U.S. patent number 3,616,170 [Application Number 05/042,483] was granted by the patent office on 1971-10-26 for foamed sheet for making stiffening elements.
Invention is credited to Addison W. Closson, Jr..
United States Patent |
3,616,170 |
Closson, Jr. |
October 26, 1971 |
FOAMED SHEET FOR MAKING STIFFENING ELEMENTS
Abstract
A novel sheet material particularly useful in formation of a
stiffening structure for incorporation into shoe counters and the
like, the structure comprising a foam sheet and a fabric sheet
adherent thereon, the foamed sheet being formed of a thermoplastic
elastomer and accounting for the major part of the thickness of the
completed element.
Inventors: |
Closson, Jr.; Addison W.
(Watertown, MA) |
Family
ID: |
26719295 |
Appl.
No.: |
05/042,483 |
Filed: |
June 1, 1970 |
Current U.S.
Class: |
442/76; 12/146D;
36/69; 428/304.4; 36/68; 36/77M; 428/332; 442/103 |
Current CPC
Class: |
B32B
5/245 (20130101); B29D 35/142 (20130101); B32B
7/12 (20130101); D06N 3/10 (20130101); A43B
23/16 (20130101); D06N 3/04 (20130101); A43B
23/17 (20130101); Y10T 428/26 (20150115); Y10T
442/2139 (20150401); B32B 2266/0221 (20130101); Y10T
428/249953 (20150401); B32B 2266/0292 (20130101); B32B
2309/105 (20130101); Y10T 442/2361 (20150401); B32B
2437/02 (20130101); B32B 2307/724 (20130101) |
Current International
Class: |
A43B
23/16 (20060101); A43B 23/17 (20060101); A43B
23/00 (20060101); D06N 3/04 (20060101); B29D
31/50 (20060101); B29D 31/518 (20060101); D06N
3/00 (20060101); D06N 3/10 (20060101); B32b
003/26 (); B32b 007/00 (); A43b 013/42 () |
Field of
Search: |
;12/146D ;36/68,69,77
;161/159,160,165 |
References Cited
[Referenced By]
U.S. Patent Documents
Primary Examiner: Van Balen; William J.
Parent Case Text
RELATED APPLICATION
This application is a continuation-in-part of U.S. application Ser.
No. 847,724 filed Aug. 5, 1969, by Addison W. Closson, Jr., and
entitled "Foamed Stiffener Element."
Claims
What is claimed is:
1. A thermoformable, moisture vapor permeable reinforcing sheet
element suitable for forming shoe stiffeners and consisting
essentially of a first layer of fabric and a second layer of
ethylene-vinyl acetate copolymer foam, said copolymer foam being of
from about 5 to 12 percent vinyl acetate content, being
substantially free from external plasticizers, and containing 20
percent to 90 percent by volume of voids, said layers bonded
together without the aid of extraneous adhesives.
2. A thermoformable sheet element as defined in claim 1 wherein
said laminate is from 0.05 to 0.10 inch in thickness.
3. A sheet element as defined in claim 1 wherein said fabric is a
drilling fabric.
4. A sheet element as defined in claim 2 wherein said fabric is a
drilling fabric.
5. A sheet element as defined in claim 1 wherein the Vicat
softening point of the foamed thermoplastic is over 140.degree.
F.
6. A sheet element as defined in claim 3 wherein said thickness of
said sheet element is below about 0.10 inch.
Description
SUMMARY OF THE INVENTION
There are numerous applications in the fabrication of wearing
apparel which require stiffening and support means in order to
reinforce or strengthen some particular section of the apparel.
Among the most important applications of such stiffening elements
are those encountered in the manufacture of shoes, sneakers, pumps,
slippers and other such footwear. For example, such stiffening
units are especially important in the construction of an ordinary
back part of a shoe. In general, it is desirable that such
components be light, withstand reasonable temperatures as may be
encountered in their ordinary use, and have a degree of resilience
and strength which will add to the comfort of the wearer of the
shoe. These advantages are preferably obtained without the addition
of any excessive weight to the shoe, and a reduction in weight
would be desirable.
In the selection of a material of construction for forming such
elements, particular care must be given not only to the resilience
but to the formability of the material from which the element is to
be constructed; thus the material cannot be so temperature and
pressure-resistant that it is not formable into a shaped stiffening
element by thermal and pressure means. On the other hand, the
material of construction should be washable to satisfy many
applications, and thus should be able to withstand temperatures of
at least from 140.degree. F. to 150.degree. F. as encountered in a
typical laundry machine. The Vicat softening point is an
appropriate criterion of the heat resistance of the polymer.
Although the above considerations are generally important, they
become particularly important in footwear-making operations wherein
a sole is molded, by thermal injection molding techniques, to a
shoe upper comprising the stiffening element therein. In such a
situation, there is often an undesirable and unsightly "bulge"
caused by pressure from the flange at the top of the mold cavity
which appears where the heel and the sole meet. This bulge not only
detracts from the appearance of the footwear, but also affects the
merchantability of the footwear.
Up until the present time, such reinforcing elements as shoe
counters have been made of a number of sheet materials most notably
calendered rubber rag stock materials or rubber saturated textiles
and fiber. These materials have generally been formed into
0.055-inch thick counters. This thickness is customary because
rubber rag stock materials are not resilient enough in lesser
thicknesses. However, with the advent of improved materials, this
thickness has not necessarily reflected a real need in terms of
reinforcing strength. Thus, present shoe manufacturing techniques
utilize a considerable quantity of material in such reinforcing
applications, but this quantity of material is in fact not really
required nor--as applicant has found in instant
invention--particularly desirable.
SUMMARY OF THE INVENTION
Therefore, it is a principal object of the present invention to
provide an improved stiffening or reinforcing sheet element for use
in the manufacture of apparel, but especially for use in
footwear.
Another object of the invention is to provide a new lightweight,
resilient, and self-adherent stiffening element.
A further object of the invention is to provide a novel stiffening
element that will shape easily under heat but will not degrade when
subjected to temperatures of 140.degree. F. and above in washing
apparatus.
Other objects of the invention will be obvious to those skilled in
the art on reading the instant specification.
The above objects have been substantially obtained by the
construction of a novel thermoformable stiffening structure
especially useful for shaping and incorporation into shoe counters
and the like. The structure comprises a foam sheet formed of an
elastomeric thermoplastic and a fabric sheet laminated thereon, the
foam sheet accounting for the major part of the thickness of the
completed element.
The foam sheet is formed of a polymeric foam material. Preferred
for use are thermoplastic elastomers, most advantageously, a
copolymer of ethylene and vinyl acetate having from 2, but most
advantageously from about 5 to 27 percent by weight of
vinyl-acetate derived mer-units therein. One such material is that
sold under the trade name Alathon 3130 by E. I. DuPont de Nemours
and Co., Inc. This material contains about 12 percent vinyl acetate
units and has been found preferable to material containing over
about 18 percent such units because the latter materials have
undesirably low softening points for many applications. Other
useful thermoplastic elastomers include styrene-butadiene rubber
such as that sold under the trade name Kraton by Shell Chemical
Company, thermoplastic polyurethane elastomers, the ionomer sold
under the trade designation Surlyn by E. I. DuPont de Nemours and
Co., Inc., and the chlorinated polyethylene sold under the trade
designation Tyrin by Dow Chemical Company, the chlorosulfonated
polyethylene sold under the trade designation Hypalon by DuPont,
and the like. This list will suggest to those skilled in the art
the wide variety of thermoplastic polymers which may be utilized in
the process of the invention; thus, the list is to be considered
illustrative only and not limiting with respect to the particular
materials that can be used to form the stiffening elements of the
invention. Such polymers must be resilient as well and
thermoformable and their use in shoe stiffeners is largely
dependent on this fact.
Resiliency is inherent in elastomers, i.e. as defined in Hackh's
Chemical Dictionary (4th Edition). Such elastomers will have a
relatively large angle of permanent deformation and the vinyl
acetate/ethylene copolymers are especially advantageous in this
respect. This resilience combined with the exceptionally good
adhesive properties of vinyl acetate at processing temperatures
make it in an ideal material for use in shoe applications. It is to
be noted that the ionic cross-linked materials are useful as
thermoplastics and, therefore, are useful. Conventionally
cross-linked or vulcanized materials like polyurethane resins and
vulcanized rubbers are not generally useful in forming sheets
according to the invention. Polystyrene, although thermoplastic, is
typical of a polymer that is insufficiently resilient and
elastomeric to be of use in forming sheets according to the
invention.
It is particularly important that a polymer system be selected
which provides the necessary degree of comfort and resilience
without the need of plasticizers. This is true because shoe
stiffeners are subjected to such varied conditions of temperature
and humidity, during wear and washing, that plasticizers tend to be
leached out--or in some way made ineffective-- during the life of
the shoe. Moreover, the migration of plasticizer to the outer
surface of a plastic article is considerably more of a problem when
that article is in the shape of a foam.
By "plasticizer" is meant that class of relatively low molecular
weight materials called "external" plasticizers, not agents causing
internal plastication by modifying the chemical nature of the
polymer itself.
The fabric which can be used in the present invention includes any
fabric, woven or unwoven, natural or synthetic, which is known to
the clothing industry as suitable for use in wearing apparel. The
use of this fabric is partially aesthetic and, in most cases, the
element would be useful for stiffening purposes even if the fabric
were not utilized. Nevertheless, because foam has an improved
moisture vapor transmission characteristic over the reinforcing
materials known to the art, it has been found that the presence of
the fabric layers plays a role in distributing, i.e. wicking,
moisture over the entire surface of the foam and thereby enhances
still further the moisture vapor transmission characteristics of
the element and improves the comfort of the apparel being
reinforced. Moreover, it has been discovered that the foamed
material laminated to a fabric substrate can serve advantageously
as liners. This is important because it means the product of the
invention can be used to form integral stiffening and lining
structures. For example, it can be used to form a single piece
serving the function of both a shoe liner and a heel stiffening
element.
In general, the foam useful in the present invention will contain
from about 20 percent to 90 percent by volume of voids. Lower void
volumes do not have any advantage over regular plastic film; higher
void volumes tend to result in materials of insufficient strength.
In a typical application, a film 0.045 inch thick will be laminated
to cloth 0.013 inch thick. The lamination process will usually
compress the laminate being formed to a thickness of from 0.05 to
0.055 inch in thickness. Sheets over about 0.10 inch are not
generally useful for a number of reasons, including the
self-insulating character of such a sheet when it is being formed
into a shaped stiffener article.
It will be noted that a great reduction in weight of polymer used
in a given stiffener is achieved as a result of the high void
volume. Moreover, when a stiffening element according to the
invention is incorporated into a shoe in a hot molding process
(such as, for example, that process whereby the fabric-type upper
used in the manufacture of sneakers is molded to the sole or
polymeric section of a sneaker), then the resilience afforded by
the presence of the foam in the back part of the sneaker
effectively reduces or eliminates the unsightly bulge which has
formerly been a problem in sneakers and other footwear formed by
this molding technique.
In typical practice, a thermoplastic material, for example, the
preferred copolymer of ethylene and vinyl acetate, will be extruded
in a thin sheet onto a continuous web of fabric. Blowing agents
will be contained in the extruded formulas which will provide the
desired amount of gas release and expansion of the thermoplastic
material as it comes out of the extruder die (or on the subsequent
activation) and is carried along on the cloth web. Alternatively,
freon gas can be introduced into the metering section of the
extruder to serve as the blowing agent. Cross-linked polymer
systems are not generally within the scope of the invention.
However, if one wishes to selectively cross-link a thin band of
polymer adjacent the surface thereof to facilitate the "sueding" by
abrasion techniques, such cross-linking may be carried out without
unduly interfering with the resilience or thermoformability of the
sheet.
Furthermore, the product of the invention may be made by forming an
aqueous emulsion of a polymer and blowing agent, coating it on the
substrate and then heating to dry the emulsion and activate the
blowing agent. Other means for forming the product of the invention
include the use of organisol or plastisol compositions containing
gas-forming agents, coating them on the paper and subsequently
heating them to activate the blowing agents and remove a suitable
quantity of the plasticizing agents. Still another processing
technique is to calendar a thermoplastic formulation, with the
resultant sheet to a substrate, and then activate a blowing agent
in the formulation by subsequent heating.
It is within the scope of the invention to add such adjuvants as
fillers, pigments, antioxidants, and reinforcing agents to the
polymer composition. However, the addition of such materials is not
critical to the practice of the invention. In this connection, it
may be noted that it is particularly advantageous to add moisture
vapor permeable fillers (such as ionomer powder, the sparingly
cross-linked ionomers known to the art, modified cellulosic powder,
cork, and other such materials known to the art) to the composition
in order to enhance the moisture vapor permeability thereof.
ILLUSTRATIVE WORKING EXAMPLE
In order to point out more fully the nature of the present
invention, the following specific example is given as an
illustration embodiment of the novel process and products of the
invention.
A formulation is prepared by dry blending, in a typical
tumbling-type blender, the following ingredients:
By Weight
__________________________________________________________________________
Blowing agent 0.6 Zinc stearate 0.6 Ethylene vinyl acetate
copolymer pellets 98.8
__________________________________________________________________________
The blowing agent is that sold under the trade designation Kempore
200 by National Polychemicals, Inc. The copolymer is that sold by
DuPont under the trade designation Alathon 3130.
The material so formulated is extruded from a 6-inch extruder
having a rear barrel temperature of 450.degree. F. and a die
temperature of about 350.degree. F. The extruded sheet is removed
from the extruder in the form of a foamed sheet about 0.055 inch
thick and 40 inches wide. The takeoff speed is approximately 5 feet
per minute. The extruded sheet has a mass of about 1.3 lbs. per
square yard. About 4 inches in front of the extruder die, the
aforesaid foamed sheet is wedded to a drilling fabric having a 2.7
yards per pound weight. The finished product has a thickness of
about 0.055 inch. It is adhesive free; that is there is no adhesive
at the interface between the polymer and fabric to interfere with
the flexible nature of the sheet.
The product, the preparation of which has been described above, is
utilized to form quarter-stiffening elements of a typical design,
known in the art, to be useful in sneakers. These counterstiffening
elements are stitched into the backpart section of the upper, or
fabric, sections of sneaker and then joined according to the
well-known Desma injection molding process, to the sole section of
the sneakers to form the completed shoe.
The injection molding operation is carried out at molding
temperatures cycling between 150.degree. F. and 240.degree. F. for
a 1.5-minute cycle on a Desma Werke Injection Molding Machine. A
commercially available, poly (vinyl chloride) base, sold
composition supplied by B. F. Goodrich Co., under the trade
designation, Pliovic, is utilized in this operation. Despite the
use of the extra-thick counter (of 0.060 inch thickness), the
sneakers formed by this process exhibit no bulge.
When the same operation is carried out with 0.060-inch thick
counter stiffeners made of conventional rag-stock rubber, a
noticeable and unsightly bulge results. Furthermore, 1.5 minutes of
heat at 150.degree. F. is not enough time and temperature to cure a
rubber rag stock formula.
Another major advantage of the foamed thermoplastic stiffening unit
is that it eliminates the back seam ridge. This ridge is formed at
the place where the quarters are stitched together and is normally
covered with an overlay of tape. Frequently, after washing, the
tape comes loose and allows this ridge to show through the lining
of the shoe. The foamed thermoplastic stiffener is compressible
when hot and allows the seam ridge to embed itself in the thickness
of the counter and thereby eliminate the possibility of its
subsequent shadowing through the lining. This feature of the
stiffener improves the looks and comfort of the shoe.
It is, of course, to be understood that the foregoing example is
intended to be illustrative, and that various changes can be made
in the ingredients, proportions and conditions set forth therein
without departing from the spirit of the invention as defined in
the appended claims.
* * * * *