Abstract:
A method is for manufacturing a battery box for footwear comprising: providing a first member and providing a second member. The method also includes connecting the first member and the second member such that the first member and the second member include a space. The method also includes placing the first and the second member in the footwear such that the first and the second member form a structure in the footwear.

Description:
FIELD OF THE INVENTION 
     The present disclosure is directed to an improved battery box of module, which is installed in outsole of footwear. More particularly, the present disclosure is directed to a battery box that is robust and waterproof and is made without any resin fill into the battery box and can be installed in footwear. More particularly, the present disclosure is directed to a two-part battery box that is sealed to be waterproof, and which may be connected into a heel of a shoe. 
     BACKGROUND OF THE RELATED ART 
     Footwear that includes an illumination device (module) is very advantageous for children. Generally, the footwear includes an illumination device that includes LED light(s) and a battery(s) and wires and a circuit and a switch. Generally, since the footwear must be utilized for all terrain and weather conditions, the module is sealed. However to make a module is very time consuming and expensive in that a great amount of resin is utilized to fill up the battery box and to ensure it is waterproof and protected. 
     Currently, this is time consuming and difficult and expensive to fill up the battery box with resin. It would be desirable to simplify the process to manufacture footwear. 
     SUMMARY OF THE INVENTION 
     According to a first aspect of the present disclosure, there is provided a method. The method is for manufacturing a battery box for footwear comprising: providing a first member and providing a second member. The method also includes connecting the first member and the second member such that the first member and the second member have a space therein. The method also includes placing the first and the second member in the footwear such that the first and the second member form a designed certain function structure in the footwear. 
     In another embodiment, the method may also include arranging the first member as a cover. In an embodiment, the method may further comprise arranging the second member as a base 
     In another aspect, there is provided a method that includes connecting the first member to the second member by any method known in the art, for example, by connecting the first member to the second member by an adhesive. 
     In yet another further aspect, the method also includes connecting the first member to the second member by any kind of hot press operation. 
     In a further aspect, the method may also include forming an exit in the battery box, and connecting the first and the second member to be waterproof. 
     In another embodiment, the method may also include operatively connecting a circuit comprising LED light(s), battery(s), wires, circuit board, and switch for illuminating the footwear. 
     Additionally, in another embodiment, the method includes placing the circuit in at least one of the first member and the second member, attaching a first end of a plurality of wires to the circuit, connecting the first member and the second member to form the battery box, forming the exit in the battery box, bringing out the second end of the plurality of wires from the battery box, and then sealing the battery box and the exit to make the battery box water proof. In this embodiment, the space within the battery box is water proof and also free from resin. 
     In another embodiment, the present disclosure may be directed to a battery box for footwear comprising: a first member; a second member being connected to the first member such that the first member and the second member include a space therein; and a footwear, wherein the first and the second member are located in the footwear. 
     In another embodiment, the footwear may include a battery box in the enclosure, and an illumination device connected to the battery. The first member may be a cover. The first member is connected to the second member and or connected by an adhesive, or connecting by any kind of hot press operation. 
     The battery box may also include the first member connected to the second member to form the battery box that can be sealed seamlessly. An exit may be formed in the battery box. The first and the second member can be connected to one another to be waterproof. The battery box may also include a circuit comprising a wire, circuit board, and switch to a battery for illuminating the footwear. 
    
    
     
       BRIEF DESCRIPTION OF THE FIGURES 
       The foregoing and other objects, features and advantages of the invention will be apparent from the following more particular description of preferred embodiments of the invention, as illustrated in the accompanying drawings in which like reference characters refer to the same parts throughout different views. The drawings are not meant to limit the invention to particular mechanisms for carrying out the invention in practice, but rather, the drawings are illustrative of certain ways of performing the invention. Others will be readily apparent to those skilled in the art. 
         FIG. 1  shows a schematic of a device for a battery box; 
         FIG. 2  show an exterior view of a cover for a new battery box of the present invention; 
         FIG. 3  shows an exterior view of a base for a new battery box according to the present disclosure; 
         FIG. 4  shows an embodiment of the cover and base seamlessly welded to form the battery box according to the present disclosure; and 
         FIG. 5  illustrates an embodiment of a footwear having the battery box with the cover and base welded. 
         FIG. 6  illustrates another view of the battery box including a first portion and a second portion with a module being separated therefrom. 
         FIG. 7  illustrates another view of the battery box having the battery box therein. 
         FIG. 8  illustrate the battery box in an outsole and free of resin. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       FIG. 1  shows a prior art battery box  10  for a footwear that is a single composite box with an exit  15  on the front end  17  of the battery box  10 . In the prior art battery box  10  of  FIG. 1 , resin is poured into the battery box  10  before sealing in order to make it waterproof. However, the use of resin will cause many problems including a weight of the battery box  10  that is about twice as much as the new battery box of the present invention. 
       FIG. 2  illustrates a first member of a new battery box that is made from, in one embodiment, plastic that is lightweight. The first member is a cover  20 . The cover  20  includes a generally straight front side  22 , a curved rear side  24  and generally straight sides  26  and  28 . The cover  20  will not be damaged when stepped on by a human being. The cover  20  also includes first and second pegs  21   a  and  21   b  for connecting with a second member. Generally, cover is  20  made very lightweight. In one embodiment, the cover  20  may be made from hard plastic, for example, Acrylonitrile Butadiene Styrene (ABS) etc. 
       FIG. 3  illustrates a second component of the battery box or the base  30 . The base  30  includes a planar member  30  that includes a front  32  and a rear  34  and sides  36  and  38 . The base  30  also includes receiving structures  31   a  and  31   b  to mate with the cover  20 . Additionally, an exit  30   a  is formed therein. Base  30  may be made from hard plastic, for example, Acrylonitrile Butadiene Styrene (ABS) etc. 
       FIG. 4  illustrates the formed battery box  40  with the cover  20  mated with the base  30 . The battery box  40  dramatically improves the current product process and solves the above problems accordingly. The battery box  40  adopts a two part  20 ,  30  structure and design, which include cover  20  and base  30 . By plugging the cover  20  into the base  30  and sealing the cover and the base using a secondary processes such as a connector, ultrasonic welding, hot-pressing or gluing, the battery box  40  will seal seamlessly and be water proof. After using a predetermined sealing material to seal the front end  42  and the exit  44 , the battery box  40  will have waterproof functionality. This invention will greatly improve the efficiency of the current production, eliminate the use of resin and is more environment-friendly. The battery box  40  when assembled includes a front  42  and a rear  44  and the front and the rear  42 . The battery box  40  also includes sides  46  and  48 . A sealed exit  40   a  is also provided to let wires come out shown in  FIG. 5 . 
     Additionally, the pegs  21   a  and  21   b  are connected to the receiving structures  31   a  and  31   b . Turning now to  FIG. 5 , there is shown the box  50  including a battery  52  within an enclosure V formed by the cover and the base  20  and  30  shown collectively as battery box  50 . A circuit  54  is also provided (including: battery  52 , wire, circuit board, switch and other electronic elements) for use in illuminating footwear will be fixed on the base  30  of the box  50 , put the cover  20  on the base  30  and then seal the box  50  with secondary process such us ultrasonic welding, hot-press or gluing etc. to make sure it waterproof. A number of leads  56  are shown to connect to a number of illumination devices  58 . Battery box  50  is preferably used for illuminating footwear and placed in the outsole of the footwear. The structure of the battery box  50  includes a cover and a base and may utilizing secondary processing technology (such us supersonic welding, hot-pressing or gluing), the battery box  50  can be sealed seamlessly. Preferably, the cover  20  and the base  30  are connected to one another by an ultrasonic welding operation. ultrasonic welding is an industrial technique whereby high-frequency ultrasonic acoustic vibrations are locally applied to work pieces  20  and  30  being held together under pressure to create a solid-state weld. It is commonly used for plastics, and especially for joining dissimilar materials. In ultrasonic welding, there are no connective bolts, nails, soldering materials, or adhesives necessary to bind the materials together. The exit  50   a  of the battery box will sealed by the special material so that it has the waterproof functionality. Battery  52  may be a button cell, like nickel cadmium battery or a lithium ion battery. Battery  52  may be either of two types of batteries: primary batteries (disposable batteries), which are designed to be used once and discarded, and secondary batteries (rechargeable batteries), which are designed to be recharged and used multiple times. Batteries come in many sizes, from miniature cells used to power hearing aids and wristwatches to relatively larger size. 
       FIG. 6  illustrates another view of the battery box  600  comprising a first member  605  and a second member  610  and a module  615 . The first and the second members  605  and  610  are made from a hard plastic and will not crack. An electric module  615  fits inside of the first and the second member  605  and  610  as shown in  FIG. 7 .  FIG. 7  illustrates that the first and the second members  605  and  610  are sealed and wires of the module  615  extend from the first and the second members  605  and  610 . The gap between the first and the second module  605  and  610  are sealed by a glue to make an integrated waterproof member. 
       FIG. 8  shows a battery box  1000  located in a cavity  1010  cut into an outsole  1005  of the footwear. The shape of the cavity  1010  conforms to the shape of the battery box  1000  and the battery box  1000  snugly fits into the cavity  1010  without any gap. There is no resin or filler between bottom and sides of the cavity  1010  and the battery box  1000 . Additionally, wires  1015  connect the electronic components  1020  and the battery  52  (shown in  FIG. 5 ) inside the battery box  1000  to a plurality of illumination devices placed along an entire outside surface of the footwear. 
     ABS box has good hardness. When users stand, run, walk or step on box  1000 , normal pressure will not cause distortion and will not damage or otherwise harm the electronic components. ABS plastic that forms the box  1000  will not crack, nor open as opposed to current materials, which are filled with resin in order to prevent water leakage and prevent cracking. The instant box  1000  does not need to be filled with resin. The box  1000  may be manufactured through melting both top and bottom, and after sealing the opening to completely seal the box  1000  and to prevent pressure cracks. By omitting the resin, box  1000  also is environmental friendly, and saves manufacturing time, increase productivity, and is easy to maintain. Electronics cannot be repaired if filled with resin. Therefore the instant box  1000  provides a methodology that components contained in the box  1000  are repairable. 
     While this invention has been particularly shown and described with references to a preferred embodiment thereof, it will be understood by those skilled in the art that is made therein without departing from the spirit and scope of the invention as defined by the following claims.