U.S. patent application number 13/726455 was filed with the patent office on 2014-06-26 for footbed and method for making the same.
The applicant listed for this patent is Kou-Bin LIN. Invention is credited to Kou-Bin LIN.
Application Number | 20140173945 13/726455 |
Document ID | / |
Family ID | 50973043 |
Filed Date | 2014-06-26 |
United States Patent
Application |
20140173945 |
Kind Code |
A1 |
LIN; Kou-Bin |
June 26, 2014 |
FOOTBED AND METHOD FOR MAKING THE SAME
Abstract
A footbed has a rigid shell and a soft body. The rigid shell has
a shell body and a supporting portion. The shell body has a rear
portion, a middle portion, and a front portion that are connected
sequentially. The supporting portion protrudes from the rim of the
rear portion. Each portion has an inner face and an outer face
opposite to the inner face. The soft body has a top face and a
bottom face opposite to the top face, and the bottom face is
laminated with each inner face of each portion. Hardness of the
rigid shell is higher than hardness of the soft body, and the rigid
shell and the soft body are integrally formed by heating a fabric
of vertical fibers. A method for making the footbed is also
provided.
Inventors: |
LIN; Kou-Bin; (Taichung
City, TW) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
LIN; Kou-Bin |
Taichung City |
|
TW |
|
|
Family ID: |
50973043 |
Appl. No.: |
13/726455 |
Filed: |
December 24, 2012 |
Current U.S.
Class: |
36/30R ;
12/146B |
Current CPC
Class: |
A43B 17/08 20130101;
A43B 17/003 20130101; A43B 17/006 20130101 |
Class at
Publication: |
36/30.R ;
12/146.B |
International
Class: |
A43B 13/14 20060101
A43B013/14 |
Claims
1. A footbed comprising: a rigid shell comprising: a shell body
comprising a rear portion, a middle portion, and a front portion,
wherein the rear portion, the middle portion and the front portion
are connected sequentially, and the rear portion, the middle
portion and the front portion respectively have an inner face and
an outer face opposite to the inner face; a supporting portion
protruding from a rim of the rear portion, and the supporting
portion has an inner face and an outer face opposite to the inner
face; a soft body comprising a top face and a bottom face opposite
to the top face, wherein the bottom face is laminated with each
inner face of the rear portion, the middle portion, the front
portion and the supporting portion; and wherein hardness of the
rigid shell is higher than hardness of the soft body, and the rigid
shell and the soft body are integrally formed by heating a fabric
of vertical fibers.
2. The footbed according to claim 1, wherein the rigid shell has a
protective portion protruding from a rim of the middle portion of
the shell body and connecting to the supporting portion, the
protective portion has an inner face and an outer face opposite to
the inner face, wherein the shell body, the protective portion and
the supporting portion form a space, and the bottom face of the
soft body is laminated with each inner face of the rear portion,
the middle portion, the front portion, the supporting portion and
the protective portion.
3. The footbed according to claim 1, wherein the rigid shell has a
protective portion protruding from each rim of the middle portion
and the front portion of the shell body and connecting to the
supporting portion, the protective portion has an inner face and an
outer face opposite to the inner face, wherein the shell body, the
protective portion and the supporting portion form a space, and the
bottom face of the soft body is laminated with each inner face of
the rear portion, the middle portion, the front portion, the
supporting portion and the protective portion.
4. The footbed according to claim 1, wherein the middle portion of
the shell body is an upward arch toward the soft body for fitting
the foot arch formed in the middle of a foot sole of a human
5. The footbed according to claim 2, wherein the middle portion of
the shell body is an upward arch toward the soft body for fitting
the foot arch formed in the middle of a foot sole of a human
6. The footbed according to claim 3, wherein the middle portion of
the shell body is an upward arch toward the soft body for fitting
the foot arch formed in the middle of a foot sole of a human
7. The footbed according to claim 4, which has a fabric layer
attached to the top face of the soft body.
8. The footbed according to claim 5, which has a fabric layer
attached to the top face of the soft body.
9. The footbed according to claim 6, which has a fabric layer
attached to the top face of the soft body.
10. The footbed according to claim 7, which has a foot pad disposed
between the soft body and the fabric layer and at a location
corresponding to the rear portion of the shell body.
11. The footbed according to claim 8, which has a foot pad disposed
between the soft body and the fabric layer and at a location
corresponding to the rear portion of the shell body.
12. The footbed according to claim 9, which has a foot pad disposed
between the soft body and the fabric layer and at a location
corresponding to the rear portion of the shell body.
13. The footbed according to claim 7, which has a foot pad disposed
between the soft body and the fabric layer and at a location
corresponding to the front portion of the shell body.
14. The footbed according to claim 8, which has a foot pad disposed
between the soft body and the fabric layer and at a location
corresponding to the front portion of the shell body.
15. The footbed according to claim 9, which has a foot pad disposed
between the soft body and the fabric layer and at a location
corresponding to the front portion of the shell body.
16. A method for making a footbed comprising: a rigid shell
comprising: a shell body comprising a rear portion, a middle
portion, and a front portion, wherein the rear portion, the middle
portion and the front portion are connected sequentially, and the
rear portion, the middle portion and the front portion respectively
have an inner face and an outer face opposite to the inner face; a
supporting portion protruding from a rim of the rear portion, and
the supporting portion has an inner face and an outer face opposite
to the inner face; a soft body comprising a top face and a bottom
face opposite to the top face, wherein the bottom face is laminated
with each inner face of the rear portion, the middle portion, the
front portion and the supporting portion; and wherein hardness of
the rigid shell is higher than hardness of the soft body; and the
method comprises steps of: providing a fabric of vertical fibers;
providing a mold, wherein the mold has a shape corresponding to a
shape of the footbed, and the mold has a heating surface; placing
the fabric of vertical fibers into the mold to abut against the
heating surface; heating the heating surface of the mold to a
temperature ranging from 160 to 200.degree. C. to heat the fabric
of vertical fibers, and then obtaining the footbed; and wherein the
rigid shell is formed between the soft body and the heating
surface.
17. The method according to claim 16, wherein the step of heating
the heating surface of the mold to a temperature ranging from 160
to 200.degree. C. to heat the fabric of vertical fibers includes
heating the heating surface of the mold to a temperature ranging
from 160 to 200.degree. C. to heat the fabric of vertical fibers
and applying a pressure to the mold simultaneously, and then
obtaining the footbed.
18. A method for making a footbed comprising: a rigid shell
comprising: a shell body comprising a rear portion, a middle
portion, and a front portion, wherein the rear portion, the middle
portion and the front portion are connected sequentially, and the
rear portion, the middle portion and the front portion respectively
have an inner face and an outer face opposite to the inner face; a
supporting portion protruding from a rim of the rear portion, and
the supporting portion has an inner face and an outer face opposite
to the inner face; a soft body comprising a top face and a bottom
face opposite to the top face, wherein the bottom face is laminated
with each inner face of the rear portion, the middle portion, the
front portion and the supporting portion; a fabric layer attached
to the top face of the soft body; and wherein hardness of the rigid
shell is higher than hardness of the soft body and the middle
portion of the shell body is an upward arch toward the soft body
for fitting the foot arch formed in the middle of a foot sole of a
human; and the method comprises steps of : providing a fabric of
vertical fibers; providing a fabric layer and then laminating the
fabric layer with the fabric of vertical fibers to obtain a fabric
of vertical fibers with the fabric layer; providing a mold, wherein
the mold has a shape corresponding to a shape of the footbed, and
the mold has a heating surface; placing the fabric of vertical
fibers with the fabric layer into the mold to abut against the
heating surface; heating the heating surface of the mold to a
temperature ranging from 160 to 200.degree. C. to heat the fabric
of vertical fibers with the fabric layer, and then obtaining the
footbed; and wherein the rigid shell is formed between the soft
body and the heating surface.
19. The method according to claim 18, wherein the step of heating
the heating surface of the mold to a temperature ranging from 160
to 200.degree. C. to heat the fabric of vertical fibers with the
fabric layer includes heating the heating surface of the mold to a
temperature ranging from 160 to 200.degree. C. to heat the fabric
of vertical fibers with the fabric layer and applying a pressure to
the mold simultaneously, and then obtaining the footbed.
Description
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a footbed, and particularly
to a footbed providing good ventilation and anti-distortion. The
present invention also relates to a method for making the
footbed.
[0003] 2. Description of the Prior Arts
[0004] Most of the conventional footbeds are made of ethylene-vinyl
acetate copolymer (EVA). The manufacturing cost of footbeds can be
reduced remarkably due to the low-cost EVA. However, the EVA
footbeds have many drawbacks such as lack of ventilation and being
impermeable to water. Accordingly, while wearing shoes with the EVA
footbeds, the wearer's feet are enclosed in shoes, which causes
discomfort of the wearer and generates foot odor due to the lack of
ventilation of the EVA footbeds. Besides, when the wearer's feet
sweat, sweat remains on the surface of the footbeds easily due to
the EVA footbeds being impermeable to water, which makes the
wearer's feet suffer from moisture and thus makes the footbed prone
to growth of bacteria. As a result, the chance is increased for the
wearer to get skin infection such as athlete's foot. Furthermore,
the EVA footbeds are not anti-distortion due to the low recovery
rate and the softness of EVA. Accordingly, after EVA footbeds are
worn for a period of time, the EVA footbeds deforms, which results
in negative effects on the wearer such as poor posture.
[0005] In addition, in order to increase the rigidity of the EVA
footbeds so as to prevent undesirable deformation, injection molded
heel cups made of polyurethane (PU) are laminated on the bottom
surface of the rear heel area of the EVA footbeds. However, the PU
heel cups still have drawbacks such as yellowing and decomposition
after a long period of time. Besides, PU heel cups easily generate
toxicity during the decomposing process, which is severely harmful
to the wearer's health. Also, the EVA footbeds with PU heel cups
still lack ventilation and are impermeable to water. Furthermore,
the EVA footbeds with PU heel cups are not integrally formed, that
is, EVA footbeds with PU heel cups are manufactured through
multiple processes. Accordingly, the manufacturing cost of the EVA
footbeds with PU heel cups is increased and the industrial
applicability of the EVA footbeds with PU heel cups is reduced.
[0006] To overcome the shortcomings, the present invention provides
a footbed and a method for making the footbed to mitigate or
obviate the aforementioned problems.
SUMMARY OF THE INVENTION
[0007] Given that the aforesaid drawbacks of the prior art such as
lack of ventilation, being impermeable to water and not
anti-distortion, the main objective of the present invention is to
provide a footbed, which comprises:
[0008] a rigid shell comprising: [0009] a shell body comprising a
rear portion, a middle portion, and a front portion, wherein the
rear portion, the middle portion and the front portion are
connected sequentially, and the rear portion, the middle portion
and the front portion respectively have an inner face and an outer
face opposite to the inner face; [0010] a supporting portion
protruding from a rim of the rear portion, and the supporting
portion has an inner face and an outer face opposite to the inner
face;
[0011] a soft body comprising a top face and a bottom face opposite
to the top face, wherein the bottom face is laminated with each
inner face of the rear portion, the middle portion, the front
portion and the supporting portion;
[0012] wherein hardness of the rigid shell is higher than hardness
of the soft body, and the rigid shell and the soft body are
integrally formed by heating a fabric of vertical fibers.
[0013] More preferably, the definition of "the bottom face is
laminated with each inner face of the rear portion, the middle
portion, the front portion and the supporting portion" is that the
bottom face is connected seamlessly to each inner face of the rear
portion, the middle portion, the front portion and the supporting
portion. Thus, the bottom face is inseparable from each inner face
of the rear portion, the middle portion, the front portion and the
supporting portion.
[0014] According to the present invention, the thickness of the
soft body is, but not limited to, between 1 mm and 5 mm.
[0015] According to the present invention, the thickness of the
rigid shell is, but not limited to, between 10 mm and 20 mm.
[0016] According to the present invention, the fabric of vertical
fibers is made of different polyester staple fibers with various
functions, through methods such as, but not limited to the
following: carding the polyester staple fibers to ensure the
blending of the fibers is uniform and separating the fibers into a
loose mass; folding the carded fibers in a vertical direction to
form a cotton web, wherein the definition of the vertical direction
is that majority of fibers are oriented perpendicular to the
surface having the largest area of the cotton web; and heat curing
the cotton web to obtain the fabric of vertical fibers.
[0017] According to the present invention, the different polyester
staple fibers with various functions include, but not limited to,
low melting point polyester staple fiber, elastic polyester staple
fiber or polyester staple fiber containing rubber.
[0018] According to the present invention, the polyester staple
fiber includes, but not limited to, polyethylene terephthalate
(PET),(poly(ethylene terephthalateco-1,4-cylclohexylenedimethylene
terephthalate), polybutylene terephthalate(PBT),(polyethylene
terephthalate/sodium 5-sulfoisophthalate copolymer fiber), or any
other suitable polyester staple fiber.
[0019] According to the present invention, the melting point of the
low melting point polyester staple fiber ranges from 115 to
180.degree. C.
[0020] According to the present invention, the elastic polyester
staple fiber is capable of increasing the rigidity of the fabric of
vertical fibers.
[0021] According to the present invention, the polyester staple
fiber containing rubber is capable of increasing the recovery rate
of the fabric of vertical fibers.
[0022] According to the present invention, the definition of the
recovery rate is the extent to which the fabric of vertical fibers
recovers after compression.
[0023] According to the present invention, the recovery rate of the
footbed is higher than 70%. Preferably, the recovery rate of the
footbed ranges from 70% to 90%.
[0024] According to the present invention, the fabric of vertical
fibers is a fiber web having vertically aligned structure, wherein
the definition of the vertically aligned structure is that majority
of fibers are oriented perpendicular to the surface having the
largest area of the fiber web.
[0025] According to the present invention, the definition of
"heating a fabric of vertical fibers" is that a fabric of vertical
fibers is heated by a heat source, and the temperature of the heat
source is slightly higher than the melting point of the material of
the fabric of vertical fibers, wherein the material includes, but
not limited to, polyester staple fiber. Preferably, the temperature
of the heat source ranges from 160.degree. C. to 200.degree. C.
[0026] According to the present invention, the definition of
"integrally formed" is that during the course of heating the fabric
of vertical fibers, the rigid shell and the soft body are
simultaneously formed. Accordingly, after heating the fabric of
vertical fibers, the rigid shell and the soft body are integrally
formed.
[0027] Preferably, the rigid shell has a protective portion
protruding from a rim of the middle portion of the shell body and
connecting to the supporting portion, the protective portion has an
inner face and an outer face opposite to the inner face, wherein
the shell body, the protective portion and the supporting portion
form a space, and the bottom face of the soft body is laminated
with each inner face of the rear portion, the middle portion, the
front portion, the supporting portion and the protective
portion.
[0028] Preferably, the rigid shell has a protective portion
protruding from each rim of the middle portion and the front
portion of the shell body and connecting to the supporting portion,
the protective portion has an inner face and an outer face opposite
to the inner face, wherein the shell body, the protective portion
and the supporting portion form a space, and the bottom face of the
soft body is laminated with each inner face of the rear portion,
the middle portion, the front portion, the supporting portion and
the protective portion.
[0029] Preferably, the middle portion of the shell body is an
upward arch toward the soft body for fitting the foot arch formed
in the middle of a foot sole of a human.
[0030] Preferably, the footbed has a fabric layer attached to the
top face of the soft body.
[0031] Preferably, the footbed has a foot pad disposed between the
soft body and the fabric layer and at a location corresponding to
the rear portion of the shell body.
[0032] Preferably, the footbed has a foot pad disposed between the
soft body and the fabric layer and at a location corresponding to
the front portion of the shell body.
[0033] Another main objective of the present invention is to
provide a method for making the footbed, which comprises steps
of:
[0034] providing a fabric of vertical fibers;
[0035] providing a mold, wherein the mold has a shape corresponding
to the shape of the footbed, and the mold has a heating
surface;
[0036] placing the fabric of vertical fibers into the mold to abut
against the heating surface;
[0037] heating the heating surface of the mold to a temperature
ranging from 160 to 200.degree. C. to heat the fabric of vertical
fibers, and then the footbed is obtained; and
[0038] wherein the rigid shell is formed between the soft body and
the heating surface.
[0039] According to the present invention, in the step of providing
a fabric of vertical fibers, the thickness of the fabric of
vertical fibers ranges from 10 to 25 mm.
[0040] According to the present invention, in the step of heating
the heating surface of the mold to a temperature ranging from 160
to 200.degree. C. to heat the fabric of vertical fibers, the time
of heating the fabric of vertical fibers is, but not limited to,
between 30 and 60 seconds.
[0041] Preferably, the step of heating the heating surface to heat
the fabric of vertical fibers includes heating the heating surface
of the mold to a temperature ranging from 160 to 200.degree. C. to
heat the fabric of vertical fibers and applying a pressure to the
mold simultaneously, and then a footbed is obtained.
[0042] According to the present invention, the time of heating the
fabric of vertical fibers and applying a pressure to the mold
simultaneously is, but not limited to, between 30 and 60
seconds.
[0043] According to the present invention, the higher the
temperature of the heating surface of the mold and the longer the
time of heating the fabric of vertical fibers and applying a
pressure to the mold, the thicker the rigid shell. For example, but
not limited to the following description: a fabric of vertical
fibers with a thickness of 13 mm is provided; the heating surface
of the mold is heated to 170.degree. C. and the time of heating the
fabric of vertical fibers and applying a pressure to the mold
simultaneously is 40 seconds, and a footbed is obtained, wherein
the thickness of the rigid shell of the obtained footbed is 1 mm
while the thickness of the soft body of the obtained footbed is 12
mm. A relative example such as a fabric of vertical fibers with a
thickness of 13 mm is provided; the heating surface of the mold is
heated to 180.degree. C. and the time of heating the fabric of
vertical fibers and applying a pressure to the mold simultaneously
is 60 seconds, and a footbed is obtained, wherein the thickness of
the rigid shell of the obtained footbed is 2mm while the thickness
of the soft body of the obtained footbed is 11 mm
[0044] Preferably, after the step of providing a fabric of vertical
fibers, the method comprises a step of providing a fabric layer and
then laminating the fabric layer with the fabric of vertical
fibers. Hence, the obtained footbed has a fabric layer attached to
the top face of the soft body.
[0045] Preferably, the step of providing a fabric layer and then
laminating the fabric layer with the fabric of vertical fibers
includes providing a foot pad and then laminating the foot pad with
the fabric of vertical fibers to obtain a fabric of vertical fibers
with the foot pad; providing a fabric layer and then laminating the
fabric layer with the fabric of vertical fibers with the footpad.
Hence, the obtained footbed has a foot pad disposed between the
soft body and the fabric layer and at a location corresponding to
the rear portion of the shell body.
[0046] According to the aforementioned structure, the advantages of
the footbed of the present invention are as follows:
[0047] 1. Because the rigid shell and the soft body of the footbed
of the present invention are integrally formed by heating a fabric
of vertical fibers and also because the rigid shell is rigid, the
rigid shell is anti-distortion, such that the footbed of the
present invention does not distort easily, which extends the
lifespan of the footbed. Besides, due to the supporting portion,
the footbed can protect the heel of the wearer and avoid a heel
strike while walking. Thus, the footbed provides higher heel
stability. Furthermore, the soft body and the rigid shell provide
good ventilation and are permeable to water. Accordingly, the
wearer's feet are kept fresh and cool while wearing a pair of shoes
with the footbeds inside and thus feet odor is prevented. Even if
the feet sweat, the surfaces of the footbeds do not become wet,
which prevents the growth of bacteria and prevent any infection. In
addition, the rigid shell and the soft body of the footbed are made
of a heated fabric of vertical fibers, wherein the fabric of
vertical fibers is a fiber web having a vertically aligned
structure. Hence, the footbed has good elasticity, high recovery
rate and provides high heat insulation, which improves the comfort
of wearing the footbed and keeps the feet warm during the winter.
Also, after the footbed is worn for a period of time, the footbed
will not collapse and will not become compressed and deformed.
Hence, the lifespan of the footbed is extended.
[0048] 2. Because the material of the fabric of vertical fibers is
polyester staple fiber, the footbed will be free from yellowing and
will not decompose to generate toxicity after the footbed is worn
for a period of time. Hence, the footbed of the present invention
is a safe product.
[0049] 3. Because the rigid shell has a protective portion, the
footbed can support the forefoot and the mid-foot well.
[0050] 4. Because the middle portion of the shell body is an upward
arch toward the soft body, the footbed supports the foot arch well
and thus provides excellent stability for the feet. Hence, wearing
shoes with the footbeds is extremely comfortable.
[0051] According to the aforementioned steps, the advantage of the
method for making the footbed of the present invention is as
follows:
[0052] The rigid shell and the soft body of the footbed of the
present invention are integrally formed through the step of heating
the fabric of vertical fibers.
[0053] Accordingly, other additional steps such as adhering a heel
cup to the rear portion of the footbed is not needed. Thus, the
method for making the footbed of the present invention is extremely
simple to reach the purpose of manufacturing a footbed having a
rigid shell and a soft body integrally formed. Accordingly, the
industrial applicability of the method for making the footbed of
the present invention is enhanced remarkably.
[0054] Other objectives, advantages and novel features of the
invention will become more apparent from the following detailed
description when taken in conjunction with the accompanying
drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0055] FIG. 1 is a top view of a first embodiment of the footbed in
accordance with the present invention;
[0056] FIG. 2 is a side view of the first embodiment of the footbed
in accordance with the present invention;
[0057] FIG. 3 is an enlarged cross section of the first embodiment
of the footbed in accordance with the present invention;
[0058] FIG. 4 is a side view of a second embodiment of the footbed
in accordance with the present invention;
[0059] FIG. 5 is an enlarged cross section of a third embodiment of
the footbed in accordance with the present invention;
[0060] FIG. 6 is a perspective view of a fourth embodiment of the
footbed in accordance with the present invention;
[0061] FIG. 7 is a top view of a fifth embodiment of the footbed in
accordance with the present invention;
[0062] FIG. 8 is a flow diagram of a sixth embodiment of the method
for making the footbed in accordance with the present
invention;
[0063] FIG. 9 is a flow diagram of a seventh embodiment of the
method for making the footbed in accordance with the present
invention; and
[0064] FIG. 10 is a flow diagram of a eighth embodiment of the
method for making the footbed in accordance with the present
invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0065] For a better understanding about the technical features of
the present invention and its effect, and for implements in
accordance with the disclosures of the specification, preferred
embodiment, details and figures are further shown as follows:
First Embodiment
[0066] With reference to FIG. 1 to FIG. 3, the first embodiment of
the footbed in accordance with the present invention has a rigid
shell 10 and a soft body 20 connected to the rigid shell 10.
[0067] The rigid shell 10 has a shell body 11, a supporting portion
12 connected to the shell body 11, and a protective portion 13
connected to the shell body 11 and the supporting portion 12. The
shell body 11 comprises a rear portion 111, a middle portion 112,
and a front portion 113, wherein the rear portion 111, the middle
portion 112 and the front portion 113 are connected sequentially.
The rear portion 111, the middle portion 112 and the front portion
113 respectively have an inner face and an outer face opposite to
the inner face. The supporting portion 12 protrudes from the rim of
the rear portion 111 of the shell body 11, and the supporting
portion 12 has an inner face and an outer face opposite to the
inner face. The protective portion 13 protrudes from each rim of
the middle portion 112 and the front portion 113 of the shell body
11 and is connected to the supporting portion 12. The protective
portion 13 has an inner face and an outer face opposite to the
inner face. The shell body 11, the protective portion 13 and the
supporting portion 12 form a space for fitting a foot of a human.
The soft body 20 has a top face 21 and a bottom face 22 opposite to
the top face 21. The bottom face 22 is laminated with each inner
face of the rear portion 111, the middle portion 112, the front
portion 113, the supporting portion 12 and the protective portion
13. The top face 21 of the soft body 20 is used to contact the foot
sole of a human
[0068] The rigid shell 10 and the soft body 20 of the present
embodiment are integrally formed by heating a fabric of vertical
fibers. The fabric of vertical fibers is made of different
polyester staple fibers of various functions. The different
polyester staple fibers with various functions include low melting
point polyester staple fiber, elastic polyester staple fiber, and
polyester staple fiber containing rubber, wherein the melting point
of the low melting point polyester staple fiber is 115.degree. C.
Based on the overall weight of the fabric of vertical fibers, the
amount of the low melting point polyester staple fiber is 20 parts
by weight, the amount of the elastic polyester staple fiber is 40
parts by weight and the amount of the polyester staple fiber
containing rubber is 40 parts by weight. Besides, the hardness of
the rigid shell 10 is higher than the hardness of the soft body 20.
The Shore hardness of the rigid shell 10 is 60 degrees and the
Shore hardness of the soft body 20 ranges from 30 to 35 degrees.
Furthermore, the thickness of the rigid shell 10 is 2 mm and the
thickness of the soft body 20 is 10 mm.
Second Embodiment
[0069] With reference to FIG. 4, the second embodiment of the
footbed in accordance with the present invention is approximately
the same as the first embodiment of the footbed. The major
difference is that the middle portion 112 of the shell body 11 of
the second embodiment is an upward arch toward the soft body 20 for
fitting the foot arch formed in the middle of a foot sole of a
human. Due to the soft body 20 laminated with each inner face of
the rear portion 111, the middle portion 112, the front portion
113, the supporting portion 12 and the protective portion 13, the
region of the soft body 20 corresponding to the middle portion 112
of the shell body 11 is also an upward arch toward the top face
21.
Third Embodiment
[0070] With reference to FIG. 5, the third embodiment of the
footbed in accordance with the present invention is approximately
the same as the second embodiment of the footbed. The major
difference is that the footbed of the third embodiment has a fabric
layer 30 attached to the top face 21 of the soft body 20. The
fabric layer 30 is used to contact the foot sole of a human
Fourth Embodiment
[0071] With reference to FIG. 6, the fourth embodiment of the
footbed in accordance with the present invention is approximately
the same as the third embodiment of the footbed. The major
difference is that the footbed of the fourth embodiment has two
foot pads 40a,40b disposed between the soft body 20 and the fabric
layer 30. One of the foot pads 40a is at a location corresponding
to the rear portion 111 of the shell body 11. The other foot pad
40b is at a location corresponding to the front portion 113 of the
shell body 11.
Fifth Embodiment
[0072] With reference to FIG. 7, the fifth embodiment of the
footbed in accordance with the present invention is approximately
the same as the first embodiment of the footbed. The major
difference is that the protective portion 13 protrudes from the rim
of the middle portion 112 of the shell body 11 and connects to the
supporting portion 12.
[0073] The present invention also relates to a method for making
the footbed aforementioned.
Sixth Embodiment
[0074] With reference to FIG. 8, the sixth embodiment provides a
method for making the first embodiment of the footbed in accordance
with the present invention, which comprises steps of:
[0075] providing a fabric of vertical fibers, and then trimming the
fabric of vertical fibers to a thickness of 12 mm and a preset
size;
[0076] providing a mold, wherein the mold had a shape corresponding
to the shape of the footbed, and the mold had a heating
surface;
[0077] placing the fabric of vertical fibers into the mold to abut
against the heating surface;
[0078] heating the heating surface of the mold to a temperature of
180.degree. C. to heat the fabric of vertical fibers and applying a
pressure to the mold simultaneously, wherein the time of heating
the fabric of vertical fibers and applying a pressure to the mold
simultaneously is 40 seconds, and obtaining a footbed.
[0079] The surface of the fabric of vertical fibers abutting
against the heating surface of the mold is formed into the rigid
shell having higher hardness due to a higher surface temperature,
while the surface of the fabric of vertical fibers opposite to the
heating surface of the mold is formed into the soft body having
lower hardness due to a lower surface temperature. Accordingly, the
rigid shell and the soft body are integrally formed during the step
of heating the fabric of vertical fibers.
Seventh Embodiment
[0080] The seventh embodiment provides a method for making a third
embodiment of the footbed in accordance with the present invention.
The present embodiment was approximately the same as the method of
the sixth embodiment. With reference to FIG. 9, the major
difference is that after the step of providing a fabric of vertical
fibers, the method comprises a step of providing a fabric layer and
then laminating the fabric layer with the fabric of vertical fibers
by a binder to obtain a fabric of vertical fibers with the fabric
layer. The binder used in the seventh embodiment is resin
adhesive.
Eighth Embodiment
[0081] The eighth embodiment provides a method for making the
fourth embodiment of the footbed in accordance with the present
invention. The eighth embodiment is approximately the same as the
seventh embodiment of the method. With reference to FIG. 10, the
major difference is that the step of providing a fabric layer and
then laminating the fabric layer with the fabric of vertical fibers
includes providing two foot pads and then laminating the foot pads
with the fabric of vertical fibers by a binder to obtain a fabric
of vertical fibers with foot pads; providing a fabric layer and
then laminating the fabric layer with the fabric of vertical fibers
with foot pads by a binder to obtain a fabric of vertical fibers
with both foot pads and the fabric layer. The binder used in the
eighth embodiment resin adhesive.
TEST EXAMPLE
[0082] A fourth embodiment of the footbed and a commercially
available EVA footbed are provided to compare the ventilation and
permeability to water of each.
[0083] The test example comprised step of blowing toward one of the
surfaces of a footbed and placing one hand next to the other
surface of the footbed at the same time. Efficiency of ventilation
was determined by the flow feel by hand. If the hand felt the flow,
the footbed was determined as having excellent ventilation. If the
hand did not feel the flow, the footbed was determined as having
poor ventilation. The obtained results are shown in Table 1.
[0084] Test of permeability to water comprised step of pouring
water on one of the surfaces of a footbed. Quality of permeability
to water was determined by the water flowing out from the other
surface of the footbed. If there was water flowing out from the
other surface of the footbed, the footbed was determined as having
excellent permeability to water. If there was no water flowing out
from the other surface of the footbed, the footbed was determined
as having poor permeability to water. The obtained results are
shown in Table 1.
TABLE-US-00001 TABLE 1 The results of ventilation and permeability
to water of each sample Sample Ventilation Permeability to water
Commercially available Poor Poor EVA footbed A fourth embodiment of
Excellent Excellent the footbed
[0085] As shown in Table 1, the ventilation and permeability to
water of a fourth embodiment of the footbed in accordance with the
present invention are obviously better than the ventilation and
permeability to water of the commercially available EVA footbed.
Furthermore, ten minutes after pouring water on one of the surfaces
of a fourth embodiment of the footbed, the surface was totally dry.
However, ten minutes after pouring water on one of the surfaces of
the commercially available EVA footbed, the surface was still wet
and even had some water remaining on it. Accordingly, integrally
formed rigid shell and the soft body of a fourth embodiment of the
footbed have excellent ventilation and excellent permeability to
water.
[0086] Even though numerous characteristics and advantages of the
present invention have been set forth in the foregoing description,
together with details of the structure and features of the
invention, the disclosure is illustrative only. Changes may be made
in the details, especially in matters of shape, size, and
arrangement of parts within the principles of the invention to the
full extent indicated by the broad general meaning of the terms in
which the appended claims are expressed.
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