US2106845A - Manufacture of shoe bottom units - Google Patents

Description

Feb. 1, 1938. R HQPK|N$ 2,106,845

MANUFACTURE OF SHOE BOTTOM UNITS Filed May 1, 1936 2 Sheets-Sheet l Feb. 1, 193

R. E. HOPKINS MANUFACTURE OF SHOE BOTTOM UNITS Filed y 1, 19 a 2 Sheet s 2 Mir/W UVVE/VTU/P- Wf W k fi Patented Feb. I, 1938 UNITED STATES MANUFACTURE OF SHOE BOTTOM UNITS Raymond E. Hopkins, Weymouth, Mass, assignor to United Shoe Machinery Corporation, Paterson, N. J., a corporation of New Jersey Application May 1, 1936', Serial No. 77,373

12 Claims.

This invention relates to the manufacture of insoles and outsoles having complementary forepart portions.

In a copending application, Serial No. 26,217, filed June 12, 1935, in the name of Albert Boot, there is disclosed a method of making a so-called insole-outsole combination consisting of an outsole having a central forepart projection and an insole having a correspondingly located opening which is complemental to the outsole projection. In the practice of the method referred to the insole and the outsole are split from a laminated blank comprising a layer of outsole material and a layer of insole material, the layers being secured together by means of cement, and the splitting operation is performed by a matrix roll type of splitting machine having matrix and die rolls which flex and deform the forepart of the blank so that the cut of a straight-edged splitting knife will form the opening in the insole and the corresponding projection on the outsole. It is desirable in some instances to have the insoles formed wholly or partially of one of the well-known fabricated or manufactured materails which are of a character adapted to serve as a substitute for leather. An example of such material is a composition of wood pulp and latex and such material is commonly supplied in sheets of laminated formation. Considerable difficulty is often experienced in performing splitting operations of the type referred to upon laminated blanks, and particularly upon blanks having insole layers of fabricated material, because of the fact that the splitting knife, in starting that portion of the out which is to form the insole opening, has a tendency to enter or follow along the plane of adhesion between the insole and outsole layers or to enter between the plies of the fabricated insole material and thus is liable to make an undesirable ragged cut through the insole material.

One object of the present invention is to overcome the above-mentioned difficulties in the manufacture of complemental insole-outsole combinations.

To the accomplishment of this object, it is proposed to prepare the blank for the splitting operation by preliminarily cutting inwardly from the upper surface of the layer of insole material thereby initiating the division of the blank into an insole having an opening therein and an outsole having a projection complemental to the insole opening, and thereafter completing the division of the blank by means of a. splitting knife which in its operation passes idly through said preliminary cut. This preliminary cut or incision may be made in the insole layer either before or after that layer has been secured to the outsole layer and preferably the out should be shaped so as to constitute part of the opening which is to be formed in the insole by the splitting knife. By properly locating such a preliminary cut in the insole layer the knife of the spitting machine, when it reaches the cut in the course of the splitting operation, will pass readily through the cut and the portion of the knife which is in line with the cut will have no tendency to remain in,

or to enter and follow along, the plane of adhesion between the insole and outsole layers after reaching the deformed portion of the blank. Moreover, in cases where insole material of laminated formation is employed, the splitting knife will have no tendency to enter between the several plies of the insole layer as it operates to cut the insole opening and the outsole projection. The presence of the preliminary cut in the insole layer thus insures clean cutting and proper shaping of the forward end portion of the insole opening and the outsole projection where, in the absence of such a cut, ragged cutting and mutilation of the insole material is very liable to take place where the splitting knife starts the cut defining the insole opening.

Invention is also to be recognized as residing in the step products hereinafter described and claimed which result from the practice of my improved method of manufacturing soles.

The invention will now be explained with reference to the accompanying drawings, in which Fig. 1 is a perspective view of a laminated sole blank of the type employed in the practice of my improved method;

Fig. 2 is a fragmentary elevational view of a portion of a sole rounding machine illustrating the operation of the machine upon the sole blank shown in Fig. 1';

Fig. 3 is a perspective view of the sole blank as it 'appears after it has been rounded to impart substantially a final edge contour thereto and after the preliminary incision has been made through the insole layer to facilitate the performance of the splitting operation;

Fig. 4 is a longitudinal sectional view of the forward end portion of the blank illustrating the operation of making the preliminary incision in the insole layer;

Fig. 5 is a cross-sectional view of a portion of a matrix roll type splitting machine showing a sole blank about to be operated upon by the splitting knife;

Fig. 6 is a fragmentary View in vertical section of the matrix rolls of the splitting machine illustrating the operation of the rolls upon the central forward portion of the sole blank;

Fig. 7 is a longitudinal sectional view on an enlarged scale of the forward portion of a laminated sole blank the margin of which is being split in the plane of adhesion between the insole and outsole layers, the figure showing how the blank is distorted by the action of the matrix rolls in the vicinity of the preliminary incision in the insole layer and showing the appearance of the blank after the splitting has proceeded to the point where the knife is about to enter that incision;

Fig. 8 is a view similar to Fig. '7 but showing the appearance of a sole blank the margin of which is being split in a plane extending through the outsole layer near the plane of adhesion between the insole and outsole layers;

Fig. 9 is a cross-sectional View of the forepart of the insole produced when the margin of a sole blank is split as indicated by Fig. 7;

Fig. 10 is a cross-sectional view of the forepart of the outsole produced when the sole blank is split as indicated by Fig. 7;

Fig. 11 is a cross-sectional view of the insole produced when the sole blank is split as indicated by Fig. 8;

Fig. 12 is a cross-sectional view of the outsole produced when the sole blank is split as indicated by Fig. 8;

Figs. 13 and 14 are perspective views of the insole and the outsole shown in Figs. 11 and 12, respectively;

Fig. 15 is a fragmentary perspective view of insole and outsole blanks which have been cut to sole shape before being secured together; and

Fig. 16 is a fragmentary perspective View of the sole blank showing a mark for gaging the location of the preliminary incision.

In the practice of my improved method of making soles, as herein illustrated, I provide a laminated sole blank 20 by securing together by means of a suitable adhesive a layer 22 of outsole material such as sole leather and a layer 24 of any suitable insole material. For convenience these two layers will be referred to hereinafter as the outsole layer 22 and the insole layer 24. The insole layer 24 may advantageously consist of fabricated or so-called manufactured material such, for example, as a composition of wood pulp and latex, and, as illustrated, the insole layer is itself of laminated formation comprising, as best shown in Figs. '7 and 8, a plurality of layers 26 which are adhesively secured together. In makin up the sole blank 20, the outsole and insole layers 22 and 24 may be secured together throughout the entire areas of their contacting faces or, if desired, the insole layer 24 may be secured to the outsole layer only in the central portion of its forepart, for example, in an area such as that bounded by the dotted line 28 in Fig. 1, such area corresponding in shape and location substantially to that of the projection which is ultimately to be formed upon the outsole.

After the outsole and insole layers have been secured together to form a laminated sole blank he blank is out to sole shape by a rounding or die-cutting operation. Preferably, although not necessarily, this sole shaping operation is performed by means of a so-called double knife rounding machine, such for example as that disclosed in the copending application Serial No. 734,650, filed July 11, 1934, in the name of F. E.

Bertrand, in order to impart to the insole layer a contour somewhat smaller than that to be imparted to the outsole layer in order to provide space for receiving the upper materials which are to be lasted over the insole without causing these materials to project over the edge of the outsole. As indicated in Fig. 2, such a double knife rounding machine comprises upper and lower patterns 32 and 34 between which the laminated sole blank is located, and upper and lower rounding knives 38 and 38 which are caused to travel around the edges of the patterns 32 and 34, respectively. In the use of this machine the lower rounding knife 38, following the contour of the pattern 34, trims both the insole and outsole ers were cemented together only in their central forward portions, the strip of waste material severed from the insole layer by the upper rounding knife 36, being unsecured to the outsole layer, will fall clear of the sole blank, whereas in cases where the insole and outsole layers are cemented together throughout the areas of their contacting surfaces the waste strip defined by the rounding knife may be readily peeled off from the outsole layer and discarded. After the removal of the waste strip the rounded sole blank will then appear as indicated in Fig. 3. It will be seen that the edge of the insole layer 24 is spaced inwardly relatively to the edge of the outsole layer 22.

In order to facilitate clean cutting during that part of the splitting operation which is to form the forward portions of the insole opening and the outsole projection, the sole blank is next prepared, in accordance with my improved method, by forming a preliminary incision 4t (Fig. 3) in the insole layer 24, the incision 46 being located where the forward end of the outsole projection is to be formed. As shown, the incision 40 is so shaped, and it is extended through the insole layer at such an angle to the surface of the latter, that when the incised portion of the sole blank has been distorted by the matrix and die rolls of the splitting machine the plane of the incision will coincide substantially with the plane of the splitting knife so that the knife will pass through the incision without cutting the insole layer. The angular relation of the incision it to the surface of the insole layer is such as to correspond to the angle of the bevel out which is to, define the insole opening and the outsole projection. Conveniently, the incision 5-53 may be formed by a hand tool, such as the chisel-like tool 42 shown in Fig. 4, the cutting edge of which is preferably curved transversely so that the cut formed thereby will be curved to correspond substantially to the lengthwise curvature of the beveled edge which is to be formed at the front end of the outsole projection. While the sole blank is distorted during the splitting operation in the manner which will be hereinafter described, the curved incision 4!] will become straightened so that it may be entered by the straight cutting edge of the splitting knife. As herein illustrated, the location of the incision in the sole blank may be gaged by means of a mark or indentation 44 75 (Fig. 1) which may be made, for example, by means of a properly located die 45 (Fig; 2) on the pattern 32 of the rounding machine.

After the incision 40 has been cut in the insole layer of the sole blank the sole blank is ready for the splitting operation which may be advantageously performed by means of a machine of the general type of that disclosed in a copending application, Serial No. 759,846, filed December 31, 1934, in the name of William D. Thomas. In the use of this machine the forepart of the sole blank is temporarily flexed or deformed by depressing a portion thereof corresponding in shape and location to that of the opening to be produced in the insole so that the depressed portion will avoid the knife of the splitting machine by means of which the blank is divided.

As indicated in Fig. 5, the splitting machine comprises a single straight-edged splitting knife 46, an adjustable upper matrix roll 48, and a lower die roll 50 which is yieldingly mounted so as to press the work toward the upper roll. The upper roll 48 has formed therein a cavity or matrix 52 shaped to conform in outline to that of the opening to be formed in the forepart of the insole, while the lower roll 55 has formed thereon a projection or die 54 that is complemental to the cavity 52 in the upper roll. The cavity 52 and the projection 54 are so related to each other and to the work, as indicated in Fig. 5, that they will coact to deform the material of the sole blank at a pointbeginning at the incision 40, as indicated in Fig. 7, and continuing rearwardly to where the rearward extremity of the outsole projection is to be located. The upper roll may be adjusted relatively to the knife 46 so that as the sole blank is being fed past the knife the knife will operate to split the marginal portion of the forepart of the blank substantially in the plane of adhesion between the insole and outsole layers, or so that the knife will pass idly between the uncemented marginal portion of those layers in cases where they are cemented together only in their central forward portions. however, the machine may be adjusted so that in splitting the marginal portion of the forepart of a laminated sole blank the knife will cut through the outsole layer close to the plane of adhesion but at a slight distance therefrom. The splitting of the marginal portion of the forepart of a sole blank in the plane of adhesion between the insole and outsole layers is illustrated in Fig. 7, whereas the splitting of that portion of a blank through the outsole layer is illustrated in Fig. 8. If the marginal portion of the blank is split through the outsole layer, as illustrated in Figs. 8, 11, 12, 13, and 14, the splitting operation, in addition to dividing the laminated sole blank into an insole and an outsole, will result also in the removal from the margin of the outsole layer of a thin waste strip or portion of scrap material around the margin of the insole. v

The manner in which the central forward portion of a sole blank is deformed by the action of the die and matrix rolls is illustrated in Figs. 6, 7, and 8 and Figs. 7 and 8 also clearly disclose the location of the preliminary incision 4t relatively to the distorted central portion of the sole blank and show that the incision, after being straightened out by the deformation of the blank, is located in position to be readily entered by the knife.

When, in the course of the feeding of the sole blank past the splitting knife, the incision 4B in the sole blank reaches the knife, the knife will Alternatively,

enter the incision and will have no tendency to tear or mutilate the material in that portion of the blank which is being temporarily held in a flexed and deformed condition by the cooperative action of the die and matrix rolls. In cases where the insole and outsole layers of a laminated sole blank are to be separated by the passage of the splitting knife along the plane of adhesion between those layers the portion of the knife which is to out around the temporarily deformed central. forward portion of the insole layer will have no tendency to remain between the insole and outsole layers but will enter and readily pass through the incision in the insole layer. In the case of a sole blank the insole layer of which is of laminated formation, there will be no tendency for the knife to enter between any of the plies of the insole material. In any case the presence of the incision 4B in the insole layer of the sole blank will insure that the opening which is to be formed in the insole and the corresponding projection which is to be formed on .the outsole as a result of the splitting operation will each be defined by a clean cut in its forward portion instead of by a ragged out such as might be produced if no preliminary incision were made in the insole layer of the blank.

After the deformed portion of the sole blank has been advanced past the splitting knife and after the material operated upon has had an opportunity to react from the deforming pressure of the matrix rolls, the resulting insole and outsole will appear as shown in Figs. 9 and 10, respectively, or as shown in Figs. 11 and 12, respectively, depending upon whether the marginal portion of the forepart of the blank is split in the plane of adhesion between the insole and outsole layers (as in Figs. 9 and 10) or in a plane intersecting the outsole layer (as in Figs. 11 and 12) bears the relation to the sole blank indicated conventionally by the dotted line 60 in Fig. 6, the insole and outsole produced by the splitting operation will appear as shown in Figs. 9 and 10, respectively, the insole 62 being composed entirely of the material of the original insole layer and the outsole 64 being composed only of the material of the original outsole layer, except in the central portion of its forepart where the projection 66 (which is complemental to the opening 68 in the insole) is composed entirely of insole material.

If, however, the adjustment of the splitting machine is such that the cutting edge of the splitting knife bears the relation to the work indicated by the dotted line 10 in Fig. 6, then the resulting insole and outsole will appear as shown in Figs. 11 and 12, respectively, the insole I62 having a thin skiving 12 of outsole material secured to the original insole layer, while the edge thickness of the outsole I64 is reduced an amount corresponding to the thickness of the skiving 12.

While, as herein described, the laminated sole blank is rounded to sole shape after its component layers have been secured together and the preliminary incision 40 is made in the insole layer after that layer has been secured to the outsole layer, it is practicable, and may in some cases be desirable, as indicated in Fig. 15, to round or die out the outsole and insole layers 22 and 24 to sole shape and to form a preliminary incision I40 in the insole layer before securing the latter to the outsole layer.

1 Having described my invention, what I claim If the adjustment of the splitting machine is such that the cutting edge of the knife 46 as new and desire to secure by Letters Patent of the United States is:

1. In shoemaking methods, that improvement which consists in securing two layers of material together by means of adhesive to form a laminated sole blank, making a preliminary cut extending through one of said layers near the toe end of the blank thereby initiating the division of said blank by a rearwardly progressing splitting operation into an insole having an opening in its forepart and an outsole havinga forepart projection complemental to said opening, and thereafter making a second cut complementing said first cut and completing said division of said blank.

2. In shoemaking methods, that improvement which consists in providing a laminated sole blank comprising an outsole layer and an insole layer having formed therein a preliminary incision adapted to constitute the forward portion of a central forepart opening subsequently to be formed in said insole layer, entering a knife within said preliminary incision, and relatively moving the blank and the knife to cause the knife to extend said incision around the central forepart portion of the insole, thereby completing the formation of a central opening in the forepart of the insole and forming on the forepart of the outsole a central projection which is complementary to the opening in the insole.

3. In shoemaking methods, that improvement which consists in forming in an insole blank a preliminary incision shaped and arranged to constitute the forward portion of a central forepart opening subsequently to be formed therein, securing said insole blank and an outsole blank together in face-to-face relation, thereby providing a laminated blank, and dividing said laminated blank into an insole having a central forepart opening and an outsole having a central forepart projection complemental to said opening by means of a splitting knife which, in the course of its operation upon the laminated blank, passes through said preliminary incision.

4. In shoemaking methods, that improvement which consists insec'uring an insole blank and an outsole blank together in face-to-face relation, thereby providing a laminated blank, making a preliminary cut extending through said insole blank, temporarily deforming said laminated blank by depressing its central forward portion and while the blank is thus deformed relatively moving the blank and a straight-edged splitting knife to cause the knife to divide the blank into an insole and an outsole and in so doing to pass through said preliminary cut and thereafter to continue said out and thereby to form an opening in the insole blank and a projection on the outsole blank complementary to said opening.

5. In shoemaking methods, that improvement which consists in securing together an insole blank and an outsole blank in their central forward portions on1y,'thereby providinga single laminated sole blank, making a preliminary incision through the insole blank at the forward end of that portion of said blank which is secured to the outsole blank, thereby initiating the division of said laminated sole blank into an insole having a central forepart opening and. an outsole having a central forepart projection complemental to said opening, passing a splitting knife through said incision in the insole blank, and thereafter operating said knife to complete the division of said laminated blank into an insole and an outsole.

6. That improvement in methods of making skeleton insoles of laminated formation which consists in making in a laminated insole blank a preliminary cut shaped and arranged to constitute part of a central opening to be formed in said blank, and subsequently deforming the central forward portion of the blank and feeding the blank thus deformed past a straight-edged splitting knife to cause said knife to pass through said preliminary cut without entering between the layers constituting said blank and. thereafter to extend said preliminary cut around the depressed portion of the blank, thereby completing the formation of said central opening in said blank.

'7. In methods of making soles, that improvement which consists in securing together in faceto-face relation by means of adhesive a blank of insole material and a blank of outsole leather, thereby forming a unitary laminated sole blank, making a preliminary incision in said blank of insole material, passing said laminated sole blank between a roller having a die shaped to flex the central forward portion of said blank out of the plane of the rest of the blank and a second roller having a matrix adapted to receive said flexed sole blank portion, and while said blank is thus flexed between said rollers, rotating said rollers and advancing the blank edgewise past a straightedged knife, thereby splitting the blank into an insole comprising said insole material and having an opening in its forepart, and an outsole having a main portion comprising said outsole material and having upon its forepart a projection cornplemental to said insole opening and during said splitting operation causing said knife to pass through said preliminary incision in said insole blank.

8. In methods of making soles, that improvement which consists in securing together in faceto-face relation by means of adhesive an insole layer and an outsole layer, thereby providing a single composite blank of laminated formation, making a preliminary cut through said insole layer in a position to coincide with the forward extremity of an opening subsequently to be formed in said layer, and dividing said composite blank into an insole having a central forepart opening and an outsole having a central forepart projection complemental to said opening by means of a splitting knife which in operating upon the marginal portion of the forepart of said blank splits the blank in a plane substantially parallel to the plane of adhesion between its layers and located within said layer of outsole material and which in operating upon the central forward portion of the blank passes first through said preliminary incision without cutting said insole layer and thereafter cuts through the central forward portion of said layer.

9. In the manufacture of soles, that step product which consists in a sole blank of a thickness equal to the combined thickness of an insole and an outsole into which said blank is to be divided and having a preliminary cut extending obliquely inward from one side of the toe portion of the blank to a depth equal to the thickness of said insole and in a position to be entered by a knife in the act of dividing the blank into an insole having a central forepart opening and an outsole having a central forepart projection complemental to said opening.

10. In the manufacture of soles, that step product which consists in a laminated sole blank comprising an insole layer and an outsole layer secured together in face-to-face relation, said blank having a preliminary cut extending through said insole layer in position to be entered by a splitting knife in the operation of dividing said blank into an insole having an opening in its forepart and an outsole having a forepart projection complemental to said insole opening, said out being located where the forward end portion of said insole opening is to be formed.

11. In the manufacture of soles, that step product which consists in a laminated sole blank comprising an insole layer and an outsole layer secured together in face-to-face relation, said blank having an incision in said insole layer shaped to correspond to the shape of the forward end portion of a central opening subsequently to be formed in said layer in the process of dividing said blank into an insole having an opening in its forepart and an outsole having a forepart projection complemental to said opening.

12. In the manufacture of soles, that step product which consists in an insole blank prepared for the performance of a skeletonizing operation thereon by having formed therein a preliminary cut for facilitating the entrance of a skeletonizing knife into the material of the insole blank, said out being shaped and arranged to constitute the forward portion of the opening to be formed in the blank.

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