WO2016133994A1 - Slipper and method for manufacturing a slipper - Google Patents

Slipper and method for manufacturing a slipper Download PDF

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Publication number
WO2016133994A1
WO2016133994A1 PCT/US2016/018232 US2016018232W WO2016133994A1 WO 2016133994 A1 WO2016133994 A1 WO 2016133994A1 US 2016018232 W US2016018232 W US 2016018232W WO 2016133994 A1 WO2016133994 A1 WO 2016133994A1
Authority
WO
WIPO (PCT)
Prior art keywords
outsole
upper
slipper
layer
fabric
Prior art date
Application number
PCT/US2016/018232
Other languages
French (fr)
Inventor
Neva KRAATZ
Lee F. SMITH
Andrew Edward GREVER
Original Assignee
R.G. Barry Corporation
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
Priority to US201562117247P priority Critical
Priority to US62/117,247 priority
Application filed by R.G. Barry Corporation filed Critical R.G. Barry Corporation
Publication of WO2016133994A1 publication Critical patent/WO2016133994A1/en

Links

Classifications

    • AHUMAN NECESSITIES
    • A43FOOTWEAR
    • A43BCHARACTERISTIC FEATURES OF FOOTWEAR; PARTS OF FOOTWEAR
    • A43B13/00Soles; Sole and heel units
    • A43B13/38Built-in insoles joined to uppers during the manufacturing process, e.g. structural insoles; Insoles glued to shoes during the manufacturing process
    • AHUMAN NECESSITIES
    • A43FOOTWEAR
    • A43BCHARACTERISTIC FEATURES OF FOOTWEAR; PARTS OF FOOTWEAR
    • A43B13/00Soles; Sole and heel units
    • A43B13/02Soles; Sole and heel units characterised by the material
    • A43B13/12Soles with several layers of different materials
    • AHUMAN NECESSITIES
    • A43FOOTWEAR
    • A43BCHARACTERISTIC FEATURES OF FOOTWEAR; PARTS OF FOOTWEAR
    • A43B23/00Uppers; Boot legs; Stiffeners; Other single parts of footwear
    • A43B23/24Ornamental buckles; Other ornaments for shoes without fastening function
    • A43B23/25Arrangement of ribbons on footwear
    • AHUMAN NECESSITIES
    • A43FOOTWEAR
    • A43BCHARACTERISTIC FEATURES OF FOOTWEAR; PARTS OF FOOTWEAR
    • A43B3/00Footwear characterised by the shape or the use
    • A43B3/10Low shoes; Slippers
    • A43B3/101Slippers
    • AHUMAN NECESSITIES
    • A43FOOTWEAR
    • A43BCHARACTERISTIC FEATURES OF FOOTWEAR; PARTS OF FOOTWEAR
    • A43B9/00Footwear characterised by the assembling of the individual parts
    • A43B9/02Footwear stitched or nailed through

Abstract

A slipper and a method of manufacturing a slipper are provided. The slipper may include an upper and a fabric insole layer stitched to the upper. The slipper also includes an outsole formed from a material such as an ethylene vinyl acetate. The outsole may include a top, a bottom tread surface, and an outer side perimeter surface. The top forms a receiving tray having a top surface and a perimeter wall extending upward from the top surface and forming at least a portion of the side perimeter surface. The slipper may include a side stitching pattern along the outer side perimeter surface attaching the upper and fabric insole layer to the outsole through the perimeter wall.

Description

SLIPPER AND METHOD

FOR MANUFACTURING A SLIPPER

Cross-Reference to Related Application

The present application is an International Patent Application claiming the benefit of U.S. Provisional Patent Application No. 62/1 17,247, filed February 17, 2015 in the United States Patent and Trademark Office, the disclosure of which is incorporated herein by reference.

Technical Field

The subject matter described herein relates to a slipper and a method for manufacturing a slipper. Background

The footwear industry is an old and crowded art. The industry is constantly attempting to design new products with aesthetic appeal, as well as being comfortable and having ease of construction.

Various designs of slippers have been available for a number of years.

Examples of slipper designs are described, for example, in U.S. Patent No. 5,392,532 (Bray, Jr. ei al.) and U.S. Patent No. 6,226,894 (Bray, Jr. et ah), both of which are incorporated by reference herein in their entirety. In general, slippers are a type of footwear having a generally soft construction and are generally washable in a conventional clothes washing machine. Slippers are typically not manufactured using a last, which is often a necessary device when manufacturing a shoe, including a hard sole and a leather upper.

Slipper outsoles are manufactured from a variety of different materials, depending upon the intended style and purpose of the slipper. For example, slippers having a cloth outsole stitched and/or glued to a cloth or fabric upper and/or insole are typically used exclusively indoors. Other slippers intended for indoor/outdoor use may utilize a formed plastic outsole typically use a thermoplastic elastomer, such as a thermoplastic rubber (TPR). Such slippers may be constructed by gluing the outsole to an upper and sock, and may have an insole inserted into a pocket formed thereby.

In some cases, slipper outsoles have been provided that make use of an ethylene vinyl acetate (EVA). Such slipper outsoles are generally softer and less durable than those made using TPR, but are both lighter and provide greater shock absorption. In cases where EVA has been used for a slipper outsole, such outsoles are glued to the upper of a slipper, for convenience. Such gluing adds weight to the overall slipper, counterbalancing the advantage of using EVA. Such gluing also tends to weaken over time, rendering such slippers useful for a limited period of time, based on the wear rate of the EVA and the resilience of the glue layer used to attach the upper of the slipper to the outsole.

Summary

A slipper and method for manufacturing a slipper are disclosed. In general, the slipper includes a side stitching pattern along an outer side perimeter surface of an outsole, fastening an insole and upper to the outsole.

According to the present subject matter, provided is a slipper that includes an upper and a fabric insole layer stitched to the upper. The slipper further includes an outsole comprising or consisting one or more material including, for example, an elastomeric polymer such as ethylene vinyl acetate, a polyurethane elastomer such as a thermoplastic polyester-polyurethane or a thermoplastic polyether-polyurethane, a natural rubber, a synthetic rubber, or the like. The outsole includes a top, a bottom tread surface, and an outer side perimeter surface. The top forms a receiving tray having a top surface and a perimeter wall extending upward from the top surface and forming at least a portion of the side perimeter surface. The slipper may also include a side stitching pattern along the outer side perimeter surface attaching the upper and fabric insole layer to the outsole through the perimeter wall.

Also provided is a method for manufacturing a slipper that includes an upper attached to an outsole. The method includes forming an outsole comprising or consisting one or more material including, for example, an elastomeric polymer such as ethylene vinyl acetate, a polyurethane elastomer such as a thermoplastic polyester- polyurethane or a thermoplastic polyether-polyurethane, a natural rubber, a synthetic rubber, or the like. The outsole includes a top, a bottom tread surface, and an outer side perimeter surface, the top forming a receiving tray having a top surface and a perimeter wall extending upward from the top surface and forming at least a portion of the side perimeter surface. The method may also include stitching a fabric insole layer to the upper, placing the fabric insole layer within the receiving tray, and stitching the fabric insole layer and upper to the outsole through the perimeter wall, forming a side stitching pattern along the outer side perimeter surface.

Brief Description of the Drawings

Figure 1 is a perspective view of a slipper construction according to an example embodiment of the present disclosure;

Figure 2 is an exploded view of the slipper construction of Figure 1.

Figure 3 is a side view of the slipper construction of Figure 1.

Figure 4 is a lengthwise side cross-sectional view of the slipper construction of Figure 1.

Figure 5 is a perspective view of an alternative embodiment of a slipper construction, according to the principles of the present disclosure.

Figure 6 is a perspective view of an alternative embodiment of a slipper construction, according to the principles of the present disclosure.

Detailed Description

Referring to Figures 1-4, a slipper according to the present disclosure is shown at reference numeral 10. The slipper 10 includes an outsole 12, an upper 14, and an insole 16. The slipper 10 can be characterized as having a generally soft construction while providing support for a wearer's foot.

The outsole 12 has a top surface 20 and a bottom surface 22. The top surface 20 includes a perimeter wall 24 extending upward from a footbed 26. The bottom surface 22 has a tread pattern molded thereon. Alternatively, the bottom surface 22 may be smooth or textured, for example to provide traction for a wearer. An outer side surface 28 of the outsole 12 extends along a perimeter of the outsole and upward from the bottom surface 22. The perimeter wall 24 extending upward from the footbed 26 is located opposed to an upper portion of the outer side surface 28. The outsole 12 may be constructed from one or more material comprising or consisting of an elastomeric polymer such as ethylene vinyl acetate, a polyurethane elastomer such as a

thermoplastic polyester-polyurethane or a thermoplastic polyether-polyurethane, , a natural rubber, a synthetic rubber, or the like. Such an outsole material provides, relative to other outsole materials, a generally softer feel and higher wear rate.

For example, the EVA may be present in the outsole 12 in an amount of about 0.01 to 100%, by weight. A rubber, either natural, synthetic or a combination of one or more natural or synthetic rubbers, may be present in an amount of, e.g., about 30%, 27.5 to 32.5%, 25 to 35%, 20 to 40%; 15 to 45%, 27.5 to 35%, 27.5 to 40%, 20 to 32.5%, or 25 to 32.5%.

The upper 14 is generally a soft fabric or other material designed to conform to a wearer's foot. The upper 14 can take any of a variety of forms. The upper 14 shown has a cloth or wool construction and a "ballet slipper" appearance. The upper 14 includes an opening 30 sized to receive a wearer's foot and exposing the insole 16, as well as a vamp 31. The upper 14 further includes a perimeter portion 32 around the opening 30, generally located at a topline of the slipper. The perimeter portion 32 can include a decorative feature, such as a stitched seam or other decorative binding. The vamp 31 can be, in various embodiments, of a closed toe or open toe design. In the example shown, the vamp 31 is a closed toe design and includes a ribbon 34 stitched thereto, near a side of the opening 30 toward a toe portion of the slipper 10.

In the example shown, the upper 14 has a closed-back construction, such that, when worn, a heel portion of the upper 14 will retain a wearer's foot within a cavity formed between the upper 14 and insole 16. However, in alternative constructions, the upper 14 can have an open-back construction or a partially open-back construction, in which a heel portion of the upper is at a reduced height or missing completely, allowing a wearer's foot to more easily be inserted into the opening 30.

The insole 16 includes a fabric layer 40 that is stitched to the upper along a perimeter edge. In arrangements in which the upper has a closed toe and closed back construction, the insole 16 is stitched to the upper 14 along the entire perimeter of the insole. The insole may alternatively be stitched to the upper at portions of the upper that are intended to also be attached to the outsole. The stitching forms a flange portion 42 that represents a portion of the insole 16 and the upper 14 that are joined together along at least a perimeter of the insole 16.

The fabric layer 40 can take any of a variety of forms. In example

embodiments, the fabric layer 40 can have a textured top surface or visual appearance that implies comfort to a wearer. For example, the fabric layer 40 can include cushioning regions in a heel area and a forefoot area, optionally interconnected to form a cushioned area 41 generally centrally located on a top surface of the insole.

Referring back to the outsole 12, the top surface 20 and perimeter wall 24 form a receiving tray 44 on which the stitched together upper 14 and insole 16 are received. To construct the slipper 10, the insole 16 and upper 14, being stitched together, are positioned on the receiving tray 44, with the flange portion 42 oriented downward toward the top surface such that the flange portion 42 of the joined upper 14 and insole 16 is generally positioned alongside and parallel with the perimeter wall 24. A side stitching pattern 50 is then applied, extending through and affixing the flange portion 42 to the outsole 12 along the entire perimeter of the outsole. When the insole 16 and upper 14 are stitched together along the entire perimeter of the insole 16, the side stitching pattern 50 will generally then affix the upper 14 and insole 16 to the outsole 12 along the entire perimeter of the outsole, i.e., along the entire perimeter wall 24. In instances when the upper 14 and insole 16 are not stitched together along the entire surface (e.g., in the case of an open toe or open back construction), an entire perimeter of the insole 16 will be stitched to the outsole 12 by the side stitching pattern 50, while the portions of the upper 14 that are stitched to the insole 16 will also be stitched to the outsole 12 by the side stitching pattern 50. As shown, the stitching will pass through the outsole 12, the upper 14, and the insole 16 layers in order, such that the upper is both: (1) separately stitched to the insole 16; and (2) positioned and stitched between the insole 16 and outsole 12. Furthermore, the side stitching pattern 50 may extend along a channel 51 formed in the outer side surface 28, for example to assist in retaining a thread forming the side stitching pattern.

As illustrated in Figs. 2 and 3, a foam layer 46 may be placed on the receiving tray 44 prior to applying the side stitching pattern 50 to attach the upper 14 and insole 16 to the outsole 12. The foam layer 46 is positioned below the insole 16 and provides additional cushioning to a wearer of the slipper 10. The foam layer can be prepared from any foam material that exhibits the desired level of support and resiliency that is appropriate for use as an insole. The foam layer may comprise or consist of one or more material including, for example, an elastomeric polymer such as ethylene vinyl acetate, a polyurethane elastomer such as a thermoplastic polyester-polyurethane or a thermoplastic polyether-polyurethane. An exemplary foam material that can be used includes ethylene vinyl acetate. A particular form of ethylene vinyl acetate that can be used is sponge ethylene vinyl acetate. The density of the foam layer should be sufficient to provide the desired level of support to a wearer's foot. If the foam density is too low, it is expected that insufficient support will be provided. If the foam density is too high, it is expected that the foam will be too rigid. A desirable foam density range can be between about 4 lb/ft2 and about 10 lb/ft2. Other foam densities can be used as well. Furthermore, although a single foam layer 46 is depicted, it is noted that one or more foam layers may be used, or that the foam layer may vary in thickness at different positions; for example, an additional foam layer may be inserted at an arch position of the slipper; alternatively, a foam layer could be constructed to have an increased thickness at an arch position.

In addition to the foam layer 46, a shoe board layer 48 can be placed on the receiving tray 44 prior to applying the side stitching pattern 50 to attach the upper 14 and insole 16 to the outsole 12. The shoe board layer provides additional rigidity to the slipper to prevent deformation of the slipper. In the embodiment shown in which the shoe board layer 48 is included with the foam layer 46, the foam layer 46 is placed above the shoe board layer, such that the shoe board layer 48 is adjacent to the top surface 20 of the outsole 12, while the foam layer 46 is positioned between the shoe board layer 48 and the fabric layer 40.

Additionally, in embodiments in which the receiving tray 44 may include gaps or ridges in the top surface 20, the shoe board layer 48 may be included to prevent the foam layer 46 or fabric layer 40 of the insole 16 to be depressed into such recesses, exposing a wearer's foot to a ridged-feeling surface and resulting discomfort. In embodiments where the top surface 20 of the outsole 12 is either flat or contoured to a shape of an intended wearer's foot, the shoe board layer 48 may be excluded entirely.

Referring now to Figs. 5-6, alternative constructions of a slipper are illustrated.

Fig. 5 illustrates a first alternative construction of a slipper 110. While slipper 10 of Fig. 1-4 resembles a ballet-style slipper, slipper 1 10 of Fig. 5 represents an espadrille- style slipper. The slipper 110 includes an outsole 1 12 that has a patterned bottom tread surface 122, as well as an upper 1 14 that includes a quilted vamp 141 and unquilted rear portion 142. A seam 144 separating the vamp 141 and unquilted heel portion 142 extents across a front portion of an opening 130 designed to receive a wearer's foot. An entire perimeter of the upper 114, including a perimeter portion of the vamp 141, unquilted rear portion 142, and seam 144 are stitched to an insole 116 and the outsole 112 by a side stitching pattern 150.

Although it is noted above that the vamp 141 is quilted and the heel portion 142 is unquilted, it is recognized that any of a variety of designs or decorative features could be applied to the upper 1 14. For example, portions of the vamp 141 and/or heel portion 142 may remain unquilted, or may have other types of stitching or decorative patterns applied thereto. Additionally, although in the embodiments shown a fabric upper is used, in alternative embodiments other materials (e.g., synthetic, non-fabric materials, suede, leather, etc.) may be used as well, to the extent such materials can be stitched to the outsole 112.

Fig. 6 illustrates another alternative construction of a slipper 210. As compared to slippers 10, 110 above, slipper 210 is of a scuff or clog style, in which the upper 214 includes a vamp 241 and a heel portion 242 that has a lowered heel entry opening. The lowered heel portion 242 allows for a wearer to put on or take off the slipper 210 more easily, in particular without using one's hands, a shoehorn, or other aid. Additionally, as shown the upper 214 can be manufactured using a thicker material, such as a wool, fur, synthetic fur, or other material, which can also be directly stitched to an outsole 212 via a side stitching pattern 250. In the example shown, a fur or synthetic fur material can be attached as a collar 220 and an inner surface 222 of the upper 214, to provide additional warmth and comfort to a wearer. As with the other embodiments disclosed herein, the upper 214 can be stitched to insole 216 prior to applying the side stitching pattern 250, and both the upper 214 and insole 216 stitched to the outsole 212, which is also constructed using a foam material including, for example, an EVA and/or other foam material. Furthermore, one or more decorative features can be added to the upper 214 as well, such as button 215 as illustrated in Fig. 6.

Although particular alternative constructions of slippers 10, 1 10, 210 are described herein, it is recognized that other slipper designs may be useable as well. For example, the same side stitching arrangement using an outsole, including, for example EVA or the like, could be used on a moccasin-style slipper, a bootie-style slipper, or an open toe or thong-style slipper in which the insole is stitched to the outsole via a side stitching arrangement and the upper is also stitched to the outsole, but only at a portion of the perimeter of the slipper.

Furthermore, and relating to Figs. 1-6 generally, it is noted that the construction of a slipper in which a side stitching arrangement is used can result in construction of a slipper that does not include a glue or other adhesive to affix the insole and/or upper to the outsole. This allows for an improved perception of quality, due to stitching being typically associated with higher end footwear products as compared to those for which adhesive is used. The lack of adhesive also reduces the weight of the slipper under construction, thereby further enhancing the comfort and lightness advantages already present in use of low density outsole. Other advantages are present as well, and are apparent from the disclosed embodiments set forth herein.

All publications cited in the specification are indicative of the level of skill of those skilled in the art to which the presently described subject matter pertains. All of these publications are hereby incorporated by reference herein to the same extent as if each individual publication were specifically and individually indicated as being incorporated by reference.

The present subject matter being thus described, it will be apparent that the same may be modified or varied in many ways. Such modifications and variations are not to be regarded as a departure from the spirit and scope of the present subject matter, and all such modifications and variations are intended to be included within the scope of the following claims.

Claims

Claims:
1. A slipper comprising:
an upper;
a fabric insole layer; stitched to the upper; and
an outsole comprising an ethylene vinyl acetate, the outsole having a top, a
bottom tread surface, and an outer side perimeter surface, wherein the top forms a receiving tray having a top surface and a perimeter wall extending upward from the top surface and forming at least a portion of the side perimeter surface; and
a side stitching pattern along the outer side perimeter surface attaching the upper and fabric insole layer to the outsole through the perimeter wall.
2. The slipper according to claim 1 , further comprising a foam layer positioned between the outsole and the fabric insole.
3. The slipper according to claim 2, wherein the foam layer resides within the receiving tray.
4. The slipper according to claim 2, further comprising a shoe board layer positioned between the top of the outsole and the foam layer.
5. The slipper according to claim 1 , wherein stitching the upper and the fabric insole layer to the upper retains the foam layer and the shoe board layer on the top surface of the tray, between the outsole and the fabric insole layer.
6. The slipper according to claim 1, wherein the upper comprises a fabric.
7. The slipper according to claim 1, wherein attachment between the upper, fabric insole layer, and outsole lacks adhesive.
8 The slipper according to claim 1, wherein the upper has an open back
construction.
9. The slipper according to claim 1 wherein the upper has a closed-toe construction.
10. The slipper according to claim 1 , wherein the upper includes a stitched seam extending along a foot entry opening.
11. The slipper according to claim 1, wherein the bottom tread surface includes a tread pattern formed thereon.
12. The slipper according to claim 1 , wherein the outsole further comprises a rubber.
13. A method for manufacturing a slipper that includes an upper attached to an outsole, the method comprising:
forming an outsole from a material comprising an ethylene vinyl acetate, the outsole including a top, a bottom tread surface, and an outer side perimeter surface, the top forming a receiving tray having a top surface and a perimeter wall extending upward from the top surface and forming at least a portion of the side perimeter surface;
stitching a fabric insole layer to the upper;
positioning the fabric insole layer within the receiving tray; and
stitching the fabric insole layer and upper to the outsole through the perimeter wall, forming a side stitching pattern along the outer side perimeter surface.
14. The method according to claim 13, further comprising, prior to placing the fabric insole layer within the receiving tray, positioning a shoe board layer within the receiving tray.
15. The method according to claim 14, wherein, after stitching the fabric insole layer and upper to the outsole through the perimeter wall, the shoe board layer is positioned between the fabric insole layer and the top surface of the outsole.
16. The method according to claim 14, further comprising, prior to placing the fabric insole layer within the receiving tray, positioning a foam layer onto the shoe board layer within the receiving tray.
17. The method according to claim 16, wherein, after stitching the fabric insole layer and upper to the outsole through the perimeter wall, the foam layer is positioned between the fabric insole layer and the shoe board layer.
18. The method according to claim 13, wherein forming an outsole from a material comprising an ethylene vinyl acetate comprises molding the material in an outsole mold.
19. The method according to claim 13, wherein stitching the fabric insole layer and upper to the outsole through the perimeter wall comprises forming a side stitching pattern through an outer perimeter surface consisting of ethylene vinyl acetate.
20. The method according to claim 13, wherein stitching the fabric insole layer to the upper occurs prior to stitching the fabric insole layer and upper to the outsole.
PCT/US2016/018232 2015-02-17 2016-02-17 Slipper and method for manufacturing a slipper WO2016133994A1 (en)

Priority Applications (2)

Application Number Priority Date Filing Date Title
US201562117247P true 2015-02-17 2015-02-17
US62/117,247 2015-02-17

Publications (1)

Publication Number Publication Date
WO2016133994A1 true WO2016133994A1 (en) 2016-08-25

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ID=56689149

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Application Number Title Priority Date Filing Date
PCT/US2016/018232 WO2016133994A1 (en) 2015-02-17 2016-02-17 Slipper and method for manufacturing a slipper

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Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US628339A (en) * 1898-03-08 1899-07-04 Andrew Lennon Insole for slippers.
US4103440A (en) * 1977-08-15 1978-08-01 Lawrence Peter A Shoe with detachable upper
US4463505A (en) * 1982-09-27 1984-08-07 Joseph M. Herman Shoe Co., Inc. Sole
US4620495A (en) * 1986-02-06 1986-11-04 R. G. Barry Corporation Machine and method for stitching a slipper upper to an outsole
US6226894B1 (en) * 1998-05-11 2001-05-08 R. G. Barry Corporation Slipper and method for manufacturing slipper
US20050072024A1 (en) * 2003-10-03 2005-04-07 Eddie Chen Shoe having a three-dimensional insole

Patent Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US628339A (en) * 1898-03-08 1899-07-04 Andrew Lennon Insole for slippers.
US4103440A (en) * 1977-08-15 1978-08-01 Lawrence Peter A Shoe with detachable upper
US4463505A (en) * 1982-09-27 1984-08-07 Joseph M. Herman Shoe Co., Inc. Sole
US4620495A (en) * 1986-02-06 1986-11-04 R. G. Barry Corporation Machine and method for stitching a slipper upper to an outsole
US6226894B1 (en) * 1998-05-11 2001-05-08 R. G. Barry Corporation Slipper and method for manufacturing slipper
US20050072024A1 (en) * 2003-10-03 2005-04-07 Eddie Chen Shoe having a three-dimensional insole

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