US3231914A - Apparatus for heat treating an article of footwear - Google Patents

Apparatus for heat treating an article of footwear Download PDF

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US3231914A
US3231914A US347073A US34707364A US3231914A US 3231914 A US3231914 A US 3231914A US 347073 A US347073 A US 347073A US 34707364 A US34707364 A US 34707364A US 3231914 A US3231914 A US 3231914A
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footwear
sole
article
insole
elastomeric
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US347073A
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Ralph J Novitske
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Ripon Knitting Works
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Ripon Knitting Works
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    • AHUMAN NECESSITIES
    • A43FOOTWEAR
    • A43DMACHINES, TOOLS, EQUIPMENT OR METHODS FOR MANUFACTURING OR REPAIRING FOOTWEAR
    • A43D95/00Shoe-finishing machines
    • A43D95/10Drying or heating devices for shoes

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  • the present invention relates generally to footwear and more particularly to a novel apparatus for heat treating an article of footwear in .manufacture thereof.
  • footwear having a light, flexible, elastomeric sole portion secured to a fabric, leather or composition upper have come into increased usage, particularly for leisure-.time wear.
  • the lightness and high degree of flexibility of the latter footwear make this type of footwear very comfortable, and in many instances this footwear has replaced the conventional leather slipper because of the relative ease of manufacture and reduction in cost.
  • certain types of footwear such as slippers having a flexible'elastomeric sole, for example, are generally made by securing an upper to a preformed elastomeric sole portion by a stitching or cementn ing operation.
  • one or more side wallsections comprising the vamp and quarter or yupper is stitched orv cemented to an insole portion which, in turn, is stitched or cemented to a preformed sole.
  • a rubber sole portion has been vulcanized to an upper by placing a pre-.assembled footwear upper and rubber solein a suitable mold and heating the assembly for an extended period to form and cure orvulcanize the rubber sole composition.
  • the vulcanization process is time-consuming and this materially adds to the cost of the article.
  • the vulcanized sole is relatively heavy and often has a disagreeable odor.
  • a at section of sponge rubber or the like having the form of the insole is often securely cemented to the insole or innervsurface of the sole by applying a continuous coating of cement tol one side of the section of sponge rubber and securing it to the insole or outer sole before joining the upper to the sole.
  • the sole material is relatively stilf or inflexible and unyielding, a thicker section of sponge rubber or the like material is requred. The latter requirement, of course, further increases the cost ofthe footwear.
  • FIG. 1 is a side elevational View partially in vertical section of an article of footwear embodying the present invention
  • FIG. 2 is a bottom plan view of the article of footwear shown in FIG. l with a portion of the structure broken away to show the interior construction;
  • FIG. 3 is a transverse vertical sectional view along the line 3 3 of FIG. l;
  • FiG. 4 is a side elevational viev/ partially in vertical section of a modified form of the present invention.
  • FIG. 5 is a fragmentary side elevational view of apparatus used in the manufacture of footwear shown in FlGS. l and 4 with wall sections of the apparatus removed to show the interior thereof;
  • FlG. 6 is a fragmentary perspective View partially in section showing additional apparatus used in the manufacture of the footwear shown in FIG. l.
  • the upper of -r an article of footwear which can be formed of knitted fabric, woven fabric, leather or the like, of any desired construction, with an elastomeric sole portion joined or fused integrally with the upper of the footwear to securely enclose and hold the lateral edge portions there of which can comprise the lower lateral surfaces of a knitted sock-type upper or the edge seams of an upper having an insole secured thereto.
  • a sponge type resilient section is secured to the lower surface of an insole section at spaced points thereon within a pocket or recess formed by the lower edge seam of the upper and insole of the footwear structure. Thereafter the exposed outer surfaces of the resilient section and the lower edges or seams of the upper are enclosed in an expanded or cellular elastomeric material which forms the sole portion of the footwear.
  • an improved article of footwear of the present invention is made by applying to an upper of any desired construction, an elastomeric sole, preferably an expanded plastic composition, by dipping the upper while mounted on a form into a solution or dispersion of an elastomeric material so as to just immerse or cover the bottom of the insole and the lower edges of the upper including the seam thereof. Thereafter, the sole is welded or fused to the upper, preferably by passing the dipped upper through a heated oven to solidify rapidly the elastomeric sole material. if required, the upper can be pretreated with a sizing material to increase the adhesion of the elastomeric material thereto, although this is generally not required.
  • the characteristics of the elastomeric sole can be largely determined by controlling the composition and viscosity of the elastomeric material. Since all the insole-upper edge seams and the cemented portions of the insole are completely sealably enclosed and held by the elastomeric sole portion in the present invention, the strength of the footwear is not dependent on the stitching or cementing operation as in the conventional footwear structure.
  • the elastomeric materials which can be used in accordance with the present invention for dipping an upper are those which can be provided as viscous solutions or dispersions at temperatures below the char temperatures of the upper to be treated therewith and which will within a reasonably short period readily solidify to form a flexible sole portion having satisfactory wear characteristics for the particular use intended.
  • the elastomeric materials which can be used'to form the improved footwear of the present invention are rubber latex solutions, both natural and synthetic, and solutions or dispersions of polyethylene, polypropylene, the Vinyl plastics and similar plastomeric materials.
  • the upper is dipped in a viscous, elastomeric solution or dispersion, such as expandable rubber latex solution or a polyethylene, polypropylene or polyvinyl chloride solution or dispersion containing a conventional blowing agent which on standing or heating produces an inner cellular structure and a smooth outer skin which can be impressed or otherwise provided with any desired design or pattern.
  • a viscous, elastomeric solution or dispersion such as expandable rubber latex solution or a polyethylene, polypropylene or polyvinyl chloride solution or dispersion containing a conventional blowing agent which on standing or heating produces an inner cellular structure and a smooth outer skin which can be impressed or otherwise provided with any desired design or pattern.
  • a particularly suitable type of expandable elastomeric material for use in the manufacture of footwear in accordance with the present invention comprises the expandable plastisols which are dispersions of a polyvinyl chloride resin in a liquid plasticizer along with stabilizers, a dispersant, any conventional blowing agent, colorants where desired, and other modifying agents.
  • the plastisol composition is formulated so that it is a relatively viscous liquid which can be poured or pumped for ease of handling.
  • the plastisol used can be formed of from ten parts to four hundred parts of plasticizer for every one hundred parts of polyvinyl chloride resin.
  • the plastisols contain little or no solvents or diluents, there is little shrinkage problem and the plastisol can be stored for long periods at normal storage temperatures without deteriorating. Where it becomes necessary to lower the viscosity, a small amount of petroleum naphtha or mineral spirits can be added.
  • the plastisol composition is readily expanded and solidified to a tough, resilient, cellular solid by heating to a temperature of between 250-400 F., although heating to a temperature of about 360-390" F. is preferred.
  • the time required for complete conversion of a plastiscl liquid preparation to a solid at the latter temperatures preferably varies between 7 to 12 minutes.
  • the temperature and time correlations required to complete fusion of the plasticizer and resin is extremely flexible and can vary between much wider limits than the preferred ranges indicated above.
  • the conversion temperature for the particular plastisol is attained, the conversion into a solid is almost instantaneous and the particles of polyvinyl chloride resin fuse with or dissolve in the plasticizer to form an integral solid compound.
  • the elastomeric solutions or dispersions can have suspended therein various solids which will impart a desirable appearance or improved surface characteristicto the elastomeric sole.
  • particles of colored Mylar plastic, or the like can be added to the elastomeric vsolution or dispersion to impart a decorative appearance.
  • Other particles, such as nylon or Teon, can be added both for improved appearance and wear properties.
  • particles of an abrasive can be suspended in the elastomeric material, if desired.
  • the construction of .the footwear upper prior to dipping in the elastomeric solution can be of any desired type including all the various insole-vamp or upper assemblies to which the presently used preformed sole sections are secured by stitching and cementing or vulcanizing.
  • the construction of .the footwear upper prior to dipping in the elastomeric solution can be of any desired type including all the various insole-vamp or upper assemblies to which the presently used preformed sole sections are secured by stitching and cementing or vulcanizing.
  • a minimum of work is required to form an upper which is satisfactory for dipping in the present invention.
  • an upper is formed by joining one or more sections of fabric, leather or plastic with the lower edge thereof lightly stitched, either inseam or outseam, to an insole section of cloth or other suitable material to form v a uniform seam or marginal an'ge completely around the edge thereof.
  • the edge seam is preferably processed to prevent irregularities in the edge portions of the dipped sole due to the presence of frayed seams, and this is conveniently effected by providing a binding strip over this entire edge seam.
  • the insole-vamp assembly when thus formed and mounted on a suitable form such as a shoe last, can then be dipped into a liquid elastomeric material of a type heretofore described to provide an elastomeric sole portion which completely encloses and securely holds when solidified the insole and upper integrally with the sole portion of the footwear.
  • a foam rubber or other resilient section can be cemented, stitched, or otherwise secured to the inner surface of the insole after the outer sole has been solidified and completed as hereinafter described.
  • the insole-vamp assembly after being sewed outseam and mounted'on a suitable form but before dipping in the elastomeric material, is provided on the outer surface of the insole with a vcushioning means, which can be a fiat resilient section of foam rubber, expanded plastic, felt or the like material having the hereinafter described properties and which preferably has the same shape as the insole.
  • a vcushioning means can be a fiat resilient section of foam rubber, expanded plastic, felt or the like material having the hereinafter described properties and which preferably has the same shape as the insole.
  • the expanded or foam rubber resilient section is secured at spaced points to the lower surface of the insole-vamp assembly, with care being taken not to form a completely vapor impervious layer over the entire surface of the insole.
  • the resilient section when the resilient section is cemented to the insole, the'cernent is applied only at spaced points thereover and not as a continuous film.
  • an elastomeric material is applied to select portions of the assembly preferably by dipping a portion of the assembly in an expanded liquid elastomeric material which tends to flow and diffuse into the fibers, pores and passages in the surfaces coated therewith.
  • the dipped assembly is passed through a heated zone, the temperature of which is regulated and the rate of passage therethrough adjusted, so that the particular elastomeric composition is properly expanded and set to form an elastomeric solid while at the same time integrally joining the elastomer sole portion to the insole-vamp assembly.
  • FIGS. l-3 of the ⁇ accompanying drawing is shown a preferred embodiment of .the present invention comprising a slipper it) formed of an upper ll stitched as at 13 (see FIG. 3) to an insole l2 around the entire periphery thereof spaced a short distance inwardly from the edge 14.
  • the edges of the upper 1l, insole 12, and Ithe stitching 13 are preferably enclosed by a binding strip 15 to eliminate frayed edges and form a marginal flange le.
  • the flange 16 preferably extends perpendicularly to the plane of the insole l2 forming a pocket 1'7 in which a resilient section 18 is held in contact with the insole l2 by means of spaced segments 19 of 'a suitable adhesive.
  • the resilient section 13 preferably has fabric covers 2d, 2li extending over the longitudinal surfaces thereof with cover 20 preferably being cemented or otherwise secured to the outer edge of the flange i6 to prevent the flange ld being accidentally deforming prior to being dipped in the expanded or cellular elastomeric material which forms ⁇ the cellular elastomeric sole 2l.
  • the outer surface of the sole 2l is preferably provided with any desired design Z2, as by embossing, to improve the appearance and provide increased friction on contact with a smooth surface.
  • a knitted type of footwear illustrated by the slipper sock is shown having integrally fused thereto an expanded or cellular type elastomeric sole 32 with the elastomeric material substantially completely impregnating the knitted sole 34 of the slipper sock to form an inseparable bond therewith.
  • an inner sole 35 can be inserted into the slipper sock prior to dipping the outer sole surface of the sock in the liquid elastomeric material.
  • the elastomeric liquid passes through the knitted sole 34 and penetrates into the fibers of the insole 3S prior to being solidified.
  • an integral sole structure comprising' an insole 35, a knitted intermediate sole 34, and the outer elastomeric sole 32, with each being welded or fusably jointed to the other by the solidified elastomeric material.
  • FIG. 5 of the drawing is shown an endless conveyor means 50 having a plurality of longitudinally spaced depending members 51 which in the form shown have generally transversely extending form supporting arms 52 rotatably mounted therein adjacent the lower end and extending outwardly therefrom in opposite directions.
  • the supporting arms 52 have at the outer Vends thereof a step-like configuration with a bracket 59 mounted on the end thereof for eng-agement with a mounting plate di? secured to ⁇ a footwear support means or form 6l.
  • a pinion 53 is ixedly secured to each of the arms 52 adjacent the rotary support therefor in the member 51.
  • the pinion 53 is adapted to engage with a short fixed horizontally disposed gear-toothed rack 54 which causes the piston 53 and the arm 52 to rotate when the conveyor moves the depending member 51 longitudinally with respect to the rack 54.
  • An open ended elongated heating zone or oven 70 having a generally rectangular form encloses a section of the conveyor means 50 and at least a major portion of the rack54.
  • the oven 70 is preferably provided with a plurality of infrared heating elements 72 in the upper portieri thereof extending substantially the length thereof which are capable of maintaining the temperatures Within the oven between about 320 and 400 F.
  • Adjacent each end of the oven 70 is a blower means '74 for providing an air curtain to retain the infrared heat inside the heating zone of the oven 70.
  • a guide rail 75 which preferably extends a short distance into the oven and also a short distance beyond the end '73 of the oven 70.
  • the nail 75 is adapted to engage the lower transversely extending section 56 of the rotatable supporting arm 52 and hold the section 56 in an elevated position so that the elastomeric sole portion 21 faces downwardly.
  • an auxiliary infrared heater 80 adjacent the lower surface of the oven 70 which extends outwardly therefrom and which is adapted to rehe'at the outer surface of the sole 21 of the footwear to facilitate embossing thereon a pattern or design 22 by means of an embossing roll 90 disposed adjacent the outer end of the heater 80.
  • the decorative design 22 can be formed on the outer surface of the lsole 2l by pressing the sole while the footwear' remains on the rigid form el and while the footwear remains on the rigid form 6l and while the surface thereof is still in a heated condition against the surface of the embossing roll which is comprised of a freely rotatable relatively large diameter roller @l having on the outer surface thereof a hard rubber cover layer 92 which has the desired design 22 Sculptured -or molded in the surface thereof.
  • Gther means for applying the design 22 can be used, such as using a heated embossing roll or the like. Additional indicia, such as the size of the footwear and a trademark designation can also be impressed in the elastomeric sole portion of the footwear in the foregoing manner.
  • EXAMPLE 1 A slipper upper and insole assembly having the form shown in FiGS. l-3 of the accompanying drawing is mounted on a wooden or metal shoe last lor form 61 and a resilient section ld is secured thereto as described above. Thereafter, the insole portion and edge seams thereof are coated by dipping at room temperature in an expandable, viscous liquid plastisol preparation having the following composition:
  • the plastisol composition is prepared in the conventional manner by blending the several ingredients which are preferably premixed prior to the nal blending operation.
  • the plastic-ol composition has a viscosity of about 12,400 centipoises at room temperature.
  • the form 61 supporting the dipped assembly is mounted on the bracket 59 which is continually rotated at a rate of between 3 and 6 revolutions -per minute for about the rst 2 to 3 minutes during the passage thereof through the oven Til or until the plastisol outer portion has solidied.
  • the slipper assembly is no longer rotated but is moved longitudinally through the oven 7@ with the fiat surface of thesole 21 lfacing upwardly toward the infrared heater elements 72 in the upper part of the oven 70 while said oven is maintained at a temperature of about 360 F.
  • the conveyor 50 moves through the oven 70 at a rate of about 1.3 ft. per minute.
  • the rotatable support arm 52 is engaged by the guide rail 75 as heretofore described to rotate the arm and slipper assembly so that the fiat portion of the sole 21 is turned downwardly to face the auxiliary infrared heater St).
  • the sole portion is softened and is thereafter immediately brought into contact with the embossing roll 90 to impress a decorative design therein.
  • the slipper is then removed from the form 61 and is ready for packaging, if desired.
  • FIGS. l-4 of the drawing are slippers, it should be understood that the present invention is applicable to the manufacture of other types of footwear, both for indoor and outdoor use.
  • a tennis and other sports or athletic shoe can be made in the above described manner. Also, with the present invention, it is possible to provide leather upperswith an intergral elastomeric sole without damaging the leather, since the leather need not be exposed to a high temperature for a prolonged period.
  • the elastomeric sole of the footwear of the present invention can be provided with a raised heel portion, if desired.
  • a felt heel 4section is well suited by being secured to the outer heel portion of the resilient section, which may also be made of felt, before dipping the assembly in the elastomerio liquid, since the felt has suiiicient body and resistance to compression to provide the desired heel lift.
  • Anapparatus for manufacturing an article of footwear comprising: a chamber having openings at opposite ends thereof, heating means mounted in said chamber for heating the interior thereof, a conveyor means with means mounting said conveyor for continuous longitudinal movement through said chamber, said conveyor means including a footwear form support arm rotatably mounted thereon for conveying an article of footwear into one end of said chamber and out the opposite end thereof, said footwear form support arm having adjacent the outer end thereof mounting means for detachably engaging a footwear form, and said support arm having engaging means formed integrally therewith and spaced inwardly from said mounting means adapted to effect rotation of said arm about the longitudinal axis of said arm during travel of said conveyor means, mechanical means mounted in said chamber for engagement with said engaging means to effect said rotation, and said mechanical means being disposed adjacent said one end and extending into said chamber to effect rotation of said article of footwear supported by said arm during the initial portion of the period said article of footwear is passing through said chamber.
  • An apparatus for manufacturing an article of footwear comprising: a chamber having openings at opposite ends thereof, heating means mounted in said chamber for heating the interior thereof, a continuous conveyor means associated therewith for rotatably supporting and conveying an article of footwear into one end of said heatedV chamber and out the opposite end thereof, mechanical means adjacent said one end and extending into said chamber which is adapted to effect rotation of said article of footwear supported by said conveyor means during at least the initial portion of the period said footwear is passing through said heated chamber, guide means adjacent said opposite end of said chamber adapted to maintain said article of footwear in a predetermined position, and auxiliary heating means disposed opposite said guide means adapted to apply heat to a predetermined portion of said article of footwear to facilitate forming indicia at said predetermined portion of said article of footwear.
  • An apparatus for manufacturing an article of footwear comprising: a chamber having openings at opposite ends thereof, heating means mounted in said chamber for heating the interior thereof, a conveyor means with means mounting said conveyor for continuous longitudinal movement through said chamber, said conveyor means including a footwear form supportarm rotatably mounted there- A on for conveying an article of footwear into one end of said chamber and out the opposite end thereof, ⁇ said footwear form support arm having adjacent the outer end thereof mounting-means for detachably engaging a footwear form and having intermediate the ends thereof a guide section, and guide means xedly mounted on saidY chamber adjacent said opposite end of said chamber for engagement with said guide section to maintain said article of footwear mounted on said footwear form in a pre-V determined position as said footwear form leaves said chamber.
  • apparatus for manufacturing an article of footwear including a continuous conveyor means and an article of footwear support carried by said conveyor means for supporting and conveying a footwear form having an article of footwear, a chamber through which said article of footwear is conveyed from the inlet end to the outlet end thereof on said conveyor means, and heating means mounted in said chamber for heating the interior thereof
  • the improvement comprising; guide means fixedly attached to said chamber and extending axially upwardly from said outlet end and engageable with said conveyor means supporting said article of footwear and maintaining said article of footwear in a predetermined position from a point within the interior of said chamber to a point spaced axially outwardly of said outlet end, and auxiliary heating means disposed opposite said guide means and extending axially outwardly from said outlet end for heating a predetermined portion of said article of footwear while supported by said conveyor means in said predetermined position.
  • said position means comprises a section of said arm which extends outwardly from the longitudinal axis about which said arm rotates and which is disposed in a downwardly depending position while said engaging means is out of engagement with said mechanical means.

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  • Footwear And Its Accessory, Manufacturing Method And Apparatuses (AREA)

Description

Feb. l, 1966 R. J. NovlTsKE APPARATUS FOR HEAT TREATING AN ARTICLE OF FOOTWEAR 2 Sheets-Sheet 1 Original Filed Jan. 13, 1961 Feb. l, 1966 R. J. NovlTsKE APPARATUS FOR HEAT TREATING AN ARTICLE OF FOOTWEAR Original Filed Jan. 13. 1961 2 Sheets-Sheet 2 Inventor Ralph J. Novitske United States Patent O 7 Claims. (Cl. 122-1) The present application is 'a 'divisional application of U.S. patent application Serial No. 82,462, filed January 13, 1961, and now abandoned.
The present invention relates generally to footwear and more particularly to a novel apparatus for heat treating an article of footwear in .manufacture thereof.
VIn recent years, footwear having a light, flexible, elastomeric sole portion secured to a fabric, leather or composition upper have come into increased usage, particularly for leisure-.time wear. The lightness and high degree of flexibility of the latter footwear make this type of footwear very comfortable, and in many instances this footwear has replaced the conventional leather slipper because of the relative ease of manufacture and reduction in cost.
In the manufacture of certain footwear having an elastomeric sole portion secured to an upper portion, it has heretofore been customary to stitch or cement the sole portion to the upper, Thus, certain types of footwear, such as slippers having a flexible'elastomeric sole, for example, are generally made by securing an upper to a preformed elastomeric sole portion by a stitching or cementn ing operation. In making the usual cloth slipper, one or more side wallsections comprising the vamp and quarter or yupper is stitched orv cemented to an insole portion which, in turn, is stitched or cemented to a preformed sole. Since the glue or cement used to secure the sole portion to the upper is subject to being washed out when contacted with hot cleaning solutions and the stitches commonly used to secure the sole portion to the upper tendk to break, the useful life of footwear of the foregoing type has been relatively limited and the multiplicity of intricate manufacturing operations are quite costly.
In other footwear, a rubber sole portion has been vulcanized to an upper by placing a pre-.assembled footwear upper and rubber solein a suitable mold and heating the assembly for an extended period to form and cure orvulcanize the rubber sole composition. The vulcanization process is time-consuming and this materially adds to the cost of the article. Moreover, the vulcanized sole is relatively heavy and often has a disagreeable odor.
In footwear of the foregoing type, it is also often desirable to provide some added cushioning means as sociated with the insole or the outer sole. Thus, a at section of sponge rubber or the like having the form of the insole is often securely cemented to the insole or innervsurface of the sole by applying a continuous coating of cement tol one side of the section of sponge rubber and securing it to the insole or outer sole before joining the upper to the sole. When the sole material is relatively stilf or inflexible and unyielding, a thicker section of sponge rubber or the like material is requred. The latter requirement, of course, further increases the cost ofthe footwear.
It is an object of the present invention to provide a novel apparatus for use in the manufacture of footwear having an elastomeric sole.
Other objects of the present invention will be apparent CAD llll Patented Fel). 1, i956 to those skilled in the art from the following detailed description and claims to follow when read in connection with the accompanying drawing wherein:
FIG. 1 is a side elevational View partially in vertical section of an article of footwear embodying the present invention;
FIG. 2 is a bottom plan view of the article of footwear shown in FIG. l with a portion of the structure broken away to show the interior construction;
FIG. 3 is a transverse vertical sectional view along the line 3 3 of FIG. l;
FiG. 4 is a side elevational viev/ partially in vertical section of a modified form of the present invention;
FIG. 5 is a fragmentary side elevational view of apparatus used in the manufacture of footwear shown in FlGS. l and 4 with wall sections of the apparatus removed to show the interior thereof; and
FlG. 6 is a fragmentary perspective View partially in section showing additional apparatus used in the manufacture of the footwear shown in FIG. l.
The foregoing objects are accomplished in one embodiment of the present invention by providing the upper of -r an article of footwear which can be formed of knitted fabric, woven fabric, leather or the like, of any desired construction, with an elastomeric sole portion joined or fused integrally with the upper of the footwear to securely enclose and hold the lateral edge portions there of which can comprise the lower lateral surfaces of a knitted sock-type upper or the edge seams of an upper having an insole secured thereto. ln one preferred embodiment of the present invention, a sponge type resilient section is secured to the lower surface of an insole section at spaced points thereon within a pocket or recess formed by the lower edge seam of the upper and insole of the footwear structure. Thereafter the exposed outer surfaces of the resilient section and the lower edges or seams of the upper are enclosed in an expanded or cellular elastomeric material which forms the sole portion of the footwear.
More particularly, an improved article of footwear of the present invention is made by applying to an upper of any desired construction, an elastomeric sole, preferably an expanded plastic composition, by dipping the upper while mounted on a form into a solution or dispersion of an elastomeric material so as to just immerse or cover the bottom of the insole and the lower edges of the upper including the seam thereof. Thereafter, the sole is welded or fused to the upper, preferably by passing the dipped upper through a heated oven to solidify rapidly the elastomeric sole material. if required, the upper can be pretreated with a sizing material to increase the adhesion of the elastomeric material thereto, although this is generally not required. The characteristics of the elastomeric sole can be largely determined by controlling the composition and viscosity of the elastomeric material. Since all the insole-upper edge seams and the cemented portions of the insole are completely sealably enclosed and held by the elastomeric sole portion in the present invention, the strength of the footwear is not dependent on the stitching or cementing operation as in the conventional footwear structure.
The elastomeric materials which can be used in accordance with the present invention for dipping an upper are those which can be provided as viscous solutions or dispersions at temperatures below the char temperatures of the upper to be treated therewith and which will within a reasonably short period readily solidify to form a flexible sole portion having satisfactory wear characteristics for the particular use intended. Among the elastomeric materials which can be used'to form the improved footwear of the present invention are rubber latex solutions, both natural and synthetic, and solutions or dispersions of polyethylene, polypropylene, the Vinyl plastics and similar plastomeric materials.
It is preferable to utilize Athe foregoing specified materials and other elastomeric materials having similar properties in their expandable form. Thus, in the preferred form of the footwear, the upper is dipped in a viscous, elastomeric solution or dispersion, such as expandable rubber latex solution or a polyethylene, polypropylene or polyvinyl chloride solution or dispersion containing a conventional blowing agent which on standing or heating produces an inner cellular structure and a smooth outer skin which can be impressed or otherwise provided with any desired design or pattern.
A particularly suitable type of expandable elastomeric material for use in the manufacture of footwear in accordance with the present invention comprises the expandable plastisols which are dispersions of a polyvinyl chloride resin in a liquid plasticizer along with stabilizers, a dispersant, any conventional blowing agent, colorants where desired, and other modifying agents. The plastisol composition is formulated so that it is a relatively viscous liquid which can be poured or pumped for ease of handling. For example, the plastisol used can be formed of from ten parts to four hundred parts of plasticizer for every one hundred parts of polyvinyl chloride resin. Since the plastisols contain little or no solvents or diluents, there is little shrinkage problem and the plastisol can be stored for long periods at normal storage temperatures without deteriorating. Where it becomes necessary to lower the viscosity, a small amount of petroleum naphtha or mineral spirits can be added. The plastisol composition is readily expanded and solidified to a tough, resilient, cellular solid by heating to a temperature of between 250-400 F., although heating to a temperature of about 360-390" F. is preferred. The time required for complete conversion of a plastiscl liquid preparation to a solid at the latter temperatures preferably varies between 7 to 12 minutes. However, the temperature and time correlations required to complete fusion of the plasticizer and resin is extremely flexible and can vary between much wider limits than the preferred ranges indicated above. When the conversion temperature for the particular plastisol is attained, the conversion into a solid is almost instantaneous and the particles of polyvinyl chloride resin fuse with or dissolve in the plasticizer to form an integral solid compound.
lf desired, the elastomeric solutions or dispersions can have suspended therein various solids which will impart a desirable appearance or improved surface characteristicto the elastomeric sole. For example, particles of colored Mylar plastic, or the like, can be added to the elastomeric vsolution or dispersion to impart a decorative appearance. Other particles, such as nylon or Teon, can be added both for improved appearance and wear properties. Also, particles of an abrasive can be suspended in the elastomeric material, if desired.
As previously indicated, the construction of .the footwear upper prior to dipping in the elastomeric solution can be of any desired type including all the various insole-vamp or upper assemblies to which the presently used preformed sole sections are secured by stitching and cementing or vulcanizing. However, because of the absence of the need for reliance on the strength of the stitches or cement for holding the parts of the sole struc- Y ture in assembled form, a minimum of work is required to form an upper which is satisfactory for dipping in the present invention.
In accordance with one embodiment of the present invention, an upper is formed by joining one or more sections of fabric, leather or plastic with the lower edge thereof lightly stitched, either inseam or outseam, to an insole section of cloth or other suitable material to form v a uniform seam or marginal an'ge completely around the edge thereof. The edge seam is preferably processed to prevent irregularities in the edge portions of the dipped sole due to the presence of frayed seams, and this is conveniently effected by providing a binding strip over this entire edge seam. The insole-vamp assembly when thus formed and mounted on a suitable form such as a shoe last, can then be dipped into a liquid elastomeric material of a type heretofore described to provide an elastomeric sole portion which completely encloses and securely holds when solidified the insole and upper integrally with the sole portion of the footwear. Where it is desirable to provide additional cushioning effect in the above structure, a foam rubber or other resilient section can be cemented, stitched, or otherwise secured to the inner surface of the insole after the outer sole has been solidified and completed as hereinafter described.
In the preferred form of the present invention, the insole-vamp assembly, after being sewed outseam and mounted'on a suitable form but before dipping in the elastomeric material, is provided on the outer surface of the insole with a vcushioning means, which can be a fiat resilient section of foam rubber, expanded plastic, felt or the like material having the hereinafter described properties and which preferably has the same shape as the insole. The expanded or foam rubber resilient section is secured at spaced points to the lower surface of the insole-vamp assembly, with care being taken not to form a completely vapor impervious layer over the entire surface of the insole. Thus, when the resilient section is cemented to the insole, the'cernent is applied only at spaced points thereover and not as a continuous film. After the resilient section is secured to the insole-vamp assembly and while remaining on the form, an elastomeric material is applied to select portions of the assembly preferably by dipping a portion of the assembly in an expanded liquid elastomeric material which tends to flow and diffuse into the fibers, pores and passages in the surfaces coated therewith. lmmediately thereafter the dipped assembly is passed through a heated zone, the temperature of which is regulated and the rate of passage therethrough adjusted, so that the particular elastomeric composition is properly expanded and set to form an elastomeric solid while at the same time integrally joining the elastomer sole portion to the insole-vamp assembly.
Immediately after dipping and during the initial portion of the passage of the dipped insole-vamp assembly through the heated zoneor oven, it is important to continuously rotate the dipped insole Vamp assembly about its longitudinal axis to prevent -the elastomeric material flowing unevenly to one portion of the sole and forming an uneven sole portion. The length of time during which the assembly must be rotated and the speed of rotation thereof will, of course, depend on the viscosity and composition of the elastomeric dip material and also on the temperature of the oven. In general, it is necessary Ito rotate the dippedfootwear for only about the iirst two or three minutes of the 7 to 12 minutes of passage through the heated oven before the elastomeric material becomes form retaining.
While the dipped insole-vamp or upper assembly passes through a heated oven to effect setting `or solidificationof the elastomeric material, the various solvents, dispersants and the like are of necessity driven from the elastomer-ic material and must escape without forming blisterstherein due to entrapment of vapors or otherwise disruptingthe The latter requirements also make it essential that `there be a discontinuous seal between the insole and the resilient section secured thereto so that there will be a plunality of readily available passage over the entire area thereof through which the gases and vapors can easily escape without encountering significant resistance to flow.
In FIGS. l-3 of the `accompanying drawing is shown a preferred embodiment of .the present invention comprising a slipper it) formed of an upper ll stitched as at 13 (see FIG. 3) to an insole l2 around the entire periphery thereof spaced a short distance inwardly from the edge 14. The edges of the upper 1l, insole 12, and Ithe stitching 13 are preferably enclosed by a binding strip 15 to eliminate frayed edges and form a marginal flange le. The flange 16 preferably extends perpendicularly to the plane of the insole l2 forming a pocket 1'7 in which a resilient section 18 is held in contact with the insole l2 by means of spaced segments 19 of 'a suitable adhesive. The resilient section 13 preferably has fabric covers 2d, 2li extending over the longitudinal surfaces thereof with cover 20 preferably being cemented or otherwise secured to the outer edge of the flange i6 to prevent the flange ld being accidentally deforming prior to being dipped in the expanded or cellular elastomeric material which forms` the cellular elastomeric sole 2l. The outer surface of the sole 2l is preferably provided with any desired design Z2, as by embossing, to improve the appearance and provide increased friction on contact with a smooth surface.
in the modified form of the present invention shown in FIG. 4 of the drawing, a knitted type of footwear illustrated by the slipper sock is shown having integrally fused thereto an expanded or cellular type elastomeric sole 32 with the elastomeric material substantially completely impregnating the knitted sole 34 of the slipper sock to form an inseparable bond therewith. If desired, an inner sole 35 can be inserted into the slipper sock prior to dipping the outer sole surface of the sock in the liquid elastomeric material. On dipping the assembly, the elastomeric liquid passes through the knitted sole 34 and penetrates into the fibers of the insole 3S prior to being solidified. When the elastomeric liquid solidifies, an integral sole structure is formed comprising' an insole 35, a knitted intermediate sole 34, and the outer elastomeric sole 32, with each being welded or fusably jointed to the other by the solidified elastomeric material.
While the process of providing the flexible or expanded elastomeric so es 21 or 32 described heretofore can be carried out entirely by hand, it has been found preferable to perform the process mechanically by utilizing a continuous conveyor means and associated apparatus for conducting the footwear through a suitable heating means to effect fusion or conversion of the fluid elastomeric material into a flexible solid. lnFIG. 5 of the drawing is shown an endless conveyor means 50 having a plurality of longitudinally spaced depending members 51 which in the form shown have generally transversely extending form supporting arms 52 rotatably mounted therein adjacent the lower end and extending outwardly therefrom in opposite directions. The supporting arms 52 have at the outer Vends thereof a step-like configuration with a bracket 59 mounted on the end thereof for eng-agement with a mounting plate di? secured to `a footwear support means or form 6l. A pinion 53 is ixedly secured to each of the arms 52 adjacent the rotary support therefor in the member 51. The pinion 53 is adapted to engage with a short fixed horizontally disposed gear-toothed rack 54 which causes the piston 53 and the arm 52 to rotate when the conveyor moves the depending member 51 longitudinally with respect to the rack 54.
An open ended elongated heating zone or oven 70 having a generally rectangular form encloses a section of the conveyor means 50 and at least a major portion of the rack54. The oven 70 is preferably provided with a plurality of infrared heating elements 72 in the upper portieri thereof extending substantially the length thereof which are capable of maintaining the temperatures Within the oven between about 320 and 400 F. Adjacent each end of the oven 70 is a blower means '74 for providing an air curtain to retain the infrared heat inside the heating zone of the oven 70.
At the outlet end '73 of the oven 70, there is provided a guide rail 75 which preferably extends a short distance into the oven and also a short distance beyond the end '73 of the oven 70. The nail 75 is adapted to engage the lower transversely extending section 56 of the rotatable supporting arm 52 and hold the section 56 in an elevated position so that the elastomeric sole portion 21 faces downwardly. Disposed immediately below the guide rail 75 is an auxiliary infrared heater 80 adjacent the lower surface of the oven 70 which extends outwardly therefrom and which is adapted to rehe'at the outer surface of the sole 21 of the footwear to facilitate embossing thereon a pattern or design 22 by means of an embossing roll 90 disposed adjacent the outer end of the heater 80.
As shown in FIG. 6, the decorative design 22 can be formed on the outer surface of the lsole 2l by pressing the sole while the footwear' remains on the rigid form el and while the footwear remains on the rigid form 6l and while the surface thereof is still in a heated condition against the surface of the embossing roll which is comprised of a freely rotatable relatively large diameter roller @l having on the outer surface thereof a hard rubber cover layer 92 which has the desired design 22 Sculptured -or molded in the surface thereof. Gther means for applying the design 22 can be used, such as using a heated embossing roll or the like. Additional indicia, such as the size of the footwear and a trademark designation can also be impressed in the elastomeric sole portion of the footwear in the foregoing manner.
In order to further illustrate the present invention and without, however, limiting the invention to the specic materials or conditions employed, the following specific example is set forth.
EXAMPLE 1 A slipper upper and insole assembly having the form shown in FiGS. l-3 of the accompanying drawing is mounted on a wooden or metal shoe last lor form 61 and a resilient section ld is secured thereto as described above. Thereafter, the insole portion and edge seams thereof are coated by dipping at room temperature in an expandable, viscous liquid plastisol preparation having the following composition:
Parts High-molecular weight polyvinyl chloride resin Di-Z-ethylhexyl phthalate plasticizer Diethylene glycol dibenzoate 20 Dibasic lead phthalate 3 p,p-Oxybis-(benzene sulfonyl hydrazide) l The plastisol composition is prepared in the conventional manner by blending the several ingredients which are preferably premixed prior to the nal blending operation. The plastic-ol composition has a viscosity of about 12,400 centipoises at room temperature.
As soon as the dipped slipper assembly is removed from the liquid plastisol composition, the form 61 supporting the dipped assembly is mounted on the bracket 59 which is continually rotated at a rate of between 3 and 6 revolutions -per minute for about the rst 2 to 3 minutes during the passage thereof through the oven Til or until the plastisol outer portion has solidied. After the pinion 53 disengages from the rack 54, the slipper assembly is no longer rotated but is moved longitudinally through the oven 7@ with the fiat surface of thesole 21 lfacing upwardly toward the infrared heater elements 72 in the upper part of the oven 70 while said oven is maintained at a temperature of about 360 F. The conveyor 50 moves through the oven 70 at a rate of about 1.3 ft. per minute.
With an oven having a heating section of about`- 12 ft. long, a period of about 9 minutes is required for the passage of the slipper assembly therethrough when a temperature of about 360 F. is maintained therein. When the temperature within the oven 76B is at about 390 F., a heating period of only about 6 minutes is required and the conveyor is adjusted accordingly.
As the slipper assembly approaches the discharge or outlet 73 of the oven, the rotatable support arm 52 is engaged by the guide rail 75 as heretofore described to rotate the arm and slipper assembly so that the fiat portion of the sole 21 is turned downwardly to face the auxiliary infrared heater St). During the vpassage over the latter heater Si), the sole portion is softened and is thereafter immediately brought into contact with the embossing roll 90 to impress a decorative design therein. The slipper is then removed from the form 61 and is ready for packaging, if desired.
While the footwear specifically shown in FIGS. l-4 of the drawing are slippers, it should be understood that the present invention is applicable to the manufacture of other types of footwear, both for indoor and outdoor use.
Thus, for example, a tennis and other sports or athletic shoe, can be made in the above described manner. Also, with the present invention, it is possible to provide leather upperswith an intergral elastomeric sole without damaging the leather, since the leather need not be exposed to a high temperature for a prolonged period.
It will also be understood that the elastomeric sole of the footwear of the present invention can be provided with a raised heel portion, if desired. Thus, for example, a felt heel 4section is well suited by being secured to the outer heel portion of the resilient section, which may also be made of felt, before dipping the assembly in the elastomerio liquid, since the felt has suiiicient body and resistance to compression to provide the desired heel lift.
lln the specification and the claims to follow the terms welded, fused and fusibly joining, as applied to the bond betwen the elastomeric material and an insole or upper,V designates the integral connection formed with the insole or upper when a iowable elastomeric material, such as a polyvinyl chloride plastisol in intimate or impregnating c-ontact with an insole or upper, is transformed from the fluid state into the solid state on attaining a predetermined temperature without requiring the application of pressure or the use of chemical agents which require a prolonged reaction period in order to form an elastomeric solid.
I claim:
1. Anapparatus for manufacturing an article of footwear comprising: a chamber having openings at opposite ends thereof, heating means mounted in said chamber for heating the interior thereof, a conveyor means with means mounting said conveyor for continuous longitudinal movement through said chamber, said conveyor means including a footwear form support arm rotatably mounted thereon for conveying an article of footwear into one end of said chamber and out the opposite end thereof, said footwear form support arm having adjacent the outer end thereof mounting means for detachably engaging a footwear form, and said support arm having engaging means formed integrally therewith and spaced inwardly from said mounting means adapted to effect rotation of said arm about the longitudinal axis of said arm during travel of said conveyor means, mechanical means mounted in said chamber for engagement with said engaging means to effect said rotation, and said mechanical means being disposed adjacent said one end and extending into said chamber to effect rotation of said article of footwear supported by said arm during the initial portion of the period said article of footwear is passing through said chamber.
2. An apparatus for manufacturing an article of footwear comprising: a chamber having openings at opposite ends thereof, heating means mounted in said chamber for heating the interior thereof, a continuous conveyor means associated therewith for rotatably supporting and conveying an article of footwear into one end of said heatedV chamber and out the opposite end thereof, mechanical means adjacent said one end and extending into said chamber which is adapted to effect rotation of said article of footwear supported by said conveyor means during at least the initial portion of the period said footwear is passing through said heated chamber, guide means adjacent said opposite end of said chamber adapted to maintain said article of footwear in a predetermined position, and auxiliary heating means disposed opposite said guide means adapted to apply heat to a predetermined portion of said article of footwear to facilitate forming indicia at said predetermined portion of said article of footwear.
3. An apparatus for manufacturing an article of footwear comprising: a chamber having openings at opposite ends thereof, heating means mounted in said chamber for heating the interior thereof, a conveyor means with means mounting said conveyor for continuous longitudinal movement through said chamber, said conveyor means including a footwear form supportarm rotatably mounted there- A on for conveying an article of footwear into one end of said chamber and out the opposite end thereof,`said footwear form support arm having adjacent the outer end thereof mounting-means for detachably engaging a footwear form and having intermediate the ends thereof a guide section, and guide means xedly mounted on saidY chamber adjacent said opposite end of said chamber for engagement with said guide section to maintain said article of footwear mounted on said footwear form in a pre-V determined position as said footwear form leaves said chamber.
il. In apparatus for manufacturing an article of footwear including a continuous conveyor means and an article of footwear support carried by said conveyor means for supporting and conveying a footwear form having an article of footwear, a chamber through which said article of footwear is conveyed from the inlet end to the outlet end thereof on said conveyor means, and heating means mounted in said chamber for heating the interior thereof, the improvement comprising; guide means fixedly attached to said chamber and extending axially upwardly from said outlet end and engageable with said conveyor means supporting said article of footwear and maintaining said article of footwear in a predetermined position from a point within the interior of said chamber to a point spaced axially outwardly of said outlet end, and auxiliary heating means disposed opposite said guide means and extending axially outwardly from said outlet end for heating a predetermined portion of said article of footwear while supported by said conveyor means in said predetermined position.
5. An apparatus for manufacturing an article of footwear as in claim 1, wherein said footwear form support arm has positioning means intermediate the ends thereof which normally maintains the said mounting means in a predetermined position while said engaging means is out of engagement with said mechanical means; whereby mounting of said footwear form on said mounting means is facilitated.
6. An apparatus as in claim 5, wherein said position means comprises a section of said arm which extends outwardly from the longitudinal axis about which said arm rotates and which is disposed in a downwardly depending position while said engaging means is out of engagement with said mechanical means.
'7. An apparatus for manufacturing an article of footwear as in claim .3, wherein said guide section comprises a generally U-shaped portion formed intermediate the ends of said footwear form support arm and said guide means comprises a cam rail extending from a point spaced inwardly from the outlet end of said chamber to a point spaced outwardly beyond said outlet end and which is adapted to engage said U-shaped portion of said support' arm and maintain said article of footwear in said predetermined position as said article of footwear leaves the vinterior of said chamber.
References Cited by the Examiner UNITED STATES PATENTS 2,308,586 1/1943 Carberry 12-142 2,355,459 8/1944 Misbella 34-105 2,443,877 6/1948 Vacin 12-1 X l0 2,655,096 10/ 1953 Ebin 99-443 X 2,940,094 6/1960 Bromeld 12-1 2,962,738 12/1960 Andrade et al 12-142 FOREIGN PATENTS 842,170 6/ 1952 Germany.
JORDAN FRANKLIN, Primary Examiner.

Claims (1)

1. AN APPARATUS FOR MANUFACTURING AN ARTICLE OF FOOTWEAR COMPRISING: A CHAMBER HAVING OPENINGS AT OPPOSITE ENDS THEREOF, HEATING MEANS MOUNTED IN SAID CHAMBER FOR HEATING THE INTERIOR THEREOF, A CONVEYOR MEANS WITH MEANS MOUNTING SAID CONVEYOR FOR CONTINUOUS LONGITUDINAL MOVEMENT THROUGH SAID CHAMBER, SAID CONVEYOR MEANS INCLUDING A FOOTWEAR FORM SUPPORT ARM ROTATABLY MOUNTED THEREON FOR CONVEYING AN ARTICLE OF FOOTWEAR INTO ONE END OF SAID CHAMBER AND OUT THE OPPOSITE END THEREOF, SAID FOOTWEAR FORM SUPPORT ARM HAVING ADJACENT THE OUTER END THEREOF MOUNTING MEANS FOR DETACHABLY ENGAGING A FOOTWEAR FORM, AND SAID SUPPORT ARM HAVING ENGAGING MEANS
US347073A 1961-01-13 1964-02-20 Apparatus for heat treating an article of footwear Expired - Lifetime US3231914A (en)

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Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2308586A (en) * 1941-04-28 1943-01-19 Penney Co J C Manufacture of rubber coated footwear
US2355459A (en) * 1942-09-29 1944-08-08 William J Miskella Apparatus for drying helmets and the like
US2443877A (en) * 1946-09-23 1948-06-22 Joyce Inc Apparatus for manufacturing footwear utilizing sub-assemblies and applying the same directly to the lasts
DE842170C (en) * 1950-12-21 1952-06-23 Werner Winterhoff Device for preparing shoe floors and soleplates or the like for gluing
US2655096A (en) * 1949-09-07 1953-10-13 Ebin Benjamin Meat broiling apparatus
US2940094A (en) * 1958-05-21 1960-06-14 Morton S Bromfield Conveyor for use in manufacture of shoes
US2962738A (en) * 1956-02-07 1960-12-06 Bristol Mfg Corp Method of making shoes

Patent Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2308586A (en) * 1941-04-28 1943-01-19 Penney Co J C Manufacture of rubber coated footwear
US2355459A (en) * 1942-09-29 1944-08-08 William J Miskella Apparatus for drying helmets and the like
US2443877A (en) * 1946-09-23 1948-06-22 Joyce Inc Apparatus for manufacturing footwear utilizing sub-assemblies and applying the same directly to the lasts
US2655096A (en) * 1949-09-07 1953-10-13 Ebin Benjamin Meat broiling apparatus
DE842170C (en) * 1950-12-21 1952-06-23 Werner Winterhoff Device for preparing shoe floors and soleplates or the like for gluing
US2962738A (en) * 1956-02-07 1960-12-06 Bristol Mfg Corp Method of making shoes
US2940094A (en) * 1958-05-21 1960-06-14 Morton S Bromfield Conveyor for use in manufacture of shoes

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