plurality of pins extending from an upper and lower mold half toward a parting line; or the core is supported on one or the other of an outsole or insole of the sole unit and closed in the mold. The material of the shell is poured or injected into the mold.

US Patent:

45519307, Nov 12, 1985

Filed:

Sep 23, 1983

Appl. No.:

6/535288

Inventors:

Kenneth W. Graham - Wakefield MA
Edward J. Norton - Ipswich MA
Shuhei Kurata - Fukuoka, JP

Assignee:

New Balance Athletic Shoe, Inc. - Lawrence MA

International Classification:

A43B 1314
A43B 1318
A43B 1304

US Classification:

36 30R

Abstract:

A sole unit for footwear such as an athletic shoe includes an integral midsole/wedge or a wedge for use with a midsole. The integral midsole/wedge unit and the wedge for use with a midsole both are formed by a shell and an encapsulated core. The shell and core comprise plastic materials which have individual strengths and weaknesses in a shoe construction, yet provide, as a composite improved results in a shock dispersion and memory system. In a second aspect, the integral midsole/wedge is a single density or a two-density unit precompressed from a low density material.

US Patent:

D2587726, Apr 7, 1981

Filed:

Jun 4, 1979

Appl. No.:

6/045184

Inventors:

Edward J. Norton - Topsfield MA
Jonathan H. Werman - Hampton Beach NH

Assignee:

New Balance Athletic Shoe, Inc. - Boston MA

International Classification:

D0204

US Classification:

D 2309

US Patent:

46549838, Apr 7, 1987

Filed:

Dec 26, 1985

Appl. No.:

6/813752

Inventors:

Kenneth W. Graham - Wakefield MA
Edward J. Norton - Oxford MA
Shuhei Kurata - Fukuoka, JP

Assignee:

New Balance Athletic Shoe, Inc. - Boston MA

International Classification:

A43B 1314
A43B 1318
A43B 1304

US Classification:

36 30R

Abstract:

The manufacture of a sole unit for footwear, such as an athletic shoe including an integral midsole/wedge or a separable wedge for use with a midsole. The integral midsole/wedge unit and the separable wedge comprise a shell and a core at least partially encapsulated within the shell. In the manufacture the core is supported in a mold by a plurality of pins extending from an upper and lower mold half toward a parting line; or the core is supported on one or the other of an outsole or insole of the sole unit and closed in the mold. The material of the shell is poured or injected into the mold.

US Patent:

48760536, Oct 24, 1989

Filed:

Jul 26, 1988

Appl. No.:

7/224247

Inventors:

Edward J. Norton - Boxford MA
Craig F. Fram - Haverhill MA
Kenneth W. Graham - Wakefield MA
James A. Smith - St. Louis Park MN

Assignee:

New Balance Athletic Shoe, Inc. - Boston MA

International Classification:

A43B 1000

US Classification:

264255

Abstract:

The process of molding a component of a sole unit for an athletic shoe comprising the steps of supporting a core of a first plastic material in a cavity of a mold, the core defining an integral part of the component and extending within a heel region toward a forefoot region, supporting at least one rigid plug member within the cavity juxtaposed and in partially surrounding relation to the core, injecting a second plastic material into the cavity to fill the cavity, to form a shell around the core, at least partially curing the injected plastic material, removing the plug member, and injecting a third plastic material which upon curing forms a second resilient plastic material having a hardness (Shore A) greater than that of the material of the core into the cavity to fill the area heretofore occupied by the plug member, the plug member being shaped such that the third plastic material forms a set of posts.