U.S. patent application number 09/994439 was filed with the patent office on 2002-12-05 for shoe.
Invention is credited to Beardsley, Jonathan, Nevans, Jason L., Sumner, Matthew, Tsen, Jimmy.
Application Number | 20020178612 09/994439 |
Document ID | / |
Family ID | 26943095 |
Filed Date | 2002-12-05 |
United States Patent
Application |
20020178612 |
Kind Code |
A1 |
Tsen, Jimmy ; et
al. |
December 5, 2002 |
Shoe
Abstract
A shoe having a sole includes a molded, rubber outsole and a
molded midsole disposed within the outsole. The midsole may be
contoured or shaped to approximate the shape of the sole of a
wearer's foot. An upper disposed around a last may have a base
portion that will take the shape of the midsole. The upper is
permanently secured to the outsole by a foxing that is cured by
application of a vulcanization process to fuse to both the outsole
and the upper.
Inventors: |
Tsen, Jimmy; (Portsmouth,
NH) ; Nevans, Jason L.; (Watertown, MA) ;
Beardsley, Jonathan; (Quincy, MA) ; Sumner,
Matthew; (Quincy, MA) |
Correspondence
Address: |
TIMOTHY A. FRENCH
Fish & Richardson P.C.
225 Franklin Street
Boston
MA
02110-2804
US
|
Family ID: |
26943095 |
Appl. No.: |
09/994439 |
Filed: |
November 26, 2001 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60253286 |
Nov 27, 2000 |
|
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Current U.S.
Class: |
36/14 ;
36/17R |
Current CPC
Class: |
A43B 13/28 20130101;
A43B 13/12 20130101; B29D 35/10 20130101 |
Class at
Publication: |
36/14 ;
36/17.00R |
International
Class: |
A43C 013/08 |
Claims
What is claimed is:
1. A shoe comprising a molded rubber outsole; a molded midsole
disposed within said outsole, said midsole being contoured to
approximate the shape of the sole of a wearer's foot; an upper; and
a foxing, said foxing being fused to said upper and said outsole
along an interface therebetween by application of a vulcanization
process permanently securing together said upper and said
outsole.
2. The shoe of claim 1, wherein said upper and said outsole define
a seam extending around said shoe at said interface, and said
foxing is disposed around said shoe over said seam to contact said
upper and said outsole across said interface.
3. The shoe of claim 1, wherein said outsole comprises a cored out
shell defining a space for receiving said midsole.
4. The shoe of claim 1, wherein said upper comprises a base panel
disposed adjacent said midsole and encasing said midsole within
said outsole.
5. The shoe of claim 1 or claim 4, wherein said upper comprises a
base panel configured to adopt the shape of a contoured midsole
when formed around a contoured last.
6. The shoe of claim 1, wherein said midsole comprises a material
relatively less dense than cured rubber.
7. The shoe of claim 6, wherein said outsole comprises rubber.
8. The shoe of claim 1 or claim 7, wherein said midsole comprises
polyvinyl urethane.
9. The shoe of claim 1, wherein said upper comprises a base panel
comprising a cradle cup heel.
10. The shoe of claim 1 or claim 9, wherein said upper comprises a
base panel comprising a molded arch.
11. The shoe of claim 1, wherein said midsole comprises a cradle
cup heel.
12. The shoe of claim 1, wherein said midsole comprises a molded
arch.
13. The shoe of claim 1, wherein said upper comprises a sheet
material selected from the group consisting of canvas and polyvinyl
urethane.
14. The shoe of claim 1, wherein components of said upper are
secured by stroebel stitching.
15. The shoe of claim 1, wherein said foxing material comprises
uncured rubber.
16. The shoe of claim 1 or claim 15, wherein said foxing is in the
form of a band.
17. The shoe of claim 1, further comprising an insole disposed over
said base panel within said upper.
18. The shoe of claim 17, wherein said insole is removable from
said shoe.
19. A method of forming a shoe, said method comprising the steps
of: positioning a molded midsole within an outsole, the midsole
being contoured to approximate the shape of a sole of a wearer's
foot; with the midsole in place in the outsole, placing an upper
over the midsole to form a seam between the upper and the outsole;
placing a foxing material around the shoe over the seam to contact
the upper and the outsole across the seam; and vulcanizing the shoe
to fuse the foxing material to the upper and the outsole.
20. The method of claim 19, wherein components of the upper are
secured by stroebel stitching.
21. The method of claim 19, wherein the upper is formed by
stretching about a last.
22. The method of claim 21, wherein the last is removed from the
upper after the shoe is vulcanized.
23. The method of claim 21, wherein the last is contoured.
24. The method of claim 23, wherein the last includes a contoured
bottom approximating the contours of the sole of a human foot.
25. The method of claim 19, comprising the further step of
inserting a removable insole into the shoe after vulcanizing.
26. The method of claim 19, comprising the further step of molding
the midsole to include a cradle heel cup and a molded arch.
27. A shoe comprising: a molded rubber outsole defining an open
area surrounded by a rim, the outsole being formed of a first
material having a first density; a molded midsole disposed within
the open area of said outsole, said midsole being formed of a
second material having relatively lower density than said first
material; an upper; and a foxing, said foxing being fused to said
upper and said outsole along an interface therebetween by
application of a vulcanization process permanently securing
together said upper and said outsole.
28. The shoe of claim 27, wherein said first material comprises
rubber.
29. The shoe of claim 27 or claim 28, wherein said second material
comprises polyvinyl urethane.
30. A shoe comprising: a molded rubber outsole defining an open
volume surrounded by a rim, said outsole being formed of a first
material having a first density; a molded midsole disposed within
said open volume of said outsole, said midsole being formed of a
second material having relatively lower density than said first
material and being contoured to approximate the shape of the sole
of a wearer's foot; an upper having a base panel contoured to
approximate the shape of the sole of the wearer's foot; and a
foxing material, the foxing material being fused to the upper and
the outsole upon application of a vulcanization process to
permanently secure the upper to the outsole.
31. The shoe of claim 30, further comprising a removable
insole.
32. The shoe of claim 30 or claim 31, wherein said midsole
comprises a cradle cup heel and a molded arch.
Description
[0001] This application claims benefit of U.S. Provisional
Application No. 60/253,286, filed Nov. 27, 2000, the complete
disclosure of which is incorporated herein by reference.
TECHNICAL FIELD
[0002] This invention relates to a shoe, and in particular, a shoe
constructed using a vulcanization process.
BACKGROUND
[0003] A typical shoe constructed using a vulcanization process
includes a heavy molded rubber outsole and an upper for receiving
the foot of a wearer. In such a shoe, the outsole has a flat upper
surface, which is placed against a flat base portion of the upper,
e.g., an insole board. To construct such a shoe, the upper is
formed on and around a non-reactive mold known as a last. The last
for this type of shoe has a flat bottom corresponding to the flat
base portion of the upper. A foxing material, i.e., a strip of
uncured rubber, is wrapped around the outside of the shoe along a
seam created by the upper placed against the outsole, such that
portions of the foxing material contact both the upper and the
outsole across the seam. The shoe, including the last and the
wrapped foxing material, is exposed to a vulcanization process,
e.g., heating to a temperature of 130.degree. F. for 70 minutes.
The vulcanization process cures the foxing material, fusing it to
both the upper and the outsole, to form a permanent bond around the
seam. The last is removed from the shoe after the foxing material
has cured. A die cut, latex foam insole may be placed within the
upper to conform to the natural shape of the wearer's foot.
[0004] In another typical shoe constructed using cold cement, an
upper placed within a contoured last and having an ergonomically
shaped base portion approximating the shape of the sole of the
wearer's foot is cemented to a molded, contoured sole with a shape
that corresponds to the base portion of the lasted upper. The sole
of such a shoe may include, e.g., an ethyl vinyl acetate midsole
and a rubber outsole. The upper for this type of shoe may be formed
on and around a last having a contoured shape corresponding to the
desired contoured shape for the base portion of the upper.
SUMMARY
[0005] The present invention relates to a shoe having a sole
including a molded, rubber outsole and a molded midsole disposed
within the outsole, which midsole may be contoured or shaped to
approximate the shape of the sole of a foot. An upper disposed
around a last is permanently secured to the outsole using an
uncured foxing material fuses to both the outsole and the upper
during curing upon the application of a vulcanization process. The
upper may have a base portion that will take the shape of a
contoured midsole when formed around a contoured last.
[0006] Advantageously, the invention features a securely
constructed, lightweight shoe. The shoe is easily constructed, and
it is shaped to fit the contours of the sole of the wearer's foot
using an ergonomic, lasted upper and a lightweight, contoured
midsole.
[0007] In general, in one aspect, the invention features a molded
midsole, which may be contoured or shaped to approximate the shape
of the sole of a foot. An outsole including a cored out shell
defines a space for receiving the midsole. An upper, which may be
formed on a contoured last, has a base panel that is disposed
against the midsole to encase the midsole within the outsole, the
upper forming a seam around the shoe between the upper and the
outsole. A foxing material is disposed around the shoe over the
seam to contact the upper and the outsole across the seam. The
foxing material fuses to the upper and the outsole upon application
of a vulcanization process to permanently secure the upper to the
outsole.
[0008] Other aspects of the invention may also include one or more
of the following features. The outsole may include rubber. The
midsole may include polyvinyl urethane or other suitable
lightweight material. The upper disposed around the last and the
midsole may include a cradle cup heel and a molded arch. The upper
may include canvas or polyvinyl urethane. The upper may be formed
by stroebel stitching or by stretching the upper around the last.
The foxing material may include uncured rubber, and may be in the
form of a band. The shoe may include an insole disposed over the
base panel within the upper.
[0009] In general, in another aspect, the invention features a
method of forming a shoe. A molded midsole is disposed within an
outsole, which midsole may be contoured or shaped to approximate
the shape of a sole of a foot. An upper, which may be formed on a
contoured last, is placed over the midsole disposed in the outsole
to form a seam between the upper and the outsole. A foxing material
is disposed around the shoe over the seam to contact the upper and
the outsole across the seam. The shoe is vulcanized to fuse the
foxing material to the upper and the outsole.
[0010] Other aspects of the invention may also include the
following feature. The last may be removed from the upper after the
shoe is vulcanized.
[0011] Other features and advantages of the invention will be
apparent from the description and drawings, and from the
claims.
DESCRIPTION OF DRAWINGS
[0012] FIG. 1 is an exploded, perspective view of a shoe according
to the present invention.
[0013] FIG. 2 is a plane, cross-sectional view of the shoe of FIG.
1.
[0014] Like reference symbols in the various drawings indicate like
elements.
DETAILED DESCRIPTION
[0015] Referring to FIGS. 1 and 2, a shoe 100 according to the
present invention includes a lower molded rubber outsole 110.
Outsole 110 may be a cored out shell defining a space 115. Outsole
110 may be made of any suitable type of rubber, particularly a
rubber providing good gripping and slip resistance when the wearer
uses the shoe.
[0016] Shoe 100 also includes a molded midsole 120. Midsole 120 is
shaped to fit within space 115 of outsole 110. The upper portion
125 of midsole 120 may also be contoured or shaped to approximate
the shape of the sole of the foot of the wearer of shoe 100. In
particular, midsole 120 may have a cradle heel cup 127 and a molded
arch 128 for stability, support and customized fit to the wearer's
foot. Midsole 120 is preferably made from polyvinyl urethane.
Midsole 120 may also be made, e.g., from any suitable blown rubber
material. In general, midsole 120 is made from a lightweight
material that is relatively lighter and less dense than, e.g.,
cured rubber.
[0017] The rubber used to make outsole 110 may wear better and
provide better traction than a comparable sole made from the
material used to make midsole 120, e.g., a lightweight material
such as polyvinyl urethane. The combination of thin, cored out
outsole 110 and lightweight midsole 120 disposed within outsole 110
creates a sole that is lightweight and that may be ergonomically
shaped with respect to the contours of the wearer's foot.
[0018] Shoe 100 further includes an upper 130. Upper 130 may be
made, e.g., from canvas, polyvinyl urethane, or any other material
appropriate for shoemaking. In particular, upper 130 may be made
from any suitable material that fits around and provides comfort to
the wearer's foot.
[0019] Upper 130 may be formed on and around a last 135, which may
have a contoured bottom 132 that approximates the shape of the sole
of the wearer's foot. Upper 130 may include, e.g., front, side and
rear panels 136, 137, 138, respectively, which are attached to a
base panel 139, such as a non-woven material. Panels 136, 137, 138
may be attached to base panel 139 by stroebel stitching, which
provides a precise fit around last 135. Alternatively, upper 130
may be formed by stretching and cementing the material of the upper
around base panel 139 to surround and take the shape of last 135.
Alternatively, last 135 may have a flat bottom. In any event, base
panel 139 takes on a shape that corresponds to the shape of last
135.
[0020] As shown in FIG. 2, shoe 100 is formed by placing upper 130,
including last 135, over outsole 110 and midsole 120. A foxing
material 140 is wrapped around the outside of the shoe along a seam
142 formed along the interface between upper 130 and outsole 110
when these elements have been placed together. Foxing material 140
is preferably made from an uncured rubber that adheres to both the
rubber material of outsole 110 and the material used to make upper
130. Foxing material 140 may be in the form of a band, e.g., with
decorative features on its outer surface. Foxing material 140
preferably contacts both upper 130 and outsole 110 across the seam
so that the foxing material may form a complete seal along the
interface between the upper and the outsole.
[0021] In initially constructing shoe 100, upper 130 may be secured
to midsole 120, and foxing material 140 may be secured to upper 130
and outsole 110, using adhesive materials such as cements and
primers. Such adhesive materials do not necessarily provide
permanent fixation of upper 130 to outsole 110 in a vulcanized
shoe. Upon application of a vulcanization process, upper 130,
outsole 110, midsole 120, and foxing material 140 are secured
together to form an integral assembled shoe 100. In particular,
upon vulcanization, i.e., by subjecting shoe 100 to a temperature
of 130.degree. F. for 70 minutes, the foxing material is caused to
cure and fuse to both outsole 110 and upper 130 to permanently
secure the elements of the shoe together.
[0022] After the foxing material has cured, last 135 is removed
from the shoe. Shoe 100 may be further finished by placing an
insole or molded footbed 150 over base panel 139 within upper 130.
Insole 150 provides additional cushioning and comfort for the
wearer's foot.
[0023] The resulting shoe 100 of the present invention may have a
shape to fit the contours of the sole of the wearer's foot. Shoe
100 is also relatively lighter in weight than prior shoes formed by
a vulcanization process because of the lightweight midsole material
and absence, e.g., of rubber coring, fillers and/or insole board.
The ergonomic features are the result of a contoured last and a
contoured midsole.
[0024] Other embodiments are within the scope of the following
claims.
* * * * *