U.S. patent application number 11/938513 was filed with the patent office on 2008-03-13 for footwear outsole and method of manufacture.
This patent application is currently assigned to WOLVERINE WORLD WIDE, INC.. Invention is credited to Wen-Jong Liu, Mark M. Morgan.
Application Number | 20080060228 11/938513 |
Document ID | / |
Family ID | 37081765 |
Filed Date | 2008-03-13 |
United States Patent
Application |
20080060228 |
Kind Code |
A1 |
Morgan; Mark M. ; et
al. |
March 13, 2008 |
FOOTWEAR OUTSOLE AND METHOD OF MANUFACTURE
Abstract
An outsole construction having an integral display layer. The
outsole includes a main body and a plurality of lugs extending from
the main body to define a plurality of ground engaging elements.
The display layer is disposed at the surface of the main body such
that it is visible in the main body of the outsole and is spaced
away from the surface of the lugs such that it is not visible on
the surface of the lugs. The display layer may include a printed
pattern, such as a camouflage pattern. The present invention also
provides a method for manufacturing an outsole including the
general steps of (a) providing a mold defining a main body and a
plurality of lugs extending from the main body, (b) placing a
permeable display layer in the mold and (c) injecting sole material
into the mold. In this method, the permeability of the display
layer and/or the viscosity of the sole material may be selected so
that the display layer lies along the surface of the main body of
the sole but not the surface of the lugs.
Inventors: |
Morgan; Mark M.; (Rockford,
MI) ; Liu; Wen-Jong; (Shi-Lin, TW) |
Correspondence
Address: |
WARNER NORCROSS & JUDD LLP
900 FIFTH THIRD CENTER
111 LYON STREET, N.W.
GRAND RAPIDS
MI
49503-2487
US
|
Assignee: |
WOLVERINE WORLD WIDE, INC.
Rockford
MI
|
Family ID: |
37081765 |
Appl. No.: |
11/938513 |
Filed: |
November 12, 2007 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
11103857 |
Apr 12, 2005 |
7313876 |
|
|
11938513 |
Nov 12, 2007 |
|
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Current U.S.
Class: |
36/103 ;
36/25R |
Current CPC
Class: |
A43B 3/0078 20130101;
B29D 35/142 20130101; A43B 1/0027 20130101; A43B 13/223 20130101;
A43B 23/24 20130101 |
Class at
Publication: |
036/103 ;
036/025.00R |
International
Class: |
A43B 13/00 20060101
A43B013/00 |
Claims
1. An outsole comprising: a main body having an outer surface; a
plurality of lugs integral with and extending from said main body,
said plurality of lugs extending from said outer surface to define
a plurality of ground engaging surfaces; a display layer integral
with the outsole, said display layer extending along said outer
surface of said main body whereby said display layer is visible on
said outer surface, said display layer being embedded within the
outsole above said ground engaging surfaces of said plurality of
lugs whereby said display layer is hidden from view above said
ground engaging surfaces.
2. The outsole of claim 1 wherein said display layer is coextensive
with the outsole.
3. The outsole of claim 1 wherein said main body and said plurality
of lugs are manufactured from an opaque sole material.
4. The outsole of claim 1 wherein said display layer includes a
pattern, said pattern being visible on said outer surface of said
main body and not being visible on said ground engaging surface of
said plurality of lugs.
5. The outsole of claim 1 wherein said display layer is
permeable.
6. The outsole of claim 1 wherein said display layer is a
fabric.
7. The outsole of claim 1 wherein said display layer is a tricot
fabric.
8. The outsole of claim 4 wherein said pattern is further defined
as a camouflage pattern.
9. An article of footwear comprising: an upper; and a sole affixed
to said upper; wherein said sole includes a sole component having
an integral display layer, said sole component including a main
body and a plurality of lugs extending from said main body, said
lugs defining a plurality of ground engaging surfaces, said display
layer being visible along a surface of said main body and not being
visible along said ground engaging surfaces of said plurality of
lugs.
10. The article of claim 9 wherein said main body includes an outer
surface, said display layer being visible along said outer
surface.
11. The article of claim 10 wherein said lugs extend from said
outer surface, whereby said display layer is visible on said main
body around said plurality of lugs.
12. The article of claim 11 wherein said display layer includes
permeable regions at least adjacent said plurality of lugs.
13. The article of claim 11 wherein said display layer is
manufactured from a permeable material.
14. The article of claim 13 wherein said display layer is a
fabric.
15. The article of claim 13 wherein said display layer is a tricot
fabric having a camouflage pattern.
16. The article of claim 11 wherein said display layer is visible
along and coextensive with said outer surface of said main
body.
17-24. (canceled)
25. An outsole comprising: a main body having an outer surface; a
plurality of lugs molded integral with and extending from said main
body, said plurality of lugs extending from said outer surface to
define a plurality of ground engaging surfaces; a fabric display
layer integral with the outsole and defining a plurality of
interstices, said display layer extending along said outer surface
of said main body whereby said display layer is visible on said
outer surface, said display layer being embedded within the outsole
above said ground engaging surfaces of said plurality of lugs with
portions of said lugs extending through said interstices, whereby
said display layer is hidden from view above said ground engaging
surfaces.
Description
BACKGROUND OF THE INVENTION
[0001] The present invention relates to footwear and more
particularly to an outsole for an article of footwear and a method
for manufacturing an outsole.
[0002] It is often desirable to provide the sole of an article of
footwear with a particular appearance. For example, in footwear
intended for use in hunting it is known to provide the outsole with
a camouflage pattern. As another example, it is known to provide
the outsole of an athletic shoe with an aesthetically pleasing
pattern that may, among other things, draw the attention of
potential purchasers. There are other applications in which it may
be desirable to provide the undersurface of a sole with a desired
printed pattern.
[0003] One construction for providing a patterned outsole is to
laminate a patterned layer to the undersurface of the outsole. In
this construction the pattern is on the surface of the outsole
where it is clearly visible. Unfortunately, the layer is also
exposed to the dangers associated with use. For example, the
patterned layer is subjected to wear, scuffing and other damage
during use. This wear or other damage can obscure the pattern over
time.
[0004] Another method for providing a pattern or other display
layer to the undersurface of a sole is to sandwich a patterned
layer within the sole. In this construction, the patterned layer
may be disposed above the outsole and the outsole may be
manufactured from a transparent or translucent material that allows
the pattern to be seen through the outsole. This construction has
the benefit of protecting the patterned layer behind the outsole.
Unfortunately, it limits the materials that can be used to
manufacture the outsole because the outsole must be at least
partially see-through. To the extent it is not fully transparent,
the outsole will obscure viewing of the patterned layer. Also, the
outsole material can be marred, scuffed or otherwise damaged during
use, thereby further obscuring view of the patterned layer.
[0005] Accordingly, there remains a longfelt and unmet need for a
construction that is simple and inexpensive, but that is durable
and aesthetically pleasing.
SUMMARY OF THE INVENTION
[0006] The aforementioned problems are overcome by the present
invention wherein an outsole having a main body and a plurality of
lugs is provided with a permeable display layer that extends along
the surface of the main body, but does not extend along the surface
of the lugs. In one embodiment, the display layer is manufactured
from a fabric that is sufficiently permeable to permit liquid
outsole material to pass through and form the lugs during injection
molding.
[0007] In one embodiment, the outsole is manufactured from an
opaque material that obscures view of the display layer when the
display layer is not exposed on the surface of the outsole. In this
embodiment, the lugs provide an opaque surface that bears a
majority of ground contact. As a result, the majority of wear
occurs on the lug surfaces where it does not impact the appearance
of the display layer.
[0008] In one embodiment, the display layer is a layer of
camouflage material. The outsole may be manufactured from an opaque
material having a color that compliments the camouflage pattern.
The camouflage material may be a tricot fabric having a printed
camouflage pattern.
[0009] In another aspect, the present invention includes a method
for manufacturing an outsole including the steps of (a) providing a
mold defining a cavity having main body region and a plurality of
lug regions extending from the main body region, (b) placing a
permeable display layer in the mold, (c) injecting sole material
into the mold, and (d) permitting the sole material to cure while
in intimate contact with the display material thereby providing a
one-piece sole having a display layer integral with the outsole;
wherein the permeability of the display layer and/or the viscosity
of the sole material is selected so that the sole material
permeates or flows through the display layer at the lug regions so
that the display layer is not visible at the surface of the
lugs.
[0010] The present invention provides a simple and effective
outsole construction that permits a display layer to be placed on
the undersurface of an outsole. Because the lugs bear a majority of
the ground contact, scuffing, marring and wear have little effect
on the display layer. Accordingly, the display layer remains
visible in good condition for a relatively long time. The
manufacturing process is simple and effective and can be
implemented without significant changes to existing tooling or
other equipment. In some applications, the display layer may simply
be closed between the mold halves without any modification to the
mold. In these applications the display layer is gripped between
the mold halves, for example, between the shut-off portions of the
mold. In other applications, the display layer may be held by pins
or not held at all.
[0011] These and other objects, advantages, and features of the
invention will be readily understood and appreciated by reference
to the detailed description of the preferred embodiment and the
drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1 is a perspective view of an outsole in accordance
with an embodiment of the present invention.
[0013] FIG. 2 is a side elevational view of a boot incorporating
the outsole.
[0014] FIG. 3 is an exploded perspective view of the boot.
[0015] FIG. 4 is a enlarged sectional view of a portion of the
outsole.
[0016] FIG. 5 is a perspective view of a mold.
[0017] FIG. 6 is a side elevational view of the mold.
[0018] FIG. 7 is a perspective view of the mold with the display
layer draped over the lower mold.
[0019] FIG. 8 is a sectional view of the closed mold showing the
mold cavity.
[0020] FIG. 9 is an enlarged sectional view of portion IX of the
mold of FIG. 8.
[0021] FIG. 10 is an enlarged sectional view similar to that of
FIG. 9 showing the mold with injected sole material.
[0022] FIG. 11 is a perspective view of a pair of molded outsoles
before trimming of excess display layer.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0023] An outsole in accordance with an embodiment of the present
invention is shown in FIG. 1 and generally designated 10. The
outsole 10 generally includes a main body 12 and a plurality of
lugs 14 extending down from the main body 12 to define a majority
of the ground engaging portion of the outsole 10. A display layer
20 is disposed along the outer surface of the main body 12, but not
the outer surface of the lugs 14. The display layer 20 may be
printed or otherwise provided with a pattern, image, text or other
visual indicia. In such cases, the visual indicia is visible on the
surface of the main body 12, but not the lugs 14. In another
aspect, the present invention is directed to a method for
manufacturing an outsole 10 for an article of footwear including
the general steps of: (a) providing a mold 200 defining a mold
cavity 202 with a main body region 204 and plurality of lug regions
206 extending from the main body region 204 (See FIG. 5), (b)
inserting a permeable display layer 20 into the mold cavity 202
(See FIG. 7) and (c) injecting sole material 18 into the mold
cavity 202; wherein the display layer 20 and/or sole material 18 is
selected so that the display layer 20 remains on or embedded in the
surface of the material 18 in the main body 12 of the sole 10 and
the material 18 passes through the permeable display layer 20 in
the lugs 14 so that the display layer 20 is not on the surface of
the lugs 14. The present invention is described in connection with
a conventional outdoor sole having a plurality of relatively
regular, pronounced lugs. It should be understood that the present
invention is well-suited for use in soles with other types of lugs,
which may include cleats, ribs, bars and other protrusions from the
main body 12 of the sole 10.
[0024] A boot 100 incorporating the sole 10 is shown in FIG. 2. The
boot 100 is shown for disclosure purposes only and is not intended
to limit the invention to use with boots. To the contrary, the
present invention is well-suited for use with essentially any type
of soled footwear. The illustrated boot 100 generally includes an
upper 102 and a sole 104 (See FIG. 2). The upper 102 is generally
conventional and therefore will not be described in detail. The
upper 102 is affixed to the sole 10 using essentially any
attachment construction. For example, the sole 10 may be cemented,
sewn, welted or directly attached to the upper. In the illustrated
embodiment, the boot 100 includes a multilayer sole 104 generally
including a footbed 106, a midsole 108 and the outsole 10 (See FIG.
3). The footbed 106 is a generally conventional footbed and may be
removably fitted within the upper 102 to directly engage the
wearer's foot. The midsole 108 is also generally conventional and
may be sandwiched between the outsole 10 and the upper 102. In the
illustrated embodiment, the midsole 108 is a relatively thick layer
of cushioning material that is fitted within a corresponding recess
22 in the upper surface of the outsole 10. The sole 104 may include
other conventional components as desired, such as a shank, heel
cushion, support plate. The present invention is not limited in use
to multilayer sole constructions, but rather may be incorporated
into essentially any sole construction. Accordingly, the
construction of sole 104 may vary from application to application
as desired.
[0025] In the illustrated embodiment, the outsole 10 is a one-piece
component having the display layer 20 integrated connected with the
sole material 18 (See FIG. 4). As described in more detail below,
the outsole 10 is molded with the display layer 20 located within
the mold 200 so that the sole material 18 directly adheres to the
display layer 20 as it cures. As noted above, the outsole 10 of the
illustrated embodiment generally includes a main body 12 and a
plurality of lugs 14 that extend from the main body 12 to define a
majority of the ground engaging surface of the sole 104. The main
body 12 of this embodiment is essentially coextensive with the sole
104 extending from heel to toe and from lateral to medial sides of
the boot 100. The outsole 10 need not, however, extend along the
entire undersurface of the sole 104. For example, the outsole 10
may include separate heel and forefoot portions (not shown) that
are separately secured to the undersurface of the sole 104 or the
outsole 10 may extend through only a select portion of the sole
104, such as only through the heel or only through the forefoot
region of the sole 104.
[0026] In the illustrated embodiment, the outsole 10 is molded from
conventional outsole materials, such as polyurethane ("PU").
Alternative outsole materials include without limitation
thermoplastic resin ("TPR"), ethylene vinyl acetate ("EVA") and
rubber. The outsole material 18 may be opaque and may have a color
selected to compliment the display layer 20. For example, if the
display layer 20 includes a camouflage pattern, the outsole
material 18 may be selected with a color that corresponds with one
of the colors in the camouflage pattern. Alternatively, the outsole
material 18 may be selected with a color that contrasts with the
display layer 20.
[0027] The display layer 20 of the described embodiment is a fabric
having interstices between the fabric material that permit the sole
material to flow through the fabric. In this embodiment, the
display layer 20 is a tricot fabric that is manufactured from 100%
nylon using a plain weave having 80 grams per square meter. The
characteristics of the fabric may vary from application to
application provided that it will remain on or embedded in the
surface of the main body of the sole while having sufficient
permeability to permit the sole material to pass through the fabric
in the lugs. Although the present invention is described in
connection with a conventional tricot fabric, it is not limited to
the use of tricot fabrics, but may instead be used with other
fabrics or other types of permeable materials, such as perforated
films or other sheet materials. In some applications, fabrics with
relatively open weaves will be desired. Open weave fabrics may
facilitate the flow of sole material through the fabric to fill the
lugs. The characteristics of the sole material may impact the
choice of materials for the display layer 20. For example, more
viscous materials may require a higher degree of permeability (e.g.
a more open weave or a more perforated material) to provide
appropriate flow-through of the sole material into the lug
regions.
[0028] The outsole 10 may be manufactured using conventional
injection molding equipment. FIG. 5 illustrates a mold 200 capable
of operating in accordance with a manufacturing method of the
present invention. The mold 200 generally includes a pair of mold
parts 220 and 222 that are selectively movable using conventional
equipment, such as hydraulic or pneumatic cylinders (not shown).
The mold parts 220 and 222 are contoured to cooperatively define a
pair of mold cavities 202 in the desired shape of the pair of
outsoles 10. The pair of mold cavities are essentially the
mirror-image of one another and are shaped to form matching left
and right outsoles 10. Given that the two cavities are essentially
identical (except of being the mirror image of one another), this
discussion will focus only on one of the two cavities. The mold
parts 220 and 222 also include marginal portions 224 and 226 that
engage one another when the mold 100 is closed. The marginal
portions 224 and 226 include the "shut-off" that prevents liquid
sole material 18 from flowing out of the cavity 202. As perhaps
best shown in FIG. 6, the upper mold part 220 is contoured to
correspond in shape with the upper surfaces of the two outsoles 10.
In this embodiment, the upper mold part 220 includes a pair of
convex surfaces 230 (only one of which is visible in the drawings)
that defines the recesses 22 in the top surfaces of the outsoles
10. The lower mold part 222 is contoured to correspond in shape
with the lower surfaces of the outsoles 10. More specifically, the
lower mold part 222 is shaped to define a main body region 204 and
plurality of lug regions 206 extending from the main body region
204 for each of the two outsoles. As shown in FIG. 8, the lug
regions 206 are extensions of the main body region 204 so that
material injected into the main body region 204 can flow into the
lug regions 206.
[0029] Although the illustrated mold 200 is intended to mold a pair
of outsoles 10, the mold may alternatively be configured to mold a
different number of outsoles. For example, the mold may be
configured to individually mold a single outsole. In this
alternative, the mold parts (not shown) may include a single mold
cavities defining either a left or right outsole. The mold may
alternatively be configured to mold more than two outsole by
shaping the upper and lower molds to define more than two separate
mold cavities.
[0030] Manufacture of the outsole 10 using the mold 200 will now be
described in connection with FIGS. 5-11. The process begins with
the mold 200 in an open position (See FIGS. 5 and 6). In this
position, the mold parts 220 and 222 are spaced far enough apart to
permit the display layer 20 to be placed between the mold parts 220
and 222, for example, atop the lower mold 222 covering the mold
contours. The display layer 20 may be of sufficient size to extend
over the entire extents of the lower mold part 222 or may be
smaller covering only portions of the lower mold part 222 (See FIG.
7). In alternative applications, the display layer 20 may include
two or more separate portions. For example, the display layer may
include a forefoot portion that covers the forefoot region of the
sole and a separate heel portion that covers the heel region of the
sole (not shown). This option may be desirable when different
patterns are desired in the forefoot and heel regions or when the
outsole includes separate forefoot and heel parts. In the
illustrated embodiment, the display layer 20 includes marginal
portions that extend beyond the extents of the mold cavity 202
where the marginal portions of the display layer 20 can be
sandwiched between the marginal portions 224 and 226 of the mold
parts 220 and 222, respectively (See FIG. 8). In this way, the mold
parts 220 and 222 cooperatively hold the display layer 20 reducing
the likelihood of the display layer 20 being forced down into the
lug regions 206 by the flow of injected sole material 18. In
alternative embodiments, the display layer 20 may be held by
clamps, pins or other mechanical features incorporated into the
mold 200 or structures adjacent to the mold 200. Fabric pins 90 are
shown in phantom lines in FIG. 8. The tension or amount of slack in
the display layer 20 may vary from application to application. For
example, in application with a deep mold cavity 202, it may be
desirable to include some slack in the display layer 20. The amount
of slack may be selected so that the flow of sole material 18 into
the mold cavity 202 is capable of pushing the display layer 20 to
the surface of the main body of the outsole 10. On the other hand,
it may be desirable in some applications to hold the display layer
20 without any slack or even under tension. For example, if the
display layer 20 is manufactured from a relatively elastic or
stretchable material or if the mold cavity is relatively flat or if
the lug regions 206 are relatively large in cross-section, it may
be beneficial to hold the display layer 20 without slack or under
tension. This may be achieved by holding the display layer 20 with
the desired degree of tension while the mold is closed either
manually or using supplemental mechanical components, such as
clamps, teeth or pins mounted adjacent to the mold parts 220 and
222. In some applications, it may not be necessary to hold the
marginal edges of the display layer 20 to prevent the display layer
20 from being pushed down to the surface of the lugs 14. For
example, if the display layer 20 has sufficient stiffness, the sole
material 18 has a sufficiently low viscosity or the lug regions 206
have a sufficiently small cross section, it may not be necessary to
hold the display layer 20 to prevent it from being pushed down into
the lugs.
[0031] Once the display layer 20 is placed between the mold parts
220 and 222, the mold 200 is closed. As noted above, the mold parts
220 and 222 in this embodiment hold the periphery of the display
layer 20 (See FIGS. 8 and 9). More specifically, the peripheral
portion of the display layer 20 is sandwiched and held between the
marginal portions 224 and 226 of the closed mold parts 220 and
222.
[0032] Liquid sole material 18 is then injected into the mold 200.
The material 18 may be introduced into the mold 200 above the
display layer 20 so that flow of the material 18 pushes the display
layer 20 down against the surface of the lower mold part 222. The
precise location of the injection inlets may vary from application
to application, but in the illustrated embodiment, a first
injection inlet is located approximately at the center of the
forefoot region and a second injection inlet is located
approximately at the center of the heel region. Additional sprues
and runners may interconnect the to cavities. As the sole material
18 pushes against the display layer 20 over the lug regions 206,
the permeability of the display layer 20 allows the sole material
to pass through the display layer 20, for example, through the
interstices between the strands of the fabric weave. As perhaps
best shown in FIG. 10, the sole material 18 flows into and fills
the lug regions 206. In alternative embodiment, the mold parts 220
and 222 may be configured to define in the outsole in an inverted
orientation (not shown). In such applications, it may be desirable
to inject the sole material 18 into the mold cavity 202 beneath the
display layer 20 so that the sole material 18 pushes the display
layer 20 up to the surface of the main body.
[0033] Once the appropriate volume of sole material has been
injected into the mold cavity 202, the sole material 18 is
permitted to cure. Depending on the nature of the sole material 18
curing may occur with the passage of time and/or by cooling. Once
the sole material 18 is sufficiently cured, the mold 200 is opened
and the outsole 10 is removed (See FIG. 11). The outsole 10 can
then be trimmed and finished as desired. The outsole 10 can then be
attached to the midsole 108 or directly to the upper 102 using
conventional techniques, for example, by stitching, cement or other
adhesives. In other applications, the outsole 10 may be directly
attached to the upper 102 or to another sole component (e.g. the
midsole 108) using conventional techniques and apparatus. For
example, the upper 102 or sole component to which the outsole 10
will be attached may be positioned within the mold 200 so that it
is directly engaged with and becomes directly attached to the sole
material as it cures.
[0034] The above description is that of a preferred embodiment of
the invention. Various alterations and changes can be made without
departing from the spirit and broader aspects of the invention as
defined in the appended claims, which are to be interpreted in
accordance with the principles of patent law including the doctrine
of equivalents. Any reference to claim elements in the singular,
for example, using the articles "a," "an," "the" or "said," is not
to be construed as limiting the element to the singular.
* * * * *