U.S. patent application number 13/810126 was filed with the patent office on 2013-05-16 for cycling footwear structure with a composite sole and a method to realise such structure.
This patent application is currently assigned to Selle Royal, S.p.A.. The applicant listed for this patent is Arthur Steven Delacruz, Stefano Segato. Invention is credited to Arthur Steven Delacruz, Stefano Segato.
Application Number | 20130118035 13/810126 |
Document ID | / |
Family ID | 43707739 |
Filed Date | 2013-05-16 |
United States Patent
Application |
20130118035 |
Kind Code |
A1 |
Segato; Stefano ; et
al. |
May 16, 2013 |
CYCLING FOOTWEAR STRUCTURE WITH A COMPOSITE SOLE AND A METHOD TO
REALISE SUCH STRUCTURE
Abstract
Cycling footwear structure including a composite sole formed by
at least one base sole and by at least one substantially annular
shaped stiffening element, equipped with a front part, and with a
back part and that extends progressively upwards until it wraps
around at least one portion of the heel of a user and a method for
making it.
Inventors: |
Segato; Stefano; (Vicenza,
IT) ; Delacruz; Arthur Steven; (Laguna Beach,
CA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Segato; Stefano
Delacruz; Arthur Steven |
Vicenza
Laguna Beach |
CA |
IT
US |
|
|
Assignee: |
Selle Royal, S.p.A.
Pozzoleone (Vicenza)
IT
|
Family ID: |
43707739 |
Appl. No.: |
13/810126 |
Filed: |
June 20, 2011 |
PCT Filed: |
June 20, 2011 |
PCT NO: |
PCT/IB2011/052694 |
371 Date: |
January 14, 2013 |
Current U.S.
Class: |
36/102 ; 12/146B;
36/103 |
Current CPC
Class: |
A43B 13/16 20130101;
A43B 13/125 20130101; A43B 7/16 20130101; A43B 23/17 20130101; A43B
13/026 20130101; A43B 5/14 20130101; A43B 13/14 20130101 |
Class at
Publication: |
36/102 ; 36/103;
12/146.B |
International
Class: |
A43B 13/14 20060101
A43B013/14 |
Foreign Application Data
Date |
Code |
Application Number |
Jul 15, 2010 |
IT |
VR2010A000144 |
Claims
1. Cycling footwear structure comprising a composite sole
comprising at least one base sole, wherein it comprises at least
one substantially annular shaped stiffening element, equipped with
a front part and with a back part and that extends progressively
upwards until it wraps around at least a portion of the heel of a
user.
2. Cycling footwear structure according to claim 1, wherein said
base sole is equipped with at least one recess arranged
substantially along at least part of the perimeter of said base
sole, in which said at least one stiffening element is at least
partially positioned.
3. Cycling footwear structure according to claim 1, wherein said at
least one stiffening element comprises at least one insert.
4. Cycling footwear structure according to claim 1, wherein said at
least one stiffening element extends progressively upwards until it
wraps around at least the upper part and/or the middle part of the
heel of a user.
5. Cycling footwear structure according to claim 1, wherein said at
least one stiffening element has sections (A', B', C' and D') of
thickness and geometry that can be varied in a predetermined
manner.
6. Cycling footwear structure according to claim 5, wherein said
section (A') is substantially two-dimensional, with the two
dimensions being substantially equal to one another, and matches
said at least one recess of said base sole.
7. Cycling footwear structure according to claim 5, wherein said
section (D') is substantially one-dimensional, with a main
dimension, of lower thickness than said section (A') and with a
substantially membrane-type configuration.
8. Cycling footwear structure according to claim 5, wherein said
sections (B', C' and D'), positioned progressively towards said
back part of the at least one stiffening element, have a
substantially elongated configuration with lower thickness than
said section (A').
9. Cycling footwear structure according to any claim 3, wherein
said at least one insert is positioned in said back part of said at
least one stiffening element.
10. Cycling footwear structure according to claim 3, wherein said
at least one insert comprises a flexible material that has
different stiffness characteristics from the material that makes up
said at least one stiffening element and said base sole.
11. Cycling footwear structure according to claim 3, wherein said
at least one insert comprises a substantially rigid material
comprising a plastic material reinforced with fibres (Fiber
Reinforced Plastic, FRP), including a polyamide and/or polyurethane
and/or, in general, thermoplastic material reinforced with carbon
fibres and/or glass fibres and/or aramid fibres and/or the same
fibres bonded to an epoxy and/or, in general, thermosetting matrix
and/or, more generally, a tough composite material with high
modulus of elasticity.
12. Cycling footwear structure according to claim 1, wherein said
at least one stiffening element comprises a base plastic material
of a thermoplastic or thermosetting type that can optionally
comprise fibres, such as kevlar fibres and/or polyester and/or
rubber and/or carbon fibres and/or glass fibres.
13. Cycling footwear structure according to claim 1, wherein said
base sole comprises an epoxy resin with which carbon fibres are
combined.
14. Method for making a cycling footwear structure comprising a
composite sole comprising at least one base sole and at least one
substantially annular shaped stiffening element, equipped with a
front part and with a back part, wherein it comprises the following
steps: providing a mould, manually or automatically inserting the
material making up said at least one stiffening element, forming
said at least one stiffening element by compression or by
injection.
15. Method for making a cycling footwear structure according to
claim 14, comprising the following steps: providing a mould,
manually or automatically inserting the material making up said
base sole, forming said base sole by compression, optionally
equipped with at least one recess arranged substantially along at
least part of the perimeter of said base sole.
16. Method for making a cycling footwear structure according to
claim 14, comprising the following steps: providing a mould,
optionally equipped with a special seat, manually or automatically
positioning at least one insert, coupling said at least one
stiffening element with said at least one insert positioned in the
back part of said at least one stiffening element.
17. Method for making a cycling footwear structure according to
claim 14, comprising a step of treating said at least one
stiffening element and/or said at least one insert and/or said at
least one base sole with compatibilizing agents.
18. Method for making a cycling footwear structure according to
claim 14, wherein said at least one stiffening element, said at
least one base sole and said at least one insert are obtained in a
single mould.
19. Method for making a cycling footwear structure according to
claim 14, wherein said at least one stiffening element, said at
least one base sole and said at least one insert are coupled
manually and/or through special machinery and/or by co-moulding
and/or by gluing of at least two of said elements together.
20. Method for making a cycling footwear structure according to
claim 14, wherein said at least one stiffening element, said at
least one base sole and said at least one insert have a
predetermined stiffness/flexibility that can undergo variations
both by modifying the composition of the various materials and by
varying their thickness and geometry.
21. Method for making a cycling footwear structure according to
claim 14, wherein said method comprises the step of trimming and
finishing the composite sole carried out mechanically.
22. Method for making a cycling footwear structure according to
claim 14, wherein said at least one insert is made according to the
following steps: providing a starting material consisting of a dry
fabric based on carbon and/or glass and/or aramid fibres, coupling
said dry fabric based on fibres with a thermoplastic or
thermosetting resin, obtaining a dry fabric based on fibres
impregnated with said thermoplastic or thermosetting resin,
obtaining said at least one insert by cutting or blanking.
23. Method for making a cycling footwear structure according to
claim 22, wherein said at least one insert is formed by compression
or thermoforming and at least matches at least one portion of the
heel of a user.
Description
TECHNICAL FIELD OF THE INVENTION
[0001] The present invention concerns a cycling footwear structure
equipped with a composite sole and a method for making such a
structure.
STATE OF THE ART
[0002] The development of technology in the field of sport footwear
in general often comes up against the need, of production
companies, to contain the production costs whilst still keeping a
high quality product.
[0003] In particular, there is often the problem of having to
abandon certain innovative technical solutions for producing high
level products, in terms of performance and comfort, due to the
high cost of procuring single moulds and/or moulds that can be
taken apart which make it possible to obtain certain desired shapes
and/or undercuts.
[0004] It is also important to be able to base the production of a
product on a small number of production steps, so as to contain the
time and costs related to the production.
SUMMARY OF THE INVENTION
[0005] One purpose of the invention is to improve the state of the
art.
[0006] Another purpose of the invention is to make a cycling
footwear structure that is equipped with a composite sole having
high stiffness and resilience so as to increase the power generated
by the athlete or by the user, and that is transmitted to the pedal
through the footwear itself, and so as to increase the safety of
the product.
[0007] According to one aspect of the present invention, these
purposes are achieved with a cycling footwear structure as
specified in the present disclosure.
[0008] A further purpose of the present invention is to provide a
method for making a cycling footwear structure which makes it
possible to contain the costs for the production equipment.
[0009] A further purpose of the present invention is to provide a
method for making a footwear structure that is equipped with a
composite sole with high stiffness so as to increase the power
generated by the athlete or by the user and that is transmitted to
the pedal through the footwear itself, and so as to increase the
safety of the product.
[0010] According to one aspect of the present invention a method is
foreseen for making a cycling footwear structure as specified in
the present disclosure.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] Further characteristics and advantages of the invention
shall become clearer from the detailed description of a cycling
footwear structure, illustrated as an indication, and not for
limiting purposes, in the attached drawings, in which:
[0012] FIG. 1 is a perspective top view of the composite sole of
the cycling footwear structure according to the invention;
[0013] FIG. 2 is a bottom view of the composite sole according to
FIG. 1;
[0014] FIG. 3 is a side view of the composite sole according to
FIGS. 1 and 2,
[0015] FIG. 4 is a bottom view of the composite sole according to
the previous figures;
[0016] FIG. 5 is a view from the section A' of the composite sole
according to the previous figures taken along the axis A-A of FIG.
4;
[0017] FIG. 6 is a view from the section B' of the composite sole
according to the previous figures taken along the axis B-B of FIG.
4;
[0018] FIG. 7 is a view from the section C' of the composite sole
according to the previous figures taken along the axis C-C of FIG.
4;
[0019] FIG. 8 is a view from the section D' of the composite sole
according to the previous figures taken along the axis D-D of FIG.
4.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS OF THE INVENTION
[0020] With reference to the figures, 1 indicates a composite sole
of a cycling footwear structure (not illustrated) according to the
present invention.
[0021] Said composite sole 1 is made up of at least two parts: the
first part that comprises a base sole 2 and the second part made up
of at least one stiffening element 3.
[0022] The stiffening element 3 is substantially annular-shaped
with a variable section passing from its front part 5 to its back
part 6.
[0023] The base sole 2, as visible in FIG. 2, has, substantially
along at least part of its perimeter, a recess 4, in which the
front part 5 of the stiffening element 3 is positioned.
[0024] As visible in FIGS. 4-8, the stiffening element 3 has, in
its front part 5, a section A', taken along the axis A-A of FIG. 4.
Such a section A' is substantially two-dimensional, with the two
dimensions being substantially equal to one another.
[0025] Section A' can also have other configurations and/or
geometries that are different from the two-dimensional one, without
for this reason departing from the scope of protection of the
present invention. Such a section A' substantially corresponds to
the shape of the recess 4, inside which the front part 5 of the
stiffening element 3 is positioned.
[0026] Sliding towards the back part 6 of the stiffening element 3,
its section undergoes a predetermined variation of thickness and of
geometry progressively becoming one-dimensional, with a main
dimension, with a lower thickness with respect to section A' and
with a substantially membrane-type configuration. Concerning this,
in FIGS. 6, 7 and 8 the sections B', C' and D' are shown obtained
by sectioning the stiffening element 3 respectively along the axes
B-B, C-C and D-D of FIG. 4. In the front area 5 of the stiffening
element 3, the dimensions of the section A' are substantially of
the same order of magnitude whereas in the back part 6 of the
stiffening element 3, one dimension of section D' has an order of
magnitude that is greater with respect to the other dimension.
[0027] In addition to its front part 5, at least also part of the
central area of the stiffening element 3, which goes from its front
part 5 until about half way, substantially at the axis C-C, is
positioned inside the recess 4 of the base sole 2. The back part 6
of the stiffening element 3 come out from the recess 4 starting
from about half way, substantially at the axis C-C, and extends
upwards, until it wraps around at least one portion of the heel of
a user, that is to say at least the upper part of the heel and/or
its central part which has a perimetral extension which is slightly
smaller with respect to the maximum perimetral extension of the
heel itself.
[0028] In such a way, the back part 6 of the stiffening element 3
blocks the heel and, thanks to the variation in its section and of
the composition of the material with which it is made, the
stiffening element 3 makes a reinforcing element that helps, while
pedalling, to reduce the power dissipated due to the elastic
deformation of the composite sole 1 and to increase the comfort,
thanks to an optimal distribution of the pressure at the interface
of the heel with the back part 6, with the variation of the
anatomical configuration of the heels of the different users.
[0029] In such a way it is possible to join the functions of
containment of the heel and of stiffening of the composite sole 1,
so as to improve and increase the power generated by the user and
transmitted to the pedal through the footwear itself.
[0030] The stiffening element 3 further comprises at least one
insert 7, positioned in the back part 6. The back part 6 of the
stiffening element 3 and the at least one insert 7 wrap around at
least one portion of the heel of a user, that is to say, at least
its upper and/or central part. Such components, in any case, can
wrap around the heel of the user either completely or only
partially, without for this reason departing from the scope of
protection of the present invention.
[0031] The insert 7 is made up of a flexible material which has
stiffness characteristics that are different from the material
forming the stiffening element 3 and from the material forming the
base sole 2.
[0032] This insert 7 determines the comfort of the fitting of the
user's foot, held by the back part 6 of the stiffening element 3
inside the footwear structure equipped with such a composite sole
1, and blocks the foot itself.
[0033] The composite sole 1, comprising components, such as the
base sole 2, the at least one stiffening element 3 and the at least
one insert 7, with different geometrical and physical
characteristics, makes it possible to easily produce a wide array
of products having different comfort and stiffness characteristics
which better adapt to the needs of the users. It is indeed possible
to make composite soles 1, possibly equipped with inserts 7 that
are integrated in the stiffening element 3, with different and
optimised characteristics according to the needs of a user,
selecting different materials for the various components and making
such components with personalised and/or variable thickness.
[0034] The insert 7 is made up of a material that is substantially
rigid comprising a plastic material reinforced with fibres (Fibre
Reinforced Plastic, FRP), like for example a polyamide and/or
polyurethane and/or, in general, thermoplastic material reinforced
with carbon fibres and/or glass fibres and/or aramid fibres and/or
the same fibres bonded to an epoxy and/or, in general,
thermosetting matrix and/or, more generally, a tough composite
material with high modulus elasticity.
[0035] In such a way, the insert 7, and in general all the back
part 6, does not have fragility problems.
[0036] The stiffening element 3 is made up of a material with a
different stiffness with respect to the material of the insert 7
and it can possibly comprise a base plastic material of a
thermoplastic or thermosetting type that, in turn, can possibly
comprise fibres, such as kevlar fibres and/or polyester and/or
rubber and/or carbon fibres and/or glass fibres.
[0037] In an alternative embodiment, the insert 7 makes it possible
to optimise the comfort of the footwear by making a variable
stiffness. In particular such a stiffness decreases starting from
the area of the insert 7 in contact with the base sole 2 until it
reaches the upper area of the insert 7.
[0038] Such a variable stiffness is obtained through a reduction of
the thickness of the stiffening element 3 and/or of the mechanical
characteristics of the insert 7.
[0039] The characteristics of the insert 7 listed above make it
possible to avoid the drawbacks of the prior art. Conventional heel
seat linings, indeed, are integrated with the sole and are made
with the same materials as the latter. However, the sole is made
with materials with high stiffness so as to transmit the power
developed by the cyclist while pedalling and this high stiffness
makes conventional heel seat linings fragile, causing them to break
easily with the consequent risk of the user getting injured.
[0040] The base sole 2 comprises an epoxy resin with which carbon
fibres are combined.
[0041] The fibres of the aforementioned materials have a preferred
flow, possibly not rigidly structured like warp and weft.
[0042] The present invention also concerns a method for making a
footwear structure equipped with a composite sole 1.
[0043] In particular, said method allows the manufacturer to lower
the costs of procuring the moulds and to obtain footwear which can
adapt to heels of different shapes and sizes.
[0044] Moreover, it is possible to reduce the investments, in
moulds, necessary for making a wide array of soles: with the
present method it is indeed possible, to modify even only one of
the production moulds to obtain composite soles with different
characteristics and/or it is possible to simplify the construction
of the production moulds by making shapes of soles or components
thereof which would otherwise require very expensive or unfeasible
moulds.
[0045] The method for making a footwear structure equipped with a
composite sole 1 comprises the following steps: providing a mould,
possibly equipped with a suitable seat for an insert 7, manually or
automatically positioning an insert 7 inside the mould, possibly in
its special seat; the method also comprises the steps of providing
a mould, manually or automatically inserting the material making up
the stiffening element 3, forming the stiffening element 3 by
compression or by injection, respectively.
[0046] In such a way at least one stiffening insert 3 and at least
one insert 7 are obtained, both made from the aforementioned
materials, selected so as to be compatible. In one alternative
embodiment, the materials with which the at least one insert 7 and
the at least one stiffening element 3 are made, are not compatible.
There is therefore a step in which such materials are treated with
known compatibilizing agents.
[0047] The method according to the invention also comprises the
following steps: providing a mould, arranging the stiffening
element 3, possibly equipped with at least one insert 7; the method
also comprises the steps of inserting the material that makes up
the base sole 2, forming the base sole 2 by compression and by
heat, possibly equipped with at least one recess 4; the method also
comprises the step of substantially positioning the front part 5 of
the stiffening element 3 in the recess 4.
[0048] In such a way at least one stiffening insert 3, at least one
insert 7 and at least one base sole 2 are obtained made in the
aforementioned materials, selected so as to be compatible. In an
alternative embodiment, the materials with which the at least one
insert 7, the at least one stiffening element 3 and the base sole 2
are made, are not compatible. There is thus a step of treating such
materials with known types of compatibilizing agents.
[0049] After the composite sole 1 has been made according to the
invention, made with the aforementioned method, there is a step of
trimming and finishing the sole, which is carried out
mechanically.
[0050] The aforementioned steps can be made in the same order as
described above or in a different order at different times;
moreover, the steps described can be made in any order. For example
it is possible to make the at least one stiffening element 3, the
at least one base sole 2 and the at least one insert 7 separately;
it is possible to make in the same mould and/or couple the at least
one stiffening element 3 and the at least one insert 7, during or
after the step of making the stiffening element 3, and couple such
components to the base sole 2; it is alternatively possible to
couple and/or make in the same mould the at least one stiffening
element 3 and the at least one base sole 2, during or after the
step for making the stiffening element 3 and/or the base sole 2 and
then couple such elements with the at least one insert 7,
etcetera.
[0051] In one alternative embodiment, the elements that form the
composite sole 1 according to the present invention can be made in
a single mould, simultaneously or in successive steps, or by
inserting a subsequent mould inside one that has already been
arranged.
[0052] The methods for coupling the aforementioned elements can be
manual and/or managed by special machinery and/or can occur by
co-moulding and/or by gluing of at least two of the elements
together. In order to make the insert 7, from composite material
with thermoplastic or thermosetting matrix, a starting material is
provided, made up of a dry fabric made from the aforementioned
carbon and/or glass and/or aramid fibres.
[0053] In the case in which the insert 7 is of the thermoplastic
matrix type, two layers of thermoplastic resin are provided and the
coupling of such a dry fabric based on fibres is carried out with
the two layers of thermoplastic resin arranged above and below the
dry fabric itself, respectively.
[0054] Such a coupling operation is carried out through heat and
pressure which, together, obtain the impregnation of the dry fabric
based on fibres described above, by the thermoplastic resin.
[0055] After such an impregnation step has been carried out, a
sheet or strip of impregnated fabric is obtained from which it is
possible to make, through cutting or blanking, at least one insert
7. The insert 7 thus obtained has a flat shape and can possibly
undergo a further thermoforming step, made in a special mould,
which makes the thermoformed insert 7 substantially U-shaped, or at
least able to match at least one portion of a heel of a user.
[0056] In the case in which the insert 7 is of the thermosetting
matrix type, a thermosetting resin is provided without
cross-linking and such a dry fabric based on fibres is coupled with
the thermosetting resin.
[0057] Such a coupling operation determines the preimpregnation
step of the dry fabric based on fibres.
[0058] After such an impregnation step has been carried out, a
sheet or strip of pre-impregnated fabric is obtained from which it
is possible to make, through cutting or blanking, at least one
insert 7. The insert 7 thus obtained is positioned in a mould and
is formed by compression with pressure and heat. In such a way, an
insert 7 is obtained that is substantially U-shaped, or at least
matches at least one portion of a heel of a user.
[0059] Also in this case, the aforementioned steps can be carried
out in the same order as described above or in different order and
at different times; moreover, the steps described can be made in
any order.
[0060] The present invention thus conceived can undergo numerous
modifications and variants all covered by the scope of protection
of the claims.
* * * * *