MOULDED FOOTWEAR

Abstract: A mould (14) for manufacturing an article of footwear comprises two mould halves (16); a hollow last (20) which includes a cylindrical downwardly open opening (30) at its foot end (26); and a first sole plate (34) which includes a projection (32) having a head portion (36) which is arranged to extend into the opening (30) in the last (20) in order to restrict movement of the last within the mould. Polyurethane is injected into cavity (44) defined between the last and mould halves (16) / sole plate (34) to form an inner sole of an article of footwear having a hole in it in a position where projection (32) cooperated with opening (30). This opening may then be plugged prior to the formation of an outer sole using a second sole plate (which does not include a projection (32)) instead of the first sole plate.

Description: MOULDEDFOOTWEAR This invention relates to footwear and particularly, although not exclusively, relates to a mould for making an article of footwear. A known mould for the manufacture of plastics footwear by injection moulding is shown diagrammatically m Figures 1 and 2 of the accompanying diagrammatic drawings wherein Figure 1 is a schematic vertical cross- section through a mould and Figure 2 is a schematic vertical cross-section through the mould rotated through 90° relative to Figure 1. Known moulds are constructed of metal or other hard, rigid materials and generally comprise four or more principal components : two mould halves 2, 4 to form a cavity of the mould; a last 6 centrally mounted within the cavity to form the core of the mould; and one or more sole plates 8 at the foot end of the mould beneath the last, to form the outsole of the article of footwear. In order to keep the last 6 in a central position between the two mould halves 2, 4, so that both sides of an article of footwear manufactured using the mould are- of equal thickness, the mould is constructed so that a considerable additional depth and thickness of material 10 is provided beyond the leg length 12 of the article of footwear to mechanically support the last 6. The last is thereby supported from only one end by a cantilever effect; however, the parts necessary for this add considerably to the size, weight and cost of the mould and, furthermore, require precise fitting and machining. Additionally, such a mould must be used with an injection moulding machine with a large and powerful press or mechanical lock that can exert sufficient clamping pressure on the parts of the mould to maintain the parts m the desired positions. Known injection moulding machines for footwear manufacture tend to be large, complex and expensive. It is an object of the present invention to address problems associated with the manufacture of articles of footwear. According to one aspect of the invention, there is provided a mould for manufacturing an article of footwear, comprising a mould body in which is arranged a last means having a leg end region which defines an extremity of an article of footwear manufacturable using the mould, wherein restrictor means is provided at a position between said leg end region and a foot end of the mould for restricting relative movement of the mould body and last means. Said mould may be for manufacturing any type of footwear for example shoes or boots. It is preferably for manufacturing an article of footwear which is waterproof. Said extremity of an article of footwear referred to suitably defines an opening into which a person' s foot initially passes for wearing the article. Where the mould is for manufacturing shoes, said leg end region of said last means may be arranged to define an extremity of an article of footwear arranged to surround the ankle of a person in use. Where the mould is for manufacturing a boot, said leg end region of said last means may be arranged to define an extremity of an article of footwear arranged to surround the calf of a person in use. Thus, it will be appreciated that the leg end region is suitably arranged to be contacted by mouldable material in use in order to define a part of the article of footwear. Said mould is suitably for manufacturing boots having a leg portion which has a length which is at least twice, preferably three times, more preferably four times, the depth of a foot portion of the boot. Said restrictor means may be provided at least one- third of the way, preferably at least half-way, more preferably at least two-thirds of the way, between said leg end region and said foot end of the mould. Preferably, said restrictor means is associated with one or more parts of the mould which is/are arranged to define the foot of said article of footwear. More preferably, said restrictor means is associated with one or more parts of the mould which is/are arranged to define a sole of the article of footwear. Thus, preferably, said restrictor means is associated with a sole defining area of said last means and/or with a sole defining area of said mould body. Said restrictor means is preferably arranged to restrict pivotal movement of the last means about a fulcrum disposed at a position beyond the leg end region of the last means in a direction away from the foot end of the mould. Said restrictor means preferably restricts pivotal movement of the last means at or adjacent a position of support of the last means on the mould body which position is beyond the leg end region of the last means in a direction away from the foot end of the mould. Said restrictor means is preferably arranged to restrict movement of the last means in a plane which extends substantially parallel to a sole defining area of the last means. Said restrictor means is preferably arranged to support the last means. Preferably, said restrictor means is arranged for supporting the foot end of the last means. Said last means preferably includes a male or female formation arranged to be engaged by the other one of a male or female formation. Preferably, a male or female formation is provided on or by said last means and a cooperable formation, suitable the other one of a male or female formation, is associated with, for example by being provided on or by said mould body. Said female formation may be fixed relative to the last means or mould body with which it is associated. The male formation may, however, be movable relative to the last means or mould body with which it is associated. For example, the male formation may be movable, for example slidable, between first and second positions. In one position, said male formation may be arranged to cooperate with a female formation, whereas in another position it may not cooperate with, for example it may be disengaged from, said female formation. Said mould body of said mould preferably includes .two mould members, for example mould halves, and a first sole member which suitably define a cavity in which said last means is arranged. Said restrictor means described is preferably associated with said last means and/or said first sole member. Preferably, said restrictor means is associated with said last means and said first sole member. In this case, in one embodiment wherein said restrictor means is associated with one or more parts which is/are arranged to define a sole of said article of footwear, a hole is formed in the sole of the article of footwear initially moulded using the mould. The hole is suitably covered in a second moulding process, wherein a second sole member which does not include and/or cooperate with a said restrictor means replaces said first sole member. Thus, preferably, the invention extends to a mould as described which includes first and second interchangeable sole members. Said mould is preferably made out of metal or plastics or any suitable hard metal. The invention also extends to a last means having a leg end region which defines an extremity of an article of footwear manufacturable using the last means and a restrictor means between said leg end region and a sole region of the last means . The invention also extends to a first sole member which include a restrictor means for cooperation with a restrictor means of a last means. The invention also extends to a last means comprising a first section and a second section wherein said sections are movable between a first configuration in which said last means defines the shape of an article of footwear to be manufactured and a second configuration in which said last means is arranged to be more easily removable from a moulded article of footwear than when said last means is in said first configuration. Said last means preferably includes last securement means for securing the last means m said first configuration. Said last secure ent means preferably includes a male member arranged to pass through an opening in said first and/or said second sections. Said last securement means is preferably arranged to pass through a hollow region of said first section which section is at a leg end of said last means. Said last securement means is preferably operable from an end remote from a foot end of the last means for releasing the last means from said first configuration Said first and second sections are preferably arranged to be moved apart between said first and second configurations . According to another aspect of the invention, there is provided a method of assembling a mould for manufacturing an article of footwear, the method comprising arranging a last means having a leg end region which defines an extremity of an article of footwear manufacturable using the mould within a mould body with a restrictor means of the mould which is provided at a position between said leg end region and a foot end of the mould being operative to restrict relative movement of the mould body and last means. According to another aspect of the present invention, there is provided a method of manufacturing an article of footwear comprising: m a first moulding process, manufacturing a first footwear moulding with a hole therein using a mould which includes restrictor means for restricting relative movement of a mould body and a last means which restrictor means causes the production of said hole; and in a second moulding process, covering said hole to produce said article of footwear. Preferably, in said second moulding process, mouldable material is caused to overlie said hole and a portion, for example the sole area of the article of footwear. In one embodiment, said hole may be plugged with a plug member prior to said second moulding process. In another embodiment, said hole may be plugged by mouldable material during said second moulding process. Thus, it will be appreciated that, suitably, said article of footwear does not include a hole formed as a result of the use of said restrictor means. Preferably, in said first moulding process a first sole member is used and in said second moulding process a second sole member which is different to said first sole member is used. Any suitable mouldable material or materials may be used in the method. Preferably, said material is flexible after curing. It may be a plastics material or the like, with polyurethane plastics material being especially preferred or it may be a rubber material or the like. The invention extends to an article of footwear manufactured using a mould as described herein. Said article of footwear is preferably substantially waterproof. Suitably, it does not include any through- openings in a foot region which extend from the outside to the inside of said article. The invention extends to an article of footwear manufactured in a method as described herein. The invention extends to an article of footwear comprising a unitary footwear moulding having a hole therein which is covered by a second moulding. Said unitary footwear moulding suitably refers to a member moulded in a single process. Although the hole in said first moulding may be plugged or otherwise filled, said plug or other filling material is not a unitary part of said first footwear moulding. Said hole is preferably provided in a sole area of said first moulding. Said second moulding is preferably an outer-sole. The invention further extends to a mould having a mould body which include first and second mould members and a last means, said mould members being movable relative to one another between operative and inoperative positions wherein a manually actuable securement means is provided for securing the first and second mould members in said operative position. Said securement means is preferably arranged to secure the mould members in position by a wholly mechanical means rather than by, for example, a pneumatic or hydraulic means. Said securement means preferably comprises a means, for example a clamp, which includes an over-centre mechanism for applying a clamping force. Said securement means preferably comprises a toggle clamp. A plurality of said securement means may be provided. Preferably, said mould members are pivotable between said operative and inoperative positions. To this end, said mould members are preferably hinged relative to one another. Said mould preferably includes a first sole member which is releasably securable to said mould members. Said first sole member preferably includes securement means as described above. Said first sole member may be hinged to said mould members. Alternatively, said first sole may be detachable from said mould members and, therefore, may not be hinged or otherwise pivoted relative to said mould members . The invention extends to a mould assembly comprising a mould and a mould support, wherein said mould is pivotable relative to the mould support so that the orientation of the mould can be adjusted. The orientation may be adjustable through at least 180°, preferably at least 270° and, more preferably, through 360°. This may allow the orientation of the mould to be optimized for a particular moulding process and/or moulding material . A pivot assembly is suitably provided for effecting said pivotal movement. Preferably, a single said pivot assembly is provided between a part of the mould and said mould support. Said mould support preferably comprises an upstanding member. In one embodiment, two moulds are pivotably mounted on a respective said mould support . Said mould assembly preferably includes a locking means for locking the mould in a selected orientation. Said locking means may comprise a male locking member provided on the mould or mould support and a cooperable female locking member provided on the other one of said mould or mould support. The invention extends to footwear manufacturing apparatus comprising a mould support and multiplicity of moulds supported thereby, a manually operable injection device being provided which includes an outlet arranged to cooperate with the moulds for delivering fluidic plastics material into the moulds. Said outlet of said manually operable injection device is preferably arranged to be manipulated by an operator for delivering material into the moulds. The outlet is preferably manipulable for delivering material to at least one quarter, more preferably, at least one half of the multiplicity of moulds supported by the mould support . Said mould support is preferably movable, at least in part, relative to said injector device for positioning selected moulds thereon closer to said device. Said mould support may be provided in various shapes and/or sizes. It may include a region which is arranged to pivot. For example, said mould support or a portion thereof may be pivotable. Preferably, two of said injector devices are provided, each being manually operable and each being arranged for serving respective moulds provided on a mould support . Any feature of any aspect of any invention described herein or any feature of any specific embodiment described herein may be combined with any feature of any other aspect of any invention described herein or with any feature of any specific embodiment described herein. Specific embodiments of the invention will now be described, by way of example, with reference to the accompanying diagrammatic drawings, in which :- Figure 1 is a schematic vertical cross-section through a known mould as described above; Figure 2 is a schematic vertical cross-section through the mould of Figure 1 rotated through 90° about its vertical axis; Figure 3 is a perspective view of parts of a mould of an embodiment of the invention, with part of the sole plate of the mould cut away; Figure 4 is a vertical cross-section through the mould of Figure 3 ; Figure 5 is an enlarged view of the portion of the mould of Figure 4 within box V; Figure 6 shows the portion within box V after a first injection with the sole plate removed; Figure 7 is a vertical cross-section through a last; Figure 8 is a vertical cross-section through another last; Figure 9 is a perspective view of a mould support apparatus supporting a mould; Figure 10 is a front view of the apparatus of Figure 9; Figure 11 is a rear view of the apparatus of Figures 9 and 10 ; Figure 12(a) to (e) show stages in the manufacture of an article of footwear; and Figure 13 is a schematic top plan view showing the layout of assembling apparatus. In the Figures, the same or similar parts are annotated with the same reference numerals. Referring to Figure 3 to 5, a mould 14 comprises two- mould halves 16 (only one of which is shown in the Figures) which are only longer by a distance "x" than the leg length "y" of the article of footwear to be manu actured. Each mould half 16 includes a respective slot (not shown) which is arranged to snugly receive a keyway 18 provided on a last 20. The last 20 is hollow. At its leg end 22 it includes an air-blow off tube 24 for blowing air into the last . The last includes perforations (not shown) via which air blown in can exit for aiding removal of a moulded article from the last. At its foot end 26, a sole part 28 of the last includes a cylindrical downwardly open opening 30 which is arranged to cooperate with a projection 32 provided on an upwardly facing surface of a first sole plate 34. The projection 32 includes a head portion 36 which in the assembled mould extends into the opening 30 and a shoulder portion 38 on which the sole part 28 is seated and supported so that a gap 40 is defined between the last 20 and sole plate 34. A passageway 42 extends from a position outside the mould 14 and opens into the gap 40. The mould 14 is assembled with the last 20 in cavity 44 defined by the two mould halves 16 and the sole plate 34. When so arranged, it should be noted that the last is supported at its leg end 22 by cooperation of the keyways 18 in the slots in the mould halves; and at its foot end 26 by engagement of the projection 32 in the opening 30 so that the last cannot move within the cavity 44. The parts of the mould 14 are clamped in position by suitable means as described hereinafter. It should be noted that, since the last is supported at its foot end 26, the length x and the thickness and weight of mould halves 16 beyond the leg length y is small compared to the amount of material 10 required in the known mould described in Figures 1 and 2 and, furthermore, the force needed to clamp the parts of the mould 14 in position is less than in the Figures 1 and 2 embodiments. The assembled mould 14 may be used as follows : In general, the last 20 of the mould will be covered with a sock, in a known manner, prior to assembly of the mould. Once assembled, with the parts of the mould clamped in position, polyurethane (PU) is injected via passageway 42 into the cavity 44 defined around the last 20 until the PU fills the cavity. After the PU has cured, the first sole plate 34 is removed. It will be appreciated that, at this stage, there will be a hole in the inner sole 46 (figure 6) of the moulded article of footwear in the region of the inner sole where the projection 32 engaged opening 30. This hole is plugged using a suitably dimensioned disc 48 of material (which could be fabric, wood, pressed paper or plastics material or the like) so that an outer wall 50 of the disc is substantially flush with the outer wall 52 of the sole 46 as shown in Figure 6. The disc 48 may be 5 mm to 10 mm in diameter and is arranged to provide a barrier against penetration by PU m subsequent steps. Next, a second sole plate (not shown) is placed in position. The second sole plate does not include a projection 32 or opening 30 and, accordingly, the last 20 is not supported at its foot end m the same manner as when the first sole plate is m position. However, it is found that with the second sole plate in position the last is sufficiently supported by the PU material which fills the cavity between the last and the two mould halves 16. Then, PU is injected into the mould to form an outer sole around the inner sole 46. The outer sole formed covers the plug 48 which is, therefore, not visible in the finished article. An alternative last 54 is shown in Figure . In the embodiment, a projection in effect is provided on the last and is arranged to be received m a suitably shaped opening defined in a first sole plate so that the last can be supported by the sole plate. More particularly, the last 54 is hollow and it includes a rod 56 having a handle 57. The rod is slidable within a collar 58 provided towards leg end 22 of the last and an opening 61 in the foot end 26. In use as part of a mould, during a first injection of PU, the rod 56 is extended so that it engages the opening in the first sole plate and, accordingly, a hole is formed m the inner sole as described above with reference to Figure 6. Next, the first sole plate is replaced with a second sole plate as before. However, in this case, there is no need to plug the opening with a disc 40 of material. Instead, the rod 56 is retracted using handle 57 to a predetermined position wherein the end 59 of the rod 56 is flush with the outer wall 60 of the last . The outer sole may then be formed as before in which case PU fills the hole formed in the first injection. In an alternative embodiment (not shown) , a rod similar to rod 56 may be associated with the first sole. In some cases, for example when a boot is large and/or includes steel toe caps, it is difficult to withdraw a last from the moulded boot at the end of the process. This problem is addressed in the embodiment of Figure 8, wherein a last 62 includes a generally solid foot part 64 and a generally hollow leg part 66 which are releasably securable to one another. In this regard, the foot part and leg part include respective abutting shaped surfaces 68, 70. A rod 72 having a screw threaded end 73 extends through aligned openings 74, 76 in the leg part 66 and is secured in a screw-threaded opening 78 in the foot part 64. A dowel 80 is received in aligned openings 82, 83 in the foot part 64 and leg part 66 respectively. A locking bolt 84 is provided for rigidly securing the foot and leg parts together. The last 62 may be arranged to cooperate with a projection 32 as in the embodiment of figures 3 to 6 if required. After an article has been moulded using the last 62, locking bolt 84 is removed and rod 72 retracted. The leg part 66 can then be removed from within the article followed subsequently by the removal of the foot part 64. Referring now to figures 9 to 11, the mould support apparatus 90 comprises a table 92 to which is bolted a rigid support member 94 having an upstanding member 96. The mould 14 is pivotably mounted, by means of a bearing arrangement 100, on the member 96 so that the mould can be pivoted through 360°. A locking pin 102 is mounted on the upstanding member 96 and is releasably engageable in suitably positioned openings provided in face 104 of the mould so that the pm 102 can be used to lock the casing in a desired position. The mould halves 16 of the mould are pivotally mounted relative to one another by respective U-bolt cast aluminium hinges 108. The mould halves 16, sole plate 34 and last 20 are held together by toggle clamps 114. It is found that such clamps are able to apply sufficient force to keep the parts of the mould together. The pivotable mounting of the mould enables it to be pivoted to an orientation in which an injection moulding process for a particular article of footwear is optimized. For example, it may be found that, for a particular article of footwear, the first injection of PU is best undertaken with the mould m the position shown m Figure 9, whereas the second injection, to form the outer sole, is best undertaken with the mould pivoted through 90° relative to the figure 9 position. The apparatus 90 can easily accommodate such situations and, accordingly, the injection moulding processes can be optimised, whereas when a mould is in a fixed position as in known apparatus, a compromise orientation must be selected. Stages in the manufacture of an article of footwear are shown in figure 12. With mould 14 assembled and held together by toggle clamps 114 and supported by apparatus 90, PU is injected into the mould via passageway 42 (Figure 12(a)) . Then, sole plate 34 is removed. A second sole plate 116 is then secured in position and the outer sole is formed by a further injection of PU (Figure 12(b)) . The second sole plate 116 is removed, the mould halves 16 pivoted relative to one another to open the mould and the last 20 (having the article of footwear thereon) is removed (Figure 12 (c) ) . In order to increase the rate of manufacture of articles, a second last (having a sock fitted thereto) may be fitted into the mould and the steps of figures 12(a) to 12(c) repeated whilst, at the same time, the removed last 20 may be taken to a second support apparatus 120 whereupon the article of footwear can be removed with the aid of air injected into the last via tube 24 (figure 12 (d) ) . The last may then be covered with a sock 126 for subsequent use. Referring now to figure 13, the assembly apparatus 128 comprises drums 130 containing PU which are seated on hot plates and are arranged to deliver heated PU to respective injector devices 132. Each device 132 includes a nozzle 134 via which PU may be injected at pressure to a desired location. A table 136 is arranged between the devices 132. It has a central area 138 which includes triangular end regions 140 and respective end members 142 which are pivotably mounted, at respective pivot points 144, on the central area so that the members 142 can be pivoted through 180° as represented by arrows 146. The central area 138 includes twelve moulds 14 wherein two moulds are supported on each support member 94. Each end member 142 includes four moulds supported in a similar manner. In use, a first operator can inject PU into each of the moulds 14 using nozzle 134a when end members 142 are suitably arranged. After this first injection of PU has cured for 3 minutes, the sole plates of each mould are replaced with second sole plates and, then, a second operator injects PU (which may have a different formulation and/or colour to the PU of the first injection) into each of the moulds 14 using nozzle 134b, with end members 142 suitably arranged. The apparatus 128 is arranged to optimise the use of space and to be serviceable with a minimum number of operators. Various other suitable arrangements are also possible . The reader's attention is directed to all papers and documents which are filed concurrently with or previous to this specification in connection with this application and which are open to public inspection with this specification, and the contents of all such papers and documents are incorporated herein by reference. All of the features disclosed n this specification (including any accompanying claims, abstract and drawings) , and/or all of the steps of any method or process so disclosed, may be combined in any combination, except combinations where at least some of such features and/or steps are mutually exclusive. Each feature disclosed in this specification (including any accompanying claims, abstract and drawings) , may be replaced by alternative features serving the same, equivalent or similar purpose, unless expressly stated otherwise. Thus, unless expressly stated otherwise, each feature disclosed is one example only of a generic series of equivalent or similar features. The invention is not restricted to the details of the foregoing embodiment (s) . The invention extends to any novel one, or any novel combination, of the features disclosed in this specification (including any accompanying claims, abstract and drawings) , or to any novel one, or any novel combination, of the steps of any method or process so disclosed.

Claims: CLAIMS 1. A mould for manufacturing an article of footwear, comprising a mould body in which is arranged a last means having a leg end region which defines an extremity of an article of footwear manufacturable using the mould, wherein restrictor means is provided at a position between said leg end region and a foot end of the mould for restricting relative movement of the mould body and last means. 2. A mould according to claim 1, wherein said restrictor means is associated with one or more parts of the mould which is/are arranged to define a sole of the article of footwear. 3. A mould according to claim 1 or claim 2, wherein said restrictor means is arranged to support the last means. 4. A mould according to any preceding claim, wherein said last means includes a male or female formation arranged to be engaged by the other one of a male or female formation. 5. A mould according to any preceding claim, wherein said mould body includes two mould members and a first sole member which together define a cavity in which said last means is arranged, said restrictor means being associated with said last means and said first sole member. 6. A mould according to any preceding claim, which includes first and second interchangeable sole members. 7. A last means having a leg end region which defines an extremity of an article of footwear manufacturable using the last means and a restrictor means between said leg end region and a sole region of the last means. 8. A first sole member which includes a restrictor means for cooperation with a restrictor means of a last means. 9. A last means comprising a first section and a second section wherein said sections are movable between a first configuration in which said last means defines the shape of an article of footwear to be manufactured and a second configuration in which said last means is arranged to be more easily removed from a moulded article of footwear than when said last means is m said first configuration. 10. A method of assembling a mould for manufacturing an article of footwear, the method comprising arranging a last means having a leg end region which defines an extremity of an article of footwear manufacturable using a mould within a mould body with a restrictor means of the mould which is provided at a position between said leg end region and a foot end of the mould being operative to restrict relative movement of the mould body and last means. 11. A method of manufacturing an article of footwear comprising: in a first moulding process, manufacturing a first footwear moulding with a hole therein using a mould which includes restrictor means for restricting relative movement of a mould body and a last means which restrictor means causes the production of said hole; and in a second moulding process, covering said hole. 12. A method according to claim 11, wherein said hole is plugged with a plug member prior to said second moulding process . 13. A method according to claim 11 or claim 12, wherein in said first moulding process a first sole member is used and in said second moulding process a second sole member which is different to said first sole member is used. 14. An article of footwear comprising a unitary footwear moulding having a hole therein which is covered by a second moulding. 15. A mould assembly comprising a mould and a mould support, wherein said mould is pivotable relative to the mould support so that the orientation of the mould can be adjusted. 16. A footwear manufacturing apparatus comprising a mould support and a multiplicity of moulds supported thereby, a manually operable injection device being provided which includes an outlet arranged to cooperate with the moulds for delivering fluidic plastics material into the moulds.

Inventors: FOLDES PETER, FOLDES, PETER
Applicants: FOLDES PETER, FOLDES, PETER
Application year: 1997
Main classification: B29D31
IPC codes: B29D31