WO2008083684A2 - Footwear and a method of producing the same - Google Patents

Footwear and a method of producing the same Download PDF

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Publication number
WO2008083684A2
WO2008083684A2 PCT/DK2008/000008 DK2008000008W WO2008083684A2 WO 2008083684 A2 WO2008083684 A2 WO 2008083684A2 DK 2008000008 W DK2008000008 W DK 2008000008W WO 2008083684 A2 WO2008083684 A2 WO 2008083684A2
Authority
WO
WIPO (PCT)
Prior art keywords
shank
sole
footwear
cover material
lower mould
Prior art date
Application number
PCT/DK2008/000008
Other languages
French (fr)
Other versions
WO2008083684A3 (en
Inventor
Hans Christian Hansen
Original Assignee
Ecco Sko A/S
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Ecco Sko A/S filed Critical Ecco Sko A/S
Publication of WO2008083684A2 publication Critical patent/WO2008083684A2/en
Publication of WO2008083684A3 publication Critical patent/WO2008083684A3/en

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Classifications

    • A—HUMAN NECESSITIES
    • A43—FOOTWEAR
    • A43B—CHARACTERISTIC FEATURES OF FOOTWEAR; PARTS OF FOOTWEAR
    • A43B13/00—Soles; Sole-and-heel integral units
    • A43B13/02—Soles; Sole-and-heel integral units characterised by the material
    • A43B13/10—Metal
    • A—HUMAN NECESSITIES
    • A43—FOOTWEAR
    • A43B—CHARACTERISTIC FEATURES OF FOOTWEAR; PARTS OF FOOTWEAR
    • A43B13/00—Soles; Sole-and-heel integral units
    • A43B13/02—Soles; Sole-and-heel integral units characterised by the material
    • A43B13/12—Soles with several layers of different materials
    • A—HUMAN NECESSITIES
    • A43—FOOTWEAR
    • A43B—CHARACTERISTIC FEATURES OF FOOTWEAR; PARTS OF FOOTWEAR
    • A43B23/00—Uppers; Boot legs; Stiffeners; Other single parts of footwear
    • A43B23/22—Supports for the shank or arch of the uppers
    • A—HUMAN NECESSITIES
    • A43—FOOTWEAR
    • A43B—CHARACTERISTIC FEATURES OF FOOTWEAR; PARTS OF FOOTWEAR
    • A43B23/00—Uppers; Boot legs; Stiffeners; Other single parts of footwear
    • A43B23/24—Ornamental buckles; Other ornaments for shoes without fastening function
    • A—HUMAN NECESSITIES
    • A43—FOOTWEAR
    • A43B—CHARACTERISTIC FEATURES OF FOOTWEAR; PARTS OF FOOTWEAR
    • A43B3/00—Footwear characterised by the shape or the use
    • A43B3/0036—Footwear characterised by the shape or the use characterised by a special shape or design
    • A43B3/0078—Footwear characterised by the shape or the use characterised by a special shape or design provided with logos, letters, signatures or the like decoration
    • A—HUMAN NECESSITIES
    • A43—FOOTWEAR
    • A43B—CHARACTERISTIC FEATURES OF FOOTWEAR; PARTS OF FOOTWEAR
    • A43B3/00—Footwear characterised by the shape or the use
    • A43B3/34—Footwear characterised by the shape or the use with electrical or electronic arrangements
    • A43B3/50—Footwear characterised by the shape or the use with electrical or electronic arrangements with sound or music sources
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
    • B29D35/00—Producing footwear
    • B29D35/06—Producing footwear having soles or heels formed and joined on to preformed uppers using a moulding technique, e.g. by injection moulding, pressing and vulcanising
    • B29D35/061—Producing footwear having soles or heels formed and joined on to preformed uppers using a moulding technique, e.g. by injection moulding, pressing and vulcanising by injection moulding

Definitions

  • the present invention relates to footwear and a method of producing footwear.
  • the footwear such as a sandal, a shoe, or a boot, has a sole, an upper, and a shank embedded in at least part of the sole which is made of a composition.
  • Some processes in the making of footwear are still manual.
  • One such manual process is the adhesive process for fastening some cover material on the sole of the footwear in order to make the sole appear as if it has been made of another material.
  • the sole When the footwear is used, the sole is compressed by the weight of the wearer. During such repeated compression of the sole, the cover material is loosened from the sole and the circumferential edge of the material thus begins to stick out from the surface of the sole. Accordingly, the footwear appears worn out after only a short period of use.
  • An aspect of the present invention is, at least partly, to overcome the disadvantages of prior art and to provide improved footwear which stays as new even when worn for some time and an improved method of manufacturing the footwear.
  • footwear such as a sandal, a shoe, or a boot, having a sole, an upper, and a shank embedded in at least part of the sole which is made of a composition, wherein the shank has an elongated part and an outer face onto which a cover material which has a front face and a circumferential edge is applied, wherein the shank is embedded so that part of the front face of the cover material is still visible on the outside of the footwear, and wherein the circumferential edge of the cover material is embedded in the sole.
  • the circumferential edge of the cover material is embedded in the sole, the edge is not loosened when the footwear is used, as is the case with some prior art footwear where the cover material is glued onto the sole after the sole is made.
  • the sole is made by injection moulding and, subsequently, a cover material such as leather is glued onto the sole in order to improve the design of the footwear.
  • a cover material such as leather is glued onto the sole in order to improve the design of the footwear.
  • the edge of the cover material tends to be released from the sole, thus giving the footwear a worn appearance.
  • the circumferential edge of the cover material may be embedded in the sole so that the sole overlaps and extends over part of the front face of the cover material.
  • the shank may be designed as a space lattice.
  • outer face may be substantially perpendicular to the elongated part of the shank.
  • the outer face of the shank has a three-dimensional pattern.
  • part of the outer face may be inclined in an angle ⁇ in relation to an axis perpendicular to an extension axis of the elongated part of the shank, and another part of the outer face may be inclined in an angle - ⁇ in relation to the axis perpendicular to the extension axis of the elongated part of the shank.
  • the sole may be made from a wear resistant material, such as ethylene vinyl acetate (EVA), natural or synthetic rubber, polyurethane (PU), thermoplastic polyure- thane (TPU) 1 thermoplastic elastomer (TPE), or latex.
  • the cover material may be leather, natural or synthetic rubber, wood-like material, light-reflecting material, or made of ethylene vinyl acetate (EVA), polyure- thane (PU), thermoplastic polyurethane (TPU), thermoplastic elastomer (TPE), or latex.
  • outer face of the shank may be formed having a three-dimensional figure, logo, or the like design.
  • the footwear may further comprise an outsole.
  • the shank has a recess for fitting a projection into a mould and fixating the shank during moulding of the sole.
  • the invention relates to a method of producing footwear according to any one of the preceding claims, wherein the shank is embedded in at least part of the sole by use of a mould comprising a last, upon which the upper is arranged, an upper mould part being divided into two side parts that are laterally movable in relation to a lower mould part between a first and second position, and the lower mould part being vertically movable in relation to the upper mould part between a third and fourth position, comprising the steps of: - placing the shank in a lower mould part of a mould,
  • the invention relates to an additional method of producing footwear according to any one of the preceding claims, wherein the shank is embedded in at least part of the sole by use of a mould comprising a last, upon which the upper is arranged, an upper mould part being divided into two side parts that are laterally movable in relation to a lower mould part between a first and second position, and the lower mould part be- ing vertically movable in relation to the upper mould part between a third and fourth position, comprising the steps of:
  • the aforementioned methods may further comprise the step of placing an outsole in the lower mould part before injecting the composition.
  • each of the methods mentioned in the above may further comprise the step of applying the cover material to the outer face of the shank.
  • Fig. 1 shows a mould with two side parts and a bottom part
  • Fig. 2 shows a sole on footwear according to the invention
  • Fig. 3 shows a sole with an embedded shank of another embodiment of the footwear according to the invention
  • Fig. 4a shows a longitudinal cross-sectional view of the sole of Fig. 3,
  • Fig. 4b shows a cross-sectional view of the heel portion of the sole of Fig. 4a
  • Fig. 4c shows a cross-sectional view of the middle portion of the sole of Fig. 4a
  • Fig. 4d shows a cross-sectional view of the toe portion of the sole of Fig. 4a
  • Fig. 5a shows a shank embedded in the sole of Fig. 4a-d in perspective
  • Fig. 5b shows the shank of Fig. 5a from above
  • Fig. 5c shows the shank of Fig. 5a from the side
  • Fig. 5d shows the shank of Fig. 5a from one end
  • Fig. 5e shows the shank of Fig. 5a from the other end
  • Fig. 6 shows yet another embodiment of a sole of footwear according to the invention
  • Fig. 7a shows a shank embedded in the sole of Fig. 6 in perspective
  • Fig. 7b shows the shank of Fig. 7a from above
  • Fig. 7c shows the shank of Fig. 7a from the side
  • Fig. 7d shows the shank of Fig. 7a from one end
  • Fig. 8 shows the shank of Fig. 5a and a cover material at its side
  • Fig. 9 shows the shank of Fig. 5a whereupon the cover material is applied
  • Fig. 10 shows another mould with two side parts and a bottom part.
  • the footwear 1 comprises an upper 2 made of leather, cloth, or the like material and a sole 3 of a wear resistant material.
  • the upper 2 of the footwear 1 is usually manufactured by sewing processes and, subsequently, the sole is made by injection moulding a composition into a cavity of a mould as shown in Fig. 1 defining the outer dimensions of the sole.
  • the footwear comprises a shank 7 embedded in the sole for supporting the arch of the foot of the wearer.
  • the shank is made of a substantially rigid material to which a plate-shaped cover material 9 is applied.
  • a plate-shaped cover material 9 is applied.
  • the cover material is applied by the use of an adhesive.
  • the cover material may be applied to the outer face of the shank by spraying the material onto the shank.
  • the cover material may also be applied to the outer face directly after the shank has been made, e.g. by injection moulding by which process the cover material is adhered to the outer face without any additional adhesive.
  • the sole is moulded around the shank with the plate-shaped cover material so as to appear both above and underneath the shank when seeing the footwear from the side.
  • the sole only appears underneath the shank with the cover material when seeing the sole of the footwear from the side.
  • the moulded sole envelops the circumferential edge of the plate-shaped cover material so that the circumferential edge of the cover material is adhered to the sole.
  • the sole holds the cover material in place also during use of the footwear, and the circumferential edge of the cover material is not loosened if the adhesive connection between the outer face of the shank and the back of the cover material is broken.
  • the adhesive connection between the sole and the cover material is also maintained during compression of the sole since the cover material adheres to the sole at the circumferential edge, meaning that the adhesive connection is not compressed during compression of the sole.
  • the cover material is loosened because it is adhered to the sole on its entire back surface, meaning that the adhesive connection is compressed along with the compression of the sole.
  • the circumferential edge of the cover material is embedded in the sole so that the sole overlaps and extends slightly over part of the front face of the cover material. In this case, the cover material is bended around the shank. When the composition spreads in the mould, it is pressed towards the front face part of the cover material bended around the shank, thus pressing the cover material more firmly towards the shank. In this way, a larger connecting surface of the cover material is obtained without diminishing the visible area of the cover material.
  • FIG. 4a-d cross-sectional views of the sole in Fig. 3 are shown.
  • Fig. 4a shows a lon- gitudinal cross-section of the sole in Fig. 3
  • Fig. 4b shows a transverse cross- sectional view of the heel portion of the sole.
  • Fig. 4c and Fig. 4d show a transverse cross-sectional view of the middle portion and the toe portion, respectively.
  • part of the shank is visible, and in Fig. 4b, the plate-shaped cover material 9 is shown embedded in the sole.
  • the shank of Fig. 4a-d is shown from different angles in Fig. 5a-e.
  • the shank is shown with an outer face 10 to which the plate-shaped cover material is to be adhered.
  • the outer face 10 of the shank is substantially perpendicular to the elongated part 11 of the shank.
  • part of the outer face is inclined in an angle ⁇ in relation to an axis 19 perpendicular to an extension axis 18 of the elongated part of the shank as shown in Fig. 5e
  • another part of the outer face is inclined in an angle - ⁇ in relation to the axis 19 perpendicular to the extension axis 18 of the elongated part of the shank.
  • the outer face of the footwear is given a three-dimensional pattern or design.
  • the shank 9 is designed in the form of a space lattice with openings 14 so that the injected composition can spread on both sides of the shank when moulding the sole.
  • the outer face of the shank is made having a three- dimensional pattern or design in the form of a logo or a figure, such as a star, a fantasy animal, or the like.
  • a logo or a figure such as a star, a fantasy animal, or the like.
  • the footwear of Fig. 3-6 is made using a method where the shank 7 is embedded in at least part of the sole by use of a mould 15 comprising a last 6, upon which the upper 2 is arranged.
  • the upper mould part 5 is divided into two side parts 5 that are laterally movable in relation to a lower mould part 4 between a first and second position, and the lower mould part 4 is vertically movable in relation to the upper mould part 5 between a third and fourth position.
  • the shank with the plate-shaped cover material is placed in the lower part 4 of the mould 15.
  • the upper 2 is placed so as to rest against the shank and hold the shank in position during the moving of the side parts 5 against each other from a first to a second position whereby the two side parts abut the upper 2 and hold the shank.
  • the lower mould part is then moved downwards and away from the shank from a fourth to a third position thus mak- ing a space underneath the shank and, subsequently, the composition for making the sole and embedding at least part of the shank into the sole is injected.
  • the lower mould part 4 is moved towards the upper 2 from a third to a fourth position whereby the space is decreased and the composition is maintained within a cavity defining an outer dimension of the sole.
  • the shank is designed with a recess 16 which fits a projection in the lower mould part so that the shank is maintained in position when the two side parts are moved towards each other for fixating the shank before the lower mould part is moved downwards.
  • the production method may differ since the shape of the outer face of the shank does not include a depression, but merely an inclined surface from the upper towards the bottom of the footwear.
  • the method of manufacturing such footwear is initiated in the same way, i.e. by placing the shank in the lower mould part of a mould. However, the placing of the upper above the shank is performed so that a distance between the shank and the upper occur. Subsequently, the side parts are moved against each other from a first to a second position whereby the two side parts abut the upper and make a space 12 between the upper and the shank.
  • composition for making the sole and embedding at least part of the shank into the sole is then injected into the space, and the lower mould part 4 is moved towards the upper 2 from a third to a fourth position so that the space is decreased and the composition is maintained within a cavity defining an outer dimension of the sole.
  • the injection step is performed by injecting the composition above the shank and the composition then spreads through the openings of the shank and is dispersed un- derneath the shank, too.
  • the shank is pressed down into the lower mould part and is held in place by the lower mould part alone, and the side parts of the mould are thus not necessary to hold it in place as is the case in regard to the method for moulding the sole of Fig. 3.
  • Both methods of producing the footwear according to the invention may further comprise the step of applying the plate-shaped cover material to the outer face of the shank.
  • the footwear may further comprise an outsole, the sole in this embodiment thus being in the form of a midsole moulded between the upper and the outsole.
  • the outsole is of a wear resistant material and the sole may be of a flexible material which does not need to be particularly wear resistant.
  • the outsole 8 of footwear is that part of the final shoe or boot that is subjected to wear when the foot of the wearer presses the shoe down on the ground during walking, running, climbing, or the like movement.
  • the outsole is made of a wear resistant material, such as synthetic or natural rubber or any suitable polymer, such as thermoplastic polyurethane.
  • the outsole is produced in a moulding process prior to the pre- sent method, but in another embodiment of the present invention, the moulding process may be a production step comprised in the present method, e.g. by using multistage injection moulding. In this way, one more step in the manufacturing process may be skipped.
  • the plate-shaped cover material may comprise a light source, such as a diode, or the shank may comprise an activation device so that e.g. music is played when the sole is compressed by the weight of the wearer during walking etc.
  • the sole is made from a wear resistant material, such as ethylene vinyl acetate (EVA), natural or synthetic rubber, polyurethane (PU), thermoplastic polyurethane (TPU), thermoplastic elastomer (TPE), or latex.
  • EVA ethylene vinyl acetate
  • PU polyurethane
  • TPU thermoplastic polyurethane
  • TPE thermoplastic elastomer
  • the cover material is either leather, natural or synthetic rubber, a wood-like material, or a light-reflecting material, or made of ethylene vinyl acetate (EVA), polyurethane (PU), thermoplastic polyurethane (TPU), thermoplastic elastomer (TPE), or latex.
  • EVA ethylene vinyl acetate
  • PU polyurethane
  • TPU thermoplastic polyurethane
  • TPE thermoplastic elastomer
  • the shank is made of a substantially rigid material, such as metal, fibre-glass, polymer, or the like material.
  • the composition is injected into the heel portion of the sole.
  • the composition may be injected into both the heel portion and the toe portion of the sole in order to ensure that the composition is able to spread out to the most distant ends of the space.
  • the composition may be injected from the same position, but into the space at two different positions in order for the composition to reach the most distant ends of the space.
  • compositions into the space 12 By injecting the composition into the space 12, other parts of the sole of the shoe, such as an insole and/or a footbed, may be fastened by the injected composition.

Abstract

The invention relates to footwear (1), such as a shoe or a boot, having a sole (3), an upper (2), and a shank (7) embedded in at least part of the sole which is made of a composition. The shank has an elongated part and an outer face onto which a cover material which has a front face and a circumferential edge is applied. Moreover, the shank is embedded so that part of the front face of the cover material is still visible on the outside of the footwear, and the circumferential edge of the cover material is embedded in the sole. The invention further relates to methods of producing the above-mentioned footwear.

Description

Title: Footwear and a method of producing the same
Technical Field
The present invention relates to footwear and a method of producing footwear. The footwear, such as a sandal, a shoe, or a boot, has a sole, an upper, and a shank embedded in at least part of the sole which is made of a composition.
Background
Some processes in the making of footwear, such as a shoe or a boot, are still manual. One such manual process is the adhesive process for fastening some cover material on the sole of the footwear in order to make the sole appear as if it has been made of another material.
When the footwear is used, the sole is compressed by the weight of the wearer. During such repeated compression of the sole, the cover material is loosened from the sole and the circumferential edge of the material thus begins to stick out from the surface of the sole. Accordingly, the footwear appears worn out after only a short period of use.
Disclosure of the Invention
An aspect of the present invention is, at least partly, to overcome the disadvantages of prior art and to provide improved footwear which stays as new even when worn for some time and an improved method of manufacturing the footwear.
This aspect and the advantages becoming evident from the description below are obtained by footwear, such as a sandal, a shoe, or a boot, having a sole, an upper, and a shank embedded in at least part of the sole which is made of a composition, wherein the shank has an elongated part and an outer face onto which a cover material which has a front face and a circumferential edge is applied, wherein the shank is embedded so that part of the front face of the cover material is still visible on the outside of the footwear, and wherein the circumferential edge of the cover material is embedded in the sole. When the circumferential edge of the cover material is embedded in the sole, the edge is not loosened when the footwear is used, as is the case with some prior art footwear where the cover material is glued onto the sole after the sole is made.
In prior art production of footwear, the sole is made by injection moulding and, subsequently, a cover material such as leather is glued onto the sole in order to improve the design of the footwear. When footwear where the cover material has been glued onto the sole is used, the edge of the cover material tends to be released from the sole, thus giving the footwear a worn appearance. By fastening the circumferential edge of the cover material during the injection moulding process in which the sole is made, the edge of the cover material is no longer loosened when the footwear is used.
In an embodiment of the present invention, the circumferential edge of the cover material may be embedded in the sole so that the sole overlaps and extends over part of the front face of the cover material.
In another embodiment of the present invention, the shank may be designed as a space lattice.
Furthermore, the outer face may be substantially perpendicular to the elongated part of the shank.
In addition, the outer face of the shank has a three-dimensional pattern.
In yet another embodiment, part of the outer face may be inclined in an angle α in relation to an axis perpendicular to an extension axis of the elongated part of the shank, and another part of the outer face may be inclined in an angle -α in relation to the axis perpendicular to the extension axis of the elongated part of the shank.
Moreover, the sole may be made from a wear resistant material, such as ethylene vinyl acetate (EVA), natural or synthetic rubber, polyurethane (PU), thermoplastic polyure- thane (TPU)1 thermoplastic elastomer (TPE), or latex. Furthermore, the cover material may be leather, natural or synthetic rubber, wood-like material, light-reflecting material, or made of ethylene vinyl acetate (EVA), polyure- thane (PU), thermoplastic polyurethane (TPU), thermoplastic elastomer (TPE), or latex.
In addition, the outer face of the shank may be formed having a three-dimensional figure, logo, or the like design.
In another embodiment, the footwear may further comprise an outsole.
In another embodiment, the shank has a recess for fitting a projection into a mould and fixating the shank during moulding of the sole.
Furthermore, the invention relates to a method of producing footwear according to any one of the preceding claims, wherein the shank is embedded in at least part of the sole by use of a mould comprising a last, upon which the upper is arranged, an upper mould part being divided into two side parts that are laterally movable in relation to a lower mould part between a first and second position, and the lower mould part being vertically movable in relation to the upper mould part between a third and fourth position, comprising the steps of: - placing the shank in a lower mould part of a mould,
- placing the upper at a distance above the shank,
- moving at least one side part against the other side part from a first to a second position whereby the two side parts abut the upper making a space between the upper and the shank, - injecting a composition into the space for making the sole and embedding at least part of the shank into the sole, and
- moving the lower mould part towards the upper from a third to a fourth position so that the space is decreased and the composition is maintained within a cavity defining an outer dimension of the sole.
In addition, the invention relates to an additional method of producing footwear according to any one of the preceding claims, wherein the shank is embedded in at least part of the sole by use of a mould comprising a last, upon which the upper is arranged, an upper mould part being divided into two side parts that are laterally movable in relation to a lower mould part between a first and second position, and the lower mould part be- ing vertically movable in relation to the upper mould part between a third and fourth position, comprising the steps of:
- placing the shank in a lower mould part of a mould,
- placing the upper to rest against the shank, - moving at least one side part against the other side part from a first to a second position whereby the two side parts abut the upper and hold the shank,
- moving the lower mould part away from the shank from a fourth to a third position making a space underneath the shank,
- injecting a composition into the space for making the sole and embedding at least part of the shank into the sole, and
- moving the lower mould part towards the upper from a third to a fourth position so that the space is decreased and the composition is maintained within a cavity defining an outer dimension of the sole.
Furthermore, the aforementioned methods may further comprise the step of placing an outsole in the lower mould part before injecting the composition.
Finally, each of the methods mentioned in the above may further comprise the step of applying the cover material to the outer face of the shank.
Brief Description of the Drawings
The invention is explained in detail below with reference to the drawings, in which
Fig. 1 shows a mould with two side parts and a bottom part,
Fig. 2 shows a sole on footwear according to the invention,
Fig. 3 shows a sole with an embedded shank of another embodiment of the footwear according to the invention,
Fig. 4a shows a longitudinal cross-sectional view of the sole of Fig. 3,
Fig. 4b shows a cross-sectional view of the heel portion of the sole of Fig. 4a, Fig. 4c shows a cross-sectional view of the middle portion of the sole of Fig. 4a,
Fig. 4d shows a cross-sectional view of the toe portion of the sole of Fig. 4a,
Fig. 5a shows a shank embedded in the sole of Fig. 4a-d in perspective,
Fig. 5b shows the shank of Fig. 5a from above,
Fig. 5c shows the shank of Fig. 5a from the side,
Fig. 5d shows the shank of Fig. 5a from one end,
Fig. 5e shows the shank of Fig. 5a from the other end,
Fig. 6 shows yet another embodiment of a sole of footwear according to the invention,
Fig. 7a shows a shank embedded in the sole of Fig. 6 in perspective,
Fig. 7b shows the shank of Fig. 7a from above,
Fig. 7c shows the shank of Fig. 7a from the side,
Fig. 7d shows the shank of Fig. 7a from one end,
Fig. 8 shows the shank of Fig. 5a and a cover material at its side,
Fig. 9 shows the shank of Fig. 5a whereupon the cover material is applied, and
Fig. 10 shows another mould with two side parts and a bottom part.
Detailed description of the preferred embodiments
In the embodiment shown in Fig. 2, the footwear 1 comprises an upper 2 made of leather, cloth, or the like material and a sole 3 of a wear resistant material. The upper 2 of the footwear 1 is usually manufactured by sewing processes and, subsequently, the sole is made by injection moulding a composition into a cavity of a mould as shown in Fig. 1 defining the outer dimensions of the sole.
Furthermore, the footwear comprises a shank 7 embedded in the sole for supporting the arch of the foot of the wearer. The shank is made of a substantially rigid material to which a plate-shaped cover material 9 is applied. When the shank is embedded in the sole, only a small part of the front face of the plate-shaped cover material is embedded into to the sole, meaning that the front face of the cover material is visible on the outside of the footwear.
In this embodiment, the cover material is applied by the use of an adhesive. In another embodiment, the cover material may be applied to the outer face of the shank by spraying the material onto the shank. The cover material may also be applied to the outer face directly after the shank has been made, e.g. by injection moulding by which process the cover material is adhered to the outer face without any additional adhesive.
In the embodiments of Fig. 2 and 3, the sole is moulded around the shank with the plate-shaped cover material so as to appear both above and underneath the shank when seeing the footwear from the side. In the embodiment shown in Fig. 6, the sole only appears underneath the shank with the cover material when seeing the sole of the footwear from the side. However, when embedding the shank with the cover material, the moulded sole envelops the circumferential edge of the plate-shaped cover material so that the circumferential edge of the cover material is adhered to the sole.
Accordingly, the sole holds the cover material in place also during use of the footwear, and the circumferential edge of the cover material is not loosened if the adhesive connection between the outer face of the shank and the back of the cover material is broken.
The adhesive connection between the sole and the cover material is also maintained during compression of the sole since the cover material adheres to the sole at the circumferential edge, meaning that the adhesive connection is not compressed during compression of the sole. In prior art, the cover material is loosened because it is adhered to the sole on its entire back surface, meaning that the adhesive connection is compressed along with the compression of the sole. In another embodiment, the circumferential edge of the cover material is embedded in the sole so that the sole overlaps and extends slightly over part of the front face of the cover material. In this case, the cover material is bended around the shank. When the composition spreads in the mould, it is pressed towards the front face part of the cover material bended around the shank, thus pressing the cover material more firmly towards the shank. In this way, a larger connecting surface of the cover material is obtained without diminishing the visible area of the cover material.
The more different the back and the front of the cover material look, the greater pur- pose the bending of the cover material around the shank serves, since an edge of such cover material would be far more visible than an edge of a cover material with almost no difference between the front and the back, should it come loose.
In Fig. 4a-d, cross-sectional views of the sole in Fig. 3 are shown. Fig. 4a shows a lon- gitudinal cross-section of the sole in Fig. 3 and Fig. 4b shows a transverse cross- sectional view of the heel portion of the sole. Fig. 4c and Fig. 4d show a transverse cross-sectional view of the middle portion and the toe portion, respectively. In Fig. 4a-c, part of the shank is visible, and in Fig. 4b, the plate-shaped cover material 9 is shown embedded in the sole.
The shank of Fig. 4a-d is shown from different angles in Fig. 5a-e. The shank is shown with an outer face 10 to which the plate-shaped cover material is to be adhered. The outer face 10 of the shank is substantially perpendicular to the elongated part 11 of the shank. However, part of the outer face is inclined in an angle α in relation to an axis 19 perpendicular to an extension axis 18 of the elongated part of the shank as shown in Fig. 5e, and another part of the outer face is inclined in an angle -α in relation to the axis 19 perpendicular to the extension axis 18 of the elongated part of the shank. Thus, the outer face of the footwear is given a three-dimensional pattern or design.
In this embodiment, the shank 9 is designed in the form of a space lattice with openings 14 so that the injected composition can spread on both sides of the shank when moulding the sole.
In another embodiment, the outer face of the shank is made having a three- dimensional pattern or design in the form of a logo or a figure, such as a star, a fantasy animal, or the like. When, subsequently, the plate-shaped cover material is adhered onto the outer face of the shank, the logo or figure will appear through the cover material.
The footwear of Fig. 3-6 is made using a method where the shank 7 is embedded in at least part of the sole by use of a mould 15 comprising a last 6, upon which the upper 2 is arranged. As shown in Figs. 1 and 10, the upper mould part 5 is divided into two side parts 5 that are laterally movable in relation to a lower mould part 4 between a first and second position, and the lower mould part 4 is vertically movable in relation to the upper mould part 5 between a third and fourth position. The shank with the plate-shaped cover material is placed in the lower part 4 of the mould 15. Subsequently, the upper 2 is placed so as to rest against the shank and hold the shank in position during the moving of the side parts 5 against each other from a first to a second position whereby the two side parts abut the upper 2 and hold the shank. The lower mould part is then moved downwards and away from the shank from a fourth to a third position thus mak- ing a space underneath the shank and, subsequently, the composition for making the sole and embedding at least part of the shank into the sole is injected. After injection of the composition, the lower mould part 4 is moved towards the upper 2 from a third to a fourth position whereby the space is decreased and the composition is maintained within a cavity defining an outer dimension of the sole.
In order to release the footwear of Fig. 3 with the moulded sole, the side parts need to be moved away from each other again due to the depression in the shape of the outer face of the shank.
In one embodiment, the shank is designed with a recess 16 which fits a projection in the lower mould part so that the shank is maintained in position when the two side parts are moved towards each other for fixating the shank before the lower mould part is moved downwards.
When moulding the sole of Fig. 6 with the shank shown in Fig. 7a-d, the production method may differ since the shape of the outer face of the shank does not include a depression, but merely an inclined surface from the upper towards the bottom of the footwear. The method of manufacturing such footwear is initiated in the same way, i.e. by placing the shank in the lower mould part of a mould. However, the placing of the upper above the shank is performed so that a distance between the shank and the upper occur. Subsequently, the side parts are moved against each other from a first to a second position whereby the two side parts abut the upper and make a space 12 between the upper and the shank. The composition for making the sole and embedding at least part of the shank into the sole is then injected into the space, and the lower mould part 4 is moved towards the upper 2 from a third to a fourth position so that the space is decreased and the composition is maintained within a cavity defining an outer dimension of the sole.
Thus, the injection step is performed by injecting the composition above the shank and the composition then spreads through the openings of the shank and is dispersed un- derneath the shank, too.
Furthermore, the shank is pressed down into the lower mould part and is held in place by the lower mould part alone, and the side parts of the mould are thus not necessary to hold it in place as is the case in regard to the method for moulding the sole of Fig. 3.
Both methods of producing the footwear according to the invention may further comprise the step of applying the plate-shaped cover material to the outer face of the shank.
The footwear may further comprise an outsole, the sole in this embodiment thus being in the form of a midsole moulded between the upper and the outsole. In this case, the outsole is of a wear resistant material and the sole may be of a flexible material which does not need to be particularly wear resistant.
The outsole 8 of footwear is that part of the final shoe or boot that is subjected to wear when the foot of the wearer presses the shoe down on the ground during walking, running, climbing, or the like movement. Typically, the outsole is made of a wear resistant material, such as synthetic or natural rubber or any suitable polymer, such as thermoplastic polyurethane. The outsole is produced in a moulding process prior to the pre- sent method, but in another embodiment of the present invention, the moulding process may be a production step comprised in the present method, e.g. by using multistage injection moulding. In this way, one more step in the manufacturing process may be skipped. In one embodiment, the plate-shaped cover material may comprise a light source, such as a diode, or the shank may comprise an activation device so that e.g. music is played when the sole is compressed by the weight of the wearer during walking etc.
The sole is made from a wear resistant material, such as ethylene vinyl acetate (EVA), natural or synthetic rubber, polyurethane (PU), thermoplastic polyurethane (TPU), thermoplastic elastomer (TPE), or latex.
The cover material is either leather, natural or synthetic rubber, a wood-like material, or a light-reflecting material, or made of ethylene vinyl acetate (EVA), polyurethane (PU), thermoplastic polyurethane (TPU), thermoplastic elastomer (TPE), or latex.
The shank is made of a substantially rigid material, such as metal, fibre-glass, polymer, or the like material.
In the present embodiment, the composition is injected into the heel portion of the sole. In another embodiment, the composition may be injected into both the heel portion and the toe portion of the sole in order to ensure that the composition is able to spread out to the most distant ends of the space. Similarly, the composition may be injected from the same position, but into the space at two different positions in order for the composition to reach the most distant ends of the space.
By injecting the composition into the space 12, other parts of the sole of the shoe, such as an insole and/or a footbed, may be fastened by the injected composition.

Claims

Claims
1. Footwear (1 ), such as a sandal, a shoe, or a boot, having a sole (3), an upper (2), and a shank (7) embedded in at least part of the sole which is made of a composition, wherein the shank has an elongated part and an outer face onto which a cover material which has a front face and a circumferential edge is applied, wherein the shank is embedded so that part of the front face of the cover material is still visible on the outside of the footwear, and wherein the circumferential edge of the cover material is embedded in the sole.
2. Footwear according to claim 1 , wherein the circumferential edge of the cover material is embedded in the sole so that the sole overlaps and extends over part of the front face of the cover material.
3. Footwear according to claim 1 or 2, wherein the shank is made as a space lattice.
4. Footwear according to any one of the preceding claims, wherein the outer face is substantially perpendicular to the elongated part of the shank.
5. Footwear according to any one of the preceding claims, wherein the outer face of the shank has a three-dimensional pattern.
6. Footwear according to any one of the preceding claims, wherein part of the outer face is inclined in an angle α in relation to an axis perpendicular to an extension axis of the elongated part of the shank, and another part of the outer face may be inclined in an angle -α in relation to the axis perpendicular to the extension axis of the elongated part of the shank.
7. Footwear according to any one of the preceding claims, wherein the sole is made from a wear resistant material, such as ethylene vinyl acetate (EVA), natural or synthetic rubber, polyurethane (PU), thermoplastic polyurethane (TPU), thermoplastic elastomer (TPE), or latex.
8. Footwear according to any of the preceding claims, wherein the cover material is leather, natural or synthetic rubber, a wood-like material, a light-reflecting material, or made of ethylene vinyl acetate (EVA), polyurethane (PU), thermoplastic polyurethane (TPU), thermoplastic elastomer (TPE), or latex.
9. Footwear according to any of the preceding claims, wherein the outer face of the shank is formed having a three-dimensional figure, logo or the like design.
10. Footwear according to any of the preceding claims, further comprising an outsole.
11. Footwear according to any of the preceding claims, wherein the shank has a re- cess for fitting a projection into a mould and fixating the shank during moulding of the sole.
12. A method of producing footwear (1) according to any one of the preceding claims, wherein the shank (7) is embedded in at least part of the sole by use of a mould com- prising a last (6), upon which the upper (2) is arranged, an upper mould part (5) being divided into two side parts (5) that are laterally movable in relation to a lower mould part (4) between a first and second position, and the lower mould part (4) being vertically movable in relation to the upper mould part (5) between a third and fourth position, comprising the steps of: - placing the shank (7) in a lower mould part (4) of a mould,
- placing the upper (2) at a distance above the shank,
- moving at least one side part (5) against the other side part (5) from a first to a second position whereby the two side parts abut the upper (2) making a space (12) between the upper and the shank, - injecting a composition into the space (12) for making the sole and embedding at least part of the shank into the sole, and
- moving the lower mould part (4) towards the upper (2) from a third to a fourth position so that the space is decreased and the composition is maintained within a cavity defining an outer dimension of the sole.
13. A method of producing footwear (1) according to any one of the claims 1-11 , wherein the shank (7) is embedded in at least part of the sole by use of a mould comprising a last (6), upon which the upper (2) is arranged, an upper mould part (5) being divided into two side parts (5) that are laterally movable in relation to a lower mould part (4) between a first and second position, and the lower mould part (4) being verti- cally movable in relation to the upper mould part (5) between a third and fourth position, comprising the steps of:
- placing the shank (7) in a lower mould part (4) of a mould,
- placing the upper (2) to rest against the shank, - moving at least one side part (5) against the other side part (5) from a first to a second position whereby the two side parts abut the upper (2) and hold the shank,
- moving the lower mould part away from the shank from a fourth to a third position making a space underneath the shank,
- injecting a composition into the space (12) for making the sole and embedding at least part of the shank into the sole, and
- moving the lower mould part (4) towards the upper (2) from a third to a fourth position so that the space is decreased and the composition is maintained within a cavity defining an outer dimension of the sole.
14. A method according to claim 12 or 13, further comprising the step of placing an outsole in the lower mould part before injecting the composition.
15. A method according to any one of the claims 12-14, further comprising the step of applying the cover material to the outer face of the shank.
PCT/DK2008/000008 2007-01-12 2008-01-11 Footwear and a method of producing the same WO2008083684A2 (en)

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Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2530039A (en) * 2014-09-09 2016-03-16 Graham Donald Evans Gordon Footwear component

Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0023356A1 (en) * 1979-07-26 1981-02-04 ESANA-Schuhfabrik Sailer GmbH Shoe, in particular a ladies' shoe
DE3046332A1 (en) * 1980-12-09 1982-07-22 Danner, Hans, 7000 Stuttgart Shoe with integral sole and edge strip - has sole moulded using edge strip as seal to mouth of mould
FR2659201A1 (en) * 1990-03-08 1991-09-13 Degorce Sa Method for manufacturing articles of footwear with a compensated (built-up) heel, mould for implementing this method and articles of footwear thus obtained
EP0799583A1 (en) * 1996-04-02 1997-10-08 TECNICA S.p.A Composite sole for shoes in general
US6416610B1 (en) * 2000-04-28 2002-07-09 Wolverine World Wide, Inc. Method for making a sole system for footwear

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0023356A1 (en) * 1979-07-26 1981-02-04 ESANA-Schuhfabrik Sailer GmbH Shoe, in particular a ladies' shoe
DE3046332A1 (en) * 1980-12-09 1982-07-22 Danner, Hans, 7000 Stuttgart Shoe with integral sole and edge strip - has sole moulded using edge strip as seal to mouth of mould
FR2659201A1 (en) * 1990-03-08 1991-09-13 Degorce Sa Method for manufacturing articles of footwear with a compensated (built-up) heel, mould for implementing this method and articles of footwear thus obtained
EP0799583A1 (en) * 1996-04-02 1997-10-08 TECNICA S.p.A Composite sole for shoes in general
US6416610B1 (en) * 2000-04-28 2002-07-09 Wolverine World Wide, Inc. Method for making a sole system for footwear

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2530039A (en) * 2014-09-09 2016-03-16 Graham Donald Evans Gordon Footwear component

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