U.S. patent application number 11/410418 was filed with the patent office on 2007-10-25 for shoe with an upper made of a flat composite and method of making the shoe.
This patent application is currently assigned to Eddie Chen. Invention is credited to Eddie Chen, Phoenix Hsu.
Application Number | 20070245595 11/410418 |
Document ID | / |
Family ID | 38618071 |
Filed Date | 2007-10-25 |
United States Patent
Application |
20070245595 |
Kind Code |
A1 |
Chen; Eddie ; et
al. |
October 25, 2007 |
Shoe with an upper made of a flat composite and method of making
the shoe
Abstract
An upper is made of a flat composite which includes a
substantially flat plastic layer molded directly over a fabric
layer. The plastic layer has at least one ventilation hole, an
inner peripheral end defining an opening, an outer peripheral end
extending around the inner peripheral end, and two opposite
marginal ends each extending from the inner peripheral end to the
outer peripheral end. The flat composite is looped and formed into
the upper when the marginal ends are connected to each other. The
plastic layer further has at least one molded ventilation hole. The
fabric layer has an integral extension flap that extends beyond the
outer peripheral end.
Inventors: |
Chen; Eddie; (Taichung City,
TW) ; Hsu; Phoenix; (Taichung City, TW) |
Correspondence
Address: |
FROMMER LAWRENCE & HAUG
745 FIFTH AVENUE- 10TH FL.
NEW YORK
NY
10151
US
|
Assignee: |
Chen; Eddie
|
Family ID: |
38618071 |
Appl. No.: |
11/410418 |
Filed: |
April 25, 2006 |
Current U.S.
Class: |
36/45 ; 36/3A;
36/47 |
Current CPC
Class: |
A43B 7/125 20130101;
A43B 9/02 20130101; A43B 23/042 20130101; A43B 7/08 20130101 |
Class at
Publication: |
036/045 ;
036/047; 036/003.00A |
International
Class: |
A43B 7/06 20060101
A43B007/06; A43B 23/00 20060101 A43B023/00 |
Claims
1. A shoe comprising an upper made of a flat composite which
includes a substantially flat molded plastic layer and a fabric
layer bonded to one side of said molded plastic layer, said plastic
layer having an inner peripheral end defining an opening, an outer
peripheral end extending around said inner peripheral end, and two
opposite marginal ends each extending from said inner peripheral
end to said outer peripheral end, both of said inner and outer
peripheral ends being terminated at said marginal ends, said flat
composite being looped and formed into said upper when said
marginal ends are connected to each other, said fabric layer
further having an extension flap that extends beyond said outer
peripheral end and that is formed as one piece with said fabric
layer.
2. The shoe as claimed in claim 1, wherein said plastic layer is
molded directly over said fabric layer.
3. The shoe as claimed in claim 1, wherein said plastic layer
further has at least one molded ventilation hole, said fabric layer
covering said ventilation hole.
4. The shoe as claimed in claim 1, wherein said marginal ends are
interconnected by sewing.
5. The shoe as claimed in claim 1, wherein said upper is composed
of an upper portion and a lower portion, said lower portion having
a toe region, two shank regions extending rearwardly from said toe
region, and a heel region connected to said shank regions, said
upper portion being connected to a top end of said lower portion,
said marginal ends are interconnected in said heel region.
6. The shoe as claimed in claim 1, wherein said plastic layer
includes a material selected from a group consisting of
thermoplastic polyurethane, thermoplastic rubber and
polyvinylchloride.
7. The shoe as claimed in claim 1, wherein said flat composite
further includes a reinforcing stitch line which extends along said
outer peripheral end of said plastic layer to secure said fabric
layer to said plastic layer.
8. The shoe as claimed in claim 1, wherein said plastic layer
includes a plurality of said ventilation holes in the form of mesh
openings, said fabric layer covering said mesh openings.
9. The shoe as claimed in claim 1, further comprising a breathable
waterproof layer disposed inside said upper and attached to said
flat composite.
10. A shoe comprising an upper made of a flat composite which
includes a substantially flat molded plastic layer and a fabric
layer adhered to one side of said molded plastic layer, said
plastic layer having an inner peripheral end defining an opening,
an outer peripheral end extending around said inner peripheral end,
and two opposite marginal ends each interconnecting said inner and
outer peripheral ends, said marginal ends being connected to each
other so that said flat composite is looped and formed into said
upper, said plastic layer further having at least one molded
ventilation hole, said fabric layer covering said ventilation hole,
wherein no cementing material is provided between said plastic
layer and said fabric layer at least in a region where said
ventilation hole is formed.
11. The shoe of claim 10, wherein no cementing material is provided
in all regions between said plastic and said fabric layers.
12. A method of making a shoe comprising: molding a substantially
flat plastic layer directly over a fabric layer to form a flat
composite, said plastic layer being formed with at least one
ventilation hole, two opposite marginal ends, and inner and outer
peripheral ends interconnecting said marginal ends, said inner
peripheral end defining an opening, said outer peripheral end
extending around said inner peripheral end, providing said fabric
layer with an extension flap that extends beyond said outer
peripheral end and between said two marginal ends and that is
formed as one piece with said fabric layer; and interconnecting
said marginal ends so that said flat composite is looped and formed
into at least a portion of an upper.
13. The method of claim 12, wherein said portion of said upper
includes a toe region, two shank regions extending rearwardly from
said toe region, and a heel region connected to said shank regions,
said marginal ends being interconnected in said heel region.
14. The method of claim 13, wherein said upper is composed of upper
and lower portions, said lower portion having said toe, shank and
heel regions, and a top end connected to said upper portion, said
lower portion being made of said flat composite.
15. The method of claim 12, further comprising trimming said fabric
layer relative to said inner and outer peripheral ends and said
marginal ends, said extension flap being provided during the
trimming of said fabric layer.
16. The method of claim 12, further comprising sewing said fabric
layer to said plastic layer along said outer peripheral end.
Description
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The invention relates to a shoe, more particularly to a shoe
having an upper made of a flat composite and a method of making the
shoe.
[0003] 2. Description of the Related Art
[0004] Referring to FIG. 1, a conventional shoe includes a sole
unit 3, an upper with a three-dimensional molded lower portion 2,
and an upper portion 1. A lower end of the upper portion 1 is
stitched to an upper end of the lower portion 2. A lower end of the
lower portion 2 is adhered to the sole unit 3. The lower portion 2
is integrally molded, and is generally formed from rubber,
thermoplastic polyurethane (TPU), thermoplastic rubber (TPR), etc.
Therefore, the lower portion 2 can afford good supportability,
protection, and water-resistance, and is adaptable for use in
hunting boots, security shoes, hiking shoes, pac boots. However, in
actual manufacture and application, the lower portion 2 suffers
from the following drawbacks:
[0005] 1. The fabrication of the lower portion 2 requires use of a
three-dimensional mold in order to match the shape of the foot.
Such three-dimensional molds are not easy to manufacture, and the
costs thereof are very expensive, thereby resulting in increased
fabrication costs.
[0006] 2. Since the lower portion 2 is molded, the shape and
dimensions thereof are substantially fixed and cannot be adjusted.
Therefore, manufacturers have to fabricate lower portions 2 of
different dimensions using different molds so as to adapt to lasts
of different specifications. This results in increased fabrication
costs.
[0007] 3. Likewise, the lower portion 2 is applicable only to a
particular shoe-making process, and is not suitable for other
processes, such as hand-sewing, lasting, etc.
[0008] 4. It is difficult to secure a fabric layer to the inner
side of the three-dimensional lower portion 2 during the molding
process. Thus, the fabric layer is adhered to the inner side of the
lower portion 2 after the lower portion 2 is formed.
[0009] 5. As the lower portion 2 is integrally molded and is formed
from air-impermeable rubber or plastic material, the lower portion
2 is not breathable, thereby resulting in discomfort to the
wearer.
[0010] 6. In order to provide the lower portion 2 with a
predetermined degree of strength, the lower portion 2 is configured
to have a large thickness, which not only increases the weight of
the shoe but also affects the bendability of the shoe, especially
at the toe region when the wearer squats.
[0011] In addition, while it is known in the art to use laminate
material in the manufacture of shoe parts, the prior art does not
emphasize that the forming of air vents in a thermoplastic material
during the molding process, nor the forming of air vents in the
thermoplastic material prior to formation of the laminates.
SUMMARY OF THE INVENTION
[0012] Therefore, the object of the present invention is to provide
a shoe having a lower portion of an upper which is made from a flat
composite and which can be produced easily at low costs.
[0013] According to one aspect of the present invention, the shoe
of this invention includes an upper made of a flat composite which
includes a substantially flat molded plastic layer and a fabric
layer adhered to an inner side of the molded plastic layer. The
plastic layer has an inner peripheral end defining an opening, an
outer peripheral end extending around the inner peripheral end, and
two opposite marginal ends each extending from the inner peripheral
end to the outer peripheral end. Both of the inner and outer
peripheral ends are terminated at the marginal ends. The flat
composite is looped and formed into the upper when the marginal
ends are connected to each other. The fabric layer further has an
extension flap that extends beyond the outer peripheral end and
between the marginal ends and that is formed as one piece with the
fabric layer.
[0014] Advantageously, the plastic layer may be further provided
with at least one molded ventilation hole, wherein the fabric layer
covers the ventilation hole.
[0015] According to another aspect of the present invention, a
method of making a shoe comprises molding a substantially flat
plastic layer directly over a fabric layer to form a flat
composite, the plastic layer being formed with at least one
ventilation hole, two opposite marginal ends, and inner and outer
peripheral ends interconnecting the marginal ends, the inner
peripheral end defining an opening, the outer peripheral end
extending around the inner peripheral end. The method further
includes: providing the fabric layer with an extension flap that
extends beyond the outer peripheral end and between the two
marginal ends and that is formed as one piece with the fabric
layer; and interconnecting the marginal ends so that the flat
composite is looped and formed into at least a portion of an
upper.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] Other features and advantages of the present invention will
become apparent in the following detailed description of the
preferred embodiments with reference to the accompanying drawings,
of which:
[0017] FIG. 1 is a side view of a conventional shoe having an upper
with a molded lower portion;
[0018] FIG. 2 is a side view of the first preferred embodiment of a
shoe according to the invention;
[0019] FIG. 3 is a schematic sectional view of the first preferred
embodiment;
[0020] FIG. 4 is a schematic rear sectional view of the first
preferred embodiment;
[0021] FIG. 5 is a schematic plan view of a flat composite used to
form a lower portion of an upper in the first preferred
embodiment;
[0022] FIG. 5A shows how the flat composite is made;
[0023] FIG. 6 is similar to FIG. 5, but showing the flat composite
in a trimmed state; and
[0024] FIG. 7 is a perspective view of the flat composite of FIG. 6
which is looped to form the lower portion of the upper.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0025] Referring to FIGS. 2, 3 and 4, a preferred embodiment of a
shoe according to the present invention is shown to include an
upper (A) and a sole unit 30.
[0026] The upper (A) includes a lower portion 20 and an upper
portion 10. The lower portion 20 has an open bottom end 24
connected to the sole unit 30, and an open top end 23 connected to
an open bottom end 12 of the upper portion 10. The lower portion 20
has a toe region 26, two shank regions 28 extending rearwardly from
the toe region 26, and a heel region 27 connected to the shank
regions 28.
[0027] Referring further to FIGS. 5 and 6, the lower portion 20 is
made of a flat composite 100 which includes a substantially flat
molded plastic layer 120, and a fabric layer 110 bonded to an inner
side of the plastic layer 120. A breathable waterproof layer 130 is
attached to an inner side of the flat composite 100. The flat
composite 100 is looped and formed into a three dimensional shape
to provide the lower portion 20. In addition, the plastic layer 120
has an inner peripheral end 121 defining an opening 122, an outer
peripheral end 123 extending around the inner peripheral end 121,
two opposite marginal ends 25 each extending from the inner
peripheral end 121 to the outer peripheral end 123. Thus, the inner
and outer peripheral ends 121, 123 extend between the marginal ends
25, and both of the inner and outer peripheral ends 121, 123 are
terminated at the marginal ends 25. The flat composite 100 is
looped and formed into the lower portion 20, as shown in FIG. 7,
when the marginal ends 25 are connected to each other in the heel
region 27. Preferably, the marginal ends 25 are interconnected by
sewing. A connection plate 40 is secured to the flat composite 100
in the heel region 27 by sewing to cover the marginal ends 25.
[0028] While the marginal ends 25 are interconnected in the heel
region 27 in this embodiment, the marginal ends 25 may also be
interconnected in the toe region 26 or one or two of the shank
regions 28 according to the present invention.
[0029] The plastic layer 120 may be made of any suitable plastic
material. Preferably, the plastic layer 120 includes a
thermoplastic material selected from a group consisting of
thermoplastic polyurethane (TPU), thermoplastic rubber (TPR) and
polyvinylchloride (PVC). The plastic layer 120 may be molded in a
mold (not shown) to form the inner and outer peripheral ends 121,
123 and the marginal ends 25. An outer patterned surface and a
plurality of ventilation holes 211 are also formed in the plastic
layer 120 during the molding of the plastic layer 120.
[0030] The fabric layer 110 is bonded to the plastic layer 120, and
may be made from a fabric subjected to an anti-splash treatment.
The anti-splash treatment may be conducted after being bonded to
the plastic layer 120. Preferably, the plastic layer 120 is bonded
to the fabric layer 110 by molding it directly over the fabric
layer 110 in a mold (see FIG. 5A). The direct molding of the
plastic layer 120 may be done by placing the fabric layer 110 in a
mold followed by the introduction of a thermoplastic material into
the mold. After the fabric layer 110 is bonded to the plastic layer
120, the fabric layer 110 is trimmed relative to the inner and
outer peripheral ends 121, 123, and the marginal ends 25 of the
plastic layer 120. The fabric layer 110, therefore, has a profile
substantially corresponding to that of the inner peripheral end 121
and the marginal ends 25. However, the fabric layer 110 is provided
with an extension flap 111 that extends beyond the outer peripheral
end 123 and between the two marginal ends 25 of the plastic layer
120. Particularly, the extension flap 111 is formed as one piece
with the fabric layer 110. To enhance the bonding between the
plastic layer 120 and the fabric layer 110, a reinforcing stitch
line 29 may be provided along the outer peripheral end 123 of the
plastic layer 120 to sew the fabric layer 110 to the plastic layer
120, as best shown in FIG. 6.
[0031] The breathable waterproof layer 130 is attached to the
fabric layer 110 opposite to the plastic layer 120. The breathable
waterproof layer 130 may be sewn to the bottom end 12 of the upper
portion 10 and the open top end 23 of the lower portion 20, and a
waterproof strip 293 may be bonded to an inner side of the lower
portion 20 and the breathable waterproof layer 130 along the open
top end 23. Alternatively, the breathable waterproof layer 130 may
be bonded to the fabric layer 110 before the latter is bonded to
the plastic layer 120. Certainly, the breathable waterproof layer
130 may also be bonded directly to the fabric layer 110 after the
latter is bonded to the plastic layer 120.
[0032] The sole unit 30 in this embodiment includes the insole 31
and an outsole 32 with a tread plate 321. The open bottom end 24 of
the lower portion 20 is lasted to a bottom side of the insole 31.
The outsole 32 is attached to the bottom end 24 of the lower
portion 20.
[0033] The extension flap 111 which extends beyond the outer
peripheral end 123 of the plastic layer 120 provides flexibility to
facilitate folding of the bottom end 24 of the lower portion 20 and
a greater bonding area for a bonding connection between the bottom
end 24 and the bottom side of the insole 31. In addition, when the
lower portion 20 is mounted on a last (not shown) for lasting the
lower portion 20 over the insole 31, a pulling force may be applied
conveniently to the extension flap 111 to pull the bottom end 24 of
the lower portion 20. The lasting operation can therefore be
facilitated. While the flat composite 100 is illustrated as being
used in a lasted shoe, the flat composite 100 may also be used in
other shoe constructions, such as, hand stitched shoes.
[0034] A preferred embodiment of a process for making the shoe of
this preferred embodiment will be described in the following
paragraphs:
[0035] Referring to FIGS. 5 and 5A, the flat composite 100 is
prepared by placing the fabric layer 110 between upper and lower
mold parts 41 and 42 and by molding the plastic layer 120 directly
over the fabric layer 110. The plastic layer 120 is therefore
adhered to the fabric layer 110 by an adhesion of the plastic layer
120 per se. The ventilation holes 211 are formed during molding and
are covered by the fabric layer 110 which is ventilative. No
cementing material, such as an adhesive which can block the
ventilation holes 211, is provided between the plastic layer 120
and the fabric layer 110 in this embodiment. However, if a
cementing material between the plastic layer 120 and the fabric
layer 110 is desired, the cementing material should not be provided
in a region where the ventilation holes 211 are formed.
[0036] Referring once again to FIGS. 5 and 6, the fabric layer 110
is trimmed relative to the inner and outer peripheral ends 121, 123
and the marginal ends 25 of the plastic layer 120 after molding so
as to have a profile substantially corresponding to that of the
plastic layer 120.
[0037] Referring once again to FIGS. 3 and 7, two opposite marginal
ends 25 of the plastic layer 120 are sewn together such that the
flat composite 100 is looped and formed into the lower portion 20.
The connection plate 40 is then secured to the flat composite 100
such as by sewing.
[0038] Referring once again to FIG. 3, the bottom end 12 of the
upper portion 10 is sewn to the top end 23 of the lower portion 20,
thereby forming the upper (A).
[0039] Referring further to FIG. 3, the bottom end 24 of the lower
portion 20 is connected to an insole 31, and the outsole 32 is
connected to the bottom end 24 of the lower portion 20. The
connection between the insole 31 and the lower portion 20 is
accomplished by a conventional lasting process. A filler 33 is
disposed between the insole 31 and the outsole 32.
[0040] Alternatively, a hemming fabric strip may be provided along
the outer peripheral end 123 to enclose the outer peripheral end
123 and an end of the fabric layer 110 bonded to the outer
peripheral end. This arrangement prevents peeling of the fabric
layer 110 from the plastic layer 120 during the lasting
operation.
[0041] The shoe of the present invention thus formed has the
following advantages:
[0042] 1. Since the lower portion 20 is formed to have an
rudimentary three-dimensional shape by sewing the marginal ends 25
of the plastic layer 120 to loop the flat composite 100, the need
to use a conventional complicated and expensive three-dimensional
mold may be eliminated.
[0043] 2. Since the lower portion 20 is made from the flat
composite 100, the lower portion 20 is more flexible to adjust or
change its dimensions compared to the molded lower portion of the
conventional upper. Thus, the cost of mold-making for the process
can be reduced.
[0044] 3. The lower portion 20 is suitable for various shoe-making
processes, such as lasting, hand stitching.
[0045] 4. The fabric layer 110 bonded to the plastic layer 120 can
serve as a lining for the lower portion 20. Such a lining can be
prepared more easily compared to a conventional lining which is
attached to an inner surface of the conventional molded lower shell
of an upper.
[0046] 5. The fabric layer 110 bonded to the plastic layer 120 is
breathable and can serve as a protection screen to block entry of
particles into the shoe through the ventilation holes 211. Thus,
the present invention eliminates the need to provide an additional
screen member which is required in a conventional ventilated shoe.
On the other hand, although the lower portion 20 is provided with
ventilation holes 211, due to the presence of the breathable
waterproof layer 130 at the inner side of the lower portion 20, the
lower portion 20 which is made of the flat composite 100 is not
only breathable but also waterproof.
[0047] 7. The fabric layer 110 reinforces the plastic layer 120 so
that the thickness and weight of the plastic layer 120 may be
reduced.
[0048] In sum, the shoe of this invention provides the advantages,
such as, reduced mold cost, light weight, good bendability and good
breathability, and can accommodate different sizes of lasts and
different shoe constructions.
[0049] While the present invention has been described in connection
with what is considered the most practical and preferred
embodiments, it is understood that this invention is not limited to
the disclosed embodiments but is intended to cover various
arrangements included within the spirit and scope of the broadest
interpretation so as to encompass all such modifications and
equivalent arrangements.
* * * * *