US2317475A

US2317475A - Shoe bottom unit and method of making the same

Info

Publication number: US2317475A
Application number: US417904A
Authority: US
Inventors: Thomas C Morris; Jr Frank S Gregory
Original assignee: United Shoe Machinery Corp
Current assignee: United Shoe Machinery Corp
Priority date: 1941-11-05
Filing date: 1941-11-05
Publication date: 1943-04-27
Anticipated expiration: 1960-04-27

Description

April 1943- T. c. MORRIS ETAL 2,317,475

SHOE BOTTOI UNITS AND METHOD OF MAKING THE SAME Filed Nov. 5, 1941 2 Sheets-Sheet 1 April 1943- I T. c. MORRIS ETAL 2,317,475

SHOE BOTTOM UNITS AND METHOD OF MAKING THE SAME Filed Nov. 5, 1941 2 Sheets-Sheet 2 Patented Apr. 27, 1943 SHOE BOTTOM UNIT AND METHOD OF MAKING THE SAME Thomas 0. Morris, Belmont, and Frank S. Gregory, Jr., Burlington, Mass, assignors to United Shoe Machinery Corporation, Flemington, N. J a corporation of New Jersey Application November 5, 1941, Serial No. 417,904

46 Claims.

This invention relates to improvements in shank pieces and bottom units for use in shoes and to improved methods of making such members.

It has been the usual practice heretofore in. the manufacture of the more common types of shoes to reinforce the shank and heel portions of the insole in order to render these portions of the shoe bottom, particularly the shank portion, hard and stiff enough to hold their shape under the weight of the body and thereby insure that the foot will be properly supported during the wearing of the shoe. The reinforcing of the shank and heel portions of the shoe bottom has usually been accomplished by attaching a piece of relatively stiff fibrous material, such as flberboard or the like, to the shank and heel portions of the insole and then introducing a r latively narrow shank stiffener between the insole and reinforcing member, the shank stiffener being composed of steel and being shaped in accordance with the longitudinal curvature of the shank and heel portions of the shoe bottom. The shank stiffener is usually positioned centrally of the insole and extends from the heel seat portion to the ball line of the shoe. It is secured in position by tacks or staples or by prongs formed on the stiffener itself. The assembled parts including the stiffener are then molded into conformity with the longitudinal contour of the bottom of a last.

While shoes reinforced in this manner or by similar means are in general satisfactory and usually give good results, the use of a steel shank stiffener in the bottom of the shoe has some disadvantages among which is the fact that the shank stiffener sometimes works loose or changes position in the shoe bottom so that it forms a floating support, or it might even break under the strains of constant and heavy pressure during wear. Moreover, as the shoe is worn a steel shank stiffener often has a tendency to work through the insole at the ball portion and thus show on the inside of the shoe. Since the shank stiffener, aithough providing the chief means of support at the shank and heel portions of the shoe bottom. is quite narrow, the foot has practically no support transversely or widthwise and consequently it may tip laterally during walking which produces an uneven tread, thereby causing the shoe to lose its shape, particularly at its heel and back portions, and to wear out too quickly, this result, of course, being detrimental to the foot. Another disadvantage of a steel shank stiffener is that in shoes having their outsoles sewed or nailed to the shoe bottom, the

shank stiffener may interfere with the sewing or nailing operation, particularly in shoes having extremely narrow shank portions.

Important objects of the present invention are to provide an improved shank piece in which the above difiiculties are overcome or eliminated, to provide an improved shoe bottom unit embodying such a shank piece, and to provide improved methods of making the shank piece and shoe bottom unit.

To these ends and in accordance with one of its aspects, the invention provides, as a new article of manufacture, an improved shank piece of laminated formation consisting of a plurality of layers of fibrous material impregnated with, and secured in assembled relation by, hardened stiffening material of an adhesive nature. As illus trated, the layers of the shank piece comprise outer layers of relatively stiif, rigid material and inner layers of relatively flexible material. Preferably, and as herein illustrated, the outer layers are composed of wood and the inner layers comprise layers of paper and layers of fabric material, a layer of wood being also included, if desired, for added strength and rigidity. It will be noted, however, that although the outer layers of the shank piece are composed of fibrous material which is normally stiffer and more rigid than the material of the inner layers, these outer layers are nevertheless of a character offering less resistance to penetration, for example, by lasting fastenings or the like than the material of the inner layers.

The reinforcing or stiffening material with V which the layers are impregnated is of an adhesive or bonding nature and is preferably also thermoplastic in character so that the layers, after being impregnated and stiffened thereby, can be rendered pliable again to permit them to be secured together in assembled relation and to be molded into the desired shape, or to permit the shank piece when completed to be remolded to a different or more accurate shape.

In order that the shank piece will support the foot transversely or widthwise as well as longitudinally, the outer layers and preferably some of the inner layers are shaped to correspond in outline to the edge contour of the shank and heel portions of an insole, for example, the insole with which the shank piece is to be used in a shoe. The rest of the inner layers are arranged to diminish graduallyin size from that of said outer layers to much smaller layers, this reduction in size taking place progressively from an upper inner layer to a lower inner layer. In

this way the shank piece is provided with a body portion which is thicker at its central portion than at its margins to provide maximum strength without being too bulky for the space it should occupy in the normal shoe bottom.

In addition to being coextensive with the shank and heel portions of an insole, the illustrated shank piece conforms approximately in shape to the longitudinal and transverse curvatures of the bottom of a last. Since the stiffening material with which the layers are impregnated is of a thermoplastic nature, the hardened materials of the shank piece can be rendered pliable again under proper activation, such as heat and pressure, and can be remolded to conform the shank piece accurately to the shape of the bottom of a particular last as, for example, the last upon which the shoe is to be made. In this way the shank piece can be made to fit the bottom of a particular last without the necessity of providing separate molds for each size and shape of last, which, of course, would require so many molds that the expense would be prohibitive.

The illustrated invention also provides, as a new article of manufacture, animproved shoe bottom unit adapted for use in a shoe without additional preparation or treatment, said unit consisting of the laminated shank piece of fibrous material having the further characteristics pointed out above, and an insole to which the shank piece is secured to reinforce the shank and heel portions of the insole and to form a complete unit. As herein illustrated, the fibrous shank piece may be attached to the outer surface of the insole by an adhesive such as latex or rubber cement or, if desired, by a thermosetting adhesive, such as neoprene. The inner surface of the shoe bottom unit provided by the insole is molded to render it substantially complemental in shape to the bottom of a particular last while the outer surface of the bottom unit, including the shank piece at the rear portion thereof, is caused to correspond generally in shape to the inner surface of the insole except at the portion formed by the shank piece which has greater curvature due to the materials making up the shank piece, that is, the inner layers forming the body portion of the shank piece. Since the hardened or stiffened material of the shank piece is capable of being rendered pliable, the shank piece can be readily remolded into accurate conformity with the last bottom at the time the insole is moulded. The completed shoe bottom unit, therefore, will have a firm, rigid shank and heel portion which is accurate in shape and is adapted to support the foot transvers'eiy in the shoe as well as longitudinally, thereby tending to produce a substantially even or uniform tread which reduces run-over heels, broken breast flaps, and shoes having bulged or distorted back parts or rear portions.

In its method aspects, the invention provides an improved method of making bottom units for shoes which consists in providing a shank piece of relatively stiff, rigid material which has been molded to conform approximately-in shape to the bottom of a last, assembling this shank piece with an insole on a last bottom, molding the insole into accurate conformity with the shape of the last bottom while simultaneously remolding the shank piece into accurate conformity with the shape of the last bottom, and securing the insole and shank piece together to com plate the shoe bottom unit. As illustrated, the shank piece is of laminated formation and is composed of fibrous material, the layers of the shank piece having been impregnated with stiffening material of an adhesive nature which is also thermoplastic in character, thereby permitting the shank piece to be rendered pliable by activation of the stifiening material when it is desired to remold the shank piece in forming the shoe bottom unit.

In still another aspect, the invention provides an improved method of making shank pieces for shoes which consists in impregnating a plurality of layers of fibrous material with stiffening material of an adhesive nature, cutting from the layers a plurality of members some of which correspond in size and shape to the shank and heel portions of insole and others of which diminish in size from the first-named members to much smaller members, assembling the members in superimposed relation with the larger, insole-shaped members forming the outer layers of the assembly, and molding the assembled members under heat and pressure to secure them in assembled relation and to fuse them together to form an integral shank piece unit while simultaneously conforming the unit to approximately the shape of the shank and heel portions of a last bottom. As illustrated, the outer or top and bottom layers of the shank piece are composed of wood and the inner layers comprise layers of wood, paper and fabric material, respectively. The inner paper layers of the shank piece are arranged so that they diminish progressively in size from an upper paper layer to a lower paper layer.

With the above and other objects and aspects in view, the invention will now be described in connection with the accompanying drawings and will thereafter be pointed out in the claims.

In the drawings:

Fig. l is a perspective view of the members which form the shank piece arranged in assembled relation;

Fig. 2 is a longitudinal section taken on the line IIII of Fig. 1;

Fig. 3 is a sectional plan view, with portions broken away, taken on the line IIIIII of Fig. 2 as viewed from below;

Fig. 4 is a plan view simiiar to Fig. 3, taken on th line IV-IV of Fig. 2 as viewed from above, with portions of the figure broken away;

Fig. 5 is a diagrammatic sectional View illustrating a method which may be used to impregnate the materials of the shank piece;

Fig. 6 is a side elevation partly in section showing the members of the shank piece being molded to secure them together and to conform them to approximately the shape of a last bottom;

Fig. 7 is a perspective view of the shank piece after it .has been molded, a portion of the shank piece being broken out to show its shape more clearly;

Fig. 8 illustrates the operation of attaching the shank piece to an insole and molding the insole and remolding the shank piece to the shape of a last bottom;

Fig. 9 is a perspective view of the outer or lower side of the insole and shank piece after they have been attached together and molded to form a single shoe bottom member or unit; and

Fig. 10 is a transverse section taken on the line X-X of Fig. 9.

The illustrated shank piece is of laminated formation and consists of a plurality of layers of fibrous material which, hereinafter explained.

are impregnated with a stiffening material of an adhesive or bonding nature to secure the layers together and to render them relatively stiff and rigid. After the layers of fibrous material have been impregnated with stiffening material, the members which are to form the shank piece are out are died out of the layers and are arranged in assembled relation, as illustrated in Figs. 1 to 4, inclusive.

Fibrous materials which may be used in making the shank piece comprise, as herein illustrated, relatively stiff, rigid material, such as wood, and relatively flexible materials such as fabric and paper. The wood members may be formed from wood veneer such, for example, as basswood which is preferably about /2:; of an inch thick. The fabric material may consist of nine-ounce Gem duck while the paper is preferably unsized kraft paper about .011 of an inch thick. As illustrated in Figs. 1 to 4, inclusive, the members or layers which form the shank piece are cut or died out of these diflerent fibrous materials and are assembled in a predetermined relation to each other in order to be made into a single unitary shank piece.

In accordance with the present method, the layers forming the shank piece are preferably assembled in the following order: The lower or bottom layer 20 is composed of wood and, as illustrated in Figs. 1 to 4, corresponds in size and shape to the edge contour of the shank and heel portions of an insole which is preferably the one which is to be used in making the shoe. The top layer 22 of the shank piece is also composed of wood and is shaped to correspond in outline to the shank and heel portions of the insole. These top and bottom or outer layers of the laminated shank piece, therefore, are composed of material which is normally relatively firm and stiff and which provides substantially rigid or non-yielding surfaces in the finished article for supporting the foot. It should be pointed out, however, that although the wood which forms the material of the outer layers of the shank piece is normally or in its natural condition more rigid and stifi than material such as cloth or paper,

which is to form the inner layers, the wood is nevertheless of a character which offers less resistance to penetration by fastenings such, for example, as lasting tacks or staples or heel attaching nails, than the fabric and paper materials forming the inner layers, particularly when the latter materials are compressed or molded under relatively heavy pressure.

Located above the bottom layer 20, as viewed in Figs. 1 to 4, is a layer 24 of paper impregnated with stiffening material, as mentioned above, and corresponding in size and shape to the bottom layer 20. Above the paper layer 24 is another layer 26 of wood which is also shaped like, or is coextensive with, the shank and heel portions of the insole so that it coincides with the

lower layers

20 and 24. Below the top layer 22 is a layer 28 of impregnated fabric material, such as the Gem duck referred to, which corresponds in size and shape with the top layer 22. Between the fabric layer 28 and the-Wood layer 26 is interposed a plurality of inner layers of the impregnated paper which, as illustrated in Figs. 2 and 3, are smaller than the outer layers and diminish progressively in size from the top paper if layer to the lower paper layer.

As herein illustrated, there are preferably seven layers of paper between the wood layer 26 and the fabric layer 28, this number being illustrative rather than an essential requirement, however, since the number may be increased or reduced if conditions seem to warrant. The upper paper layer 30 corresponds substantially in shape to the fabric layer 28 but is somewhat smaller, as shown in Figs. 2 and 3. Below the layer 30 is another paper layer 32 similar to, but smaller than, the layer 30 and below the layer 32 are three more paper layers 34, 36 and 38, smaller than the layer 32 and tapering somewhat toward their forward or right-hand end, as viewed in Fig. 3, the

layers

34, 3B and 38 being substantially equal in size and shape. Below the layer 38 are two smaller paper layers 40, 42 substantially rectangular in shape and of equalsize. As stated above, the paper is preferably unsized kraft paper which may be readily impregnated with stiffen- .ing material to render it considerably stiffer and less flexible than it is normally.

In order to facilitate the assembling of the im-' pregnated layers of the shank piece in the manner just described, the upper fabric layer 28 and the seven inner paper layers may be first assembled, as shown in Figs. 2 and 3, and secured in assembled relation by a single staple 44 to form a unit, the staple being clinched against the upper fabric layer 28. Also, if desired, the three lower layers 21], 24, 26 of wood, paper, and wood, respectively, may be adhesively united during or after the impregnating operation so that, when the shank piece members of proper size and shape are cut from these layers, these three lower members will form a unit which may be assembled in the same manner as the fabric and inner paper layers. The remaining top layer 22 of wood can be assembled on the others separately. By this procedure there will be a maximum of only three separate members or units to assemble and each unit will contain at least one layer which corresponds in size and shape to the shank and heel portions of the insole so that the three units can be readily located with respect to one another.

The stiffening material with which the layers of fibrous material are impregnated comprises a substance or solution which, as herein illustrated. is preferably both thermosetting and thermoplastic in character but in which the thermoplastic quality predominates. Moreover, as indicated above, the stiffening material is also of an adhesive or bonding nature so that it will act as a bonding or fusing agent as well as a stiffening medium. One material that has been found to meet the above requirements comprises a thermm plastic impregnating varnish containing a medium quantity of 'thermosetting resin, the mixture being such that when the varnish is applied to fibrous materials, such as cloth, wood or paper and the solvent is removed, the stiffening rial will, under proper activation, for example, heat and pressure in the present case, bond or fuse the layers of fibrous material firmly together into a single integral mass or unit which is relatively firm and stiff at room temperature but which can be rendered pliable again at elevated temperature so that the unit can sub-se quently be remolded and conformed to any desired shape under comparatively low pressure. One example of a stiffening material or varnish which be used is the following:

Acetone (solvent) 199g I Part :Vinylite-XYSG (vinyl acetal resin) 150 One Step Phenolic Resin 150 Ethyl alcohol .(solvent) 1260 impregnating the different layers of fibrous materials Part A and Part B of the formula are mixed in equal volumes. The unsized kraft paper and the fabric layers may be treated by passing them through the mixture followed by airdrying and heating at 105 C. for a predetermined period. Figure 5 illustrates a convenient method of impregnating the paper and fabric layers which consists of drawing a layer or strip .43 of either material around a rotary supporting roll 18 and passing it under a pair of submerging rolls 59,52 rotatably mounted in a tank 5% con taining stiffening material Tl e strip 55 passes from the tank around another supporting roll 58 and is g ided through a horizontal drying chamber 50 from whence it may be wound upon a receiving roll (not shown) and then heated for 20 to minutes at a temperature of 105 C.

While the wood veneer, such as the basswood which forms the outer layers of the shank piece, can be used without impregnating it with stiffening material because the wood is normally hard and stiff enough to be used without additional stiffening, the wood layer may, if desired, be impregnated the same as the cloth and paper layers by submerging it in the stifl'enin' solution for about 15 minutes and then air-drying the wood and heating it at 105 C. for 15 or 20 minutes. Since layers of fibrous material treated in the manner amount of lateral displacement or flow when embodied under pressure in articles of laminated formation, the several members forming the shank piece may all be cut to their proper shapes and sizes at the time they are died out of the various layers of impregnated fibrous materials. It should be pointed out, however, that while the wood layers have practically no. displacement or flow under relatively heavy pressure, the inner or paper and fabric layers do flow sufiiciently under heavy pressure to permit the unit to be molded to tr e required shape both laterally and longitudinally.

The members which make up the shank piece, including the outer wood layers if desired, having been impregnated and arranged in assembled relation, as illustrated in Figs. 1 to 4:, inclusive, the assembly is next molded under heat and pressure to secure the layers in assembled relation and to bond or fuse them together into a single, integral shank piece unit and simultaneously to conform the'unit to approximately the shape of the shank and heel portions of a last bottom, the stiffening material rendering the unit relatively hard and stiff after the molding operation so that it will retain the shape imparted to it by the molds. The molding operation may be performed in any usual or convenient manner as, for example, in a press 62 (Fig. 6) which, as illustrated, is provided with upper and lower molds 64, 66 having formed respectively therein molding surfaces 68 and iii, the molding surface (52 being shaped to conform approximately to the longitudinal and transverse curvatures of the shank and heel portions. of the bottom of a last of medium or average size and shape, and the surface 10 being generally similar in shape to the upper surface 68 but having more pronounced or sharper curvatures for accommodating the materials displaced by the upper molding surface described do not have a very great I ag ng;

68. The molds 64, ,66 are .guidedrelatively-to each other in operation by dowels-12 and .eachis provided with a pair of electric heating units 14, as illustrated in Fig. 6. The total pressure exerted by the molds upon the shank piece members to obtain the desired results ;is about ,1 6 tons or approximately 4000 pounds to thesquare inch and this pressure is maintained for about ten minutes. The molds are heated to about 300 F. in order to bond or fuse the layers together into a single, integral unit whilesimultaneously rendering the materials sufliciently pliable to permit the apparatus to mold them to the shape defined by the molding surfaces-68 and 10,

After the layers have been united and molded to the desired shape, the heat, may be turned off and the materials permittedto cool sufficiently while still under pressure to form a relatively stiff and rigid shank piece unit 75, such as that illustrated in Fig. '7. As shown in that figure the shank piece has an inner surface ,18 which conforms approximately in shape -to the longitudinal and transverse curvatures of alast :bottom of average size and shape, and an outersurface which is more sharply rounded-or curved owing to the thicknesses of the inner layers of fibrous materials which were interposed between the top layer 22 and the bottom layer 26. Moreover, as illustrated in Fig. '7, the shank piece is firm and stiff enough after the molding operation to retain indefinitely the shape impartedto it by the molds.

The present invention contemplates not only the provision of an improved shank piece composed of fibrous materials, but also the provision, as a new article of manufacture, of an integral shoe bottom unit adapted without additional preparation to be used in a shoe. In carrying out this aspect of the invention, the molded shank piece 16 is united with an insole 32 (Fig. 9.) to form a complete shoe bottom unit. It is desirable, however, besides securing the shank piece and insole together to form a single shoe bottom unit, to have the unit, including the shank piece, conform accurately to the shape of the bottom of a particular last, as for example, the last upon which the shoe is to be built. Accordingly, the hardened shank pi ce 16 is positioned upon the outer or lower surface of the insole 82, which may be readily accomplished because the peripheries or edge contours of the insole and shank piece correspond accurately to one another. The assembled insole and shank piece are next mounted on the bottom of a last 84 (Fig. 8) upon which the shoe is to be builtv and are pressed against the bottom of the last under pressure and heat sufiicient to mold the insole accurately to the shape of the last bottomand to render the shank piec pliable again and to remold it accurately to the shape of the shank and heel portions of the last bottom or, in other words, into accurate conformity with the rear portion of the molded insole;

The molding of the insole and remolding of the shank piece may be accomplished in any usual or conventional type of press such, for example, as a sole attaching press of the general type disclosed in Patent NO. l,9llf.,5 i6, granted March 14, 1933, upon an application filed in the name of George H. Barge. The sole attaching press, as illustrated in the Barge patent, is provided with a flexible bladder or bag 86 carried in a base 88 and filled with liquid, such as water, which is heated by an electricheating unit through the base nto the bladder. on th st i" pr d against the flexzm 92 pivoted on a pin 9% and arranged to swung downwardly toward the bladder by a pair of springs 96 which are tensioned manually to apply pressure by suitable mechanism (not shown), the pressure being maintained by a latch arranged to engage notches 93 formed in the rear end of the arm 92. The arm 92 carries pressure applying abutments I00, Hi2 arranged respectively to engage and apply pressure to the forward portion of the last and its rear or heel portion.

The pressure desired for molding the insole and remolding the shank piece to the shape of the last bottom is preferably from 100 to 300 pounds to the square inch, which is much less pressure than was utilized for initially fusing and molding the several layers to form the shank piece unit and for conforming the unit approximately to the contour of a medium shaped last bottom. This relatively low pressure, however, is sufiicient to mold the insole and to remold the shank piece as described with the advantage that it is not great enough to damage the last used in this final molding operation as the much heavier pressure of the initial molding operation clearly would be. The heat applied in this second molding operation preferably ranges from 250 to 300 F. which renders the shank piece pliable and permits it to be readily remolded into accurate conformity with the transverse and longitudinal curvatures of the insole and last bottom. The pressure and heat are maintained on the insole and shank piece from 10 to minutes. Since the insole and shank piece are to form a single, integral shoe bottom unit, the shank piece must also be permanently attached to the insole and this may be accomplished during the molding operation by applying adhesive such as latex or rubber cement to the opposing surfaces of the insole and shank piece prior to assembling them on the bottom of the last. If desired, a thermosetting adhesive such as neoprene may be used for this purpose instead of the adhesives mentioned above. After the unit has been molded and conformed, the heat is turned off and the unit is permitted to 0001 under the full pressure to eliminate any strains set up in the molding operation so that the unit will retain its shape permanently unless remolded.

Although the operation of molding the insole and shank piece into an integral shoe bottom unit is disclosed herein by way of example as being performed in a sole attaching press of the type disclosed in the Barge patent, this operation can obviously be carried out with other types of presses adapted to apply heat and pressure to the bottom of a last or shoe. Moreover, it is not essential that the molding press be adapted to apply heat to the last or shoe parts since the shank piece may, if desired, be heated to the required temperature separately in an oven or other heating device and the positioned on the cementcoated outer surface of the insol and assembled with the insole on the last bottom, the assembly being then mounted, for example, in a sole attaching press arranged to apply pressure to the last bottom. A press which is well adapted for use in molding the shoe bottom unit after the shank piece has been heated separately, as described above, is a press or pad box of the general type disclosed in Letters Patent of the United States No. 2,047,185, granted July 14, 1936, on an application filed in the name of Milton H. Ballard et al.

Although it is not essential to carrying out the method, the cooling of the shoe bottom unit While under pressure may be accelerated by circulating cold water around or through the pad or bladder, thereby speeding up this operation and reducing the time and expense of producing the units in quantity or on a production basis.

Fig. 9 illustrates the completed shoe bottom unit I84 consisting of the molded insole 82, conforming accurately in shape to the bottom contour or curvature of the last 84, and the laminated shank piece 16 permanently attached by adhesive to the outer face of the insole, the shank piece having been remolded to conform accurately in shape to the shank and heel portions of the in- .sole and last bottom. Fig. 10 illustrates the transverse curvatures which are imparted to the insole and shank piece at an intermediate portion of the unit or at a point located forwardly of the heel breast line in a finished shoe.

It will be observed in Figs. 9 and 10 that the longitudinal and transverse curvatures of the rear portion of the shoe bottom unit I04 are somewhat greater or more sharply rounded than th corresponding curvatures of the shank piece illustrated in Fig. 7 because of the conformation of the unit to a particular last bottom. These greater curvatures of the completed bottom unit will be retained permanently in the finished article because of th character of the materials making up the shank piece and also because of the nature of the stiffening material with which the materials of the shank piece were impregnated. However, if it should be desired to change the shape of the shoe bottom unit after it has been completed, this can be done, as indicated above, by merely activating the stiffening material by applying heat to the shank piece to render it pliable again and then remolding the shoe bottom unit to the shape desired. It should be noted that, since the shank piece is coextensive in outline with the shank and heel portions of the insole, the unit as a whole will support the foot Widthwise or transversely as well as longitudinally.

Although the shoe bottom unit of Figs. 9 and 10 is stiff and rigid enough to support the foot, including its shank and heel portions, in proper position both longitudinally and transversely during the wearing of the shoe, it nevertheless has sufilcient resiliency to permit it to yield or flex slightly at the shank under relatively heavy pressure. For all practical purposes, however, the shank and heel portions of the unit comprise a substantially rigid, non-yielding arch or bridge which provides a firm, positive support for the rear portion of the foot both laterally and longitudinally, thereby increasing the comfort of the wearer and tending to produce a tread in walking which is substantially even or uniform which, in turn, reduces the tendency to wear out the heel or the top lift of the shoe unevenly or prematurely, and also minimizes the chances of distorting or running over the counter or back part of the shoe or breaking the heel breast flap, which often occurs in such cases.

Although the shank piece member of the shoe bottom unit is extremely stiff and hard after being fused and molded into the unitary member, it is not so hard or rigid that it will prevent or interfere with the usual shoemaking operations such, for example, as lasting the upper or attaching a heel to the shoe. An upper may, therefore, be worked over the shoe bottom unit and secured in lasted relation thereto by tacks or staples in the usual manner. As pointed out above, the material forming the outer layers of the shank piece, namely, the wood, is of a character which offers less resistance to penetration than the materials forming the inner layers, particularly when the latter are compressed or molded and, accordingly, the tacks, staples or other fastenings will readily enter the shank piece when driven without being bent or deflected from the line of drive. It is preferable, however, in lasting the upper, to perform this operation with tacks or staples which do not extend completely through the shoe bottom unit at its shank and heel portions and which will not have to be clinched against the inner surface of the unit or insole. In other words, the composition or density of the shank piece is such that, while fastenings such as nails, tacks or staples can be readily driven into or through the shank piece, the latter will hold the fastenings firmly without being clinched and accordingly short tacks and staples may be used, if desired, in place of longer lasting tacks adapted to be clinched or curved staples ordinarily used for lasting the forepart and side portions of the upper. It should be pointed out, however, that long lasting tacks or curved staples may be used if preferred.

The relatively great holding power of the fastenings in the present shoe bottom unit will tend to prevent the upper from creeping or becoming displaced lengthwise at the shank portion of the shoe and the firmness or rigidity of the shank piece will also provide a better anchorage than usual for the heel attaching nails and consequently will contribute toward a stronger attachment of the heel to the shoe bottom. Moreover, since the shank piece is coextensive with the periphery of the insole at the heel seat portion of the shoe, the heel attaching nails will pass through the shank piece as well as through the insole and will thus secure or look the heel, the counter stiffener, and the insole including the shank piece, into one firm, rigid assembly which is much stronger than the usual construction in which the heel is attached only to the relatively flimsy insole at the heel seat.

The shoe bottom unit of the present invention, therefore, provides a firm, rigid support for the foot which supports the rear portion thereof laterally and longitudinally, and it also provides a stronger or firmer base than usual for receiving and holding lasting tacks and staples. Since the shank piece extends over the entire heel seat portion of the shoe bottom, the heel attaching nails will pass through it thereby locking the heel, counter and bottom unit together as a solid unit which results in a much stronger attachment of the heel to the shoe and also provides additional support for the rear portion of the upper. By reason of the above features and characteristics of the shoe bottom unit, the shoe is rendered more comfortable to the wearer and tends to cause the wearer to tread more evenly or uniformly in walking which, as stated, prevents the heel from being run over, the breast fiap from breaking, and the counter or back part of the shoe from being distorted or bulged out of shape.

Having thus described our invention, what we claim as new and desire to secure by Letters Patent of the United States is:

1. As a new article of manufacture, a shank piece of laminated formation consisting of a plurality of layers of fibrous material secured together by hardened stiffening material of an adhesive nature, said layers comprising outer layers of relatively stiff material and inner layers of relatively flexible material.

2. As a new article of manufacture, a shank piece of laminated formation comprising a plurality of layers of fibrous material secured together by a hardened reinforcing substance of an adhesive nature, the material of the outer layers of said shank piece being of a character offering less resistance to penetration by lasting fastenings or the like than the material of the inner layers of said shank piece.

3. As a new article of manufacture, a shank piece of laminated formation consisting of a plurality of layers of fibrous material impregnated with, and secured in assembled relation by, hardened stiffening material of an adhesive nature, said layers comprising outer layers of Wood and inner layers of fibrous composition material.

4. As a new article of manufacture, a shank piece of laminated formation consisting of a plurality of superimposed layers of fibrous material impregnated with stiffening material of a bonding nature which stiifens said layers and secures them together in assembled relation to each other, said layers comprising outer layers of relatively hard, stiff fibrous material and inner layers of fibrous materials of different degrees of hardness and flexibility.

5. As a new article of manufacture, a shank piece of laminated formation consisting of a plurality of layers of fibrous material impregnated with, and secured together by, hardened stiffening material of a thermoplastic nature, said layers comprising top and bottom layers of equal hardness and rigidity, an inner layer of the same hardness and rigidity as the top and bottom layers, and additional inner layers which are normally softer and more flexible than said top and bottom layers.

6. As a new article of manufacture, a shank piece of laminated formation consisting of a plurality of layers of fibrous material secured together by hardened stiffening material of an adhesive nature, said layers comprising outer layers of relatively stiff material and inner layers of relatively flexible material, said inner layers being impregnated with said stiffening material to render them relatively hard and stiff, and said outer layers being unimpregnated With stiffening material and being less resistant to penetration by driven fastening members than said inner layers.

'7. As a new article of manufacture, a shank iece of laminated formation consisting of outer layers of Wood, and a plurality of inner layers composed respectively of wood, paper and fabric material.

8. As a new article of manufacture, a shank piece of laminated formation consisting of a plurality of layers of fibrous material impregnated with, and secured in assembled relation by, hardened stiffening material of an adhesive nature, said layers comprising top and bottom layers of wood, and intermediate layers composed respectively of paper, wood and fabric material.

9. As a new article of manufacture, a shank piece of laminated formation comprising a plurality of layers of fibrous material united into a single unit, said layers consisting of top and bottom layers of wood and inner layers comprising, respectively, a layer of fabric material below the top wood layer, a plurality of layers 'of paper below said fabric layer, a layer of wood below said paper layers, and a layer of paper between the last-named wood layer and the bottom wood layer.

10. As a new article of manufacture, a shank piece of laminated formation consisting of a plurality of layers of fibrous material secured togather in assembled relation by hardened stiffening material of an adhesive nature, said layers comprising outer layers composed of wood and inner layers composed respectively of wood, paper and fabric material, said inner layers being impregnated with said stiffening material to render them relatively hard and stiff, and said outer wood layers being unimpregnated with stiffening material and ofiering less resistance to penetration than said inner layers.

11. As a new article of manufacture, a shank piece of laminated formation consisting of a plurality of superimposed layers of fibrous material secured together by hardened stiffening material of an adhesive nature before hardening, said layers comprising top and bottom layers of wood, a layer of fabric material and a layer of paper next to said top and bottom layers respectively, a layer of wood next to said layer of paper, and a plurality of layers of paper between the last-named wood layer and the layer of fabric material.

12. As a new article of manufacture, a shank piece of laminated formation consisting of a plurality of layers of fibrous material impregnated with, and secured in assembled relation by, hardened stiffening material of an adhesive nature, said layers comprising outer layers of equal size and shape and inner layers which diminish gradually in size.

13. As a new article of manufacture, a shank piece of laminated formation consisting of a plurality of superimposed layers of fibrous ma terial impregnated with, and secured together in assembled relation by, hardened stiffening material of an adhesive nature, said layers comprising top and bottom layers of equal size and shape, and inner layers which gradually diminish in size progressively from an upper inner layer to a lower inner layer.

14. As a new article of manufacture, a shank piece of laminated formation consisting of a plurality of layers of fibrous material impregnated with, and secured in assembled relation by, hardened stiffening material of a bonding nature, said layers comprising outer layers of equal size and shape composed of relatively stiff, rigid material and inner layers composed of relatively flexible material, said inner layers diminishing gradually in size from that of said outer layers from an upper inner layer to a lower inner layer.

15. As a new article of manufacture, a shank piece of laminated formation consisting of a plurality of layers of fibrous material impregnated with, and secured in assembled relation by, hardened stiffening material of an adhesive nature, said layers comprising top and bottom layers of equal size and shape composed of wood, said layers corresponding in shape to the shank and heel portions of an insole, and inner layers comprising, respectively, a layer of fabric below said top wood layer and equal in size and shape thereto, a plurality of layers of paper below said fabric layer, said paper layers diminishing gradually in size from the top to the lowermost layer thereof, a layer of wood below said paper layers and equal in size and shape to said top and bottom layers, and another layer of paper between the last-named wood layer and the bottom wood layer and equal in size and shape to said bottom wood layer.

16. As a new article of manufacture, a shank piece of laminated formation consisting of a plurality of layers of fibrous material impregnated with, and secured together in assembled relation by, hardened thermoplastic impregnating varnish, said layers including layers of wood and layers of fibrous material more flexible than wood but also more resistant than wood to penetration by driven fastenings.

17. As a new article of manufacture, a shank piece of laminated formation consisting of a plurality of layers of fibrous material impregnated with, and secured in assembled relation by, hardened stiffening material of an adhesive nature, said layers comprising outer layers of basswood, and inner layers composed respectively of cloth, basswood and unsized kraft paper, said stiffening material consisting of a thermoplastic impregnating varnish. I

18. As a new article of manufacture, a shank piece of laminated formation consisting of a plurality of united layers of fibrous material, said layers comprising outer layers of wood and inner layers composed respectively of wood, paper and fabric material, said shank piece corresponding in outline to the shank and heel portions of an insole, and conforming approximately in shape to the bottom of a last.

19. As a new article of manufacture, a unitary shank piece of laminated formation consisting of a plurality of layers of fibrous material impregnated with, and secured together in assembled relation by, hardened stiffening material of an adhesive nature, said shank piece corresponding in outline to the edgecontour of the rear portion of an insole and conforming approximately in shape to the curvatures of a last bottom, said layers comprising outer layers of relatively stiff, rigid material and inner layers of relatively flexible material.

20. As a new article of manufacture, a shank piece of laminated formation consisting of a plurality of layers of fibrous material impregnated with, and secured together in assembled relation by, hardened stifiening material of an adhesive nature, said layers comprising outer layers of relatively stiff, rigid material and inner layers of relatively flexible material, said outer layers corresponding in size and shapeto the shank and heel portions of an insole, and said inner layers diminishing gradually in size from said outer layers from an upper inner layer to a lower inner layer.

21. As a new article of manufacture, a unitary shank piece of laminated formation consisting of a plurality of layers of fibrous material impregnated with, and secured in assembled relation by, hardened stiffening material of an adhesive nature, said layers comprising outer layers of relatively hard, stiff material and inner layers of relatively yielding, flexible material, said outer layers corresponding in outline to the edge contour of the shank and heel portions of an insole and conforming approximately in shape to the longitudinal and transverse curv atures of a last bottom, and said inner layers diminishing progressively in size from the size of said outer layers from an upper inner layer to a lower inner layer.

22. As a new article of manufacture, a shank piece of laminated formation consisting of a plurality of superimposed layers of fibrous material impregnated with and hardened by stiffen- 'ing material of an adhesive nature which fuses the layers together in assembled relation to each other, said layers comprising outer layers of relatively stiff material and inner layers of relatively flexible material, said shank piece corresponding in outline to the shank and heel portions of an insole and having its inner surface conforming approximately in shape to the curvatures of the shank and heel portions of a last bottom, the outer surface of said shank piece corresponding generally to the shape of said inner surface but having greater curvature imparted thereto by said inner layers.

23. As a new article of manufacture, a shank piece of laminated formation consisting of a plurality of layers of fibrous material impregnated with, and secured in assembled relation by, hardened stiffening material of an adhesive nature, said layers comprising top and bottom layers of equal size composed of wood, and inner layers composed respectively of wood and composition fibrous material, said inner layers diminiehing progressively in size from an upper inner layer to a lower inner layer, and said top and bottom layers corresponding in outline to the shank and heel portions of an insole with said top layer conforming approximately in shape to the shank and heel portions of a last bottom and said bottom layer conforming generally in shape to said top layer but being of greater curvature by reason of the diminishing inner layers between said top and bottom layers.

24. As a new article of manufacture, a shoe bottom unit comprising an insole, and a shank piece of laminated formation secured to said insole and reinforcing the shank and heel portions thereof, said shank piece consisting of a plurality of layers of fibrous material impregnated with, and secured in assembled relation by, hardened stiffening material of an adhesive nature, the inner surface of said unit conforming accurately in shape to the bottom surface of a last, and the outer surface of said unit corresponding generally to the shape of said inner surface but having greater curvature by reason of the layers of said shank piece.

25. As a new article of manufacture, a shoe bottom unit comprising an insole, and a shank piece of laminated formation adhesively secured to the outer surface of said insole and reinforcing the shank and heel portions thereof, said shank piece consisting of a plurality of layers of fibrous material impregnated with, and secured together in assembled relation by, hardened stiffening material of an adhesive nature, said layers comprising outer layers of relatively stifi, rigid material and inner layers of relatively flexible material, the inner surface of said unit being complemenial in. shape to the bottom surface of a last.

26. As a new article of manufacture, a shoe bottom unit comprising an insole, and a shank piece of laminated formation secured to the insole by cement and reinforcing the shank and heel portions thereof, said shank piece consisting of a plurality of layers of fibrous materiail the outer layers of which are composed of wood and the inner layers of which are composed respectively of wood, paper, and fabric material, said layers being hardened and secured together in assem- I bled relation by stiffening material of an'adhesive nature.

27. As a new article of manufacture, a shoe bottom unit comprising an insole, and a shank piece of laminated formation adhesively secured to the outer surface of the insole and reinforcing the shank and heel portions thereof, said shank piece consisting of a plurality of layers of fibrous material impregnated with, and secured together in assembled relation by, hardened stiffening material of an adhesive nature, said layers comprising outer layers of wood and inner layers of wood, paper, and fabric material respectively, said outer layers corresponding in outline to the shank and heel portions of the insole and said inner layers diminishing in size from that of said outer layers from an upper inner layer to a lower inner layer, and the inner surface of said unit conforming accurately in shape to the bottom surface of a last.

28. As a new article of manufacture, a shoe bottom unit comprising an insole, and a shank piece of laminated formation secured by adhesive to the outer surface of said insole and reinforcing the shank and heel portions thereof, said shank piece consisting of a plurality of layers of fibrous material impregnated with, and secured together in assembled relation by, hardened stiffening material of an adhesive nature, said layers comprising top and bottom layers corresponding in outline to the edge contour of the insole, and inner layers which diminish gradually in size from an upper inner layer to a lower inner layer, the inner surface of said unit being complemental in shape to the bottom surface of a last, and the outer surface of the unit conforming generally in shape to its inner surface but being more sharply curved laterally and longitudinally by reason of the inner layers of said shank piece.

29. As a new article of manufacture, a shoe bottom unit comprising an insole, and a shank piece of laminated formation secured by cement to the outer surface of the insole and reinforcing the shank and heel portions thereof, said shank piece consisting of a plurality of superimposed layers of fibrous material impregnated and hardened with, and secured in assembled relation by, stiffening material comprising a thermoplastic impregnating varnish, said layers comprising top and bottom layers of equal size and shape composed of wood, and inner layers composed respectively of wood, paper, and fabric material, said inner layers diminishing gradually in size from an upper to a lower inner layer, the inner surface of said bottom unit conforming accurately in shape to the bottom surface of a last, and the outer surface of said unit including the shank piece corresponding generally to the shape of said inner surface but being more sharply curved by reason of the inner layers of said shank piece.

30. That improvement in methods of making bottom units for shoes which consists in providing a shank piece of relatively stiff, rigid fibrous material which corresponds in outline to the shank and heel portions of an insole and has been molded to conform approximately in shape to the bottom of a last, the material of said shank piece being of a nature which permits it to be rendered pliable again, securing the shank piece to an insole on the bottom of a last, and molding the insole into accurate conformity with the shape of the last bottom while simultaneously rendering the shank piece pliable and remolding it into conformity with said last bottom.

31. That improvement in methods of making bottom units for shoes which consists in molding.

a shank piece of relatively stiff fibrous material to conform it approximately to the shape of the bottom of a last. assembling the shank piece with an insole on a last bottom with adhesive between the insole and shank piece, and applying heat and pressure to the insole and shank piece to unite them adhesively and to mold the insole to the shape of the last bottom, and simultaneously to remold the shank piece accurately to the shape of the insole and last bottom.

32. That improvement in methods of making bottom units for shoes which consists in providing a shank piece of relatively stiff, rigid material which corresponds in outline to the shank and heel portions of an insole and has been molded to conform approximately in shape to the bottom of a last, assembling the shank piece with an insole on a last bottom, and molding the insole and remolding the shank piece accurately to the shape of the last bottom while simultaneously attaching the shank piece to the insole.

33. That improvement in methods of making bottom units for shoes which consists in providing a shank piece of fibrous material which has been molded to conform approximately in shape to the bottom of a last and has been impregnated with stiffening material to render it relatively stiff and rigid, assembling said shank piece with an insole on the bottom of a last with adhesive between the insole and shank piece, and applying heat and pressure to the assembled members to mold the insole to the shape of the last bottom and to remold the shank piece to said shape while simultaneously attaching the shank piece adhesively to the insole.

34. That improvement in methods of making bottom members for shoes which consists in providing a shank piece of fibrous material which is coextensive in edge contour with the shank and heel portions of an insole and has been molded to conform approximately in shape to the bottom of a last, said shank piece being impregnated with stiffening material of a thermoplastic nature to render it relatively hard and stifi, assembling ie shank piece with an insole on the bottom of a last, and applying heat and pressure to the insole and shank piece to mold the insole to the shape of the last bottom and to render the shank piece pliable and to remold it accurately to the shape of the insole and last bottom.

35. That improvement in methods of making bottom units for shoes which consists in providing a shank piece of laminated formation consisting of a plurality of layers of fibrous material impregnated with, and secured together by, hardened stiffening material of an adhesive nature, said shank piece being molded to conform approximately in shape to the bottom of a last, 1

assembling the shank piece with an insole on the bottom of a last, applying heat and pressure to the assembled members to mold the insole into conformity with the last bottom and to remold the shank piece accurately to the shape of the insole and last bottom, and cement attaching the shank piece to the insole.

36. That improvement in methods of making bottom units for shoes which consists in providng a shank piece of fibrous material molded to conform approximately in shape to the bottom of a last and impregnated with stiffening material of a thermoplastic nature to render it relatively hard and stiff, assembling the shank piece with an insole on the bottom of a last with cement between the insole and the shank piece, applying and pressure to the assembled members to mold the insole to the shape of the last bottom, to render the shank piece pliable and remold it accurately to the shape of the insole and last bottom, and also to cause the shank piece to become attached to the insole by the cement therebetween, and shutting off the heat but maintaining the pressure upon said members until they have cooled sufliciently to cause the shank piece to harden so that it will retain its shape permanently.

37. That improvement in methods of making bottom units for shoes which consists in providing a shank piece of laminated formation consisting of fibrous materials molded to conform approximately in shape to the bottom of a last and impregnated with hardened stiffening material of a thermoplastic nature to render it relatively stiff and rigid, applying heat to said shank piece to render it relatively pliable, assembling the shank piece with an insole on the bottom of a last with cement between the insole and shank piece, applying pressure to the assembled members to mold the insole to the shape of the last bottom and to remold the pliable shank piece to the shape 01 the insole and last bottom, said pressure also causing the shank piece to become cement attached to the insole, and maintaining the pressure until the shank piece has cooled sufficiently to harden again so that it will retain its remolded shape permanently at normal temperature.

38. That improvement in methods of making shoe bottom units which consists in providing a shank piece of fibrous material of laminated formation which corresponds in outline to the shank and heel portions of an insole and is impregnated with a thermoplastic stiffening material to render it relatively stifi and rigid, molding the shank piece between members arranged to apply heat and pressure to render the fibrous material pliable and to mold it to approximately the shape of the bottom of a last, permitting the shank piece to stiffen again and positioning it on the outer surface of an insole with cement between the insole and shank piece, mounting the insole and shank piece on the bottom of a last, and applying heat and pressure to the insole and shank piece to mold the insole to the shape of the last bottom and to render the shank piece pliable again and to remold it accurately to the shape of the insole and last bottom, and simultaneously to attach the shank piece adhesively to the outer surface of the insole.

'39. That improvement in methods of making shoe bottom members which consists in providing a plurality of layers of fibrous material some of which correspond in outline to the shank and heel portions of an insole, said layers being impreg'nated and hardened with stiifening material of a thermoplastic nature, assembling said layers in superimposed relation and molding them under heat and pressure to render them pliable and to fuse them together into a unitary shank piece and simultaneously to conform said shank piece to approximately the shape of the shank and heel portions of a last bottom, assembling the shank piece with an insole on a form, and pressing the insole and shank piece and the form together under heat to mold the insole to the shape 'of the form and to render the shank piece pliable again and to remold it accurately to the shape of said form.

40. That improvement in methods of making shank pieces which consists in impregnating a plurality of layers of different fibrous materials with stiffening material of an adhesive nature to render the fibrous materials relatively stifi and rigid, cutting from said layers members which vary in size and shape and the largest members of which correspond in outline to the shank and heel portions of an insole, arranging said members in assembled relation with the largest members forming the outer layers of the assembly, and molding the assembled members to secure them in said assembled relation and to conform them to approximately the shape of the bottom of a last. v

41. That improvement in methods of making shank pieces which consists in impregnating layers of relatively stiff fibrous material and layers of relatively flexible fibrous material with stiffening material of an adhesive nature, cutting from said' layers members which correspond in size and shape to the shank and heel portions of an insole and other members which diminish in size from said first-named members to much smaller members, assembling said members in superimposed relation with the members of stiff, fibrous material forming the outer layers of the assembly and the members of relatively flexible material, including the diminishing members, forming the inner layers of said assembly, and molding the assembled members under heat and pressure to fuse them together into a unitary shank piece of laminated formation and simultaneously to conform the shank piece to approximately the shape of the shank and heel portions of a last bottom.

42. That improvement in methods of makin shank pieces for shoes which consists in impregnating a layer of paper and a layer of fabric material with stiffening material of an adhesive nature, thereby rendering said layers relatively stiff and rigid, cutting from said layers members which correspond in size and shape to the shank and heel portions of an insole and other members which diminish gradually in size from said first-named members to much smaller members, cutting from a layer of wood a plurality of members which correspond in size and shape to the shank and heel portions of an insole, arranging the wood, fabric, and paper members in assembled relation with wood members forming the top and bottom layers of the assembly and with wood, fabric, and paper members, including the diminishing members, forming the inner layers of said assembly, and molding the assembled members under heat and pressure to render the stiffened members pliable and to unite them adhesively into an integral shank piece of laminated formation, and simultaneously to conform said shank piece to approximately the shape of the shank and heel portions of a last bottom.

43. That improvement in methods of making shank pieces which consists in impregnating a layer of paper and a layer of fabric material with a plastic stiffening material of an adhesive nature to render them relatively stiff and rigid, cutting from said layers members which correspond in size and shape to the shank and heel portions of an insole, cutting from the paper layer further members which diminish gradually in size from the first-named members to much smaller members, providing a layer of wood unimpregnated with stiffening material and of a character which offers less resistance to penetration than the paper and fabric layers, cutting from the wood layer a plurality of members equal in size and shape to said first-named members of paper and fabric material. assemblin said members in superimposed relation with the unimpre nated wood members forming the outer layers of the assembly and the other members of wood,

paper, and fabric forming the inner layers thereof, activating the plastic stiifening material to render said inner layers pliable, and molding the assembled members to secure them together into a unitary shank piece of laminated formation and to conform said shank piece to approximate ly the shape of the bottom of a last.

44. That improvement in methods of making shank pieces for shoes which consists in impregnating a plurality of layers of fibrous material with stiffening material of a thermoplastic nature to render said layers relatively stiff, said layers being composed respectively of wood, fabric material, and unsized paper, cutting from said layers members which correspond in size and shape to the shank and heel portions of an insole and from the paper layer only cutting additional members which diminish gradually in size from that of said first-named members to much smaller members, assembling said members in superimposed relation with the wood members forming the top and bottom layers of the assembly and with a fabric member and a paper member located next to said top and bottom layers, respectively, with a wood member located next to said paper member, and with the diminishing paper members interposed between the last-named wood member and the fabric member, said paper members being arranged so that they diminish progressively in size from the top to the lowest member thereof, and subjecting the assembled members to relatively great heat and pressure between molds adapted to conform the assembly to approximately the shape of the shank and heel portions of a last bottom and to fuse the members together by reason of said stiffening material, thereby producing a unitary shank piece of laminated formation composed of fibrous material and conforming approximately in shape to the shank and heel portions of a last bottom.

45. That improvement in methods of making shank pieces for use in shoes which consists in impregnating a plurality of layers of fibrous material with plastic stiffening material of an adhesive nature to render said layers relatively stiff and rigid, cutting from said layers members which correspond in size and shape to the shank and heel portions of an insole and other members which diminish gradually from said size to much smaller members, assembling said members in superimposed relation with the first-named members forming the outer layers of the assembly, activating the plastic stiffening material to render said members pliable, molding said members to unite them into a unitary shank piece of laminated formation and to conform said shank piece to approximately the shape of the bottom of a last, activating the stiffening material in the unitary shank piece unit to render it pliable again, and remolding said shank piece into ac curate conformity with the shank and heel portions of a last bottom.

45. That improvement in methods of making shank pieces for use in shoes which consists in impregnating a plurality of layers of fibrous material with thermoplastic stiifening material of an adhesive nature to render the materials relatively hard and stiff, cutting from said layers members which correspond in size and shape to the shank and heel portions of an insole and other members which diminish gradually in size from said first-named members to relatively small members, arranging said members in assembled relation with the first-named members forming the top and bottom layers of the assembly, molding the assembled members under substantial heat and pressure to render them pliable and to fuse them together into an integral shank piece of laminated formation and simultaneously to conform the shank piece to approximately the shape of the shank and. heel portions of a last bottom, and thereafter remolding the shank piece under less heat and pressure to render it pliable again and then to conform it accurately to the shape of the shank and heel portions of a particular last bottom.

THOMAS C. MORRIS. FRANK S. GREGORY, JR.