U.S. patent application number 11/107451 was filed with the patent office on 2005-11-03 for thermoplastic printed film innersole for shoes.
Invention is credited to Fox, Robert B., Mulligan, Ron, Sipes, Charles, Swain, Bernie.
Application Number | 20050241186 11/107451 |
Document ID | / |
Family ID | 35185592 |
Filed Date | 2005-11-03 |
United States Patent
Application |
20050241186 |
Kind Code |
A1 |
Mulligan, Ron ; et
al. |
November 3, 2005 |
Thermoplastic printed film innersole for shoes
Abstract
The present invention relates generally to a printed film
innersole (PFI) and a process for making the same. The present
invention provides to a PFI and a process for the construction of
an innersole for post-insertion into a shoe that can have
significant design details added to the bottom surfaces.
Inventors: |
Mulligan, Ron; (Rawtenstall,
GB) ; Fox, Robert B.; (Mashpee, MA) ; Swain,
Bernie; (Baligen, DE) ; Sipes, Charles;
(Harrisville, RI) |
Correspondence
Address: |
FOLEY & LARDNER LLP
111 HUNTINGTON AVENUE
26TH FLOOR
BOSTON
MA
02199-7610
US
|
Family ID: |
35185592 |
Appl. No.: |
11/107451 |
Filed: |
April 16, 2005 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60562893 |
Apr 16, 2004 |
|
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Current U.S.
Class: |
36/43 |
Current CPC
Class: |
A43B 23/24 20130101;
A43B 13/386 20130101; A43B 17/00 20130101; A43B 17/006 20130101;
A43B 3/0078 20130101 |
Class at
Publication: |
036/043 |
International
Class: |
A43B 013/38 |
Claims
What is claimed is:
1. An innersole comprising: a) a first layer made of a printed
thermoformable film; and b) a second layer made of a one or more
cast cushioning foam materials wherein the second layer is
positioned beneath and is distinct from the first layer and the
first and second layers have planes being directly adjacent.
2. The innersole of claim 1, wherein the printed thermoformable
film is a thermoplastic urethane film.
3. The innersole according to claim 1, further comprising a fabric
layer contacted with the first layer made of the printed
thermoformable film wherein the fabric layer is positioned on top
of the printed thermoformable film.
4. A shoe containing the innersole of claim 1.
5. A process of making an innersole comprising the steps of: (a)
providing a thermoformable film; (b) printing at least one design
element onto the thermoformable film to yield a printed
thermoformable film; (c) forming the printed thermoformable film
into a shell; and (d) casting a cast cushioning foam material
directly into the shell.
6. The process according to claim 5, wherein the thermoformable
film is a thermoplastic urethane film.
Description
RELATED APPLICATION
[0001] This application claims the benefit of priority under 35
U.S.C. .sctn.119(e) from U.S. Ser. No. 60/562,893, filed on Apr.
16, 2004, the contents of which are incorporated herein by
reference in its entirety.
FIELD OF THE INVENTION
[0002] The present invention relates generally to a printed film
innersole (PFI) and a process for making the same. More
specifically the present invention related to a PFI and a process
for the construction of an innersole for post-insertion into a shoe
that can have significant design details added to the bottom
surfaces.
BACKGROUND OF THE INVENTION
[0003] The use of innersoles (a.k.a., insoles) for footwear, e.g.,
shoes, is well known in the art. Typically, innersoles are made of
cast polyurethane both single density and with various cast
elastomer drops, e.g., ethylene vinyl acetate (EVA) thermoformed
insoles and other various thermoformable materials, i.e.,
thermoplastic materials. Other various cushioning materials are
also utilized by die cutting sheet stock materials.
[0004] While conventional innersole devices may be suitable for the
particular purpose to which they address, they are not as suitable
for the construction of an innersole for post-insertion into a shoe
that can have significant design details added to the bottom
surfaces. A limitation of conventional innersoles are that they
cannot be printed. Adding graphics to the innersole bottom offers
unique design advantages. Another limitation of conventional
innersoles are restriction in colors or other design features. This
is both expensive and labor intensive.
[0005] There is a need in the art for devices suitable for
construction of an innersole for post-insertion into a shoe that
can have design details added to the bottom surfaces.
SUMMARY OF THE INVENTION
[0006] The present invention relates generally to a printed film
innersole (PFI) and a process for making the same. The present
invention provides a PFI and a process for the construction of an
innersole for post-insertion into a shoe that can have significant
design details added to the bottom surfaces. In one aspect, the
invention provides an innersole comprising: a) a first layer made
of a printed thermoformable film; and b) a second layer made of a
one or more cast cushioning foam materials, wherein the second
layer is positioned beneath and is distinct from the first layer
and the first and second layers have planes being directly
adjacent. In one embodiment of the innersole, the printed
thermoformable film is a thermoplastic urethane film. In one
embodiment of the innersole, the innersole further comprises a
fabric layer contacted with the first layer made of the printed
thermoformable film wherein the fabric layer is positioned on top
of the printed thermoformable film. In one embodiment, the
invention provides a shoe containing the innersole of the
invention.
[0007] In another aspect, the invention provides a process of
making an innersole comprising the steps of: (a) providing a
thermoformable film; (b) printing at least one design element onto
the thermoformable film to yield a printed thermoformable film; (c)
forming the printed thermoformable film into a shell; and (d)
casting a cast cushioning foam material directly into the shell. In
one embodiment of the process, the thermoformable film is a
thermoplastic urethane film.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] The drawing figure depicts a preferred embodiment by way of
example, not by way of limitation. The present invention is not
limited in its application to the details of construction and to
the arrangements of the components set forth in the following
description or illustrated in the drawing. The invention is capable
of other embodiments and of being practiced and carried out in
various ways. Various other objects, features and attendant
advantages of the present invention will become fully appreciated
as the same becomes better understood when considered in
conjunction with the accompanying drawings, in which like reference
characters designate the same or similar parts throughout the
several views, and wherein:
[0009] FIG. 1 illustrates one embodiment of the process of making a
PFI device of the invention using thermoplastic urethane film
(TPU). Panel A is a photograph of the clear TPU in roll form. Panel
B is a photograph of TPU after printing. Panel C is a photograph of
printed TPU after forming in a support tool. Panel D is a
photograph of the bottom view of a PFI for a shoe.
DETAILED DESCRIPTION OF THE INVENTION
[0010] It is to be appreciated that certain aspects, modes,
embodiments, variations and features of the invention are described
below in various levels of detail in order to provide a substantial
understanding of the present invention. The PFI for shoes according
to the present invention substantially departs from the
conventional concepts and designs of conventional innersole
devices, by providing an apparatus primarily developed for the
purpose of the construction of an innersole for post-insertion into
a shoe that can have significant design details added to the bottom
surfaces.
[0011] In one aspect, the present invention provides a PFI device
for shoes that overcomes the shortcomings of the conventional
innersole devices. In one embodiment, the PFI present invention
comprises: a thermoformable film, a printed film, a formed shell
and a cast cushioning foam materials. In one embodiment of the
invention the thermoformable film is a thermoplastic film. In a
preferred embodiment of the device, the thermoformable film is a
TPU.
[0012] In one embodiment, the device of the invention is a PFI
useful for post-insertion into a shoe that can have design details
added to the surfaces of the device, e.g., bottom surfaces. The
device of the invention offers significantly different design
advantages over conventional devices. In one embodiment, at least
one color design is added to the surface of the PFI device. In
another embodiment, two or more colors appear in the design added
to the surface of the PFI device.
[0013] In another aspect, the invention provides a process of
printing designs in the flat and then thermoforming a shell into a
device of the invention. That is, printing is performed in the flat
utilizing at least one printing technique and then the printed
thermoformable film is formed into the shell to yield the PFI
device of the invention. In one embodiment of the process of the
invention, a formed shell is created from the thermoformable film,
e.g., TPU, into which soft cushioning foam can be cast.
Process of Making the PFI of the Invention
[0014] The invention provides a process for making a PFI device.
The thermoformable films are first printed then formed into the
shell configuration to provide a molded shape into which the
castable foam is dispensed, formed and demolded. The process of
making a PFI device of the invention comprises the steps of: (a)
providing a thermoformable film; (b) printing at least one design
element onto the thermoformable film to yield a printed
thermoformable film; (c) forming the printed thermoformable film
into a shell; and (d) casting a cast cushioning foam material
directly into the shell.
[0015] Turning now descriptively to the drawings, in which similar
reference characters denote similar elements throughout the several
views, the attached figure illustrates the process for making a PFI
device of the invention. As noted above and shown on FIG. 1, in one
embodiment, the PFI device of the invention comprises a TPU (panel
A), a printed TPU (panel B), a formed shell (panel C) and a cast
cushioning foam materials.
[0016] As shown in FIG. 1, panel A and panel B, the thermoformable
film is printed in the flat sheet form prior to forming.
Thermoformable films useful in the process of the invention are
manufactured by means of extrusion or are blown films and are
purchased in roll form or sheet form. Thermoformable films useful
in the process of the invention are either TPU or other materials
that offer the ability to thermoform and provide adhesion to the
castable cushioning foam. TPU useful in the method of the present
invention is commercially available (Deerfield Urethane, Bayer
MaterialScience Company, Pittsburgh, Pa., USA).
[0017] Soft flexible thermoformable films are selected that have
certain characteristics that can include, but are not limited to,
e.g., a high coefficient of friction, good abrasion resistance, and
are absent from any processing aids or slip aids. These
thermoformable films have low coefficient of friction so as to
reduce slipping or movement inside the shoe once inserted. TPU or
other thermoformable films that provide both good adhesion of
printing inks and cast cushioning material are useful in the
process of making the PFI devices of the invention. For example,
TPUs are useful in the PFI devices of the invention as they do not
include slip agents that would impede the adhesion for both the
printing inks and or the cast cushioning foam. Thermoformable films
useful in the process of the invention are also generally soft and
flexible to the hand and have the ability to be printed. The
thermoformable film can be matte finish, gloss finish, or embossed.
They can be printed to significantly cover the entire bottom of the
formed innersole or be printed selectively to provide detail or
graphics to the innersole design. Printing may completely cover the
bottom so as to provide an opaque shell or can be light enough to
allow a translucent look to view the cast cushioning foam component
through the film. Printing can be both single color or
multi-color.
[0018] In one embodiment of the process, the thermoformable film is
printed by at least one screen printing technique. Other printing
techniques useful for printing the thermoformable film in the
process of the invention includes, but is not limited to, e.g., ink
jet, flexography, and hot stamp printing technique. Screen
printing, ink jet, flexography and hot stamp printing are know in
the art. Printing can also be performed in rolls on high speed
printing equipment. Specially formulated print inks compatible with
the film materials are employed. Materials useful for screen
printing are commercially available, e.g., U.S. Screen Printing
Institute (Tempe, Ariz., USA). The inks must provide excellent
adhesion to the film and be flexible enough to withstand the
manufacturing process.
[0019] Once the inks are dry, substantially rectangular sheets are
cut and the printed film is placed into a support frame that
supports the entire perimeter of the cut sheet. The formed shell
can be thermoformed or vacuum-formed to create a molded shell into
which the castable cushioning foam is dispensed. As shown in FIG.
1, panel B and panel C, the printed thermoformable film, e.g., TPU,
is formed to create a shell. Techniques useful to mold
thermoformable film to create shell include, but are not limited
to, thermoforming processes such as vacuum forming, match mold
forming, pressure forming, and foam-in-place forming. In a
preferred embodiment of the process, the printed film is formed by
means of a thermoforming. In another preferred embodiment of the
process, the printed film is formed by means of vacuum-forming
operation. The printed film is heated substantially near its melt
temperature. The frame with the printed film is then heated to a
point that the material starts to deform. Typically, this is
slightly below the actual melt temperature of the thermoformable
film. Specifically, the support frame and softened printed film are
introduced to the vacuum-forming tool. In one embodiment of the
process, the frame is lowered down around the vacuum-forming tool
until the film comes in contact with the vacuum-forming tool. Once
the film contacts the tool surface a box closes around the
perimeter of the vacuum-forming tool so as to provide a complete
seal for the film. A vacuum is then pulled through and around the
perimeter of the vacuum-forming tool. This draws the heated,
printed film in close contact to the vacuum-forming tool. The film
is then allowed to cool on the unheated mold surface wherein it
returns to its original solid state. The vacuum is then released
and the molded printed shell is carefully removed from the mold
surface. The molded shell is trimmed of excess film materials. This
molded shell can then be placed directly into a support tool that
substantially supports the molded shell (FIG. 1, panel C).
[0020] In one embodiment of the process, a cast cushioning foam
material is cast directly into the molded shell. During this
process it is useful to support the molded shell with a support
tool (see FIG. 1, panel C). A castable cushioning material is the
dispensed directly into this shell by a mixing metering unit. This
unit casts a predetermined amount of material directly into the
open shell. Since the castable cushion material is a blown or
expanded material, the mold shell is filled approximately 40% full.
The cast foam material useful in the process of the invention is
any castable foam material that will provide both cushioning
properties as well as excellent adhesion to the formed shell. In a
preferred embodiment of the process, the castable foam material is
a water blown, polyether polyurethane foam. Such water blown foam
is a flexible polyurethane foam in which the gas for expansion is
carbon dioxide generated by the reaction between water and an
isocyanate material. All flexible polyurethane foam is water blown,
although auxiliary blowing agents are often used to obtain special
physical properties. Water blown, polyurethane foam is commercially
available from The Dow Chemical Company (USA). This material is
dispensed directly into the molded shell that is supported by a
support tool.
[0021] Once filled, the top mold is then closed to contain the
foaming process. Once the mold is closed and clamped in place, the
reaction of the castable material then causes the foaming to
initiate. This foaming fills the mold and forms the final part
shape. Fabrics may also be introduced and molded in place by means
of temporarily pinning these to the support tool lid or top cover.
These fabrics are then cast onto the top surface of the finished
part. Once cured, (approximately 5 minutes) the molded assembly is
removed form the support tool. To complete the process, this part
is either die cut or trimmed to remove excess film, fabric and or
the cushioning foam material to yield the PFI of the invention
(FIG. 1, panel D).
Equivalents
[0022] From the foregoing detailed description of the invention, it
should be apparent that the present invention provides a unique PFI
for shoe innersole construction wherein the same can be utilized
for the construction of an innersole for post-insertion into a shoe
that can have design details added to the bottom surfaces, as well
as method of making the same. Although particular embodiments have
been disclosed herein in detail, this has been done by way of
example for purposes of illustration only, and is not intended to
be limiting with respect to the scope of the appended claims, which
follow. In particular, it is contemplated by the inventor that
substitutions, alterations, and modifications may be made to the
invention without departing from the spirit and scope of the
invention as defined by the claims. With respect to the above
description then, it is to be realized that the optimum dimensional
relationships for the parts of the invention, to include variations
in size, materials, shape, form, function and manner of operation,
assembly and use, are deemed readily apparent and obvious to one
skilled in the art, and all equivalent relationships to those
illustrated in the drawings and described in the specification are
intended to be encompassed by the present invention.
* * * * *