U.S. patent application number 12/184103 was filed with the patent office on 2010-02-04 for method of making footwear.
This patent application is currently assigned to Columbia Sportswear Company. Invention is credited to Tim Boyle, Mark Dube, Daniel Laska, Brian Nolan.
Application Number | 20100024253 12/184103 |
Document ID | / |
Family ID | 41606825 |
Filed Date | 2010-02-04 |
United States Patent
Application |
20100024253 |
Kind Code |
A1 |
Boyle; Tim ; et al. |
February 4, 2010 |
METHOD OF MAKING FOOTWEAR
Abstract
A method of making a shoe and the resulting novel shoe involve
forming a sole member with at least one flange member that extends
upwardly from the top side of the sole member. An upper member is
positioned on the top side of the sole member with the flange
member disposed inside of a flange attachment portion. The upper is
then attached to the upwardly extending flange member.
Inventors: |
Boyle; Tim; (Portland,
OR) ; Laska; Daniel; (Portland, OR) ; Dube;
Mark; (Portland, OR) ; Nolan; Brian; (Zhuhai
City, CN) |
Correspondence
Address: |
KLARQUIST SPARKMAN, LLP
121 SW SALMON STREET, SUITE 1600
PORTLAND
OR
97204
US
|
Assignee: |
Columbia Sportswear Company
|
Family ID: |
41606825 |
Appl. No.: |
12/184103 |
Filed: |
July 31, 2008 |
Current U.S.
Class: |
36/114 ;
12/146BC; 12/146C; 36/25R; 36/45 |
Current CPC
Class: |
A43B 5/08 20130101; A43B
9/02 20130101 |
Class at
Publication: |
36/114 ; 36/25.R;
36/45; 12/146.BC; 12/146.C |
International
Class: |
A43B 5/00 20060101
A43B005/00; A43B 13/00 20060101 A43B013/00; A43B 23/00 20060101
A43B023/00; A43D 8/00 20060101 A43D008/00 |
Claims
1. A method of making a shoe comprising: forming a sole member of
EVA, the sole member having a top side, a bottom side, a lateral
side edge, a medial side edge, a toe side edge, and a heel side
edge, the sole member having at least one flange member integrally
formed with the sole member and extending upwardly from the top
side of the sole member, the at least one flange member extending
at least substantially around the perimeter of the shoe and the at
least one flange member being disposed inward of each of the
lateral side edge, the medial side edge, the toe side edge, and the
heel side edge; forming an upper member, the upper member having a
foot covering portion and a flange attachment portion, the flange
attachment portion being located substantially at a lower edge of
the upper member; positioning the upper member on the top side of
the sole member with the at least one flange member disposed inside
of the flange attachment portion of the upper member; and attaching
the at least one flange member to the flange attachment
portion.
2. The method of claim 1, wherein the at least one flange member
comprises a single, continuous flange member extending completely
around the perimeter of the sole member.
3. The method of claim 2, wherein a ledge is formed between the
flange member and the lateral side, medial side, toe side, and heel
side edges of the sole member, and wherein the lower edge of the
upper member abuts the ledge when the upper member is positioned on
the top side of the sole member.
4. The method of claim 1, wherein the at least one flange member is
formed with an inner curved portion.
5. The method of claim 4, wherein the inner curved portion varies
along the length of the sole member.
6. The method of claim 5, wherein the inner curved portion is
defined by an inner radius and the inner radius is larger along the
length of the sole member at locations closer to the heel side edge
of the sole member than it is at locations closer to the toe side
edge.
7. The method of claim 1, wherein the at least one flange member
has a thickness that varies along the length of the sole
member.
8. The method of claim 1, wherein the attaching of the at least one
flange member to the flange attachment portion is achieved by
machine stitching.
9. The method of claim 1, wherein the machine stitching is
performed using a round point needle.
10. The method of claim 1, the method further comprising: forming a
pathway on a top side of the sole member for directing water from
the top side of the sole member to one or more of the lateral side,
medial side, toe side, or heel side edges; and forming an opening
in at least one of the lateral side, medial side, toe side, or heel
side edges of the sole member, the opening being in fluid
connection with the pathway when water is introduced to the top
side of the sole member.
11. The method of claim 1, wherein the shoe is a closed shoe with
the foot covering portion of the upper member being configured to
substantially cover an upper portion of a foot when the shoe is
being worn by a person.
12. The method of claim 1, the method further comprising treating
the upper member to be hydrophobic.
13. The method of claim 1, wherein the EVA sole member is formed by
injection molding.
14. The method of claim 1, wherein the EVA sole member is formed by
compression molding.
15. The method of claim 1, further comprising: positioning a fabric
between the flange member and the flange attachment portion of the
upper member prior to attaching the flange member to the flange
attachment portion.
16. A shoe comprising: a sole member, the sole member comprising an
EVA material and having a top side, a bottom side, a lateral side
edge, a medial side edge, a toe side edge, and a heel side edge, at
least one flange member extending upwardly from the top side of the
sole member, the at least one flange member being integrally formed
with the sole member and extending at least substantially around
the perimeter of the shoe; and an upper member, the upper member
having a foot covering portion and a flange attachment portion, the
flange attachment portion being located substantially at a lower
edge of the upper member, the flange attachment portion being
attached to the at least one flange member; wherein the upper
member is disposed on the top side of the sole member with the at
least one flange member disposed inside of the flange attachment
portion of the upper member.
17. The shoe of claim 16, wherein the at least one flange member
comprises a single, continuous flange member extending completely
around the perimeter of the sole member.
18. The shoe of claim 17, wherein the flange member is disposed
inward of the lateral side, medial side, toe side, and heel side
edges to form a ledge between the flange member and the lateral
side, medial side, toe side, and heel side edges of the sole
member, and wherein the lower edge of the upper member abuts the
ledge.
19. The shoe of claim 16, wherein the at least one flange member is
formed with an inner curved portion.
20. The shoe of claim 19, wherein the inner curved portion varies
along the length of the sole member.
21. The shoe of claim 20, wherein the inner curved portion is
defined by an inner radius and the inner radius is larger along the
length of the sole member at locations closer to the heel side edge
of the sole member than it is at locations closer to the toe side
edge.
22. The shoe of claim 16, wherein the at least one flange member
has a thickness that varies along the length of the sole
member.
23. The shoe of claim 16, wherein the flange attachment portion is
attached to the at least one flange member with an adhesive.
24. The shoe of claim 23, wherein the flange attachment portion is
attached to the at least one flange member by stitching at least a
portion of the at least one flange member to the flange attachment
portion.
25. The shoe of claim 24, wherein the portion that is stitched
comprises portions in a heel area and a forefoot area of the
shoe.
26. The shoe of claim 16, wherein the at least one flange member is
machine stitched to the flange attachment portion.
27. The shoe of claim 16, the sole member further comprising: a
pathway on a top side of the sole member for directing water from
the top side of the sole member to one or more of the lateral side,
medial side, toe side, or heel side edges; and an opening formed in
at least one of the lateral side, medial side, toe side, or heel
side edges of the sole member, the opening being in fluid
connection with the pathway when water is introduced to the top
side of the sole member.
28. The shoe of claim 16, wherein the shoe is a closed shoe with
the foot covering portion of the upper member being configured to
substantially cover an upper portion of a foot when the shoe is
being worn by a person.
29. The shoe of claim 16, wherein the shoe is a boat shoe and the
upper member comprises a leather portion that has been treated to
be hydrophobic.
30. The shoe of claim 16, wherein the shoe is a boat shoe and the
upper member comprises a canvas portion that has been treated to be
hydrophobic.
31. The shoe of claim 16, wherein the EVA sole member is formed by
injection molding.
32. The shoe of claim 16, wherein the EVA sole member is formed by
compression molding.
33. The shoe of claim 16, further comprising a fabric disposed
between the flange member and the flange attachment portion of the
upper member.
Description
FIELD
[0001] This application relates to footwear and, in particular, to
a shoe that can be worn in activities that take place in wet
environments, such as boating.
BACKGROUND
[0002] Traditional footwear manufacturing methods (e.g., Strobel or
board lasting) generally include a lasting step. Lasting describes
how the upper is attached to the midsole. For example, in the
Strobel lasting method, the upper is stitched to an insole or other
shoe liner and then the combination is pulled onto a last so that a
midsole can be attached. In the board lasting method, an upper is
glued to a piece of cardboard or fiberboard, and then the resulting
product is subsequently attached to a midsole. Such manufacturing
techniques that include an insole or other shoe liner increase the
manufacturing costs by increasing the amount of materials and labor
required to produce a shoe. In addition, such insoles and liners
tend to get waterlogged and uncomfortable when exposed to water,
which make such shoes uncomfortable to wear in wet
environments.
[0003] Attempts to create footwear that does not include an insole
or require the lasting methods discussed above have been primarily
limited to sandals or other open footwear that does not offer
sufficient comfort, support, or protection to the feet of the user,
especially when worn in wet conditions.
SUMMARY
[0004] In one embodiment, a novel method of making a shoe is
disclosed. The method includes forming a sole member of EVA and
forming an upper member. The sole member has a top side, a bottom
side, a lateral side edge, a medial side edge, a toe side edge, and
a heel side edge. The sole member has at least one flange member
integrally formed with the sole member and extending upwardly from
the top side of the sole member. The flange member extends at least
substantially around the perimeter of the shoe and is disposed
inward of each of the lateral side edge, the medial side edge, the
toe side edge, and the heel side edge. The method further comprises
forming an upper member that has a foot covering portion and a
flange attachment portion. The flange attachment portion is located
substantially at a lower edge of the upper member. The upper member
is positioned on the top side of the sole member with the flange
member disposed inside of the flange attachment portion of the
upper member. The flange member is attached to the flange
attachment portion.
[0005] In one embodiment, the flange member comprises a single,
continuous flange member extending completely around the perimeter
of the sole member.
[0006] In another embodiment, a ledge is formed between the flange
member and the lateral side, medial side, toe side, and heel side
edges of the sole member. The lower edge of the upper member abuts
the ledge when the upper member is positioned on the top side of
the sole member.
[0007] In another embodiment, the flange member is formed with an
inner curved portion. In specific implementations, the inner curved
portion varies along the length of the sole member and the inner
curved portion can be defined by an inner radius. The inner radius
may be larger along the length of the sole member at locations
closer to the heel side edge of the sole member than it is at
locations closer to the toe side edge. The flange member can also
have a thickness that varies along the length of the sole
member.
[0008] In other embodiments, the attaching of the flange member to
the flange attachment portion comprises applying an adhesive
between the flange member and the flange attachment portion. In
addition, the attachment can include stitching at least a portion
of the flange member to the flange attachment portion. The portion
that is stitched can comprise portions in a heel area and a
forefoot area of the shoe.
[0009] In other embodiments, the attaching of the flange member to
the flange attachment portion can be achieved by machine stitching.
The machine stitching can be performed using a round point
needle.
[0010] In specific implementations, a pathway on a top side of the
sole member can be formed for directing water from the top side of
the sole member to one or more of the lateral side, medial side,
toe side, or heel side edges. An opening can also be formed in at
least one of the lateral side, medial side, toe side, or heel side
edges of the sole member. The opening can be in fluid connection
with the pathway when water is introduced to the top side of the
sole member.
[0011] In specific implementations, the shoe is a closed shoe with
the foot covering portion of the upper member being configured to
substantially cover an upper portion of a foot when the shoe is
being worn by a person. The shoe can also be a boat shoe, with the
upper member comprising a leather portion or a canvas portion that
has been treated to be hydrophobic.
[0012] In other embodiments, the EVA sole member is formed by
injection molding. In other embodiments, a fabric can be positioned
between the flange member and the flange attachment portion of the
upper member prior to attaching the flange member to the flange
attachment portion.
[0013] In other embodiments, a recess is formed on the bottom side
of the sole member, and a rubber outsole is formed and positioned
in the recess formed on the bottom side of the sole member. The
rubber outsole is attached to the sole member.
[0014] A novel shoe is disclosed. The shoe comprises a sole member
and an upper member. The sole member comprises an EVA material and
has a top side, a bottom side, a lateral side edge, a medial side
edge, a toe side edge, and a heel side edge. At least one flange
member extends upwardly from the top side of the sole member. The
flange member is integrally formed with the sole member and extends
at least substantially around the perimeter of the shoe. The upper
member has a foot covering portion and a flange attachment portion.
The flange attachment portion is located substantially at a lower
edge of the upper member. The flange attachment portion is attached
to the flange member. The upper member is disposed on the top side
of the sole member with the flange member disposed inside of the
flange attachment portion of the upper member.
[0015] In specific implementations, the flange member comprises a
single, continuous flange member that extends completely around the
perimeter of the sole member. In other implementations, the flange
member is disposed inward of the lateral side, medial side, toe
side, and heel side edges forming a ledge between the flange member
and the lateral side, medial side, toe side, and heel side edges of
the sole member. The lower edge of the upper member may abut the
ledge.
[0016] In other embodiments, the flange member is formed with an
inner curved portion. The inner curved portion may vary along the
length of the sole member. The inner curved portion can also be
defined by an inner radius, with the inner radius being larger
along the length of the sole member at locations closer to the heel
side edge of the sole member than it is at locations closer to the
toe side edge. The flange member can also have a thickness that
varies along the length of the sole member. In other specific
implementations, the flange member is machine stitched to the
flange attachment portion.
[0017] In other embodiments, the sole member further comprises a
pathway on a top side of the sole member for directing water from
the top side of the sole member to one or more of the lateral side,
medial side, toe side, or heel side edges; and an opening formed in
at least one of the lateral side, medial side, toe side, or heel
side edges of the sole member. The opening is in fluid connection
with the pathway when water is introduced to the top side of the
sole member.
[0018] In specific implementations, the shoe is a closed shoe with
the foot covering portion of the upper member being configured to
substantially cover an upper portion of a foot when the shoe is
being worn by a person. The shoe can also be a boat shoe with an
upper member that comprises a leather portion or a canvas portion
that has been treated to be hydrophobic.
[0019] In specific implementations, the EVA sole member is formed
by injection molding. In other implementations, the shoe further
comprises a recess on the bottom side of the sole member; and a
rubber outsole positioned in the recess on the bottom side of the
sole member. The rubber outsole is attached to the sole member. In
other embodiments, a fabric is disposed between the flange member
and the flange attachment portion of the upper member.
[0020] The foregoing and other objects, features, and advantages of
the invention will become more apparent from the following detailed
description, which proceeds with reference to the accompanying
figures.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] FIG. 1A is a lateral side perspective view of a shoe
comprising an upper member secured to a sole member.
[0022] FIG. 1B is a medial side perspective view of a shoe
comprising an upper member secured to a sole member, with portions
of the upper member removed for clarity.
[0023] FIG. 2 is a bottom view of the sole member of FIG. 1B.
[0024] FIG. 3 is a front (toe) view of the sole member of FIG.
1B.
[0025] FIG. 4 is a medial side view of the sole member of FIG.
1B.
[0026] FIG. 5 is a back (heel) view of the sole member of FIG.
1B.
[0027] FIG. 6 is a lateral side view of the sole member of FIG.
1B.
[0028] FIG. 7 is a top view of the sole member of FIG. 1B.
[0029] FIG. 8 is a cross section view of the sole member of FIG.
1B, taken along lines A-A1 of FIGS. 2 and 7.
[0030] FIG. 9 is a partial cross section view of the sole member of
FIG. 1B, taken along lines f-f1 of FIG. 2.
[0031] FIG. 10 is a cross section view of the sole member of FIG.
1B, taken along lines B-B1 of FIGS. 2 and 7.
[0032] FIG. 11 is a cross section view of the sole member of FIG.
1B, taken along lines C-C1 of FIGS. 2 and 7.
[0033] FIG. 12 is a cross section view of the sole member of FIG.
1B, taken along lines D-D1 of FIGS. 2 and 7.
[0034] FIG. 13 is a cross section view of the sole member of FIG.
1B, taken along lines E-E1 of FIGS. 2 and 7.
[0035] FIG. 14 is a cross section view of the sole member of FIG.
1B, taken along lines F-F1 of FIGS. 2 and 7.
[0036] FIG. 15 is a cross section view of the sole member of FIG.
1B, taken along lines G-G1 of FIGS. 2 and 7.
[0037] FIG. 16 is a cross section view of the sole member of FIG.
1B, taken along lines H-H1 of FIGS. 2 and 7.
[0038] FIG. 17 is a cross section view of a shoe illustrating an
upper member attached to a sole member with fabric disposed between
the area of attachment.
DETAILED DESCRIPTION
[0039] FIG. 1A is a lateral side perspective view of a shoe 10.
Shoe 10 in this embodiment is a boat shoe that is appropriate for
being worn in wet conditions. The term boat shoe generally refers
to a low-cut shoe that has a slip-resistant sole and can include,
for example, shoes that are useful for boating, kayaking, canoeing,
fishing, and other water-associated activities. Shoe 10 comprises
an upper member 12 and a sole member 14. Upper 12 is constructed so
that the resulting shoe is a "closed" type shoe (rather than an
"open" type shoe) that substantially covers the upper portion of
the foot of a wearer. For the purposes of this disclosure, a foot
is considered substantially covered if at least 50% of the upper
surface of a wearer's foot is covered by the upper. Closed type
shoes provide greater structural support and more protection from
the environment than open type shoes.
[0040] The upper can be constructed of a variety of materials,
including, for example, leather, canvas, or mesh. Desirably, the
selected material is either naturally hydrophobic or it is
chemically treated so that the material acts in a hydrophobic
manner. The upper can include laces 16 that pass through eyelets 18
in vamp 20. Sole 14 desirably includes openings 22 that permit
water to drain from shoe 10. The upper 12 is stitched directly to
sole 14 using stitches 24.
[0041] FIG. 1B is a medial side view of shoe 10, with portions of
the upper 12 cut away for clarity. As shown in FIG. 1B, upper 12 is
stitched on the outside of an upwardly extending flange member 26,
with stitches 24 passing through the upper 12 and directly through
flange member 26. FIG. 1B shows portions of the upper removed to
expose flange member 26. Since upper 12 was removed after being
stitched to flange member 26, stitching holes 28 are shown at the
locations where upper 12 was removed.
[0042] Upper 12 is desirably perimeter stitched to flange member 26
using a stitching machine and a round point needle. Razor edged
needles create a slice that is less desirable when working with
relatively thin portions of EVA material. Slices formed by razor
edged needles may create weaknesses in the EVA material that can
introduce or encourage tearing or other failures in the EVA
material. Accordingly, it is more desirable to stitch upper 12 to
flange member 26 using a needle that creates independent and
substantially round holes. The distance between the holes formed
during the stitching process is desirably about 0.5 mm. If the
holes are formed too close together, flange member 26 may tear or
fail; however, if the holes are formed too far apart, the strength
of the connection between flange member 26 and the flange
attachment portion of upper 12 may be insufficient. In addition, it
may be desirable to include an adhesive between the stitched
portions of the upper and flange member.
[0043] In another embodiment, upper 12 can be bonded to flange
member 26 using adhesive alone, or in combination with a portion of
the stitching described above and shown in FIGS. 1A and 1B. Any of
the various footwear adhesives that are commercially available can
be selected and used for this application. The application of an
adhesive between the upper 12 and the flange member can provide
sufficient bonding strength that it is not necessary to include
separate stitching as discussed above. Alternatively, it may be
desirable to stitch a portion of the upper to the flange member to
reinforce the bond formed by the adhesive between the upper and the
flange member. If only a portion of the upper and flange member is
stitched together, desirably the portion that is stitched is the
portion of the upper and flange member that are located in the heel
area and the forefoot area. If desired, a middle section, the area
between the heel and forefoot may include only adhesive, without
any stitching.
[0044] Desirably, flange member 26 is disposed inward from the
outer edge of sole 14, creating a ledge 30. This can be seen
clearly in FIG. 1B where a portion of flange member 26 has been
removed. As shown in FIGS. 1A and 1B, upper 12 does not extend
below ledge 30 or underneath flange member 26. Traditional shoe
construction generally has the upper extending around and under an
insole material. In the embodiment shown in FIGS. 1A and 1B,
however, the lower edge of upper 12 abuts the upper surface of sole
14 at ledge 30. Accordingly, since the upper does not extend
beneath ledge 30 or wrap under flange member 26, less upper
material is required to produce the shoe. In addition, by securing
upper 12 to the outside of flange member 26, it is possible to
obtain a better water barrier, thereby limiting the amount of water
that enters the shoe at the point of attachment of the upper to the
flange member.
[0045] FIGS. 2-16 show various views of sole 14 and flange member
26. FIG. 2 is a bottom view of sole 14. As discussed in more detail
below, the sole is desirably constructed primarily of ethylene
vinyl acetate (EVA). Alternatively, sole 14 can be constructed of
other appropriate materials, such as Polyurethane.
[0046] EVA is known as a midsole material and is used in various
running shoes to provide cushioning. EVA has also been used as a
material for use with sandals and other "open" footwear. However,
it is believed that EVA has not been used as the sole material in a
closed shoe design with an upper attaching directly (i.e., without
a lasting step) to the EVA sole in the manner discussed below.
[0047] Although sole 14 can be constructed of just one type of
material, such as EVA, sole 14 desirably also includes a relatively
thin stock-fitted rubber outsole 32 that is attached to a recess in
a bottom portion of sole 14. Outsole 32 is desirably attached to
sole 14 using an industry accepted footwear adhesive. The rubber
material of outsole 32 can be a non-marking gum rubber. Since gum
rubber provides a "stickier" surface than EVA materials, a gum
rubber outsole 32 provides shoe 10 with improved traction when used
in wet conditions. In addition, outsole 32 desirably includes
treads 34. Treads 34 are indentations or raised markings that
further improve the ability of shoe 10 to grip surfaces, including
wet surfaces, without slipping.
[0048] Flange member 26 is desirably formed integrally with sole
14. Flange member 26 can be formed integrally with the sole using a
molding process. This molding process can be, for example, either
compression molding or injection molding. Injection molding,
however, is more preferred since it is more efficient than
compression molding and produces less material waste.
[0049] FIG. 3 is a front (toe) perspective view showing flange
member 26 extending upwardly from sole 14, and outsole 32 disposed
in a recessed portion at the bottom of the sole. As seen in FIG. 3,
flange member 26 is desirably located inward from the outer side
edges of sole 14, forming ledge 30. FIG. 4 is a medial side view of
sole 14 and FIG. 6 is a lateral side view of sole 14. As seen in
FIGS. 4 and 6, openings 22 in sole 14 permit water to drain easily
from inside the shoe. FIG. 5 is a rear (heel) view of sole 14. In
addition to the openings 22 in the sides of sole 14, openings at
the rear of sole 14 are provided to permit water drainage.
[0050] FIG. 7 is a top view of sole 14. As seen in FIG. 7, sole 14
has a top side and a bottom side. Sole 14 also has outer perimeter
that is defined by its lateral side edge (left side in FIG. 7), its
medial side edge (right side in FIG. 7), its toe side edge (top
side in FIG. 7), and its heel side edge (bottom side in FIG. 7).
Flange member 26 extends at least substantially around the entire
perimeter of the upper surface of sole 14. Desirably, flange member
extends around the entire perimeter as a single continuous flange
member. Alternatively, however, flange member can extend
substantially around the perimeter such that it extends around at
least half the perimeter of sole 14. If the flange member does not
extend continuously around the perimeter of sole 14, the flange
member can comprise any number of discrete segments, so long as the
flange cumulatively extends around at least half of the
perimeter.
[0051] Flange member 26 extends upward and is disposed inward of
each of the lateral side, medial side, toe side, and heel side
edges of sole 14. Flange member 26 is desirably disposed inward
from the edges, thereby forming ledge 30. Ledge 30 extends from
flange member 26 to the outer edge of sole 14. Referring to FIG.
1A, upper 12 has a foot covering portion 31 and a flange attachment
portion 33. The flange attachment portion 33 is located at a lower
edge of upper 12. The lower edge desirably abuts ledge 30 when the
flange is positioned on sole 14 for attachment.
[0052] The top surface of sole 14 is desirably textured to provide
a smooth, but non-slippery surface on which the foot can rest.
Therefore, texture 36 is provided on the upper surface of sole 14.
In addition, water draining pathways 38 are provided to direct
water in the shoe to openings 22. Pathways 38 are indentations or
depressions in the top surface of sole 14 that function to direct
water to holes 40 at the end of pathways 38, which are in fluid
connection with openings 22. Thus, if water were to cover the
surface of sole 14, the water would be directed through pathways 38
to holes 40, and then out the side of sole 14 through openings 22.
FIG. 9, which is a cross section view taken along lines f-f1 of
FIG. 4, further shows the relationship between openings 22,
pathways 38, and holes 40.
[0053] FIG. 8 is a cross section view of sole 14 taken along line
A-A1 of FIGS. 2 and 7. Flange member 26 is desirably formed with an
inner curved portion. Desirably, the inner curved portion is curved
on the inside (toward the foot) and substantially straight on the
outside (away from the foot). R8 is the inner radius of flange
member 26 at the heel portion of sole 14. In one embodiment, R8 is
approximately equal to 9 mm. R9 is the inner radius of flange
member 26 at the toe portion of sole 14. In one embodiment, R9 is
approximately equal to 4 mm.
[0054] FIGS. 10-16 are cross section areas taken along lines B-B1,
C-C1, D-D1, E-E1, F-F1, G-G1, and H-H1, respectively, in FIGS. 2
and 7. FIGS. 10-16 identify inner radii R1, R2, R3, R4, R5, R6, and
R7 of flange member 26. It should be noted that the inner radius is
the same on both sides of the sole. That is, the inner radius R1
(shown on the left side of FIG. 10) is preferably the same as the
inner radius of the flange member on the right side of FIG. 10.
[0055] Desirably, the inner radius of flange member 26 varies along
the length of the shoe. The inner radius is desirably larger near
the heel area and smaller near the toe area. In one embodiment, in
a U.S. size 9 shoe, moving from toe to heel, the inner radii vary
as follows: R1=5 mm; R2=5 mm; R3=7 mm; R4=13.5 mm; R5=14 mm; R6=14
mm; R7=12 mm. Accordingly, the inner radius of the flange member 26
is desirably at least twice as large at the back as it is at the
front. The varying radius of flange member 26 increases the
structural stability of the shoe (e.g., the strength of the
attachment of flange member to the upper), as well as produces a
more ergonomically correct shoe, which increases comfort to the
wearer.
[0056] Desirably, the thickness of flange member 26 also varies
along the length of sole 14. The thickness of the flange at the top
portion in FIGS. 10-16 is identified by T1, T2, T3, T4, T5, T6, and
T7, respectively. Like the inner radii, the thicknesses of the
flange member on both the left and right sides of FIGS. 10-16 are
preferably the same. The variation in thickness of the flange
member can provide for reinforcement of the flange member at the
areas that are most susceptible to failure due to the exertion of
higher forces during wear.
[0057] In one embodiment, in a U.S. size 9 shoe, the thickness of
the flange member 26 varies as follows: T1=0.8 mm; T2=1.0 mm;
T3=1.0 mm; T4=1.0 mm; T5=0.8 mm; T6=0.8 mm; and T7=0.8 mm.
[0058] In another embodiment, referring again to FIGS. 8 and 10-16,
a U.S. size 7 shoe can have the following radii and thicknesses:
R1=4 mm; R2=6 mm; R3=9 mm; R4=12 mm; R5=10 mm; R6=10; R7=8 mm; R8=9
mm; R9=6.5 mm; T1=0.8 mm; T2=0.8 mm; T3=0.8 mm; T4=0.8 mm; T5=0.8
mm; T6=0.8 mm; and T7=0.8 mm.
[0059] Flange member 26 is desirably positioned so that the inner
side of flange member 26 is just lightly resting against the
outside of a wearer's foot. The variation in inner radii, as
discussed above, desirably takes into account the anatomy of the
wearer's foot.
[0060] FIG. 17 shows another embodiment where a fabric or cloth
material is positioned between the flange attachment portion and
the flange member. The fabric or cloth material disposed between
the flange attachment portion and the flange member can be any of a
variety of natural and synthetic fiber materials, such as, for
example, cotton, nylon, or polyester.
[0061] FIG. 17 is a cross section view of a shoe 10 taken along a
central portion of the shoe, similar to the view shown in FIG. 12
and further including an upper attached to the sole. As shown in
FIG. 17, it may be desirable to include a piece of fabric 42
between flange attachment portion 33 of upper 12 and flange member
26. Fabric 42 can increase the strength of the attachment of the
upper 12 to flange member 26, and reduce the likelihood of tears or
rips occurring in the flange member 26. In addition, if tears or
rips should occur, fabric 42 can reduce the likelihood that such
tears or rips will spread or propagate through flange member 26.
Fabric 42 can run around the entire flange member 26 or,
alternatively, the fabric can be placed at intermittent locations
around flange member 26. For example, it may be desirable to place
fabric 42 at locations in the forefoot where increased stress may
be exerted on the upper to flange member connection. Fabric 42 can
be any thin or light fabric, such as, for example, a light twill
fabric.
[0062] The novel method of manufacturing a shoe that comprises an
upper attached directly to an integral flange on a sole formed of
EVA material has numerous advantages. The method eliminates many of
the traditional steps required for manufacturing closed form shoes,
such as attaching the upper to an insole or other type of shoe
liner. Instead, the upper can be stitched directly to the flange,
either by hand or machine, without requiring any extra materials or
labor-intensive steps.
[0063] The reduction of materials can also be significant. First,
there is no insole board or sock material associated with the
manufacture of the shoe. Thus, that material can be eliminated. In
addition, since the upper can be shorter than a traditional upper,
the amount of material required to produce an upper is reduced. As
noted above, the upper does not wrap around an insole; rather, it
sits on a ledge outside of the flange member. As such, less upper
material is required to produce a finished product. The elimination
of the insole and lasting step also eliminates or greatly reduces
the amount of adhesive that is required to manufacture the closed
form shoe.
[0064] The EVA sole is both comfortable and light-weight. By
eliminating the materials discussed above, the overall weight of
the shoe can be reduced without sacrificing comfort or stability of
the shoe. In addition, EVA has little or no odor, is resistant to
UV radiation, and has good barrier properties, which prevents water
and other harmful or odorous liquids or vapors from being absorbed
by the sole. In addition, EVA is highly resistant to cracks and has
good anti-microbial properties.
[0065] Various alternatives of the configurations disclosed above
are possible without departing from the scope of the invention. For
example, the water draining openings, holes, and pathways could be
configured differently and located at other locations in the
sole.
[0066] In view of the many possible embodiments to which the
principles of the disclosed invention may be applied, it should be
recognized that the illustrated embodiments are only preferred
examples of the invention and should not be taken as limiting the
scope of the invention. Rather, the scope of the invention is
defined by the following claims. We therefore claim as our
invention all that comes within the scope and spirit of these
claims.
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