WO2005115732A1

WO2005115732A1 - Adjustable size mold

Info

Publication number: WO2005115732A1
Application number: PCT/US2005/017103
Authority: WO
Inventors: Kevin Mccoy
Original assignee: New Balance Athletic Shoe, Inc.
Priority date: 2004-05-20
Filing date: 2005-05-16
Publication date: 2005-12-08
Also published as: TW200602177A

Abstract

An adjustable mold (1) for making footwear components with different sizes. The mold comprising a first mold half (2), a second mold half (3) for closing against the first mold half to define a mold cavity (11), a first wedege insert (4) and a second wedge insert (5). The first and second mold halves each have a medial portion (6, 8, respectively) and a lateral portion (7, 9, respectively). The medial and lateral portions are operatively connected for permitting the medial and lateral portions to move with respect to each other, preferably about an axis point (10, 12) located at an end of the mold half, leaving a space between the medial and lateral portions. When the medial and lateral portions of the first and second mold halves are in a closed position, the mold has a first width. The mold has a second width with the inserts installed.

Description

TITLE Adjustable Size Mold

CROSS-REFERENCE TO RELATED APPLICATION This application claims priority of Provisional Application No. 60/573,031, filed on

May 20, 2004, which is incorporated herein by reference in its entirety.

BACKGROUND OF THE INVENTION Conventional methods for making shoe soles typically require one injection or compression mold for each shoe size to be made. This not only increases the manufacturing cost, but also requires substantial manufacturing plant space for storing the molds. To reduce the cost and plant space required for the manufacture of shoe soles, various molding devices have been developed over the past years which allow adjustment of certain mold features so that different soles or multiple elements of a sole can be made with a single mold device. For example, U.S. Patent No. 4,165,958 discloses an apparatus for injection molding shoe soles. The apparatus is equipped with at least two bottom stamps, each stamp being attached to a separate supporting arm, which are directed towards each other at an angle, specifically at right angles. The right angle arms supporting mold bottom stamps pivot about an axis at the intersection of the arms to present in sequence the bottom stamps into underlying position with respect to an upper mold and a side mold to form in sequence first and second mold cavities limited respectively by the bottom stamps to permit multiple layer shoe soles to be molded to a shoe upper. However, this apparatus does not allow adjustment of the sizes of the shoe soles to be made. U.S. Patent No. 4,556,191 discloses a shoe mold device having a base mold portion containing a cavity and a top mold portion with two or more mold surfaces and rotatably associated with the base mold portion. A shoe sole comprised of a plurality of different colored or shaped layers is manufactured using the mold by successively utilizing different mold surfaces of the top mold portion to contact and close the cavity in the base mold portion. Although this mold device permits change of mold surfaces for making different layers of a sole in a single mold device, it does not allow adjustment of the mold size for manufacturing shoes of different sizes. U.S. Patent No. 5,307,862 discloses an adjustable mold for continuous casting of articles of different thicknesses. The mold comprises a fixed longitudinal frame and a movable longitudinal frame which can be opened or closed by remote control, and a pair of fixed lateral frame members to which variable lateral frame members are detachably attached. A bracket provided on each of the variable lateral frame members is brought into engagement with a bracket receiving recess formed in each of the fixed lateral frame members in order to position the lower end portions of the lateral frame members. In this manner, replacement of the lateral frames having a size corresponding to a desired thickness of cast pieces can be achieved. This mold has a very complex construction. U.S. Patent No. 5,855,925 discloses a plastic injection apparatus for making shoes that includes one molding block composed of two halves that define a cooperative cavity for forming the sole of the shoe. The cavity includes an inwardly extending peripheral flange at its upper edge. The shoe molds have such dimensions that an adjusting peripheral line is defined around each one of the shoe molds of such dimensions that when both shoes are placed in the molding block, the flange is brought adjacent to the adjusting peripheral line. This injection apparatus allows one molding block to be used for two shoe molds of two consecutive shoe sizes. However, the size or width of the shoe molds can not be adjusted. There exists a need for a molding device which can be easily adjustable for making footwear soles of different sizes, so that the cost and space required for the manufacture of shoe soles can be minimized.

SUMMARY OF THE INVENTION In view of the foregoing, it is an object of the present invention to provide a molding device which can be easily adjustable for making molded objects with different dimensions, especially for making footwear components with different widths or sizes. It is also an object of the present invention to provide a molding device which can be used to produce molded objects, especially footwear components with varying widths or sizes, while minimizing the tooling cost and space required for storing the tools. It is another object of the present invention to provide a mold which allows for a spacer of a defined width to be inserted into the top and/or bottom plates of the tool , thus allowing multiple width components to be built off a single tool. It is a further object of the present invention to provide a molding tool which is built in a base width or size and which has a mechanism allowing a defined width spacer to be inserted into the top and/or bottom plates of the tool. This spacer is to allow for material to fill the newly created gap in the tool thus allowing the single tool to create components in two or more different widths or sizes. In accordance with an aspect of the present invention, there is provided an adjustable mold for making a molded object, comprising: a first mold half comprising a first medial portion and a first lateral portion, the first medial and lateral portions being operatively connected at a first axis point for permitting the first medial and lateral portions to move about the first axis point, leaving a first space between the first medial and lateral portions; a second mold half comprising a second medial portion and a second lateral portion, the second mold half being cooperatively associated with the first mold half for closing against the first mold half and for defining a mold cavity between the first and second mold halves, the second medial and lateral portions being operatively connected at a second axis point for permitting the second medial and lateral portions to move about the second axis point, leaving a second space between the second medial and lateral portions; a first wedge insert adapted for occupying the first space; and a second wedge insert adapted for occupying the second space. In accordance with another aspect of the present invention, there is provided an adjustable mold for making a molded object, comprising: a first mold half comprising a first medial portion and a first lateral portion, the first medial and lateral portions being operatively connected for permitting the first medial and lateral portions to move with respect to each other, leaving a first space between the first medial and lateral portions; a second mold half being cooperatively associated with the first mold half for closing against the first mold half and for defining a mold cavity between the first and second mold halves; and a first insert adapted for occupying the first space. In accordance with a further aspect of the present invention, there is provided an adjustable mold for making a molded object, comprising: a first mold half comprising a first medial portion and a first lateial portion, the first medial and lateial portions being operatively connected for permitting the first medial and lateral portions to move with respect to each other, leaving a first space between the first medial and lateral portions; a second mold half comprising a second medial portion and a second lateral portion, the second mold half being coopei atively associated with the first mold half for closing against the fust mold half and for defining a mold cavity between the first and second mold halves, the second medial and lateral portions being operatively connected for permitting the second medial and lateral portions to move with respect to each other, leaving a second space between the second medial and lateral portions, a first insert adapted for occupying the first space, and a second insert adapted for occupying the second space The first mold half has a first toe end and a first heel end, and the first medial and lateral portions are operatively connected at one of the first toe and heel ends so that the first medial and lateral portions are moveable with respect to each other at the other of the fust toe and heel ends Similarly, the second mold half has a second toe end and a second heel end, and the second medial and lateral portions are operatively connected at one of the second toe and heel ends so that the second medial and lateral portions are moveable with respect to each other at the other of the second toe and heel ends Alternatively, the first medial and lateral portions are operatively connected at both of the first toe and heel ends, and the second medial and lateral portions are operatively connected at both of the second toe and heel ends.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is an exploded view of an adjustable mold according to the present invention when the second mold half is of an original position with a first mold width. FIG. 2 is an exploded view of the adjustable mold when the second mold half is of an expanded position. FIG. 3 is an exploded view of the adjustable mold when the second wedge insert is inserted in the expanded second mold half, resulting in a second mold width. FIG. 4 is a perspective view of the adjustable mold with a second mold width when the two mold halves are closed against each other.

DETAILED DESCRIPTION OF THE INVENTION The present invention can be better understood from the following description of preferred embodiments, taken in conjunction with the accompanying drawings. It should be apparent to those skilled in the art that the described embodiments of the present invention provided herein are merely exemplary and illustrative and not limiting. All features disclosed in the description may be replaced by alternative features serving the same or similar purpose, unless expressly stated otherwise. Therefore, numerous other embodiments of the modifications thereof are contemplated as falling within the scope of the present invention and equivalents thereto. Referring to FIGS. 1-4, the adjustable mold 1 of the present invention comprises a first mold half 2, a second mold half 3, a first wedge insert 4 and a second wedge insert 5. The first mold half 2 is also called the bottom mold half or the cavity portion of the mold. The second mold half 3 is also called the bottom mold half or the core portion of the mold.

The first mold half 2 includes a first medial portion 6 and a first lateral portion 7. The second mold half 3 includes a second medial portion 8 and a second lateral portion 9. The first medial portion 6 and the first lateral portion 7 are operatively connected at a first axis point 10 for permitting the first medial portion 6 and the first lateral portion 7 to move about the first axis point 10 by a slider, a spring system, a hinge, any similar construction, or any mechanism that performs the same function, leaving a first space 13 between the first medial portion 6 and the first lateral portion 7. The second mold half 3 is cooperatively associated with the first mold half 2 for closing against the first mold half 2 and for defining a mold cavity 11 between the first mold half 2 and the second mold half 3. Similar to the first medial and lateral portions, the second medial portion 8 and the second lateral portion 9 are operatively connected at a second axis point 12 for permitting the second medial portion 8 and the second lateral portion 9 to move about the second axis point 12, leaving a second space (shown to be occupied by the first wedge insert 5) between the second medial portion 8 and the second lateral portion 9. In this embodiment, the space between the medial and lateral portions of the mold half has an increasing width from the axis point on one end of the mold to the other end of the mold. Preferably, the first space is located on the longitudinal center line of the first mold half, and the second space is located on the longitudinal center line of the second mold half. The first mold half 2 has a first toe end 14 and a first heel end 15. The second mold half 3 has a second toe end 16 and a second heel end 17. In the exemplary embodiment shown in FIGS. 1-4, the first axis point 10 of the first mold half 2 is located at the first heel end 15, and the second axis point 12 of the second mold half 3 is located at the second heel end 17. However, it is also contemplated that on each of the first and second mold halves, the axis point can be located on either of the toe and heel ends, or on any location on the periphery of the mold half, for adjustment of width or length of the mold or a combination thereof as desired. The first wedge insert 4 can be inserted into the first mold half 2 to occupy the first space 13 between the first medial portion 6 and the first lateral portion 7. The surface of the first wedge insert 4, which when inserted in the first mold half 2 faces the mold cavity 11 , has a contour which integrates with the adjacent areas of the first medial portion 6 and the second lateral portion 7 to form a smooth inner surface of the mold cavity on the first mold half 2 with an expanded width. Similarly, the second wedge insert 5 can be inserted into the second mold half 3 to occupy the second space between the second medial portion 8 and the second lateral portion 9. The surface of the second wedge insert 5, which when inserted in the second mold half 3 faces the mold cavity 11, has a contour which integrates with the adjacent areas of the second medial portion 8 and the second lateral portion 9 to form a smooth inner surface of the mold cavity on the second mold half 3 with an expanded width. The widths of the first and second wedge inserts increase from one end to the other end, corresponding to the widths of the first and second spaces created in the first and second mold halves respectively. Although in the exemplary embodiment shown in FIGS. 1-4, only one insert is shown for each of the first and second mold halves, it is contemplated that more than one inserts can be inserted to occupy each of the first and second spaces. It is also contemplated that the adjustable mold may be equipped with multiple inserts with varying widths so that an insert can be selected depending on the desired width of the shoes to be manufactured. In use, as shown in FIG. 1, the medial and lateral portions 6, 7 of the first mold half 2 are in a closed position so that the first mold half 2 has a first width. To create a second width of the mold, the medial and lateral portions 6, 7 of the first mold half 2 are opened, leaving a first space 13 in between, as shown in FIG 2 Subsequently, the first wedge insert 4 slides in to occupy the fu st space 13 to cicate a mold half having a second width as shown in FIG 3 The width of the second mold half can be adjusted similarly so that the two mold halves can be closed, as shown in FIG 4, for molding It is also contemplated that multiple inserts or an insert of a diffeient width can be used to create a third width, and similarly additional widths can be cieated Furthermore, although the adjustment of the width of the mold is piimanly discussed in the descriptions herein, it is contemplated that by changing the location of the axis point on a mold half, or by appropriately arranging two points about which the medial and lateral portions of the mold half aie movable with lespect to each othei , the width oi the length of the mold or a combination thereof can be adjustable as desired In accordance with another embodiment of the present invention, the adjustable mold comprises a first mold half which is adjustable in width, at least one second mold half which is not adjustable, and a fu st insert for insertion into the first mold half The adjustable first mold half comprises a medial portion and a lateral portion The medial and lateral portions are operatively connected for permitting the medial and lateral portions to move with respect to each other, leaving a space between the medial and lateral portions The first insert is adapted for insertion into the space in the first mold half One oi more unadjustable second mold halves with variable widths are available, from which an appiopnate insert can be selected to be cooperatively associated with the first mold half of a desired width for closing against the first mold half and for defining a mold cavity between the first and second mold halves Alternatively, the mold may have a second mold half which is adjustable in width and at least one first mold half which is not adjustable In accoidance with a further embodiment of the present invention, the adjustable mold compiises fu st and second mold halves and fust and second inserts adapted to be insetted into the fust and second mold halves respectively The first mold half has a first toe end and a first heel end, and the first medial and lateral portions are operatively connected at both of the first toe and heel ends The second mold half has a second toe end and a second heel end, and the second medial and lateial portions aie opeiatively connected at both of the second toe and heel ends Thus, in the first and second mold halves, the medial and lateral portions can be moved with respect to each other on both the toe and heel ends, so that the first and second spaces each may have a substantially uniform width from the toe end to the heel end Altei natively, the medial and lateral portions may be moved with respect to each other at different degiees at the toe end and the heel end so that the spaces created between the medial and lateral portions have tapeπng widths along the longitudinal axis of the mold The adjustable mold of the present invention is useful in making various molded objects, especially footweai components such as shoe soles The adjustable mold can be used in various molding operations including compression molding and injection molding with a vaπety of mateπals such as thermoplastic, thermosetting, or vulcanizable mateπals or other settable or moldable materials While vanous embodiments and individual features of the piesent invention have been illustrated and described, it would be obvious to those skilled in the art that vanous other changes and modifications can be made without departing from the spirit and scope of the present invention As will also be apparent to those skilled in the art, vanous combinations of the embodiments and features taught in the foregoing description are possible and can result in prefeired executions of the present invention. Accordingly, it is intended that such changes and modifications fall within the scope of the present invention as defined by the claims appended hereto.

Claims

What is claimed is' 1 An adjustable mold for making a molded object, compnsing a fust mold half compnsing a fust medial portion and a fust lateial portion, said fust medial and lateial portions being operatively connected at a fust axis point for permitting said first medial and lateral portions to move about said first axis point, leaving a fust space between said first medial and lateial portions, a second mold half compnsing a second medial portion and a second lateral portion, said second mold half being cooperatively associated with said first mold half for closing against said first mold half and foi defining a mold cavity between said first and second mold halves, said second medial and lateral portions being opeiatively connected at a second axis point for permitting said second medial and lateial portions to move about said second axis point, leaving a second space between said second medial and lateral portions; a first wedge insert adapted for occupying said first space, and a second wedge insert adapted foi occupying said second space

2. The adjustable mold of claim 1, which is for compression molding or injection molding of a footwear component.

3. The adjustable mold of claim 2, wherein said footwear component is a shoe sole.

4. The adjustable mold of claim 1 , wherein said first mold half has a first toe end and a first heel end, and said fust axis point is located at one of said first toe and heel ends 5 The adjustable mold of claim 4, wherein said fust axis point is located at said fust heel end

6 The adjustable mold of claim 5, wherein said second mold half has a second toe end and a second heel end, and said second axis point is located at said second heel end

7 The adjustable mold of claim 1 , wherein the width of the mold is adjustable

8 The adjustable mold of claim 1, compnsing one or more first wedge inserts adapted foi occupying said fust space, and one or more second wedge inserts adapted for occupying said second space

9 An adjustable mold for making a molded object, compnsing a fust mold half comprising a first medial portion and a first lateral portion, said fust medial and lateral portions being operatively connected for permitting said first medial and lateral portions to move with respect to each other, leaving a first space between said first medial and lateral portions; a second mold half being cooperatively associated with said fust mold half for closing against said fust mold half and foi defining a mold cavity between said first and second mold halves, and a first insert adapted for occupying said first space fust heel end, and said fust medial and lateial portions aie opeiatively connected at one of said fust toe and heel ends, so that said fust medial and lateial portions are moveable with lespect to each other at the othei of said fust toe and heel ends

11 The adjustable mold of claim 9, which is for compiession molding or injection molding of a footwear component

12 The adjustable mold of claim 9, wheiein the width of the mold is adjustable

13 An adjustable mold for making a molded object, compnsing a first mold half compnsing a first medial portion and a fust lateral portion, said first medial and lateial portions being opciatively connected for peimitting said first medial and lateial portions to move with respect to each other, leaving a first space between said first medial and lateral portions, a second mold half compnsing a second medial portion and a second lateral portion, said second mold half being coopeiatively associated with said first mold half for closing against said first mold half and foi defining a mold cavity between said first and second mold halves, said second medial and lateral portions being operatively connected for permitting said second medial and lateral portions to move with respect to each other, leaving a second space between said second medial and lateral portions, a first insert adapted for occupying said first space, and a second insert adapted for occupying said second space 14 The adjustable mold of claim 13, which is for compression molding or injection molding of a footwcai component

15 The adjustable mold of claim 13, wherein the width of the mold is adjustable

16 The adjustable mold of claim 13, wheiein said first space is located on the longitudinal centei line of said first mold half, and said second space is located on the longitudinal centei line of said second mold half.

17 The adjustable mold of claim 13, comprising one or more first inserts adapted foi occupying said first space, and one or moie second inserts adapted foi occupying said second space

18 The adjustable mold of claim 13, wherein said first mold half has a first toe end and a first heel end, and said first medial and lateral portions are operatively connected at one of said first toe and heel ends so that said first medial and lateral portions are moveable with respect to each other at the other of said first toe and heel ends, and wheiein said second mold half has a second toe end and a second heel end, and said second medial and lateial portions aie operatively connected at one of said second toe and heel ends so that said second medial and lateral portions are moveable with respect to each other at the other of said second toe and heel ends 19 The adjustable mold of claim 13, wherein said first mold half has a first toe end and a first heel end, and said first medial and lateral portions are operatively connected at both of said first toe and heel ends, and wherein said second mold half has a second toe end and a second heel end, and said second medial and lateial portions are operatively connected at both of said second toe and heel ends.

20. The adjustable mold of claim 19, wherein said first space has a substantially uniform width from said first toe end to said first heel end, and said second space has a substantially uniform width from said second toe end to said second heel end.