U.S. patent application number 13/311223 was filed with the patent office on 2012-11-08 for method for fabricating a footwear sole.
Invention is credited to Fuqiang Wang, Chengjie Xu.
Application Number | 20120279089 13/311223 |
Document ID | / |
Family ID | 44488225 |
Filed Date | 2012-11-08 |
United States Patent
Application |
20120279089 |
Kind Code |
A1 |
Xu; Chengjie ; et
al. |
November 8, 2012 |
METHOD FOR FABRICATING A FOOTWEAR SOLE
Abstract
A method for forming a footwear sole is disclosed. Specifically,
there is provided a sole mould for fabricating high-quality shoe
soles with great efficiency and a method of using such a mould,
wherein the soles feature good air permeability and perfect match
with the feet by automatically adapting themselves to the shape of
the feet. The sole mould includes a first mould for
injection-moulding the underside of a leather layer, and a second
mould for injection-moulding the upper surface of the leather layer
to form the sole. Further, the first mould is configured in the
same shape as the fore sole of the foot and the second mould is
configured in the shape of a complete sole.
Inventors: |
Xu; Chengjie; (Dongguand
City, CN) ; Wang; Fuqiang; (XiangFan City,
CN) |
Family ID: |
44488225 |
Appl. No.: |
13/311223 |
Filed: |
December 5, 2011 |
Current U.S.
Class: |
36/25R ;
12/146B |
Current CPC
Class: |
B29D 35/142 20130101;
A43B 13/26 20130101; A43B 13/122 20130101; B29D 35/0018
20130101 |
Class at
Publication: |
36/25.R ;
12/146.B |
International
Class: |
A43D 8/00 20060101
A43D008/00; A43B 13/14 20060101 A43B013/14; A43B 13/00 20060101
A43B013/00 |
Foreign Application Data
Date |
Code |
Application Number |
Dec 3, 2010 |
CN |
201010572489.1 |
Claims
1. A method for forming a footwear sole comprising a fore sole and
a rear sole, the method comprising: providing a midsole layer
having one or more midsole injection holes and one or more midsole
bores distributed thereon, the midsole injection holes and the
midsole bores extending between an underside of the midsole layer
and an upper surface of the midsole layer; providing a first female
mould comprising one or more first downward concave cavities and
first raised areas; placing said midsole layer onto said first
female mould, and aligning said midsole injection holes and said
midsole bores with said first downward concave cavities provided in
said first female mould; providing a first male mould comprising a
first injection area comprising one or more of first bores and one
or more first injection holes; assembling and fixing said first
male mould and said first female mould so that each of said midsole
bores and said midsole injection holes are respectively aligned
with each of said first bores and each of said first injection
holes; and a step A3 comprising infusing a first formula plastic
into said first male mould by way of said first injection holes and
said midsole injection holes into said first downward concave
cavities, wherein said first formula plastic is channeled through
each of said first injection holes and each of said midsole
injection holes into each of said downward concave cavities and
shaped up resulting in raised soles lines on said fore sole, and
further wherein said first formula plastic inside each of said
first downward concaves passes through each of said midsole bores
and into each of said first bores to form one or more protuberances
which are embedded with said midsole layer; and splitting said
first male mould and said first female mould to remove said midsole
layer comprising said raised sole lines and said protuberances; and
a step B comprising taking said midsole layer out of said first
male mould and said first female mould and placing said midsole
layer into a shoe sole-shaped second mould for injection moulding
with a second formula plastic to form one or more second raised
sole lines on the upper surface of the midsole layer, the second
raised sole lines being embedded with the protuberances to thereby
anchor the first raised sole lines with the second raised sole
lines.
2. The method of claim 1, wherein said step B comprises: a step B1
comprising providing a second female mould and placing said midsole
onto said second female mould so that said first raised lines match
with said one more second downward concaves of said second female
mould; a step B2 comprising providing a second male mould
comprising a second injection area comprising one or more second
upward concave cavities and one or more second injection holes and
assembling and fixing said second male mould and said second female
mould, such that each of said one or more protuberances protrudes
inside each of said one or more second upward concave cavities; and
a step B3 comprising infusing said second formula plastic into each
of said one or more second upward concave cavities through said one
or more second injection holes such that said second formula
plastic is moulded with said midsole layer and with each of said
one or more protuberances to form said one or more second raised
sole lines on the upper surface of the midsole layer.
3. The method of claim 2, wherein said step B1 further comprises:
positioning a middle plate on top of the said second female mould;
placing said midsole layer on said middle plate; matching said
first raised injection area on said underside with said one or more
second downward concave cavities of said second female mould; and
infusing said second formula plastic into an upwardly-concaved
third injection area for forming said rear sole.
4. The method according to claim 1, wherein said first formula
plastic is softer than said second formula plastic.
5. The method according to claim 1, wherein said bores and said
injection holes have a diameter of 2 mm to 10 mm.
6. The method according to claims 1, wherein said midsole layer
comprises leather.
7. A footwear sole fabricated according to the method of claim 1.
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims benefit of Chinese Application
Serial No. 201010572489.1, filed on Dec. 3, 2010, which is
incorporated herein in its entirety by reference.
BACKGROUND OF THE INVENTION
[0002] The present invention relates to a technology for making
footwear, and particularly relates to a mould for making shoe soles
and its usage.
[0003] Ordinary shoe soles are generally formed up by one or two
types of materials, which have poor air permeability and tend to
fatigue the feet after long-term wear. Besides, they fit badly with
the feet and may easily cause the fore part of the foot to deform
if worn for a long time.
[0004] WO 2010/012401 by O'Connor et al. discloses a footwear
outsole 1 made of a lather lamina 3 with ground contact lugs 4
moulded at the bottom of the layer lamina 3 and a series of very
thin parallel strips 9 bonded with adhesive at the top of the
leather lamina 3. An outsole moulding 2 may be stitched 6 or
moulded around the outer edges of the leather lamina 3. A problem
with such outsole 1 is that the lugs 4 and strips 9 may become
detached from the leather lamina, during use for example, because
the bonding between the lamina 3 and the lugs 4 and strips 9 is not
strong enough. Also, using stitching 6 to bond the outsole 2 adds
an additional stitching step using stitching machinery in addition
to the other manufacturing and moulding steps using moulding
machinery and potentially increases the costs and complexity.
[0005] There is therefore a need in the market for a more durable
shoe sole, while maintaining fabrication costs and complexity at
low levels.
[0006] The present invention discloses a technology which overcomes
the above-mentioned shortcomings by providing a sole which can fit
snugly with the foot, has good air permeability and elegant
appearance. It can automatically adapt to the shape of the foot,
and is therefore suitable for long-term wear.
SUMMARY OF INVENTION
[0007] According to a preferred embodiment of the present
invention, there is provided a method for forming a footwear sole
comprising a fore sole and a rear sole. The method comprises:
providing a midsole layer having one or more midsole injection
holes and one or more midsole bores distributed thereon, the
midsole injection holes and the midsole bores extending between an
underside of the midsole layer and an upper surface of the midsole
layer; providing a first female mould comprising one or more first
downward concave cavities and first raised areas; placing said
midsole layer onto said first female mould, and aligning said
midsole injection holes and said midsole bores with said first
downward concave cavities provided in said first female mould;
providing a first male mould comprising a first injection area
comprising one or more of first bores and one or more first
injection holes; assembling and fixing said first male mould and
said first female mould so that each of said midsole bores and said
midsole injection holes are respectively aligned with each of said
first bores and each of said first injection holes; infusing a
first formula plastic into said first male mould by way of said
first injection holes and said midsole injection holes into said
first downward concave cavities, wherein said first formula plastic
is channeled through each of said first injection holes and each of
said midsole injection holes into each of said downward concave
cavities and shaped up resulting in raised soles lines on said fore
sole, and further wherein said first formula plastic inside each of
said first downward concaves passes through each of said midsole
bores and into each of said first bores to form one or more
protuberances which are embedded with said midsole layer; splitting
said first male mould and said first female mould to remove said
midsole layer comprising said raised sole lines and said
protuberances; taking said midsole layer out of said first male
mould and said first female mould and placing said midsole layer
into a footwear sole-shaped second mould for injection moulding
with a second formula plastic to form one or more second raised
sole lines on the upper surface of the midsole layer, the second
raised sole lines being embedded with the protuberances to thereby
anchor the first raised sole lines with the second raised sole
lines.
[0008] Advantageously, the provision of bores in the midsole layer
allow for better anchoring of the first sole lines on one side of
the midsole layer with the second sole lines on the other side of
the midsole layer by means of the protruding protuberances being
embedded with the second formula plastic.
[0009] Preferably, the sole mould is used to fabricate high-quality
soles with great efficiency, wherein the sole features good air
permeability and is suitable for long-term wear because it can fit
snugly with the foot by adapting itself automatically to the shape
of the foot.
[0010] Preferably, the second mould may further include a second
female mould and a second male mould, both configured in the same
shape as a complete foot sole and can fit into each other. Further,
the aforementioned first female mould and the first male mould,
both resembling the fore part of the sole, also match the fore part
of the sole-shaped second female mould and the second male mould.
The said second female mould further includes a second downward
concave in the same shape as and at the corresponding position of
the first downward concave of the first female mould. The said
second male mould further features a second injection area in the
same shape as and at the corresponding position of the second
downward concave. Still further, a second injection hole (which
passes through the leather layer) is designed on the said second
injection area. The second male mould further features an
upward-concaved third injection area in the rear part of the sole,
as well as a second injection hole (which passes through the
leather layer) in the said third injection area. The leather layer,
having been processed by the first female mould and the first male
mould, is further processed by the second female mould and the
second male mould, generating an injection-moulded shoe sole with
an embedded leather layer. Meanwhile, a raised injection area is
formed on the upper side of the said leather layer.
[0011] A middle plate may be inserted between the second female
mould and the second male mould when the two are assembled to
process the leather layer through injection moulding, so as to
produce a cambered or arcuate shoe sole.
[0012] Preferably, the first injection hole passes through the
first male mould through an injection channel; the second injection
hole passes through the second male mould through an injection
channel.
[0013] The soft plastic used may be thermoplastic polyurethane
(TPU). Preferably, the first formula plastic is softer than said
second formula plastic.
[0014] Preferably, the cylindrical bores and the injection holes
have a diameter of about 2 mm to 10 mm.
[0015] The sole mould described in this Invention is simple in
structure and easy to operate. It is capable of manufacturing
quality foot soles of good air permeability with high efficiency.
Moreover, these shoe soles can perfectly match the feet by
automatically adapting themselves to the shape of the feet, and are
therefore suitable for wear for a long time. Moreover, the product
yield is relatively high.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] FIG. 1 is a side sectional view of a shoe sole formed by the
sole mould and method, according to a preferred embodiment of the
present invention;
[0017] FIG. 2 is a top view of the shoe sole of FIG. 1;
[0018] FIG. 3 is a sectional view of a first female mould and a
first male mould in an assembled position, according to a preferred
embodiment of the present invention;
[0019] FIG. 4 is a sectional view of a second female mould and a
second male mould in an assembled position, according to a
preferred embodiment of the present invention;
[0020] FIG. 5 is a top view of two leather layers used by a sole
mould for making shoe soles, according to a preferred embodiment of
the present invention;
[0021] FIG. 6 is a top view of a left and right first female
moulds, according to a preferred embodiment of the present
invention;
[0022] FIG. 7 is a bottom view of a left and right first male
moulds, according to a preferred embodiment of the present
invention;
[0023] FIG. 8 is a sectional view of the leather layer of FIG. 5
after being injection moulded using a first female mould and a
first male mould, according to a preferred embodiment of the
present invention;
[0024] FIG. 9 is a top view of a left and right second female
moulds, according to a preferred embodiment of the present
invention;
[0025] FIG. 10 is a bottom view of a left and right second male
moulds, according to a preferred embodiment of the present
invention;
[0026] FIG. 11 is a flow process of one example of a method for
using the sole mould, according to a preferred embodiment of the
present invention; and
[0027] FIG. 12 is a flow process of another example of a method for
using the sole mould, according to a preferred embodiment of the
present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0028] The preferred embodiments of this Invention will now be
described by referring to the attached drawings.
[0029] Now referring to FIG. 1 and FIG. 2, there illustrated a shoe
sole 10 fabricated according to a method of the present invention.
The shoe sole has good air permeability and is suitable for
long-time wear, as mentioned in the Background. This shoe sole 10
fits snugly with the foot (not shown) by automatically adapting
itself to the shape of the foot. The main body or midsole layer 12
of the fore sole 14 is illustratively a leather layer which is
primarily made of leather materials. By way of injection-moulding
soft plastics, one or more first raised sole lines 16 and one or
more second raised sole lines 18 are formed respectively on an
underside 20 of the midsole leather layer 12 to thus form an outer
sole portion 19 and an upper surface 22 of the midsole leather
layer 12 to thus form an inner sole portion 17. A rear part 24 of
the sole 10 is also obtained by injection-moulding the same
plastics and is integrated with the leather layer 12 to constitute
a complete shoe sole 10. The raised sole lines 16, 18 are shaped
like ribs that define channels in between these ribs, which ensure
good air circulation.
[0030] Now referring to FIG. 3, FIG. 4 and FIG. 5, in addition to
FIG. 1, there is illustrated a sole mould according to an
illustrative embodiment of the present invention. The sole mould
includes two parts: a first mould 26 which resembles a fore sole 14
and a second mould 28 which has the shape of a complete foot sole.
The first mould 26 and the second mould 28 are used successively to
produce the shoe sole 10. Firstly, the first mould 26 is used to
treat the leather layer 12, in particular the fore part 14 of the
shoe sole 10, by injection moulding, which forms the one or more
first raised sole lines 16 on the underside 20 of the leather layer
12. Secondly, the second mould 28 is used to treat the leather
layer 12 bearing the first raised sole lines 16, resulting in one
or more second raised sole lines 18 on the upper surface 22 of the
leather layer 12. Meanwhile, the rear part 24 of the shoe sole 10
is obtained by injection-moulding soft plastics in the second mould
28 such that the rear part 24 is integrated with the leather layer
12. A finished sole 10 comprising one or more second raised sole
lines 18 of the fore sole 14 on the upper surface 22 of the midsole
12 to form the inner sole portion 17 and the one or more first
raised sole lines 16 of the fore sole 14 on the underside 20 of the
shoe sole 10 to form the outer sole portion 19 is produced by the
moulds, 26 and 28.
[0031] Now referring to FIG. 6, in addition to FIG. 1, FIG. 3, FIG.
4 and FIG. 5, the first mould 26 further includes a first female
mould 32 and a first male mould 34, both of which are available as
a pair to produce a pair of shoe soles 10. The first female mould
32 and the first male mould 34 are configured in the same shape as
the fore sole 14 of the foot and fit into each other when assembled
as illustrated. The first female mould 32 further contains one or
more first downward concave cavities as in 36 and a first raised
area 38 which when injected moulded, or infused with plastic, form
the raised sole lines 16 on the underside 20 of the leather layer
12.
[0032] Now referring to FIG. 7 and FIG. 8, in addition to FIG. 3,
the first male mould 34 includes one or more cylindrical bores 40
and one or more first injection holes 42 in a first injection area
44 each one of which are in fluid communication with one of the one
ore more first downward concave cavities 36 via each of one or more
second injection hole 45 and each of one or more second cylindrical
bore 47 respectively provided for in the layer 12. The one or more
second cylindrical bores 47 and the one or more second injection
hole 45 provide fluid communication for the plastic between the one
or more first downward concave cavities 36 and the one or more
first cylindrical bores 40 and the one or more first injection
holes 42 through the layer 12 when respectively aligned therewith.
Illustratively, through the one or more first injection hole 42,
each of which are in fluid communication with an injection channel
46, soft plastic is supplied from the injection channels 46 to be
infused into the one ore more first downward concave cavities 36
via the one or more second injection holes 45. Once plastic is
infused into the one or more first downward concave cavities as in
36, plastic is allowed to pass through the layer 12 via the one or
more second cylindrical bores as in 47 and into the one or more of
first cylindrical bore 40 provided for in the first male mould 34
such that one or more plastic protuberances as in 49 are embedded
within the midsole layer 12 and extend from the upper surface. The
first female mould 32 and the first male mould 34 are then
assembled to mould the plastic, leaving the one or more first
raised sole lines 16 on the under side 20 of the leather layer
12.
[0033] Now referring to FIG. 9 and FIG. 10, the second mould 28
further includes a second female mould 48 and a second male mould
50, both of which are available in pair to produce a pair of shoe
soles 10. The said second female mould 48 and second male mould 50
are configured in the same shape as a complete foot sole 10 and can
fit into each other. Furthermore, the aforementioned first female
mould 32 and the first male mould 34 also match the fore part 14 of
the sole-shaped second female mould 48 and the second male mould
50. The second female mould 48 further includes one or more second
downward concave cavities as in 52 in the same shape as and at the
corresponding position of the one or more first downward concave
cavities as in 36. The second male mould 50 further features a
second injection area 54 comprising one or more second upward
concave cavities as in 55 in the same shape as and at the
corresponding position of the one or more second downward concave
cavities as in 52. Still further, one or more second injection
holes 56 are provided in the second injection area 54 for each of
the one or more second upward concave cavities as in 55.
[0034] Still referring to FIG. 10, the second male mould 50 further
features an upward-concaved third injection area 58 to form the
rear part 24 of the sole 10 when it is injected moulded, as well as
a second injection hole 56 for injecting plastic into the third
injection area 58. The leather layer 12, having been processed
using the first female mould 32 and the first male mould 34, is
further processed using the second female mould 48 and the second
male mould 50, generating an injection-moulded shoe sole 10 with an
embedded leather layer 12 by infusing soft plastic into the second
injection area 54 and the third injection area 58 through the
second injection hole 56 and the injection channels 46. As a
result, the one or more second raised sole lines 18 are formed on
the upper surface 22 of the leather layer 12.
[0035] It should be noted that the soft plastic being used for
injection purposes for the sole mould described herein is
illustratively thermoplastic polyurethane (TPU). Illustratively,
the plastic used to form the one ore more first raised sole lines
16 may be harder than the plastic used to form the one or more
second raised sole lines 18.
[0036] Now referring back to FIG. 1 and FIG. 4, the sole mould
provided in the present Invention further includes a middle plate
60, which is inserted between the second female mould 48 and the
second male mould 50 when the two are assembled for injection
moulding the leather layer 12. The ultimate purpose is to produce a
curved shoe sole, for instance the curved rear part of high-heeled
leather shoes for women.
[0037] The sole mould described in this Invention is simple in
structure and easy to operate. It is capable of manufacturing
quality foot soles of good air permeability with high efficiency.
Moreover, these shoe soles 10 can perfectly match the feet by
automatically adapting themselves to the shape of the feet, and are
therefore suitable for wear over a long period of time. Moreover,
the product yield is relatively high.
[0038] Now referring to FIG. 12, there is provided an illustrative
example of the method of using the sole mould which comprises the
following steps.
[0039] Step S102: Assemble the fore sole-shaped first mould 26 onto
an injection machine (not shown). After that, place the leather
layer 12 into the first mould 26 for injection moulding to form the
first raised area 38 on the underside 20 of the leather layer 12
comprising one or more first raised sole lines 16.
[0040] Step S104: Take the leather layer 12 out of the first mould
26 and put it into the foot sole-shaped second mould 28 for
injection moulding to produce a shoe sole 10 with an embedded
leather layer 12 comprising the second raised injection area 54 on
the upper surface 22 of the leather layer 12 comprising the one or
more second raised sole lines 18.
[0041] Now referring to FIG. 12, there is provided another
illustrative example of the method of using the sole mould is
composed of the following steps:
[0042] Step S202: Assemble the fore sole-shaped first female mould
32 of the first mould 26 onto the injection machine. Place the
leather layer 12 on top of the first female mould 32 with the
underside 20 facing downwards and align the each pre-designed one
or more second cylindrical bores 47 and one or more second
injection holes 45 on the leather layer 12 with the each of the one
or more first downward concave cavities 36 of the first female
mould 32.
[0043] Step S204: Assemble and fix the fore sole-shaped first male
mould 34 and the first female mould 32, making sure that each of
the first cylindrical bores 40 and each of the first injection
holes 42 located on the first male mould 34 are aligned with each
of second cylindrical bores 47 and each of the second injection
holes 45 on the leather layer 12 respectively. Then, place a puller
plate 64 on top of the first male mould 34.
[0044] Step S206: By way of the one or more first injection hole 42
and the one or more injection channels 46, infuse the soft plastic
into the first male mould 34 by using an injection machine (not
shown). The soft plastic, after going through the one or more first
injection holes 42 on the first male mould 34 is channelled into
the one or more first downward concave cavities 36 of the first
female mould 32 and shaped up, resulting in the first raised area
38 on the underside 20 of the leather layer 12 to form the first
one or more first raised sole lines 16. Further, the soft plastic
inside the one or more first downward concave cavities 36 moves
through the one or more second cylindrical bores 47 of the leather
layer 12 and into the one or more first cylindrical bores 40 to
form one or more pyramidal protuberances 49, which are integrated
with the leather layer 12. After that, the first male mould 34 and
the first female mould 32 are split to remove the leather layer 12
bearing a first injection area 44 on the underside 20.
[0045] Referring back to FIG. 5, it is preferable to pre-punch the
midsole layer 12 to form holes matching with the cylindrical bores
47 and the injection holes 45 prior to placing the midsole 12 on
top of the first female mould 32. Alternatively, the cylindrical
bores 47 and the injection holes 45 may be punched in the midsole
12 once the midsole is in the first female mould 32.
[0046] Step S208: Assemble the foot sole-shaped second female mould
48 of the second mould 28 onto the injection machine and place the
middle plate 60 on the said second female mould 48. Lay up the
leather layer 12 onto the middle plate 60, making sure that the
underside 20 of the leather layer 10 faces downward and that the
first injection area 44 on the underside 20 of the leather layer 10
shall match with the second downward concave cavities 52 of the
second female mould 48. The final purpose is to produce arcuation
on the leather layer 12;
[0047] Step S210: Assemble and fix the foot sole-shaped second male
mould 50 and the second female mould 48 of the second mould 28,
making sure that the second injection area 54 of the second mould
is aligned with the one or more second downward concave cavities
52. When aligned, the one or more pyramidal protuberances 49 on the
leather layer 12 are suspended, or project, inside the second
injection area 54. Then, place the puller plate 64 on top of the
second male mould 50.
[0048] Step S212: By way of the one or more second injection holes
56 on the second male mould 50 and the one or more injection
channels 46, infuse the soft plastic into the second male mould 50
by using an injection machine. The soft plastic is moulded into a
shoe sole 10 to combine with embedded leather layer 12 and the one
or more pyramidal protuberances 49 inside the second injection area
54 and the third injection area 58. During this process, the one or
more pyramidal protuberances 49 as mentioned in Steps S206 and S210
are embedded into the plastic injected into the one or more second
upward concave cavities 52, therefore leaving a second raised
injection area 54 of second raised sole lines 18 on the upper
surface 22 of the leather layer 12.
[0049] Easy to operate, the sole mould described in this Invention
is capable of manufacturing quality shoe soles of good air
permeability with high efficiency. These shoe soles can perfectly
match the feet by automatically adapting themselves to the shape of
the feet, and are therefore suitable for wear over a long time.
Moreover, the product yield is relatively high.
[0050] The shoe sole is particularly comfortable to wear when using
a leather midsole. Indeed, because of the relatively high
elasticity of leather, the shoe sole may wrap up feet of different
shapes. Because parts of the leather midsole are not covered with
plastic, it provides with good air permeability and ventilation.
The shoe sole is comfortable, cooler and drier compared to other
existing shoe soles and solves problems of long-time wearing, poor
air permeability, dampness and heating.
* * * * *