AU750421B2

AU750421B2 - Method of making a shoe having a foamed insole

Info

Publication number: AU750421B2
Application number: AU68068/00A
Authority: AU
Inventors: Cheng-Hsian Chi
Original assignee: Individual
Current assignee: Individual
Priority date: 2000-10-24
Filing date: 2000-10-24
Publication date: 2002-07-18
Anticipated expiration: 2020-10-24
Also published as: CA2330517A1; CA2330517C; AU6806800A

Description

AUSTRALIA

Patents Act 1990 COMPLETE SPECIFICATION STANDARD PATENT

C

Applicant(s): CHENG-HSIAN CHI Invention Title: METHOD OF MAKING A SHOE HAVING A FOAMED INSOLE The following statement is a full description of this invention, including the best method of performing it known to me/us:

IA,

METHOD OF MAKING A SHOE HAVING A FOAMED INSOLE This invention relates to a method of making a shoe, more particularly, to a method of making a shoe in which a foamed insole blank is formed into a finished and patterned insole during the course of assembly of the insole blank and other shoe components, such as an upper and an outsole.

It is known to produce shoes having insoles made of resilient foamed materials, such as EVA foams, which possesses good softness to provide comfortable feeling and which has good resiliency to absorb shock. Such insoles may be fabricated by forming a foamable EVA composition ~introduced into a mold, or by forming in a mold an insole blank cut from a preformed EVA casting. The insoles as formed are usually bonded to uppers and outsoles by gluing processes.

15 In the manufacture of many sport shoes, foamed insoles are ooeo provided with relief-like patterns at the peripheries thereof before they are glued to uppers and outsoles.

For example, U.S. Patent No. 5,843,352 owned by the applicant of this application discloses a method of producing 20 EVA insoles having ornamental peripheral borders. This method employs the steps of separately forming of an insole and a blank strip, forming the blank strip into a desired shape with an embossed pattern, and attaching the embossed strip to the periphery of the insole by adhesive bonding.

R.O.C. Patent No. 287091 to Jih et al discloses a method forming a foamed EVA insole, wherein an insole blank cut from a cast EVA sheet is foamed in a heated mold and formed into a finished insole which has an upwardly projecting peripheral flange for attachment of an ornamental strip by gluing. The presence of the peripheral flange on the insole facilitates attachment of the ornamental strip.

U.S. Patent No. 5,560,877 to Yung et al discloses a process for manufacturing an EVA sole, wherein an unfoamed EVA blank sheet is placed in a first mold unit to form a foamed insole blank which in turn is placed in a heated second mold to form an embossed finished insole.

All of the processes disclosed in the aforesaid patents require the first step of forming an insole blank and the second step of embossing or ornamenting the insole blank to

:.ZZ

form a finished insole structure. These patents merely disclose or teach how an insole is made and patterned before attachment of the insole to other components of a shoe, such as an upper and an outsole.

U.S. Patent No. 5,463,824 to Barna et al suggests a process for manufacturing an arch support system for a shoe.

The teachings therein are directed to the bonding of a foamed layer for a shoe component to other materially different 20 layers of shoe components by applying heat and pressure in a mold. The process disclosed in this patent is related solely to a bonding method and is totally irrelevant to the patterning or embossing of a foamed layer.

Likewise, U.S. Patent No. 4,231,169 to Toyama et al discloses a bonding method which is independent from the pattern-forming of a shoe component. In the method disclosed therein, a shank comprising a fiber-reinforced resin sheet is placed on an insole element and is adhered thereto under heat and pressure.

While the prior art suggests many processes available for bonding and patterning shoe components bonding and patterning of shoe components are usually carried out in separate operational steps which are laborious and timeconsuming. It is desirable that bonding and patterning of shoe components can be performed simultaneously in order to facilitate and speed up the production of shoes.

SUMMARY OF THE INVENTION According to one aspect of the present invention, there is provided a method of making a shoe comprising: preparing an insole blank having top and bottom surfaces and a peripheral portion extending around the top and bottom surfaces; applying an adhesive to the top of an outsole; positioning the adhesive-applied outsole in a mold assembly which includes at least two opposite side mold parts S. having forming patterns for forming the peripheral portion of the insole blank; 20 placing the insole blank in the mold assembly with the bottom surface being disposed adjacent the top of the outsole while the insole blank is being softened by heat to a plastic state, said insole blank being arranged so as to contact said side molds directly when said mold assembly is closed; and closing said mold assembly to press the insole blank in the plastic state against the outsole so as to 25 bond the insole blank and the outsole and to contact said side molds directly with the peripheral portion of the insole blank so as to press and pattern the peripheral portion of the insole blank via the side mold parts, wherein the bonding of the insole blank and the outsole, and the patterning of the peripheral portion of the insole blank are carried out simultaneously by closing the mold assembly.

An advantage of the present invention is that ornamentation of an insole blank is carried out simultaneously with the bonding of the insole blank to an upper and/or an outsole.

Other advantages of the present invention will become apparent in the following detailed description of the preferred embodiment with reference to the accompanying drawings of which: Figure 1 is a perspective view showing an insole blank and an outsole which are to be assembled in a first embodiment of the method according to the present invention; Figure 2 is a perspective view showing a mold assembly used in the first embodiment of the present invention; Figure 3 is a perspective view showing the insole blank and the outsole assembled according to the first embodiment of the present invention; Figure 4 is a perspective view illustrating assembly of an upper and an insole blank in a mold assembly according to the method of a second embodiment .of the present invention; S.Figure 5 is a cross-sectional view of an ornamental strip to be attached to S"the upper and the insole blank in the second embodiment; S. •20 Figure 6 is a cross-sectional view showing the ornamental strip, the upper and the insole blank assembled according to the second embodiment; Figure 7 is a perspective view illustrating assembly of 0 0.

.0 o an upper, an insole blank and an outsole in a mold assembly according to a third embodiment of the present invention; Figure 8 is a cross-sectional view of the mold assembly of the third embodiment in a closed position; Figure 9 is a perspective view illustrating the manufacturing of a sandal via a mold assembly according a fourth embodiment of the present invention; Figure 10 is a schematic view of the sandal assembled in the fourth embodiment when the mold assembly is closed; 10 Figure 11 is a schematic cross-sectional view showing an alternative mold assembly for manufacturing a sandal; and Figure 12 is a schematic cross-sectional view ~illustrating assembly of an outsole and an insole blank enclosing an air cushion pocket in accordance with a fifth embodiment of the present invention Referring to Figures i, 2 and 3, a first preferred embodiment of the method of making a shoe according to the present invention is directed to the assembly of a foamed insole blank 11 and an outsole 12. The foamed insole blank 20 11 is prepared from an EVA polymer in a conventional manner, such as by forming a foamable EVA composition into the shape of an insole in a suitable mold, or by tailoring a preformed EVA foam. The foamed insole blank 11 is substantially flat and has top and bottom surfaces surrounded by a peripheral portion 110. The dimensions of the top and bottom surfaces of the foamed insole blank 11 are slightly greater than the dimensions of the top surface of the outsole 12. A mold assembly 1 used in this embodiment includes a bottom mold part 101 for positioning the outsole 12, two opposite side mold parts 102 and 103, and a top mold part 104 having a last.

The side mold parts 102, 103 are provided with forming patterns 102', 103' for forming the peripheral portion of the insole blank 11.

In operation, an adhesive, such as a heat-fusible adhesive, is applied to the top surface of the outsole 12, and the outsole 12 coated with the adhesive is positioned on the bottom mold part 101. The insole blank 11 is softened by heat to a plastic state and is placed in the mold assembly :1 while in the plastic state, with the bottom surface of the insole blank 11 in contact with the top surface of the I outsole 12. The peripheral portion of the insole blank 11 projects outwardly of the periphery of the outsole 12.

15 Ornamental pieces 111 having different colors are placed in the side mold parts 102, 103. The ornamental pieces 111 may be made of the same material as the insole blank 11 or a different material. In this embodiment, the ornamental pieces 111 are of the same material as the insole blank 11 20 and are preferably heated to a plastic state prior to placement in the side mold parts 102, 103. When the mold assembly 1 is closed at the plastic state of the insole blank 11, the insole blank 11 is pressed against and bonded to the outsole 12. At the same time, the peripheral portion of the insole blank 11 is pressed to project upward and patterned by the side mold parts 102', 103', and the ornamental pieces 111 positioned on the side mold parts 102, 103 are bonded to the peripheral portion of the insole blank 11, as shown in Figure 3. Due to the forming patterns 102', 103' of the side mold parts 102, 103, a relief-like pattern is produced on the peripheral portion of the insole blank 11.

Alternatively, the two side mold parts 102, 103 of the mold 1 may be replaced with a single one-piece mold part which has a mold cavity opening at both of the top and bottom sides thereof. In this case, the bottom mold part 101 is fitted in the bottom side of the single one-piece mold part.

Referring to Figure 4, in a second embodiment of the method of making a shoe according to the present invention, a foamed insole blank 21 and an upper 22 are assembled by •o o using a mold assembly 2. The foamed insole blank 21 differs from the insole blank 11 in that the peripheral portion of the insole blank 21 has a peripheral upward flange 211. The :"15 mold assembly 2 includes a top mold part 201, a pair of clamp parts 202, 203, two opposite side mold parts 204, 205, and a bottom mold part 206. The inner surfaces of the side mold S" parts 204, 205 are provided with forming patterns for patterning the peripheral upward flange 211 of the insole blank 21. The upper 22 is positioned to the top mold part 201 after an adhesive is applied to the bottom of the upper 22. The insole blank 21 is heated to a plastic state and is placed in the mold assembly 2 with the top surface thereof in contact with the bottom of the upper 22. The peripheral upward flange 211 of the insole blank 21 extends around the bottom of the upper 22. Referring to Figures 5 and 6 in combination with Figure 4, an ornamental strip 23 is positioned around the peripheral upward flange 211 of the 8 insole blank 21 by means of fastening elements or strings 231 which tie the ornamental strip 23 and the insole blank 21 together. The ornamental strip 23 is of the same material as the insole blank 21 and is heated to a plastic state prior to placement in the mold assembly 2.

When the mold assembly 2 is closed, the insole blank 21 and the ornamental strip 23, which are in the plastic state, are pressed and embossed and are bonded to the bottom of the upper 22. The peripheral upward flange 211 of the insole 10 blank 21 is therefore patterned and ornamented by the ornamental strip 23.

Referring to Figure 7, a third embodiment of the method of making a shoe according to the present invention is purposed to assemble an upper 32, an insole blank 31, and 00.0 0.0 015 an outsole 33. In this embodiment, the insole blank 31 in the plastic state is placed in a mold assembly 3 together with the upper 32 and the outsole 33 coated with an adhesive.

The mold assembly 3 includes a bottom mold part 301, a top I. :mold part 302, left and right clamping parts 303, 304, and a pair of side mold parts 305, 306 with inner surfaces provided with forming patterns 305", 306". When the mold 3 is closed, the upper 32, the insole blank 31 and the outsole 33 are assembled integrally together. At the same time, the insole blank 31 is formed into a final desired shape with the peripheral upward flange 311 thereof being embossed and patterned.

Note that the mold assembly 3 is provided with fence plates 307, 308 adjacent the top end of the side mold parts 305, 306. The fence plates 307, 308 are configured as elongated strips which are curved to conform to the contour of the upper 32. When the mold 3 is closed, the bottom ends of the fence plates 307, 308 abut against the top of the peripheral upward flange 311 of the insole blank 31, as shown in Figure 8, so that the flash produced from the insole blank 31 is blocked from flowing upward and is diverted to flow outwardly of the fence plates 307, 308. As such, no brow formation will occur around the insole blank 31 after assembly. The flash formed outwardly of the fence plates 307, 308 can be removed easily.

oooo "*'*"Referring again to Figure 7, during the forming operation in the mold assembly 3, front and rear stop plates 331, 332 are disposed at the front and rear ends of the outsole 33 *.15 at locations corresponding to the front and rear seams of the two side mold parts 305, 306. The stop plates 331, 332 can be bonded to the front and rear ends of the upper 32 and the insole 31. The seams formed on the stop plates 331, 332 due to the front and rear seams of the side mold parts 305, 306 may be removed, if desired, by pressing and embossing the seams with a heated embossing tool.

Figures 9 and 10 illustrate a fourth embodiment of the method of making a sandal. In this embodiment, an insole blank 31' is provided with through-holes 311' at the margin thereof. The upper 32' includes a plurality of sandal straps 321' attached with fastening elements 322' After the straps 321' pass through the through-holes 311' in the insole blank 31' which has been heated, the fastening elements 322' are connected to each other, thus bringing together the upper 32' and the insole 31' The upper 32' and the insole 31' are then placed within a top mold part or last 302' and left and right clamping parts 303', 304', as shown in Figure When the mold assembly 3' is closed by bringing together the top mold part 302, the left and right clamping parts 303', 304', side mold parts, 305', 306', and a bottom mold part 310', the upper 32' and the insole 31' are united integrally together with an outsole 33' 10 Referring to Figure 11, in place of the aforesaid mold assembly another mold which has mother and daughter mold o.

members may be used for making a sandal. A mold part 4 is provided with a cavity 401 opening at one side of the mold part 4. After a daughter mold member 402 is inserted into an upper 32", the daughter mold member 402 together with the upper 32" is placed in the cavity 401. An insole 31" and oooo an outsole 33" are then placed on the upper 32". The mold part 4 is closed by a mold cover 403 to assemble the insole

.V*

31", the outsole 33" and the upper 32" Referring to Figure 12, in a fifth embodiment of the present invention, an air cushion pocket 54 is attached to an insole blank 51 during assembly of the insole blank 51 and an outsole 53 in a mold assembly 5. The outsole 53 is first positioned in a top mold 504, and the insole blank 51, which is heated to a plastic state, is placed onto the outsole 53. The air cushion pocket 54 is further placed on the insole blank 51 and covered by a cover plate 52 which is made of the same material as the insole blank 51. When the mold assembly 5 is closed by moving side mold parts 502, 503 and a bottom mold part 501 toward the top mold part 504, the cover plate 52 is bonded to the insole blank 51, enclosing the air cushion pocket 54 therebetween, and the insole 51 and the outsole 53 are united together. As the air cushion pocket 54 is inflated by injecting air through an air passage 56 after the mold assembly 5 is closed, the insole blank 51 and the cover plate 52 are pressurized to abut against the inner surface of the side mold parts 502, 503. As a result, a clear embossed pattern is formed on the peripheral portion of the insole blank 51. The product as formed possesses good shock *oo* absorbing characteristics due to the presence of the air cushion pocket 54.

Shoes having shock absorbing properties may be oo 15 fabricated by incorporating a PU foam into an insole in place of the air cushion pocket 54. In manufacturing, a liquid PU foam material is introduced into a mold between an outsole and an insole. Prior to introduction of the PU foam material r into the mold, air is blown into the mold between the outsole and the insole to create a space therebetween. At the same time, the peripheral portion of the insole blank in the plastic state is pressurized to abut against the inner surface of the mold. The PU foam material is introduced into the space as soon as the blowing of the air is stopped A clear embossed pattern can be formed on the peripheral portion of the insole blank.

It is to be understood that, if any prior art publication is referred to herein, such reference does not constitute an admission that the publication forms a part of the common general knowledge in the art, in Australia or any other country.

For the purposes of this specification it will be clearly understood that the word "comprising" means "including but not limited to", and that the word "comprises" has a corresponding meaning.

*e

Claims

1. A method for making a shoe, characterised by: preparing an insole blank having top and bottom surfaces and a peripheral portion extending around said top and bottom surfaces; applying an adhesive to the top of an outsole; positioning the adhesive-applied outsole in a mold assembly which includes at least two opposite side mold parts having forming patterns for forming said peripheral portion of said insole blank; placing said insole blank in said mold assembly with said bottom surface being disposed adjacent to the top of said outsole while said insole blank is being softened by heat to a plastic state, said insole blank being arranged so as to contact said side molds which said mold assembly is closed; and closing said mold assembly to press said insole blank in said plastic state and said outsole so as to bond said insole blank and said outsole and to contact 20 said molds directly with said peripheral portion of said insole blank so as to press and pattern said peripheral portion of said insole blank via said side mold parts, wherein the bonding of said insole blank and said outsole and the patterning of said peripheral portion of said insole blank are carried out simultaneously by closing said mold assembly.

2. The method as claimed in claim 1, characterised in that said peripheral portion of said insole blank is embossed to form a relief-like pattern.

The method as claimed in claim 2, characterised in that said top and bottom surfaces of said insole blank have dimensions greater than those of said outsole so that said peripheral portion of said insole blank extends outward beyond the periphery of said outsole when said insole blank is placed on said outsole, said peripheral portion of said insole blank being pressed by said mold parts to project upward and to create said relief-like pattern on said peripheral portion.

4. The method as claimed in Claim 2, characterized in that said peripheral portion of said insole blank has an upwardly extending peripheral flange, said peripheral flange being pressed and formed by said side mold parts to create S- 10 said relief-like pattern on said peripheral flange.

5. The method as claimed in Claim 3, further characterized by applying an adhesive to the bottom of an upper, and placing said upper in said mold assembly with the bottom of said upper in contact with said top surface of said 15 insole blank before said mold assembly is closed, wherein said peripheral portion is pressed against the bottom of said upper and is formed by said two side mold parts to create said relief-like pattern.

6.The method as claimed in Claim 4, further characterized by applying an adhesive to the bottom of an upper, and placing said upper in said mold assembly with the bottom of said upper in contact with said top surface of said insole blank and being surrounded by said peripheral flange before said mold assembly is closed, wherein said peripheral flange of said insole blank is pressed and formed by said two side mold parts to create said relief-like pattern.

7. The method as claimed in Claim 6, further characterized by preparing an ornamental element, placing insole blank and being surrounded by said peripheral flange before said mold assembly is closed, wherein said peripheral flange of said insole blank is pressed and formed by said two side mold parts to create said relief-like pattern. 7. The method as claimed in Claim 6, further characterized by preparing an ornamental element, placing said ornamental element in said mold assembly around said peripheral flange of said insole blank before said mold assembly is closed, and pressing said ornamental element *"10 against said peripheral flange of said insole blank to bond said ornamental element to said peripheral flange and to *create said relief-like pattern.

8. The method as claimed in Claim 7, characterized in that said ornamental element is made of the same material 15 as said insole blank.

9. The method as claimed in Claim 7, characterized in that said ornamental element is configured as a strip, said strip having fastening elements for positioning said strip around said peripheral flange of said insole blank before said mold assembly is closed.

The method as claimed in Claim 7, characterized in that said ornamental element includes a plurality of ornamental pieces positioned around said peripheral flange of said insole blank before said mold assembly is closed.

11. The method as claimed in Claim 1, characterized by comprising the steps of placing an air cushion pocket on said insole blank, and placing a cover plate, which is made of the same material as said insole blank, on said air cushion pocket before said mold assembly is closed, the step of pressing said cover plate against said insole blank to bond said cover plate and said insole blank by closing said mold assembly, thus enclosing said air cushion pocket, and the step of inflating said air cushion pocket so as to pressurize said insole blank and said cover plate against said mold assembly when said mold assembly is closed.

12. The method as claimed in Claim 5, characterized in that said upper includes a plurality of sandal straps. 1. 0

13. The method as claimed in Claim 1, characterized t .o in that said mold assembly further includes a bottom mold 5..part for positioning said outsole, and a top mold part opposite to said bottom mold part, said top mold part including a last. 15

14. The method as claimed in Claim 13, characterized in that said bottom mold part is a separate piece from said opposite side mold parts.

The method as claimed in Claim 12, characterized that said mold assembly further includes a bottom mold part for positioning said outsole, and a top mold part with a cavity for positioning said upper, said top mold part having a daughter mold part for positioning said sandal straps.

16. The method as claimed in Claim 5, characterized in that said mold assembly further comprises a bottom mold part for positioning said outsole, and a top mold part for positioning said upper, said top mold part including a last and fence plates, said fence plates being disposed at the bottom of said top mold part and extending to the top ends -16- of said opposite side mold parts so as to block the top end of said peripheral portion of said insole blank, whereby flash resulting from said insole blank can be diverted to flow outwardly of said fence plates.

17. A method of making a shoe, characterised by: preparing an insole blank having top and bottom surfaces and a peripheral portion extending around said top and bottom surfaces; applying an adhesive to the bottom of an upper; positioning the adhesive-applied upper in a mold assembly which includes at least two opposite side mold parts having forming patterns for forming said peripheral portion of said insole blank; placing said insole blank in said mold assembly with said top surface being disposed adjacent the bottom of said upper while said insole blank is being softened by heat to a plastic state, said insole blank being arranged so as to contact said molds when said mold assembly is closed; S-closing said mold assembly to press said insole blank in said plastic state 20 and said upper so as to bond said insole blank and said upper, and to contact said side molds directly with said peripheral portion of said insole blank so as to press and pattern said peripheral portion of said insole blank, wherein the bonding of said insole blank and said upper and the patterning of said peripheral portion of :said insole blank are carried out simultaneously by closing said mold assembly.

18. A method as hereinbefore described with reference to and as illustrated in the accompanying drawings. Dated this 22nd day of May 2002 CHENG-HSIAN CHI By his Patent Attorneys: GRIFFITH HACK Fellows Institute of Patent and Trade Mark Attorneys of Australia