EP2804502A1 - Dispositif d'amortissement doté d'une ventilation - Google Patents

Dispositif d'amortissement doté d'une ventilation

Info

Publication number
EP2804502A1
EP2804502A1 EP13738797.3A EP13738797A EP2804502A1 EP 2804502 A1 EP2804502 A1 EP 2804502A1 EP 13738797 A EP13738797 A EP 13738797A EP 2804502 A1 EP2804502 A1 EP 2804502A1
Authority
EP
European Patent Office
Prior art keywords
layer
cushioning device
bottom layer
air
plastic
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
EP13738797.3A
Other languages
German (de)
English (en)
Other versions
EP2804502A4 (fr
Inventor
Jerome Gross
Joseph Skaja
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
SKYSOLE CORP
Original Assignee
SKYSOLE CORP
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by SKYSOLE CORP filed Critical SKYSOLE CORP
Publication of EP2804502A1 publication Critical patent/EP2804502A1/fr
Publication of EP2804502A4 publication Critical patent/EP2804502A4/fr
Withdrawn legal-status Critical Current

Links

Classifications

    • A—HUMAN NECESSITIES
    • A43—FOOTWEAR
    • A43B—CHARACTERISTIC FEATURES OF FOOTWEAR; PARTS OF FOOTWEAR
    • A43B17/00—Insoles for insertion, e.g. footbeds or inlays, for attachment to the shoe after the upper has been joined
    • A43B17/08—Insoles for insertion, e.g. footbeds or inlays, for attachment to the shoe after the upper has been joined ventilated
    • A—HUMAN NECESSITIES
    • A43—FOOTWEAR
    • A43B—CHARACTERISTIC FEATURES OF FOOTWEAR; PARTS OF FOOTWEAR
    • A43B1/00—Footwear characterised by the material
    • A43B1/0045—Footwear characterised by the material made at least partially of deodorant means
    • A—HUMAN NECESSITIES
    • A43—FOOTWEAR
    • A43B—CHARACTERISTIC FEATURES OF FOOTWEAR; PARTS OF FOOTWEAR
    • A43B17/00—Insoles for insertion, e.g. footbeds or inlays, for attachment to the shoe after the upper has been joined
    • A43B17/003—Insoles for insertion, e.g. footbeds or inlays, for attachment to the shoe after the upper has been joined characterised by the material
    • A43B17/006—Insoles for insertion, e.g. footbeds or inlays, for attachment to the shoe after the upper has been joined characterised by the material multilayered
    • A—HUMAN NECESSITIES
    • A43—FOOTWEAR
    • A43B—CHARACTERISTIC FEATURES OF FOOTWEAR; PARTS OF FOOTWEAR
    • A43B17/00—Insoles for insertion, e.g. footbeds or inlays, for attachment to the shoe after the upper has been joined
    • A43B17/02—Insoles for insertion, e.g. footbeds or inlays, for attachment to the shoe after the upper has been joined wedge-like or resilient
    • A—HUMAN NECESSITIES
    • A43—FOOTWEAR
    • A43B—CHARACTERISTIC FEATURES OF FOOTWEAR; PARTS OF FOOTWEAR
    • A43B17/00—Insoles for insertion, e.g. footbeds or inlays, for attachment to the shoe after the upper has been joined
    • A43B17/02—Insoles for insertion, e.g. footbeds or inlays, for attachment to the shoe after the upper has been joined wedge-like or resilient
    • A43B17/023—Insoles for insertion, e.g. footbeds or inlays, for attachment to the shoe after the upper has been joined wedge-like or resilient wedge-like
    • A—HUMAN NECESSITIES
    • A43—FOOTWEAR
    • A43B—CHARACTERISTIC FEATURES OF FOOTWEAR; PARTS OF FOOTWEAR
    • A43B17/00—Insoles for insertion, e.g. footbeds or inlays, for attachment to the shoe after the upper has been joined
    • A43B17/14—Insoles for insertion, e.g. footbeds or inlays, for attachment to the shoe after the upper has been joined made of sponge, rubber, or plastic materials
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
    • B29D35/00—Producing footwear
    • B29D35/12—Producing parts thereof, e.g. soles, heels, uppers, by a moulding technique
    • B29D35/14—Multilayered parts
    • B29D35/142—Soles

Definitions

  • the present invention relates to foot wear, and more particularly to a novel insole for insertion into a shoe, or other cushioning applications, that provides padding and forced ventilation using a unique multi-layer layer composition.
  • shoe inserts and pads on the market today that are intended to be placed inside a shoe for the purpose of providing comfort to the foot . It has long been known that shoe inserts and pads can provide a softening mechanism to absorb the shock as the foot bears the weight of the user, and the result of this shock absorbing function provides many orthopedic-related beneficial results.
  • the following references provide background into the current art of shoe insert devices.
  • Huiskamp U.S. Patent No. 1,605,588, discloses a sole of a shoe with a pneumatic cushion captured between a lower sole and an upper surface.
  • the pneumatic cushion extends between the ball and the toe, and the device further includes perforations that compress when the wearer walks, to pump up the sole for a softer and gentler sole.
  • Burnham U.S. Patent No. 3,225,463, discloses another air ventilated insole, including a compressible chamber in the heel portion and an exhaust valve directed toward the toes.
  • the chamber acts as a pump to drive air out of the valve and across the surface of the foot.
  • Outlet holes are placed around and between the toes to carry the air to the toe area before leaving the shoe.
  • Sandmeier U.S. Patent No. 4,215,492 discloses an insole for a shoe that provides an air flow pattern over the foot.
  • the insole includes dimples that massage the foot, and have two layers that are separated by a spacer to create a gap therebetween.
  • the upper layer has an air inlet that lets air into the gap, and as the user walks the air is forced toward the toe area where openings are located that vent the air. As the pressure is relieved, the air once again fills the gap in a repetitive manner.
  • U.S. Patent No. 5,400,526 discloses a tri-layer footwear sole that has a continuous bottom surface, and a middle layer that forms air pockets or bulb with the bottom layer.
  • the top layer had vertical air channels leading from the air pockets to the upper surface, where the air can contact the foot. Air is drawn into the sole at the back of the insert by the heel, and forced upward across the foot.
  • Cintron U.S. Patent No. 5,675,914, discloses a removable footbed insert with a single volume structure at the heel, formed in a molded lower layer and further including a foam upper layer.
  • the layers have perforations that serve as air channels, and the volume structure acts as a bellows that drives air through all three layers.
  • Skaja et al., U.S. Patent No. 7,178,267 discloses a footwear structure where two material layers are overlaid such that the two material layers are in contact with one another. The two material layers are heated to a forming temperature and are then vacuum-formed together to form a composite material layer in a three-dimensional form of the footwear structure.
  • the sole assembly includes a first material layer made of a plastic, and a second material layer attached to the first material layer.
  • a multi-layer cushioning device adapted to conform to a human body part includes a bottom layer formed of a plastic material, the bottom layer having a lower surface including a plurality of uniformly spaced apart dome shaped structures (normal or inverted) extending substantially a length and a width of the lower surface.
  • the cushioning device further comprises a porous middle layer on top of the bottom layer, which can be gas, foam, or other shock absorbing material.
  • a top layer is also provided that has a plurality of vertical apertures that extend from the top layer through the middle layer and down to the bottom layer, providing a multitude of airways between the top and bottom layers.
  • the cushioning device also includes an upwardly extending lateral protrusion that serves as an arch support, where the upwardly extending lateral protrusion includes column-shaped vertical recesses on an outer surface for communicating air thereinthrough.
  • FIG. la is a side view of a first embodiment of the present invention.
  • FIG. lb is an opposite side view of the embodiment of FIG. la;
  • FIG. 2 is a top view of the embodiment of FIG. la;
  • FIG. 3 is a bottom view of the embodiment of FIG. la;
  • FIG. 4a is a cross sectional view of the embodiment of FIG. 2 taken along lines 4a - 4a;
  • FIG. 4b is a cross sectional view of the embodiment of FIG. 2 taken along lines 4b - 4b.
  • FIGs. 1-4 A first embodiment of the present invention is shown in FIGs. 1-4.
  • An insert 10 is characterized by a cushioning device that circulates air between an bottom layer 12 and an upper layer 14. The air is directed to designated areas of the insert 10 via apertures 16, which circulate air to and over the foot of a user.
  • the bottom layer 12 and the upper layer 14 are separated by an air layer 18, or alternatively the middle layer can be a foam or other light weight but breathable material.
  • the insert is shaped to contour to a human foot and fit snugly inside a shoe, although other cushioning embodiments such as gloves, knee pads, and the like could also be incorporated into the present invention.
  • the bottom surface 20 of the insert 10 includes a multitude of deformable geometries, such as inverted, dome shaped elements 22 generally uniformly spaced across the bottom surface as shown in Figure 3.
  • the dome shaped structures 22, which can serve as tack points to connect the adjacent layers, are designed to collapse under the pressure of a user when weight is applied, as when a step is taken, forcing air to escape the dome shaped structure and circulate within the shoe and around the bottom layer. Some of this air is forced through apertures 16 that extend vertically between the bottom layer 12 and the top layer 14 to expel the air below the bottom of the foot.
  • the dome shaped structures 22 therefore not only cushion the foot by absorbing some of the energy from the downward pressure of the foot in its weight bearing capacity, but also provide a forced air stream around and vertically through the insert at designated locations.
  • the insert is preferably formed with laterally extending protrusion or wing 26 that extends upward from the bottom surface 12 so as to contour to the arch of a user.
  • the wing's upper surface is smooth, and its lower surface 26b is characterized by column-shaped recesses 28 that extend substantially the height of the wing 26.
  • the top of the wing 26 forms an arc 32 that may vertically extend slightly above the height of the heel 34.
  • the column- shaped recesses 28 serve two purposes, namely they add rigidity to the insert 10 while providing vertically channels along the outside of the insert for air to move from the bottom surface to the top surface. These channels or recesses help to circulate the air inside the shoe as the user walks and compresses the dome shaped structure 22.
  • the periphery of the insert 10 may include a lip 30 that extends around the insert.
  • the lip 30 can help position the insert 10 inside the shoe and prevent shifting of the insert, and can also form a semi-seal with the inner surface of the shoe to force more air through the vertical apertures 16 extending between the lower 12 and upper 14 surfaces.
  • the cross section of the insert 10 is shown in FIGs. 4a and 4b, showing the top surface and bottom surface separated by an intermediate layer preferably of air 18.
  • the air layer 18 is replaced with a soft, permeable foam or other lightweight breathable material.
  • the dome-shaped structures 22 extend generally the length and width of the bottom surface and extend roughly half way between the lower surface 12 and the upper surface 18 into the foam material 18.
  • Each dome shaped structure has an arch profile uniformly spaced from adjacent profiles.
  • the vertical apertures 16 are uniformly spaced apart (but could alternatively be irregularly spaced for various functional or cosmetic objectives), and extend from the bottom surface 12 to the top surface 14, providing channels by which air can pass from the bottom of the insert to the top of the insert.
  • the dome-shaped structures 22 collapse under the weight of the user's foot, forcing air trapped in the cavity of the dome- shaped structure 22 to be expelled along the bottom surface of the insert.
  • the shape, thickness, and material properties of the domes are selected to collapse at a predetermined rate so as to control the flow of air through the insole.
  • dome shaped structures 22 could serve the function of the dome shaped structures 22, such as cones, blocks, and volumes of various shapes and sizes, inverted or non-inverted, and still operate within the scope of the present invention. No intention is implied that any particular shape or configuration is limiting in any manner with respect to the descriptions or depictions in the drawings.
  • the insert 10 is created in such a manner that there is an airspace or foam 18 between the upper layer 14 and the bottom layer 12.
  • the bottom layer is preferably fabricated from a plastic material that is formed into a negative mold of the insert.
  • the interfacing upper layer is heated to a forming temperature and placed over the bottom layer. Pressure is then applied to the composite structure so that it forms and contacts the attachment points of the plastic bottom layer 12.
  • an adhesive is applied to the attachment points to create an instant and permanent bond between the plastic bottom layer and the interfacing upper layer.
  • a sheet of material is loaded into a clamping frame.
  • the frame is closed to secure the edges of the sheet and reliably hold it during the process.
  • the clamp frame with the sheet is placed in a highly temperature controlled oven, preferably in between 2 ovens for optimum heat saturation of the material.
  • the material reaches its melt point, it is then lowered over a mold with either male or female features.
  • the oven can be moved and the mold can take its place, without moving the material.
  • a vacuum is applied, pulling the material tightly to the mold surface.
  • the mold is kept at a stable temperature at 60 degrees Celsius, which is significantly lower than traditional melt temperatures which can be up to 180 degrees Celsius, leading to a quicker cool down period to cure the material.
  • Fans directed at the molded part are also turned on to hasten the curing.
  • the clamp frame then pulls the molded part off the mold or the mold is lowered to accomplish the same.
  • the molded insert bottom layer is then removed from the machine and the process repeated. This can all be completed in less than 10 seconds. For this insert, the cycle can be in the 60 second range. Multiple insoles can be thermoformed at the same time using the proper molds and clamps.
  • a foam layer 18 may be added to the insole 10.
  • the foam 18 (such as ethyl vinyl acetate) is heated and then positioned over the plastic cushioning layer 12. This plastic layer 12 is left in the female mold so that all contact points are reinforced by the mold. A top mold is lowered onto the female forming mold, thus trapping and sealing off the foam layer 18.
  • the heated foam layer 18 with a heat activated adhesive or hot melt is then pressed to designated attachment points by accurately applied air pressure. At the same time, the edge of the foam layer 18 is pressed tightly to the plastic cushioning layer. This process securely and consistently attaches the foam layer 18 to the bottom plastic layer 12 very accurately and allows manipulation of the intervening space between the lower and upper layers.
  • This simultaneous molding of the foam layer eliminates the pre-molding foam operation and equipment. It also cuts the total process time in half, and reduces the need for precision matched tooling that is needed without this process.
  • Plastic meshes can also be used as the lower layer 12. These meshes are breathable materials that can be thermoformed into any shape by installing a vacuum barrier in the forming machine. This barrier is preferably a silicone sheet which traps the mesh between itself and the vacuum, thus pulling the mesh into the mold surface. All the other process remains the same. The present inventors are unaware of any other process that can produce parts with the level of porosity available using this method. Injection molding, for example, can mold mesh, but only on a relatively flat surface and the cost is prohibitive for any product that requires multiple molds such as footwear.
  • the above-described process greatly reduces mold costs that are typical for footwear products.
  • the low pressure molds are generally made of aluminum, and require no match mold sets.
  • the cost of these molds is less than half the cost of typical compression molds and 80-90% less than injection molds.
  • the cycle time of this process is many times faster than typical compression mold cycles of footwear products so that multiple molds are not required to meet manufacturing objectives further reducing mold costs.
  • an entire set of molds and molding equipment is eliminated.
  • the bottom layer is preferably an elastomer with high recovery properties and very high physical properties.
  • Plastic or thermoplastic urethane (TPU) has a combination of properties, including process properties relative to thermoforming that work well with the above-described process and product, such as excellent "hot strength” and a very short "forming window.” These two properties are important because it allows the insole to be demolded quickly and stretched over mold features and undercuts during demolding. It then snaps back to the formed shape with no ill effects. This feature dramatically reduces mold costs versus injection and can make shapes that other processes cannot make at commercially viable prices.
  • the TPU material is extruded into the desired sheet dimensions.
  • a suitable thickness for this insole is 0.5mm, with the width and length relative to the thermoforming machine requirements.
  • the sheet can be fed into the thermoforming machine in rolls or in sheets.
  • Other materials are suitable, such as block amids, polyesters, eva, olefin, tpo, tpe, thermoset materials, and others. Foams and layers of material can also be used in this process.
  • TPU has an optimum combination of process and physical properties as well as a relatively low cost. It is also over engineered for human use, so it is a safe material to use for most applications without a great deal of testing.
  • thermoforming machine types There are three basic thermoforming machine types that can be used to process the present invention.
  • A) Cut Sheet Shuttle This equipment utilizes sheets of material that have been cut to an appropriate size. The material is then shuttled between the ovens and the mold.
  • the material can stay in one position and then the ovens and mold are over or under the material.
  • This machine is more economical and simpler than other equipment. It is also easier to control material waste with this equipment. Process flexibility is also very high. Cycle time potential, and therefore output is limited, however. As with all types of thermoforming equipment, computer controlled ovens and machine movements are desirable to control product consistency and production efficiency.
  • Rotary Thermoforming This equipment moves the material in a circle, as it passes through the oven(s), then to molding and to demolding stations. It allows for more operations in a smaller space. Operations such as insert loading or pre-heating the material are easily done with this equipment. Even multiple molding stations or simultaneous molding of multiple materials can be accomplished. Due to better access and more space, semi or even full automation is possible. Top and bottom molds and other devices can be operated independently so that various layers and inserts can be managed in one machine in a simultaneous or sequential manner with minimal cycle time loss.
  • In-line Roll Fed This equipment uses rolls of material that pass over the ovens, then over the mold, cooling and then die cutting, while still in a roll format. Even the waste material is automatically rolled up after die cutting. It is then recycled back into the material. The advantage of this equipment is speed. Cycle times as fast as ten seconds are common. Even the material extrusion process can be integrated with this equipment, drastically reducing the cost of raw material. The capital cost of this equipment is higher than other types and there is much more set up and process restriction.
  • inserts of almost any material can be added to the product during the thermoforming process.
  • the inserts are securely attached. In some cases, no adhesives are necessary.
  • Complete layers of material can be inserted for various functional and decorative objectives.
  • Inserts can be made in a number of ways, but they are preferably made by the same thermoforming process and equipment. This is a very efficient way to manufacture the inserts and it tends to lower their costs because of the unique ability of thermoforming machines to mold very thin parts. This also optimizes over head of the forming equipment and factory.
  • a myriad of other types of inserts designed to enhance the finished product can be added as well during the manufacturing process. Issues of comfort, traction, bacteria control, conductivity, design, decoration, branding, perception, temperature control, functional adjustment and many other finishing details can be addressed via in-mold insertion.
  • any design or graphic can be pre or post applied to the materials.
  • Textures can be applied to the forming molds and or the materials. Most plastic materials can be extruded transparently, so that decoration can be added to either side or both sides, yielding very desirable decoration. Paints and transfers can be also be applied to the mold prior to forming so that the plastic picks up the material.
  • the molds and or material can also be texturized. By applying air pressure to the top of the material as it is being thermoformed, the mold texture and detail will transfer to the material at a very high level.
  • Male molds can also be used to form the present invention.
  • Male molds have the advantage of the availability of severe undercuts in the finished part. These are not readily available with other molding techniques. "Undercuts" combined with materials such as TPU, open the door to product features not possible previously. Cushioning elements aligned precisely to impacts on contoured objects such as body parts can be inexpensively made this way.
  • Another advantage of males molds is that an entire layer of plastic can be molded over an insert or layer. This makes the surface of the finished product tougher and protects the insert.
  • thermoforming process does not require match mold sets and because materials such as TPU have tremendous hot strength, shapes and parts that previously could not be demolded are easily demolded. Moreover, because the thermoforming process carries heat with the finished part, secondary and undesirable adhesion operations can be eliminated. Adhesives that activate only when heated to specific temperatures are well suited for attaching the layers of the present invention. Adhesive application is then limited to the sheets of material prior to thermoforming. This operation can be highly controlled and automated and toxic releases and direct human exposure eliminated.
  • Supplemental components can be attached to the thermoformed insert by simply placing them into the forming mold and then forming the plastic sheet over them. In most cases a heat activated adhesive must first be applied to the component to that it bonds to the plastic sheet during forming. The same can be done in a female mold, but in this case the component would not be overmolded but simply attached to the plastic sheet.
  • a second material can be simultaneously molded and attached to the plastic sheet. This is a useful feature in making the plastic more comfortable and perceptually acceptable for consumers.
  • a foam or fabric layer is important as a skin interface.
  • the technique of using pressure to attached the two materials is important in assembling a finished product. Otherwise, a matched set of tools, and very accurate material dimensions are required, thus driving up the cost of the finished product and the reject rate. This would make the finished product far too expensive and not viable. This is particularly true of more contoured products such as helmets, protective gear and other products that are contoured to fit various areas of the body.
  • the insole may also include a non- stretch material that acts like a moderator, such as a non- woven polyester fabric, which can better distribute the impact load.
  • a moderator can also prevent the bottom layer from compacting around the dome- shaped structures.
  • the moderator can be added to any layer, but is located adjacent the bottom layer.
  • the insole can also be specially tuned or adjusted to a particular user by judicious selection of the dome shape, size, and thickness, to control pronation, weight distribution, comfort, and other factors.
  • other dispersals such as deodorant, sanitizer, and the like can also be distributed across the insole. This component has become beneficial in assembling the eva to the thermoplastic domes without the domes showing through the top of the insole.
  • Chitin a material that shares some properties with cellulose and is soft, biocompatible, can inhibit bacteria growth and is easily dyed to create colorful patterns on the top of the insole.
  • Another assembly option is to form each layer of material separately, coating them with heat activated adhesives and then aligning them together. The assembly is then inserted into a mold and heated. Pressure is then exerted on the top layer to compress all layers together. Tack points can be used to attach the materials only where desired. Individual layers or the entire product can be post perforated for breathability or perceptual objectives.
  • the multi-layer cushioning device of the present invention can be stacked or layered to increase the functional cushioning, particularly in other applications. Using multiple cushioning devices in a stacked or nested arrangement can dramatically increase the overall cushioning capability, and provides a low cost alternative to other materials that are far more complex and expensive.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Chemical & Material Sciences (AREA)
  • Materials Engineering (AREA)
  • Wood Science & Technology (AREA)
  • Footwear And Its Accessory, Manufacturing Method And Apparatuses (AREA)

Abstract

La présente invention a trait à une semelle destinée à une chaussure qui est caractérisée par un dispositif d'amortissement qui fait circuler l'air entre une couche inférieure de plastique et une couche supérieure poreuse et douce. L'air est dirigé vers des zones désignées de la semelle par l'intermédiaire d'ouvertures verticales, qui font circuler l'air vers le pied d'un utilisateur et au-dessus de celui-ci. La couche inférieure est constituée de structures de capture d'air qui lorsqu'elles s'écroulent expulsent l'air qui est amené de force par les ouvertures et l'amène jusqu'à la surface du pied de l'utilisateur. La couche inférieure et la couche supérieure sont séparées par une couche centrale poreuse qui peut être de la mousse ou tout autre matériau léger mais perméable à l'air.
EP13738797.3A 2012-01-17 2013-01-16 Dispositif d'amortissement doté d'une ventilation Withdrawn EP2804502A4 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US13/351,943 US20130180023A1 (en) 2012-01-17 2012-01-17 Cushioning device with ventilation
PCT/US2013/021763 WO2013109643A1 (fr) 2012-01-17 2013-01-16 Dispositif d'amortissement doté d'une ventilation

Publications (2)

Publication Number Publication Date
EP2804502A1 true EP2804502A1 (fr) 2014-11-26
EP2804502A4 EP2804502A4 (fr) 2015-11-11

Family

ID=48750154

Family Applications (1)

Application Number Title Priority Date Filing Date
EP13738797.3A Withdrawn EP2804502A4 (fr) 2012-01-17 2013-01-16 Dispositif d'amortissement doté d'une ventilation

Country Status (4)

Country Link
US (1) US20130180023A1 (fr)
EP (1) EP2804502A4 (fr)
CN (1) CN103202576B (fr)
WO (1) WO2013109643A1 (fr)

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CN103202576A (zh) 2013-07-17
US20130180023A1 (en) 2013-07-18
CN103202576B (zh) 2015-05-13
EP2804502A4 (fr) 2015-11-11
WO2013109643A1 (fr) 2013-07-25

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