U.S. patent application number 12/697206 was filed with the patent office on 2010-08-05 for composite sole.
This patent application is currently assigned to DASHAMERICA, INC. D/B/A PEARL IZUMI USA, INC., DASHAMERICA, INC. D/B/A PEARL IZUMI USA, INC.. Invention is credited to Mark Kerns, Christopher J. King, Philip Majure, Kurtis Sakai, Tony L. Torrance.
Application Number | 20100192421 12/697206 |
Document ID | / |
Family ID | 42396518 |
Filed Date | 2010-08-05 |
United States Patent
Application |
20100192421 |
Kind Code |
A1 |
Kerns; Mark ; et
al. |
August 5, 2010 |
COMPOSITE SOLE
Abstract
The invention relates to a composite sole for a shoe, more
particularly to an insert adhesively laminated to one or both of
opposing upper and lower component to form the sole of an athletic
shoe. The insert is adhesively incompatible with the upper and
lower sole components and an adhesion promoter may be positioned
between the insert and at least one of the upper and lower sole
components to adhesively bond the insert to at least one or both of
the upper and lower sole components.
Inventors: |
Kerns; Mark; (Golden,
CO) ; King; Christopher J.; (Boulder, CO) ;
Sakai; Kurtis; (Ventura, CA) ; Torrance; Tony L.;
(Boulder, CA) ; Majure; Philip; (Louisville,
CA) |
Correspondence
Address: |
SHERIDAN ROSS PC
1560 BROADWAY, SUITE 1200
DENVER
CO
80202
US
|
Assignee: |
DASHAMERICA, INC. D/B/A PEARL IZUMI
USA, INC.
Louisville
CO
|
Family ID: |
42396518 |
Appl. No.: |
12/697206 |
Filed: |
January 29, 2010 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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12176883 |
Jul 21, 2008 |
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12697206 |
|
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10710476 |
Jul 14, 2004 |
7401424 |
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12176883 |
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Current U.S.
Class: |
36/3B ; 12/146B;
36/19.5; 36/30R; 36/59R |
Current CPC
Class: |
A43B 7/06 20130101; A43B
13/12 20130101; A43B 5/14 20130101; A43B 13/04 20130101; A43B
13/026 20130101; A43B 13/10 20130101 |
Class at
Publication: |
36/3.B ; 36/59.R;
36/19.5; 36/30.R; 12/146.B |
International
Class: |
A43B 7/06 20060101
A43B007/06; A43C 15/00 20060101 A43C015/00; A43B 13/32 20060101
A43B013/32; A43B 13/12 20060101 A43B013/12; A43D 8/00 20060101
A43D008/00 |
Claims
1. A composite sole, comprising an insert positioned between upper
and lower materials, wherein the insert is adhesively incompatible
with the upper and lower materials, wherein the upper and lower
materials are adhesively bonded together, wherein an adhesion
promoter is positioned between the insert and at least one of the
upper and lower materials to adhesively bond the insert to at least
one of the upper and lower materials.
2. The composite sole of claim 1, wherein the upper and lower
materials comprise a polymer material and wherein the insert
comprises a metal or metal alloy.
3. The composite sole of claim 2, wherein the insert comprises one
of: titanium, a titanium alloy, magnesium, a magnesium alloy,
aluminum, or aluminum alloys.
4. The composite sole of claim 2, wherein the polymeric material
comprises one of a thermosetting and/or thermoplastic resin.
5. The composite sole of claim 3, wherein the thermosetting resin
is substantially at least mostly, if not completely, a C-staged
thermosetting resin.
6. The composite sole of claim 1, wherein the upper and lower
materials are carbon fiber laminates.
7. The composite sole of claim 1, wherein the insert is chemically
and/or mechanically adhesively bonded to one or both of upper and
lower materials and wherein the upper material is chemically and/or
mechanically adhesively bonded to the lower material.
8. The composite sole of claim 7, wherein the adhesion promoter is
chemically and/or adhesively bonded to the insert and at least one
of the upper and lower materials.
9. The composite sole of claim 1, wherein individually and
separately the upper and lower materials comprise a homopolymer,
copolymer and/or polymer alloy selected from the group of polymers
consisting of polyolefins, polystyrenes, polyvinyls, polyacrylics,
polyhalo-olefins, polydienes, polyoxides, polyesthers, polyacetals,
polysulfides, polythioesters, polyamides, polythioamides,
polyurethanes, polythiourethanes, polyureas, polythioureas,
polyimides, polythioimides, polyanhydrides, polythianhydrides,
polycarbonates, polythiocarbonates, polyimines, polysiloxanes,
polysilanes, polyphosphazenes, polyketones, polythioketones,
polysulfones, polysulfoxides, polysulfonates, polysulfoamides,
polyphylenes, and combinations and/or mixtures thereof.
10. The composite sole of claim 1, further comprising one or more
of: a) one or more vent ports; b) one or more cleat interconnecting
elements; and c) one or more studs.
11. The composite sole of claim 1, wherein the insert further
comprises one or more tabs extending radially from the insert.
12. The composite sole of claim 11, wherein the composite sole
further comprises opposing interior and exterior surfaces, wherein
insert further comprises interior and exterior portions, wherein
the interior portion of the insert comprises the one or more tabs
positioned between the upper and lower materials and wherein the
exterior portion of the insert comprises the portion of the insert
forming at least a portion of the exterior surface of the composite
sole.
14. A shoe, comprising an upper interconnected to a composite sole
comprising an insert positioned between upper and lower materials,
wherein the insert is adhesively incompatible with the upper and
lower materials, wherein the upper and lower materials are
adhesively bonded together, wherein an adhesion promoter is
positioned between insert and at least one of the upper and lower
materials to adhesively bond the insert to at least one of the
upper and lower materials.
13. A method for making a composite sole, comprising: a) providing
an insert and upper and lower sole materials, wherein the insert is
adhesively incompatible with the upper and lower materials; b)
treating at least one of the insert, the upper material and lower
material with an adhesion promoter; c) positioning in registration,
at least some of the insert between the upper and lower materials
in a mold, wherein the insert positioned in registration with upper
and lower materials forms a composite sole assembly; d) applying at
least one of heat and pressure to the composition sole assembly to
adhesively bond the insert to at least one of the upper and lower
materials to form a composite sole; and e) removing the composite
sole from the mold.
13. The method of claim 12, wherein the insert comprises one of:
titanium, a titanium alloy, magnesium, a magnesium alloy, aluminum,
or aluminum alloys and wherein the polymeric material comprises one
of a thermosetting and/or thermoplastic resin.
14. The method of claim 13, wherein the applied heat and/or
pressure are sufficiently affective to at least mostly, if not
completely, C-stage the thermosetting resin.
15. The method of claim 12, wherein the upper and lower materials
are carbon fiber laminates.
16. The method of claim 12, wherein the adhesion promoter is
chemically and/or adhesively bonded to the insert and at least one
of the upper and lower materials.
17. The method of claim 12, wherein individually and separately the
upper and lower materials comprise a homopolymer, copolymer and/or
polymer alloy selected from the group of polymers consisting of
polyolefins, polystyrenes, polyvinyls, polyacrylics,
polyhalo-olefins, polydienes, polyoxides, polyesthers, polyacetals,
polysulfides, polythioesters, polyamides, polythioamides,
polyurethanes, polythiourethanes, polyureas, polythioureas,
polyimides, polythioimides, polyanhydrides, polythianhydrides,
polycarbonates, polythiocarbonates, polyimines, polysiloxanes,
polysilanes, polyphosphazenes, polyketones, polythioketones,
polysulfones, polysulfoxides, polysulfonates, polysulfo amides,
polyphylenes, and combinations and/or mixtures thereof.
18. The method of claim 12, wherein the insert has one or both of
a) one or more vent ports and b) one or more cleat interconnecting
elements; and wherein one or more studs are formed on the composite
sole during the step d).
19. The method of claim 12, wherein the insert further comprises
one or more tabs extending radially from the insert.
20. The method of claim 19, wherein the composite sole further
comprises opposing interior and exterior surfaces, wherein insert
further comprises interior and exterior portions, wherein the
interior portion of the insert comprises the one or more tabs
positioned between the upper and lower materials and wherein the
exterior portion of the insert comprises the portion of the insert
forming at least a portion of the exterior surface of the composite
sole.
Description
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application is a continuation-in-part of U.S. patent
application Ser. No. 12/176,883, filed on Jul. 21, 2008, which is a
continuation of U.S. patent application Ser. No. 10/710,476, filed
on Jul. 14, 2004 now U.S. Pat. No. 7,401,424 both entitled
"Composite Outsole." Each of these patents is hereby incorporated
by reference in its entirety.
FIELD OF INVENTION
[0002] The present invention relates to a composite sole for a
shoe, more particularly to an insert component laminated to one or
both of opposing upper and lower sole components.
BACKGROUND OF THE INVENTION
[0003] Shoe soles have been improved and specialized for years.
Currently, specialized shoe soles are provided for many athletic
shoes, such as running, tennis, cycling, football, golf, track and
field, baseball, walking, cross-training, shoes for use in
inclement weather, etc. Accordingly, the sole of a shoe is
typically designed for the intended use of the shoe. For example,
running shoes are designed with vibration absorbing soles, while
cycling shoes are fabricated to include rigid soles, which are
designed for efficient energy transfer from the foot of the cyclist
to the bicycle.
[0004] Despite previous improvements in sole construction and
specialization, methods for addressing sole construction and for
making the same continue to improve. For example, in the area of
cycling, a continued need exists for lighter weight, more rigid
cycling soles and efficient and effective ways of making these
soles and the cycling shoes that include these soles. Thus, an
improved cycling shoe sole that increases sole rigidly and/or
reduces sole weight is desirable.
[0005] Embodiments of the present invention describe such improved
soles for cycling shoes and cycling shoes incorporating the
improved soles.
SUMMARY OF INVENTION
[0006] The present invention is directed generally to a composite
sole for shoes, and preferably for athletic shoes, and most
preferably for bicycling shoes.
[0007] It is one aspect of the present invention to provide a
composite sole comprising incompatible first and second materials
that differ in composition. More specifically, by "incompatible" it
is meant that it is substantially difficult to adhesively bond the
first and second materials together.
[0008] It is another aspect of the present invention to provide a
composite sole comprising an insert, an upper material, and a lower
material. The upper and lower materials differ in composition from
the insert. The compositions of the insert and the upper and lower
materials substantially differ, such that an adhesion promoter is
used to bond the insert to one or both of the upper and lower
materials to form a composite sole.
[0009] More specifically, a preferred embodiment of the present
invention is a composite sole comprising an insert positioned
between upper and lower materials, wherein the insert is adhesively
incompatible with the upper and lower materials and the upper and
lower materials are adhesively bonded together. An adhesion
promoter is positioned between the insert and at least one of the
upper and lower materials to bond the insert to at least one of the
upper and lower materials. The composite sole further comprises
opposing interior and exterior surfaces. The insert also optionally
comprises interior and exterior portions. The optional exterior
portion of the insert may form at least a portion of the exterior
surface of the composite sole. Preferably, the insert is chemically
and/or mechanically bonded to one or both of upper and lower
materials and the upper material is chemically and/or mechanically
bonded to the lower material. More preferably, the adhesion
promoter is chemically and/or adhesively bonded to the insert and
at least one of the upper and lower materials.
[0010] In a preferred embodiment, the composite sole comprises the
insert adhesively bonded to the upper and lower materials.
Furthermore, the upper and lower materials may be bonded together.
The composite sole may be formed by adhesively bonding at least
some of the insert between the upper and lower materials. That is,
in this embodiment, the composite sole has at least some of the
insert positioned between the upper and lower materials. The
portion of the insert positioned between upper and lower materials
forms an interior portion of the insert, while a portion of the
insert that is not positioned between the upper and lower materials
forms an exterior portion of the insert.
[0011] In some of these embodiments of the present invention, the
insert has a perimeter comprising one or more tabs. The one or more
tabs may extend radially from the insert in the form of arms. The
one or more tabs may be positioned substantially uniformly around
the entire perimeter of the insert. In some related configurations,
the one or more tabs may extend from some portions of, but not the
entire perimeter of, the insert. In yet other related
configurations, the one or more tabs may extend from the insert in
a manner resembling a symmetrical arrangement (given the
asymmetrical nature of the sole of a shoe). Preferably, the one or
more tabs are positioned between the upper and lower materials.
More preferably, the one or more tabs are positioned between the
upper and lower materials and the portion of the insert that is
free of tabs forms an exterior portion of the insert.
[0012] In some of these embodiments, the exterior portion of the
insert may comprise at least some, if not most, of the exterior
portion of the composite sole and the insert may optionally contain
one or more vent ports. Preferably, the exterior portion of the
insert contains some, if not most or all of the one or more vent
ports. The one or more vent ports comprise voids and traverse the
insert. Optionally, at least some, if not all, of the one or more
vent ports may comprise voids that traverse the composite sole. The
insert may optionally also contain one or more cleat
interconnecting elements for attaching one or more cleats to the
composite sole. It can be appreciated that a single cleat may
require the one or more cleat interconnecting elements to connect
the cleat to the composite sole (such as in the case of a cycling
cleat) or that each of several cleat interconnecting elements will
accept a single cleat (as in the case of a football shoe).
[0013] The insert may comprise without limitation, a metal or metal
alloy (such as, but not limited to titanium and its alloys, iron
and its alloys, magnesium and its alloys, aluminum and its alloys),
a polymeric material (such as, without limitation, rubber,
poly(acrylonitrile, butadiene styrene), polyvinyl chloride,
ethylene vinyl acetate, polyurethane), and/or a polymeric laminate
(such as, without limitation, laminates comprising one or more of
carbon fibers, Kevlar.TM., aluminum, steel, and/or fiberglass with
an epoxy, polyester, vinyl ester, and/or nylon resin). In a
preferred embodiment, the insert comprises a metal or a metal
alloy. In a more preferred embodiment, the metal comprises titanium
or a titanium alloy. In another embodiment, the insert comprises a
polymeric laminate. In a preferred embodiment, the insert comprises
a substantially rigid material. In a more preferred embodiment, the
insert comprises a light-weight material having substantial
rigidity. The rigidity of insert can be expressed in terms of one
or more of yield strength, tensile strength and/or modulus of
elasticity, while the light-weight character of the insert can be
expressed in terms of density.
[0014] The yield strength of the insert can range from about 100
MPa to about 1200 MPa. Preferably, the yield strength can range
from about 200 MPa to about 1000 MPa. More preferably, the yield
strength can range from about 400 MPa to about 900 MPa.
[0015] The tensile strength of the insert can range from about 100
MPa to about 10,000 MPa, preferably from about 300 MPa to about
8000 MPa. More preferably, the tensile strength of the insert can
range from about 800 MPa to about 7000 MPa.
[0016] The modulus of elasticity of the insert can range from about
3 GPa to about 450 GPa. Preferably, the modulus of elasticity can
range from about 40 GPa to about 120 GPa. Even more preferably, the
modulus of elasticity of the insert can range from about 100 GPa to
about 115 GPa.
[0017] The density of the insert can range from about 1 g/cc to
about 5 g/cc. Preferably, the density of the insert is from about
1.5 g/cc to about 4 g/cc. More preferably, the density is from
about 2 g/cc to about 4 g/cc. Even more preferably, the density is
about 4 g/cc.
[0018] The upper and lower materials may comprise without
limitation, a polymeric material (such as, without limitation,
rubber, poly(acrylonitrile, butadiene styrene), polyvinyl chloride,
ethylene vinyl acetate, polyurethane), and/or a polymeric laminate
(such as, without limitation, laminates comprising one or more of
carbon fibers, Kevlar.TM., aluminum, steel, and/or fiberglass with
an epoxy, polyester, vinyl ester, and/or nylon). The polymeric
material may comprise one of a thermosetting resin, a thermoplastic
resin, or a combination thereof.
[0019] In a preferred embodiment, the upper and lower materials
comprise a polymeric laminate. In a more preferred embodiment, the
polymeric laminate comprises a fiber-reinforced laminate comprising
carbon fibers and a resin. Preferably, the fiber-reinforced
laminate comprises an A- and/or B-staged thermosetting resin. That
is, the fiber reinforced laminate is not completely C-staged.
However, in a preferred embodiment of the present invention, the
upper and lower materials of the composite sole comprise at least
mostly, if not completely, C-staged thermosetting resins.
[0020] Preferably, the upper and lower materials have substantially
similar compositions. More preferably, the upper and lower
materials have substantially identical compositions. That is, the
upper and lower materials substantially comprise the same
fiber-reinforced laminates having substantially similar, if not
identical, fiber reinforcements and resins. In other embodiments,
one or both of the fiber reinforcements and/or resins of the upper
and lower materials are different.
[0021] In yet other embodiments, one of the upper or lower
materials may comprise a fiber laminate, while the other of the
upper or lower materials can comprise a polymeric material lacking
fiber reinforcement. The resins comprising the upper and lower
materials can be the same or different resins.
[0022] In a preferred embodiment, the upper and lower materials
comprise thermosetting resins that chemically react to at least
substantially cross-link and/or chemically bond the upper and lower
materials together. That is, the upper and lower materials bond,
one to the other, without the use of adhesive. Stated another way,
the bond of the upper material to the lower material is
substantially free of an adhesive. The composite sole of these
embodiments comprises thermosetting upper and lower materials that
at least mostly, if not completely, cross-link, one with the other.
Preferably, the upper and lower materials comprise C-stage
thermosetting materials that are substantially, if not completely,
cross-linked together. Furthermore, one or both of the upper and
lower materials are one or both of chemically and/or mechanically
bonded to at least some of the insert. The chemical and/or
mechanical bond linking one or both of the upper and lower
materials with the insert comprises the reaction product of the
adhesion promoter with the insert and one or both of upper and
lower surfaces. Similarly, the chemical and/or mechanical bonding
of the insert with one or both of the upper and lower materials
further comprises the chemical and/or mechanical interaction of the
insert with one or both of upper and/or lower materials. In a
preferred embodiment, the upper and lower materials comprising the
composite sole are chemically cross-linked together, and to the
insert, to form a single adhesively-bonded composite sole.
Furthermore, the insert is chemically and/or mechanically bonded to
the cross-linked upper and lower materials.
[0023] In another embodiment, one or both of the upper and lower
materials can comprise a thermoplastic material. The one or more
thermoplastic upper and lower materials can be adhesively bonded
together by flowing and/or intermixing together when heat and/or
pressure are applied during the adhesive bonding process.
Furthermore, the insert can be adhesively bonded to the one or more
thermoplastic materials by the adhesion promoter in at least one of
a chemical and/or mechanical adhesion process. That is, when at
least one of the upper and lower materials comprises a
thermoplastic material, the upper and lower materials bond, one to
the other, without the use of adhesive. Stated another way, the
bond of the upper material to the lower material is substantially
free of an adhesive.
[0024] It is another aspect of the present invention to provide a
method for bonding first and second materials together to form a
composite sole. In these embodiments, a first material, comprising
one of the insert, upper material or lower material, and a second
material, comprising one of the insert, upper material or lower
material, are adhesively bonded to form a composite sole. More
specifically, the method comprises adhesively bonding the insert
and the upper and/or lower materials together to form the composite
sole. Preferably, the adhesive bonding process further comprises an
adhesion promoter. The adhesion promoter modifies one or more of
the insert, upper material and lower material to facilitate bonding
of at least one of the insert, upper material, and/or lower
material without the use of an adhesive. That is, the adhesion
promoter chemically and/or mechanically modifies one or more of the
insert, the upper material and lower material to achieve bonding of
the insert, upper material and lower materials together,
substantially free of an adhesive. Stated another way, the adhesion
promoter modifies at least one of the insert, upper material, and
lower material, such that the least one of the insert, upper
material, and lower material may bond with at least one of another
of the insert, upper material, and lower material.
[0025] In a preferred embodiment related to this aspect of the
invention, the adhesion promoter is positioned adjacent to and/or
between the first and second materials. The adhesion promoter
modifies at least one of the first and second materials such that
at least one of the first and second materials may bond to the
other of the first and second materials to form an adhesive
assembly having an adhesive bond strength that is greater with the
adhesion promoter than without the adhesion promoter. The adhesion
promoter may be applied to one or both of the first and second
materials prior to and/or simultaneously with contacting of the
first and second materials. More preferably, the adhesive bonding
process further comprises a lamination process comprising applying
one or both of heat and pressure to an assembly comprising the
insert and the upper and lower materials.
[0026] In one embodiment, the adhesion promoter chemically reacts
with one or both of the first and second materials to chemically
bond the first and second materials together. That is, the first
material and the second materials are at least partially bonded
together by a chemical process comprising a reaction product formed
by the chemical reaction between the adhesion promoter with one or
both of the first and second materials.
[0027] In another embodiment, the adhesion promoter interacts with
one or both of the first and second materials to increase adhesive
bond strength by one or more of a mechanical (such as, but not
limited to mechanical interlocking), chemical (such as, but not
limited to chemical bonding) and/or physical (such as, but not
limited to electrical, van der Waals and/or London forces)
processes. It can be appreciated that the adhesion promoter may
refer to a composition of matter (such as, but limited to silane,
titanate, or zirconate coupling agents), to a process (such as
abraiding, ionizing or chemically functionalizing one or both of
the first and second material surfaces), or a combination of
both.
[0028] In a preferred embodiment, the adhesion promoter comprises a
chemical entity described by the following chemical formula:
X--R--Y (1)
wherein, X depicts a chemical entity that chemically reacts with
the insert to form a chemical bond with the insert. A non-limiting
example of the chemical entity X is a silicon or polysiloxane
entity comprising one or more --Si--O-- entities. While not wanting
to be limited by theory, it is believed that the one or more
--Si--O-- can chemically react with a titanium surface to form a
Ti--O--Si-- linkage. X may also comprise --Ti--O-- and/or --Zr--O--
entities that respectively form linkages comprising Ti--O--Ti--
and/or Ti--O--Zr--. In a similar manner, the X entity can react
with the insert surface to form a linkage substantially comprising
one of --Si--O-insert, --Ti--O-insert, and/or --Zr--O-insert
linkages.
[0029] Y depicts a chemical entity that chemically reacts and/or
interacts with one or both of the upper and lower materials to form
a chemical bond with one or both of the upper and lower materials.
It can be appreciated that the Y entity can vary depending on the
chemical composition of the upper and/or lower materials. For
example, if one or both of the upper and lower materials comprise
an epoxy, the Y entity would preferably comprise an epoxy
cross-linking entity, such as, but not limited to, amine and/or
mercapto functionalities.
[0030] R depicts a hydrocarbon entity. The hydrocarbon entity can
be linear, branched, and/or cyclic. Furthermore, the hydrocarbon
can be saturated or unsaturated, the unsaturated hydrocarbon can be
conjugated, non-conjugated, or a combination thereof.
[0031] Non-limiting examples of suitable adhesion promoters having
the chemical formula of X--R--Y are: vinyl silianes, epoxy
silianes, methacryl silianes, amino silianes, mercapo silianes,
ureido silianes, monoalkoxy titanates, chelate titanates,
quaternary titanates, neoalkoxy titantes, cycloheteroatom
titanates, coordination zirconates, neoalkoxy zirconates, zirconium
propionates, zirconaluminates, zirconium acetylacetones, zirconium
methacrylates and mixtures thereof.
[0032] In a related embodiment, the adhesion promoter may comprise
a composition that forms one or more of the following on the insert
surface: hydroxyapatite-containing coating, a sol-gel-containing
coating, a phosphate-containing coating, and/or an
acetylacetone-containing coating. Such coatings can improve the
adhesion of the insert to one or both of the upper and lower
materials.
[0033] Another aspect of the present invention is a shoe comprising
the composite sole embodiments described above. More specifically,
a shoe comprising an upper interconnected to a composite sole
comprising an insert positioned between upper and lower materials,
wherein the insert is adhesively incompatible with the upper and
lower materials, wherein the upper and lower materials are
adhesively bonded together. In one embodiment, an adhesion promoter
is positioned between the insert and at least one of the upper and
lower materials to bond the insert to at least one of the upper and
lower materials. In a preferred embodiment, the shoe comprises an
athletic shoe having the composite sole of the present invention.
In a more preferred embodiment, the shoe comprises a cycling shoe
having the composite sole of the present invention. In an even more
preferred embodiment, the cycling shoe further comprises a titanium
insert. Optionally, these embodiments may include cleat
interconnecting elements for attaching one or more cleats to the
composite sole of the shoe.
[0034] Another aspect of the present invention is a method of
making a composite sole comprising: a) providing an insert and
upper and lower sole materials, wherein the insert is adhesively
incompatible with the upper and lower materials; b) treating at
least one of the insert, the upper material and lower material with
an adhesion promoter; c) positioning in registration, at least some
of the insert between the upper and lower materials in a mold,
wherein the insert positioned in registration with upper and lower
materials forms a composite sole assembly; d) applying at least one
of heat and pressure to the composition sole assembly to adhesively
bond the insert to at least one of the upper and lower materials to
form a composite sole; and e) removing the composite sole from the
mold. Preferably, the applied heat and/or pressure are sufficiently
affective to at least mostly, if not completely, C-stage the
thermosetting resin.
[0035] As use herein, "polymeric material" means any homopolymer,
copolymer and/or polymer alloy comprising one or more of
polyolefins, polystyrenes, polyvinyls, polyacrylics,
polyhalo-olefins, polydienes, polyoxides, polyesthers, polyacetals,
polysulfides, polythioesters, polyamides, polythioamides,
polyurethanes, polythiourethanes, polyureas, polythioureas,
polyimides, polythioimides, polyanhydrides, polythianhydrides,
polycarbonates, polythiocarbonates, polyimines, polysiloxanes,
polysilanes, polyphosphazenes, polyketones, polythioketones,
polysulfones, polysulfoxides, polysulfonates, polysulfoamides,
polyphylenes, and combinations and/or mixtures thereof.
[0036] As used herein, "A-stage" means an early stage in the
reaction of certain thermosetting resins in which the resin is
fusible and still soluble in certain liquids.
[0037] As used herein, "B-stage" means an intermediate stage in the
reaction of certain thermosetting resins in which the resin softens
when heated and swells when in contact with certain liquids, but
may not entirely fuse or dissolve.
[0038] As used herein, "C-stage" means the final stage in the
reaction of certain thermosetting resins in which the material is
relatively insoluble and infusible.
[0039] As used herein, a "thermosetting resin" is usually in an
uncured stage when in the A- and/or B-stage and the thermosetting
resin is fully cured when in the C-stage.
[0040] As used herein, "bond strength" means the unit load applied
in one or more of tension, compression, flexure, peel, impact,
cleavage, or shear, required to break an adhesive assembly with
failure occurring in or near the adhesive bond comprising the
adhesive assembly.
[0041] As used herein, the term "a" or "an" entity refers to one or
more of that entity. As such, the terms "a" (or "an"), "one or
more" and "at least one" can be used interchangeably herein. It is
also to be noted that the terms "comprising", "including", and
"having" can be used interchangeably. The terms "at least one",
"one or more", and "and/or" are open-ended expressions that are
both conjunctive and disjunctive in operation. For example, each of
the expressions "at least one of A, B and C", "at least one of A,
B, or C", "one or more of A, B, and C", "one or more of A, B, or C"
and "A, B, and/or C" means A alone, B alone, C alone, A and B
together, A and C together, B and C together, or A, B and C
together.
[0042] The preceding is a summary of the invention to provide an
understanding of some aspects of the invention. This summary is
neither an extensive nor exhaustive overview of the invention and
its various embodiments. It is intended neither to identify key or
critical elements of the invention nor to delineate the scope of
the invention but to present selected concepts of the invention in
a simplified form as an introduction to the more detailed
description presented below. As will be appreciated, other
embodiments of the invention are possible utilizing, alone or in
combination, one or more of the features set forth above or
described in detail below.
BRIEF DESCRIPTION OF DRAWINGS
[0043] The accompanying drawings, which constitute a part of this
specification, illustrate embodiments of the present invention, and
together with the description, serve to explain the principles
thereof. Like items in the drawings are referred to using the same
numerical reference.
[0044] FIG. 1 is a side elevation view of a composite sole
consistent with an embodiment of the present invention;
[0045] FIG. 2 is a bottom plan view of the composite sole of FIG. 1
consistent with an embodiment of the present invention;
[0046] FIG. 3 is a side-by-side exploded view of the lower material
and the insert of the composite sole of FIG. 1 consistent with an
embodiment of the present invention;
[0047] FIG. 4 is a cross-sectional view the composite sole of FIG.
1 consistent with an embodiment of the present invention; and
[0048] FIG. 5 depicts a process for making a composite sole of an
embodiment of the present invention.
DETAILED DESCRIPTION
[0049] The present invention will now be described with reference
to FIGS. 1-5. While the present invention is described with
reference to a composite sole, a person of ordinary skill in the
art will recognize on reading this disclosure, that the composite
sole could be used with other shoes, such as, for example, track
and filed shoes, baseball shoes, football shoes, snow and/or ice
shoes, soccer shoes, golf shoes, therapy shoes, or other such
shoes. The examples of other shoes are exemplary and
non-limiting.
[0050] A composite sole 300 is depicted in FIGS. 1, 2 and 4. The
composite sole 300 comprises an insert 304 and upper 301 and lower
302 materials. The composite sole 300 further has opposing interior
320 and exterior 325 surfaces and may optionally have one or more
studs 306 extending from the exterior surface 325. The one or more
studs 306 may be formed in the composite sole during forming of the
composite sole 300 or may be attached to composite sole 300 by any
technique well known within the art. The one or more studs 306 may
be attached to insert 304 and/or to the upper 301 and/or lower 302
materials.
[0051] In one embodiment, the upper 301 and lower 302 materials
individually and separately comprise a homopolymer, copolymer
and/or polymer alloy selected from the group of polymers consisting
of polyolefins, polystyrenes, polyvinyls, polyacrylics,
polyhalo-olefins, polydienes, polyoxides, polyesthers, polyacetals,
polysulfides, polythioesters, polyamides, polythioamides,
polyurethanes, polythiourethanes, polyureas, polythioureas,
polyimides, polythioimides, polyanhydrides, polythianhydrides,
polycarbonates, polythiocarbonates, polyimines, polysiloxanes,
polysilanes, polyphosphazenes, polyketones, polythioketones,
polysulfones, polysulfoxides, polysulfonates, polysulfoamides,
polyphylenes, and combinations and/or mixtures thereof.
[0052] The composite sole 300 can be contoured similar to a
conventional shoe sole. Preferably, the composite sole 300 is
contoured similar to a conventional bicycling shoe sole. More
preferably, the composite sole 300 is contoured similar to
bicycling sole selected from the group of bicycling soles
consisting of mountain bicycling soles and road bicycling
soles.
[0053] The composite sole 300 may optionally have one or more vent
ports 402. The one or more vent ports 402 comprise voids. The voids
may traverse the insert 304. In another embodiment, the one or more
vent ports 402 may optionally traverse the composite sole 300 and
extend from the interior 320 to the exterior 325 surfaces. That is,
the one or more vent ports extend through the upper 301 and lower
302 materials and the insert 304. The one or more vent ports 402
can be located anywhere on the composite sole 300. Preferably, the
one or more vent ports 402 are located on the insert 304. The vent
ports may have any shape. Moreover, the one or more vent ports 304
can vary in size. That is, the size of the one or more vent ports
402 can differ from one another.
[0054] The composite sole 300 may have one or more cleat
interconnecting elements for attaching one or more cleats to the
composite sole. It can be appreciated that, one or more cleat
interconnecting elements may be required to attach a single cleat
to the composite sole 300. While in other configurations of the
present invention, each of the one or more cleat interconnecting
elements each accepts a single cleat. Furthermore, it can be
appreciated that the location of the one or more interconnecting
elements on the composite sole 300 depends on the use and function
of the composite sole 300. For example, the placement and number of
the one or more interconnecting elements for a cycling composite
sole 300 differ in the placement and number of the one or more
interconnecting elements for a football, or golf, or inclement
weather composite sole 300.
[0055] In a preferred embodiment, the insert 304 has a perimeter
514 having one or more tabs 502 extending radially from the insert
304. The one or more tabs 502 are in the form of arms extending
from the insert 304. The one or more tabs 502 may be positioned
substantially uniformly around the perimeter 514 of the insert 304.
The one or more tabs 502 may extend from some portions but not
other portions of the perimeter 514.
[0056] Reference is now made to FIG. 5 which depicts a process for
making a composite sole. In step 1, an insert is provided. The
insert may or may not have been treated with an adhesion promoter
treatment. If the insert lacks an adhesion promoter, step 1 may
optionally include treating at least some of the insert with an
adhesion promoter. Preferably, at least some of the insert may be
treated with an adhesion promoter. Preferably at least most, if not
all, of the one or more tabs may be treated with the adhesion
promoter. As described above, the adhesion promoter may comprise a
chemical composition that chemically reacts with the insert.
Furthermore, the adhesion promoter may comprise one or more of a
chemical element and/or a physical process that increases the
adhesive bond strength between the insert and one or both of the
upper and lower materials by a chemical (such as for example, by
one or more of covalent, hydrogen, and/or ionic bonds and/or by
electrostatic and/or dispersive forces and/or interactions, such
as, van der Waals and/or London forces) and/or a mechanical (such
as for example by mechanical interaction) processes.
[0057] In step 2, the upper and lower materials are provided. When
at least some of the insert forms a portion of the exterior
surface, the lower material has a void substantially corresponding
in shape and area to the portion of the insert forming the exterior
surface. The upper and lower may comprise two separate entities or
may comprise a single entity that folds over on itself and/or has a
void for accepting the insert.
[0058] In step 3, the upper and lower materials and the insert are
positioned substantially in registration with one another in a
mold. The insert and the upper and lower materials can be
positioned in the mold sequentially or substantially
simultaneously. The insert is positioned between, and in contact
with, the upper and lower materials. When the lower material
contains one or more voids, the insert is contacted substantially
in registration with the void(s). In one configuration, the insert
and the upper and lower materials are contacted in registration
prior to positioning within the mold.
[0059] In step 4, one or both of heat and pressure are applied to
the insert and upper and lower materials positioned within the
mold. One or both of heat and pressure are applied for a
substantial period of time to adhesively bond the insert to the
upper and lower materials and to adhesively bond the upper and
lower materials to one another.
[0060] In step 5, the composite sole is removed from the mold. The
composite sole may be removed from the mold while still hot from
the heat applied in step 4. In another embodiment, the composite
sole may be cooled before removing from mold. In one embodiment,
the composite sole may be attached to a shoe upper to form a shoe.
In another embodiment, the composite sole may be provided to a
vendor for fabricating a shoe therefrom.
[0061] The present invention, in various embodiments, includes
components, methods, processes, systems and/or an apparatus
substantially as depicted and described herein, including various
embodiments, subcombinations, and subsets thereof. Those of skill
in the art will understand how to make and use the present
invention after understanding the present disclosure. The present
invention, in various embodiments, includes providing devices and
processes in the absence of items not depicted and/or described
herein or in various embodiments hereof, including in the absence
of such items as may have been used in previous devices or
processes, e.g., for improving performance, achieving ease and\or
reducing cost of implementation.
[0062] The foregoing discussion of the invention has been presented
for purposes of illustration and description. The foregoing is not
intended to limit the invention to the form or forms disclosed
herein. In the foregoing Detailed Description for example, various
features of the invention are grouped together in one or more
embodiments for the purpose of streamlining the disclosure. The
features of the embodiments of the invention may be combined in
alternate embodiments other than those discussed above. This method
of disclosure is not to be interpreted as reflecting an intention
that the claimed invention requires more features than are
expressly recited in each claim. Rather, as the following claims
reflect, inventive aspects lie in less than all features of a
single foregoing disclosed embodiment. Thus, the following claims
are hereby incorporated into this Detailed Description, with each
claim standing on its own as a separate preferred embodiment of the
invention.
[0063] Moreover, though the description of the invention has
included description of one or more embodiments and certain
variations and modifications, other variations, combinations, and
modifications are within the scope of the invention, e.g., as may
be within the skill and knowledge of those in the art, after
understanding the present disclosure. It is intended to obtain
rights which include alternative embodiments to the extent
permitted, including alternate, interchangeable and/or equivalent
structures, functions, ranges or steps to those claimed, whether or
not such alternate, interchangeable and/or equivalent structures,
functions, ranges or steps are disclosed herein, and without
intending to publicly dedicate any patentable subject matter.
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