U.S. patent application number 12/589227 was filed with the patent office on 2011-04-21 for fabric footwear outsole and method of manufacturing same.
This patent application is currently assigned to Jimlar Corporation. Invention is credited to Hyun Ho Park.
Application Number | 20110088288 12/589227 |
Document ID | / |
Family ID | 43878204 |
Filed Date | 2011-04-21 |
United States Patent
Application |
20110088288 |
Kind Code |
A1 |
Park; Hyun Ho |
April 21, 2011 |
Fabric footwear outsole and method of manufacturing same
Abstract
The method for fabricating the fabric footwear outsole begins by
forming a rubber outsole base with an unfinished exterior surface
section. A non-woven fabric sheet and an unvulcanized rubber sheet
are separately formed and joined together. The sheets are cut to
the shape of the unfinished exterior surface section of the base to
form a fabric member. The fabric member is joined to the unfinished
exterior surface section of the base by glue. Thereafter, the
rubber outsole base and the fabric member assembly are heated to
vulcanize the rubber sheet and to securely and permanently attach
the fabric member to the outsole.
Inventors: |
Park; Hyun Ho; (Yongin,
KR) |
Assignee: |
Jimlar Corporation
|
Family ID: |
43878204 |
Appl. No.: |
12/589227 |
Filed: |
October 20, 2009 |
Current U.S.
Class: |
36/25R ;
12/146B |
Current CPC
Class: |
B29D 35/142 20130101;
A43D 29/00 20130101; A43B 13/122 20130101; A43B 13/04 20130101;
A43D 8/04 20130101 |
Class at
Publication: |
36/25.R ;
12/146.B |
International
Class: |
A43B 13/14 20060101
A43B013/14; A43D 8/00 20060101 A43D008/00 |
Claims
1. A method of fabricating an outsole comprising the steps of: (a)
forming a rubber outsole base with an unfinished exterior surface
section; (b) forming a non-woven fabric sheet; (c) forming an
unvulcanized rubber sheet; (d) joining the sheets; (e) cutting the
joined sheets to the shape of the unfinished exterior surface
section to form a fabric member; (f) joining the fabric member to
the unfinished exterior surface section of said base to form an
assembly; and (g) heating the assembly to vulcanize the rubber
sheet and permanently secure the fabric member to said base to form
the outsole.
2. The method of claim 1 wherein the step of forming the rubber
outsole base comprises the step of forming the rubber outsole base
with a finished exterior surface section.
3. The method of claim 1 wherein the step of forming the rubber
outsole base comprises the step of forming the rubber base with a
finished exterior surface section proximate the unfinished exterior
surface section.
4. The method of claim 1 wherein the step of joining the rubber
sheet and the fabric sheet comprises the step of cementing the
sheets together.
5. The method of claim 1 wherein the step of joining the rubber
sheet and the fabric sheet comprises squeezing the sheets
together.
6. The method of claim 4 wherein the step of joining the rubber
sheet and the fabric sheet further comprises squeezing the sheets
together.
7. The method of claim 1 wherein the step of forming an
unvulcanized rubber sheet comprises the step of forming an
unvulcanized rubber sheet approximately 1 mm in thickness.
8. The method of claim 1 wherein the step of forming an
unvulcanized rubber sheet comprises the step of squeezing
unvulcanized rubber into a sheet.
9. The method of claim 1 wherein the steps of forming an
unvulcanized rubber sheet and forming the fabric sheet take place
simultaneously.
10. The method of claim 1 further comprising the step of embossing
the surface of the non-woven fabric.
11. The method of claim 1 further comprising the step of buffing
the surface of the unfinished exterior surface section prior to
joining the fabric member thereto.
12. The method of claim 1 wherein the step of joining the fabric
member to the unfinished exterior surface section comprises the
step of cementing the fabric member to the unfinished exterior
surface section.
13. The method of claim 1 wherein the step of joining the fabric
member to the unfinished exterior surface section comprises the
step of cementing the fabric member to the unfinished exterior
surface section with rubber glue.
14. A method of fabricating footwear with a fabric outsole
comprising the steps of: (a) forming a rubber outsole base with an
unfinished exterior surface section; (b) forming a non-woven fabric
sheet; (c) forming an unvulcanized rubber sheet; (d) joining the
sheets; (e) cutting the joined sheets to the shape of the
unfinished exterior surface section to form a fabric member; (f)
joining the fabric member to the unfinished exterior surface
section; (g) heating the assembly to vulcanize the rubber sheet and
permanently secure the fabric member to said base to form the
outsole; (h) forming an upper; and (i) attaching the upper to the
outsole.
15. The method of claim 14 wherein the step of forming the rubber
outsole base comprises the step of forming a rubber outsole base
with a finished exterior surface section.
16. The method of claim 15 wherein the step of forming the rubber
outsole base comprises the step of forming a rubber outsole base
with a finished exterior surface section proximate the unfinished
exterior surface section.
17. The method of claim 14 wherein the step of joining the rubber
sheet and the fabric sheet comprises the step of cementing the
sheets.
18. The method of claim 14 wherein the step of joining the rubber
sheet and the fabric sheet comprises squeezing the sheets
together.
19. The method of claim 18 wherein the step of joining the rubber
sheet and the fabric sheet comprises squeezing the sheets
together.
20. The method of claim 14 wherein the step of forming an
unvulcanized rubber sheet comprise the step of forming an
unvulcanized rubber sheet 1 mm in thickness.
21. The method of claim 14 wherein the step of forming an
unvulcanized rubber sheet comprises the step of squeezing
unvulcanized rubber into a sheet.
22. The method of claim 14 wherein the step of forming an
unvulcanized rubber sheet and the fabric sheet take place
simultaneously.
23. The method of claim 14 further comprising the step of embossing
the surface of the fabric.
24. The method of claim 14 further comprising the step of buffing
the surface of the unfinished exterior surface section prior to
joining the fabric member thereto.
25. The method of claim 14 wherein the step of joining the fabric
member to the unfinished exterior surface section comprises the
step of cementing the fabric member to the unfinished exterior
surface section.
26. The method of claim 14 wherein the step of joining the fabric
member to the unfinished exterior surface section comprises the
step of cementing the fabric member to the unfinished exterior
surface section with rubber glue.
27. An outsole with a fabric member comprising a rubber outsole
base with an exterior surface comprising an unfinished section of a
given shape and size; a fabric member substantially of said given
shape and size comprising a fabric layer and a rubber layer, and
means for joining said fabric member to said unfinished section of
said base.
28. The outsole of claim 27 wherein said base and said fabric
member are heated to vulcanize said rubber sheet subsequent to
being joined.
29. The outsole of claim 27 wherein said rubber layer is
unvulcanized prior to forming said fabric member.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] Not Applicable
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not Applicable
REFERENCE TO A "SEQUENCE LISTING", A TABLE, OR A COMPUTER PROGRAM
LISTING APPENDIX SUBMITTED ON COMPACT DISC
[0003] Not Applicable
BACKGROUND OF THE INVENTION
[0004] 1. Field of the Invention
[0005] The present invention relates to footwear constructions,
particularly footwear outsoles and more particularly to a fabric
footwear outsole, a method for manufacturing a fabric footwear
outsole and a method of manufacturing footwear with the fabric
outsole.
[0006] 2. Description of Prior Art Including Information Disclosed
Under 37 CFR 1.97 and 1.98
[0007] Footwear with fabric outsoles is known in the art as having
certain desirable wear and traction characteristics. Various fabric
footwear constructions and techniques for fabricating fabric
outsoles for use in such footwear are known. Those fabricating
techniques in general include molding fabric sheets to outsole
bases, cementing fabric sheets within recesses formed in outsole
bases and applying layers of cement to the surface of an outsole
base, embedding fabric fibers into the cement using an
electrostatic field and then curing the cement. However, none of
those methods produce a product with a fabric outsole that is
sufficiently durable, at a price that is competitive with
comparable products with all rubber outsoles.
BRIEF SUMMARY OF THE INVENTION
[0008] It is, therefore, a prime object of the present invention to
provide a fabric footwear outsole.
[0009] It is another object of the present invention to provide
footwear with a fabric outsole.
[0010] It is another object of the present invention to provide a
method for manufacturing a fabric footwear outsole.
[0011] It is another object of the present invention to provide a
method for manufacturing footwear with a fabric outsole.
[0012] It is another object of the present invention to provide a
fabric footwear outsole formed of a rubber outsole base with a
fabric member joined thereto.
[0013] It is another object of the present invention to provide a
fabric footwear outsole including a fabric member formed of a
fabric sheet cemented to a rubber sheet.
[0014] It is another object of the present invention to provide a
fabric footwear outsole with a fabric member wherein the rubber
sheet remains unvulcanized until after the outsole components are
assembled.
[0015] It is another object of the present invention to provide a
fabric footwear outsole with a fabric member wherein the rubber
sheet is vulcanized after the other outsole components are
assembled in order to securely and permanently attach the fabric
member to the outsole base.
[0016] It is another object of the present invention to provide
footwear with a fabric outsole formed as described herein.
[0017] The above objects are achieved by the present invention, one
aspect of which relates to method of fabricating a fabric footwear
outsole. The method begins by forming a rubber outsole base with an
unfinished exterior surface section. A non-woven fabric sheet and
an unvulcanized rubber sheet are formed and joined together. The
sheets are cut to the shape of the unfinished exterior surface
section of the base to form a fabric member. The fabric member is
joined to the unfinished exterior surface section of the base.
Thereafter, the rubber outsole base and the fabric member assembly
is heated to form the outsole.
[0018] The step of forming the rubber outsole base includes forming
a rubber outsole base with a finished exterior surface section. The
finished exterior surface section is formed proximate the
unfinished exterior surface section of the base.
[0019] The step of joining the rubber sheet and the fabric sheet
includes cementing the sheets together. The rubber sheet and the
fabric sheet may be squeezed together during the joining
process.
[0020] The step of forming an unvulcanized rubber sheet includes
forming an unvulcanized rubber sheet approximately 1 mm in
thickness. The sheet may be formed by squeezing unvulcanized rubber
into a sheet.
[0021] The steps of forming an unvulcanized rubber sheet and
forming the fabric sheet may take place simultaneously, in a single
machine.
[0022] Preferably, the surface of the non-woven fabric is embossed
to provide a textured surface. The embossing step can take place
before or after the joined fabric sheet and unvulcanized rubber
sheet is cut to size.
[0023] The method further comprises the step of buffing the surface
of the unfinished exterior surface section of the base prior to
joining the fabric member thereto.
[0024] The step of joining the fabric member to the unfinished
exterior surface section includes cementing the fabric member to
the unfinished exterior surface section. Rubber glue may be used
for that purpose.
[0025] In accordance with another aspect of the present invention,
a method of fabricating footwear with a fabric outsole is provided.
The method begins by forming a rubber outsole base with an
unfinished exterior surface section. A non-woven fabric sheet and
an unvulcanized rubber sheet are formed and joined together. The
sheets are cut to the shape of the unfinished exterior surface
section of the base to form a fabric member. The fabric member is
joined to the unfinished exterior surface section of the base.
Thereafter, the rubber outsole base and the fabric member assembly
is heated to form the fabric outsole. An upper is formed and
attached to the fabric outsole to complete the footwear.
[0026] The step of forming the rubber outsole base includes forming
a rubber outsole base with a finished exterior surface section. The
finished exterior surface section is formed proximate the
unfinished exterior surface section of the base.
[0027] The step of joining the rubber sheet and the fabric sheet
includes cementing the sheets together. The rubber sheet and the
fabric sheet may be squeezed together during the joining
process.
[0028] The step of forming an unvulcanized rubber sheet includes
forming an unvulcanized rubber sheet approximately 1 mm in
thickness. The sheet may be formed by squeezing unvulcanized rubber
into a sheet.
[0029] The steps of forming an unvulcanized rubber sheet and
forming the fabric sheet may take place simultaneously, in a single
machine.
[0030] Preferably, the surface of the non-woven fabric is embossed
to provide a textured surface.
[0031] In accordance with another aspect of the present invention,
an outsole with a fabric member is provided. The outsole includes a
rubber outsole base with an exterior surface having an unfinished
section of a given shape and a fabric member substantially of the
same shape as the unfinished base section. The fabric member
includes a fabric layer and a rubber layer. Means are provided for
joining the fabric member to the unfinished section of the
base.
[0032] The rubber layer is unvulcanized prior to forming the fabric
member.
[0033] The base and the fabric member are heated subsequent to
being joined.
[0034] In accordance with another aspect of the present invention,
footwear with a fabric outsole is provided. The outsole includes a
rubber outsole base with an exterior surface having an unfinished
section of a given shape and a fabric member substantially of the
same shape as the unfinished base section. The fabric member
includes a fabric layer and a rubber layer. Means are provided for
joining the fabric member to the unfinished section of the base to
form the fabric outsole. An upper is provided as are means for
attaching the upper to the fabric outsole.
[0035] The rubber layer is unvulcanized prior to forming the fabric
member.
[0036] The base and the fabric member are heated subsequent to
being joined.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF DRAWINGS
[0037] To these and to such other objects that may hereinafter
appears, the present invention relates to a fabric footwear
outsole, footwear with a fabric outsole, a method for fabricating a
fabric footwear outsole and a method for fabricating footwear with
a fabric outsole as described in detail in the following
specification and recited in the annexed claims, taken together
with the accompanying drawings, in which like numerals refer to
like parts and in which:
[0038] FIG. 1 is a perspective view of a shoe with the fabric
outsole of the present invention;
[0039] FIG. 2 is a perspective view of a machine joining the fabric
sheet and unvulcanized sheet and embossing same.
[0040] FIG. 3 is a more detailed view of the sheets prior to
embossing as seen in the dashed circle labeled 3 of FIG. 2;
[0041] FIG. 4 is a more detailed view of the sheets after embossing
as seen in the dashed circle labeled 4 of FIG. 2;
[0042] FIG. 5 illustrated the step of cutting the sheets to the
size and shape of the unfinished base section to form the fabric
member;
[0043] FIG. 6 is a perspective view of the outsole base;
[0044] FIG. 7 is a perspective view of the outsole base as the
unfinished section is buffed;
[0045] FIG. 8 is a perspective view of the outsole base as rubber
cement is applied to the unfinished section;
[0046] FIG. 9 is an exploded perspective view of the outsole base
and the fabric member before the fabric member is placed on the
layer of rubber glue; and
[0047] FIG. 10 is a perspective view of the fully assembled fabric
outsole as it is being vulcanized.
DETAILED DESCRIPTION OF THE INVENTION
[0048] The fabrication process begins, as illustrated in FIG. 2, by
joining a continuous non-woven fabric sheet 10 fed from a supply
roller 12 with a continuous unvulcanized rubber sheet 14 fed from a
supply roller 16. The rubber sheet is preferably approximately 1 mm
thick as it comes from the roller. The sheets are joined using a
layer of rubber glue 18 supplied from a glue supply tray 20.
[0049] Pressure is applied to the sheets, with the glue layer 18
therebetween, to squeeze the sheets together. The pressure is
applied by pressure rollers 22. After passing between the pressure
rollers, the sheets appear as seen in FIG. 3.
[0050] In one preferred embodiment, the sheets then pass under an
embossing roller 24 which imparts a herring bone like pattern on
the surface thereof, as illustrated in FIG. 4. In that case, the
fabric members 26 are formed from the glued and embossed sheets by
die cutting the embossed sheets into sections of the desired size
and shape. The members are cut by a reciprocating die 28, as seen
in FIG. 5.
[0051] In a second preferred embodiment, the sheets pass through
the reciprocating die 28 of the die cutting press, as illustrated
in FIG. 5, and then the cut members 26 are embossed by an embossing
roller, so as to appear as illustrated in FIG. 4.
[0052] Separately, an outsole base, generally designated 30, made
of rubber or other flexible material is formed in a conventional
manner except that the bottom surface of base 30 has three distinct
surface sections. The central section 32 of the base surface is
unfinished. The toe section 34 and the heel section 36 are finished
and preferably have embossed or roughened surfaces.
[0053] Central section 32 of base 30 is recessed relative to the
toe and heel sections 32 and 34 by a distance equal to the
thickness of fabric member 26 such that when the fabric member is
received in the recess, the surface of the fabric member will be
coplanar with the surface of the toe section and of the heel
section. Further, the interior edge of toe section 34 is adjacent
to the front edge of unfinished section 32. Likewise, the interior
edge of heel section 36 is adjacent to the rear edge of unfinished
section 32. Accordingly, once the fabric member is in place on the
base, the exposed surface of the fabric member and the exposed
surfaces of toe and heel sections of the base form a single planar
sectioned surface suitable for use as a footwear outsole.
[0054] Prior to mounting the fabric member on the base, the
unfinished section 32 of the base surface is buffed using spaced
buffing rollers 38, 40, as illustrated in FIG. 7. After buffing, a
layer of rubber glue 42 is applied to the surface of the unfinished
section by a movable nozzle 46, as seen in FIG. 8. The fabric
member 26, which has been cut to have the same size and shape as
the unfinished section 32 of base 30, is then placed onto layer 42
of rubber glue previously deposited over the unfinished base
section. The assembly, as shown in FIG. 10 is heated in order to
vulcanize the rubber layer formed from sheet 14. The heat causes
that rubber layer to cure and to securely and permanently attach
the fabric member to the unfinished section of the surface of the
base.
[0055] The shoe is completed by securing the upper 48 to the
completed fabric outsole 50, as illustrated in FIG. 1. The upper
can be attached to the outsole using any conventional method, such
as glue, stitching or a combination thereof.
[0056] As will now be appreciated, the present invention relates to
a method for fabricating a fabric footwear outsole. The method
begins by forming a rubber outsole base with an unfinished exterior
surface section. A non-woven fabric sheet and an unvulcanized
rubber sheet are formed and joined together. The sheets are cut to
the shape of the unfinished exterior surface section of the base to
form a fabric member. The fabric member is joined to the unfinished
exterior surface section of the base. Thereafter, the rubber
outsole base and the fabric member assembly is heated to vulcanize
the rubber layer of the fabric member to secure and permanently
attach the fabric member to the outsole base.
[0057] The rubber outsole base has a finished exterior surface
section proximate the unfinished exterior surface section of the
base.
[0058] The rubber sheet is joined to the fabric sheet by cementing
the sheets together. The rubber sheet and the fabric sheet may be
squeezed together during the joining process. Preferably, the
rubber sheet has a thickness of approximately 1 mm. The sheet may
be formed by squeezing unvulcanized rubber into a sheet. The
forming of the rubber sheet and forming the fabric sheet may take
place simultaneously, in a single machine.
[0059] Preferably, the surface of the non-woven fabric is embossed
to provide a textured surface. The embossing step can take place
before or after the sheets are die cut to form the fabric members.
The surface of the unfinished exterior surface section of the base
is preferably buffed prior to joining the fabric member thereto.
The fabric member is joined to the unfinished exterior surface
section by rubber glue.
[0060] The completed outsole may then be attached to an upper,
using conventional methods, to form the shoe.
[0061] It will be further appreciated that the present invention
also relates to the fabric outsole itself. The outsole includes a
rubber outsole base with an exterior surface having an unfinished
section of a given shape and a fabric member substantially of the
same shape as the unfinished base section. The fabric member
includes a fabric layer and a rubber layer. Means are provided for
joining the fabric member to the unfinished section of the base.
The rubber layer is unvulcanized prior to forming the fabric
member. The base and the fabric member are heated subsequent to
being joined to secure and permanently affix the fabric member to
the outsole base.
[0062] While only a single preferred embodiment of the present
invention has been disclosed for purposes of illustration, it is
obvious that many modifications and variations could be made
thereto. It is intended to cover all of those modifications and
variations which fall within the scope of the present invention, as
defined by the following claims.
* * * * *