Method for manufacturing shoes with foamed soles

Abstract: A method for manufacturing shoes with foamed soles includes: (a) providing a foamable mixture; (b) heating and foaming the foamable mixture to form a foamed insole blank (32); (c) providing a sole (35); (d) providing a shoe tree (39); (e) providing a vamp (30) on the shoe tree; (f) placing the sole coated with glue, the foamed insole blank coated with glue, the vamp, and the shoe tree into a pressing mold for pressing and bonding them together; (g) heating an outer periphery of the foamed insole blank locally; and (h) pressing the outer periphery of the foamed insole blank so as to form knurls on the outer periphery of the foamed insole blank, thereby forming a final shoe product.

Description: FIELD OF THE INVENTION The present invention relates to a method for manufacturing shoes with foamed soles. DESCRIPTION OF THE RELATED ART The closest prior art of which the applicant is aware is disclosed in his U.S. Patent No. 5,843,352, entitled by "PRODUCTION METHOD FOR PERIPHERAL ORNAMENTAL STRIPS FOR FOAMED INSOLES": However, in said prior art reference, the foamed insole and the ornament strips are respectively foamed, and are then coupled together with each other so that it needs to provide molds or machines of much cost, and the manufacturing process is more complex. SUMMARY OF THE INVENTION In accordance with one aspect of the present invention, there is provided a method for manufacturing shoes with foamed soles comprising the steps of: (a) providing a foamable mixture; (b) heating and foaming the foamable mixture to form a foamed insole blank; (c) providing a sole; (d) providing a shoe tree; (e) providing a vamp on the shoe tree; (f) placing the sole coated with glue, the foamed insole blank coated with glue, the vamp, and the shoe tree into a pressing mold for pressing and bonding them together; (g) heating an outer periphery of the foamed insole blank locally; and (h) pressing the outer periphery of the foamed insole blank so as to form knurls on the outer periphery of the foamed insole blank, thereby forming a final shoe product. According to an embodiment of the present invention, the method includes heating and foaming the foamable mixture to form an elongated flat foamed body, and then cutting the foamed body into a plurality of foamed insole blank. According to another embodiment of the present invention, the method includes forming the foamable mixture into an insole blank with a scale-down size, and then heating and foaming the insole blank into a foamed insole blank. In accordance with another aspect of the present invention, there is provided a method for manufacturing shoes with foamed soles comprising the steps of: (a) providing a vamp on a shoe tree; (b) providing a bottom pad on the vamp; (c) providing a heated foamed insole blank on a bottom of the vamp; (d) providing a peripheral flange on a periphery of the foamed insole blank; (e) providing a sole coated with glue on the foamed insole blank; (f) providing a bottom mold base on the sole; (g) placing the sole, the foamed insole blank, and the vamp between the bottom mold base and the shoe tree for pressing and bonding the sole, the foamed insole blank, and the vamp together; and (h) pressing the periphery of the heated foamed insole blank so as to form knurls on the periphery of the foamed insole blank, thereby forming a final shoe product. The method further comprises the steps of: providing an ornamental strip bonded on a periphery of the vamp; providing a pull line around a periphery of the ornamental strip; mounting the peripheral flange of the foamed insole blank between the vamp and the ornamental strip; and tightening the pull line such that the ornamental strip securely encompass the foamed insole blank. The step (h) further includes the steps of: providing a pair of pivotally connected mold clamps to press the periphery of the foamed insole blank for forming knurls on the periphery of the foamed insole blank; providing a corrugated peripheral profile on a top edge of each of the pair of mold clamps; providing two side mold bases to press the foamed insole blank for forming knurls on the periphery of the foamed insole blank; and providing a corrugated peripheral profile on a bottom edge of each of the two side mold bases and mating the corrugated peripheral profile of the top edge of each of the pair of mold clamps so as to precisely form knurls on the periphery of the foamed insole blank. In accordance with a further aspect of the present invention, there is provided a method for manufacturing shoes with foamed soles comprising the steps of: (a) providing a shoe tree; (b) providing a heated foamed insole blank on the shoe tree and having two opposite sides; (c) providing two connecting pieces on each of the two opposite sides of the foamed insole blank; (d) providing a sole coated with glue on the foamed insole blank; (e) providing a bottom mold base on the sole; (f) placing the sole and the foamed insole blank between the bottom mold base and the shoe tree for pressing and bonding the sole and the foamed insole blank together; (g) pressing a periphery of the heated foamed insole blank so as to form knurls on the periphery of the foamed insole blank; and (h) bonding a sandal vamp to the connecting pieces of the foamed insole blank, thereby forming a final shoe product. The method further comprises the steps of: providing a plurality of slots in the periphery of the foamed insole blank; providing a plurality of connecting plates on a periphery of the sandal vamp; providing a pull line on each of the connecting plates; moving each of the connecting plates to extend through each of the slots of the foamed insole blank; bending each of the connecting plates to press a bottom of the foamed insole blank; and tightening the pull line of each of the connecting plates for securing the foamed insole blank and the sandal vamp together. In accordance with a further aspect of the present invention, there is provided a method for manufacturing shoes with foamed soles comprising the steps of: providing a foamable mixture of ethylene vinyl acetate E.V.A., a foaming component blowing agent and a binder cross-linking agent which are prepared and stirred; heating and foaming the foamable mixture to form a heated foamed insole blank; the foamed insole blank being processed by an initial pattern generating step for facilitating embedding a shock absorbing pad in a recess defined in the top edge of the foamed insole blank; providing a sole; providing a shoe tree; providing a vamp fitted on the shoe tree; placing the sole coated with glue, the foamed insole blank coated with glue, the vamp, and the shoe tree into a set of pressing molds which are upward and downward slidable relative to each other for vertically pressing and bonding them together so that the shoe parts are integrally bonded and pressingly formed; heating an outer periphery of the foamed insole blank locally by a heating machine; and pressing the outer periphery of the foamed insole blank by two side pattern generating molds horizontally moving toward each other so as to form knurls on the outer periphery of the foamed insole blank, thereby forming a final shoe product. The heated foamed insole blank can also be placed in a pattern generating mold so that the heated foamed insole blank can be pressed into a foamed insole semi-product by a pattern pressing process. Further benefits and advantages of the present invention will become apparent after a careful reading of the detailed description with appropriate reference to the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS Fig. 1 is a perspective view of a foamed insole blank in accordance with the present invention; Fig. 2 is a perspective view of a foamed insole blank in accordance with another embodiment of the present invention; Fig. 3 is an exploded view of one of a pair of shoes in accordance with the present invention; Fig. 4 is a perspective assembly view of the shoe as shown in Fig. 3; Fig. 5 is an exploded view of one of a pair of shoes in accordance with another embodiment of the present invention; Fig. 6 is a side plan partially cross-sectional view of the shoe as shown in Fig. 5; Fig. 7 is an operational view of the shoe as shown in Fig. 6; Fig. 8 is an assembly view of the shoe as shown in Fig. 6; Fig. 9 is an exploded view of one of a pair of shoes in accordance with a further embodiment of the present invention; Fig. 10 is a view of the shoe as shown in Fig. 9; Fig. 11 is a perspective view of a pair of mold clamps of the shoe as shown in Fig. 9; Fig. 12 is a front plan partially cross-sectional view of the shoe as shown in Fig. 9; Fig. 13 is a front plan view of the shoe as shown in Fig. 9; Fig. 14 is an exploded view of one of a pair of shoes in accordance with a further embodiment of the present invention; Fig. 15 is a front plan partially cross-sectional assembly view of the shoe as shown in Fig. 14; Fig. 16 is a front plan partially cross-sectional assembly view of the shoe as shown in Fig. 14; Fig. 17 is a front plan partially cross-sectional assembly view of the shoe as shown in Fig. 14; Fig. 18 is an exploded view of one of a pair of shoes in accordance with a further embodiment of the present invention; Fig. 19 is a perspective assembly view of the shoe as shown in Fig. 18; Fig. 20 is a front plan partially cross-sectional assembly view of the shoe as shown in Fig. 18; Fig. 21 is a top plan assembly view of the shoe as shown in Fig. 18; and Fig: 22 is an exploded view of one of a pair of shoes in accordance with a further embodiment of the present invention. DETAILED DESCRIPTION OF THE INVENTION Referring to the drawings and initially to Figs. 1-4, a method in accordance with the present invention is used for manufacturing foamed shoes and comprises the steps of: (a) providing a foamable mixture of ethylene vinyl acetate (E.V.A.), a foaming component (blowing agent) and a binder (cross-linking agent) which are prepared and stirred; (b) heating and foaming the foamable mixture to form a foamed insole blank 11 (or 13); (c) providing a sole 17; (d) providing a shoe tree 19; (e) providing a vamp 18 on the shoe tree 19; (f) placing the sole 17 coated with glue, the foamed insole blank 11 (or 13) coated with glue, the vamp 18, and the shoe tree 19 into a pressing mold (not shown) for pressing and bonding them together; (g) heating an outer periphery of the foamed insole blank locally; and (h) pressing the outer periphery of the foamed insole blank by a pattern generating mold (not shown) so as to form knurls on the outer periphery of the foamed insole blank 11 (or 13), thereby forming the parts as shown in Fig. 3 into a final shoe product as shown in Fig. 4. The method also comprises the step of: pressing a shock absorbing pad 15 into a recess 14 defined in the foamed insole blank for providing a shock absorbing function; and pressing a plurality of ornamental plates 151 onto the outer periphery of the foamed insole blank for providing a decorative function. As shown in Fig. 1, in accordance with an embodiment of the present invention, the step (b) includes heating and foaming the foamable mixture to form an elongated flat foamed body 10, and then cutting the foamed body 10 into a plurality of foamed insole blank 11. As shown in Fig. 2, in accordance with another embodiment of the present invention, the step (b) includes forming the foamable mixture into an insole blank 12 with a scale-down size, and then heating and foaming the insole blank 12 into a foamed insole blank 13 by a heat forming mold (not shown). The method further comprises the step of: filling a thermoplastic foamable material made of polyurethane (P.U.) between the foamed insole blank 13 and the vamp 18. In such a manner, the P.U. thermoplastic foamable material can be foamed in the hollow air cells (not shown) contained in the foamed insole blank 13 so that the foamed insole blank 13 is integrally filled and formed with P.U. thermoplastic foamable material. The foamed insole blank 13 pressed in the pattern generating mold (not shown) will form knurls on the outer periphery of the foamed insole blank 13, thereby forming a semi-final product of foamed insole 16 with knurls and various patterns thereon. As shown in Fig. 3, a method for manufacturing foamed shoes comprises the steps of: providing a foamable mixture of ethylene vinyl acetate E.V.A., a foaming component blowing agent and a binder cross-linking agent which are prepared and stirred; heating and foaming the foamable mixture to form a heated foamed insole blank 16; the foamed insole blank being processed by an initial pattern generating step for facilitating embedding a shock absorbing pad 15 in a recess defmed in the top edge of the foamed insole blank 16; providing a sole 17; providing a shoe tree 19; providing a vamp 18 fitted on the shoe tree 19; placing the sole 17 coated with glue, the foamed insole blank coated with glue, the vamp 18, and the shoe tree 19 into a set of pressing molds (not shown) which are upward and downward slidable relative to each other for vertically pressing and bonding them together so that the shoe parts are integrally bonded and pressingly formed; heating an outer periphery of the foamed insole blank 16 locally by a heating machine (not shown); and pressing the outer periphery of the foamed insole blank 16 by two side pattern generating molds (not shown) horizontally moving toward each other so as to form knurls on the outer periphery of the foamed insole blank 16, thereby forming a final shoe product as shown in Fig. 4. The heated foamed insole blank can also be placed in a pattern generating mold so that the heated foamed insole blank can be pressed into a foamed insole semi-product by a pattern pressing process. The shoe tree 19 is preferably a pneumatic shoe tree structure. The foamed insole blank has a width slightly greater than that of the cavity wall of the pattern generating molds. The foamed insole blank can also be made with a hollow air cell structure so that when the insole blank is placed in the pattern generating molds, the air cells are inflated and pressed to form an inflatable foamed insole. Referring to Figs. 5-8, in accordance with another embodiment of the present invention, the method used for manufacturing foamed shoes comprises the steps of: providing a vamp 20 mounted on a shoe tree 29; providing a bottom pad 21 on the vamp 20; providing a heated foamed insole blank 24 on a bottom of the vamp 20; providing a peripheral flange 25 on a periphery of the foamed insole blank 24; providing an ornamental strip 22 bonded on a periphery of the vamp 20; providing a pull line 23 around a periphery of the ornamental strip 22; mounting the peripheral flange 25 of the foamed insole blank 24 between the vamp 20 and the ornamental strip 22 as shown in Fig. 7; tightening the pull line 23 so that the ornamental strip 22 securely encompass the foamed insole blank 24 as shown in Fig. 8; providing a sole 26 coated with glue on the foamed insole blank 24; providing a bottom mold base 28 on the sole 26; placing the sole 26, the foamed insole blank 24, and the vamp 20 between the bottom mold base 28 and the shoe tree 29 to be pressed by a hydraulic or pneumatic cylinder (not shown) for pressing and bonding the sole 26, the foamed insole blank 24, and the vamp 20 together; and finally pressing the periphery of the heated foamed insole blank 24 so as to form knurls on the periphery of the foamed insole blank 24, thereby forming a final shoe product. The method further comprises the steps of: providing a leading guard 261 on a first end of the sole 26; and providing a trailing guard 262 on a second end of the sole 26. The method also includes providing two side mold bases 27 moved relative to each other by a hydraulic or pneumatic cylinder (not shown) so as to press the foamed insole blank 24 for forming knurls on the periphery of the foamed insole blank 24. Referring to Figs. 9-13, in accordance with a further embodiment of the present invention, which is similar to the embodiment as shown in Fig. 5-8, the method used for manufacturing foamed shoes comprises the steps of: providing a vamp 30 mounted on a shoe tree 39; providing a bottom pad 31 on the vamp 30; providing a heated foamed insole blank 32 on a bottom of the vamp 30; providing a peripheral flange 33 on a periphery of the foamed insole blank 32; providing a sole 35 coated with glue on the foamed insole blank 32; providing a bottom mold base 38 on the sole 35; placing the sole 35, the foamed insole blank 32, and the vamp 30 between the bottom mold base 38 and the shoe tree 39 to be pressed by a hydraulic or pneumatic cylinder (not shown) for pressing and bonding the sole 35, the foamed insole blank 32, and the vamp 30 together; and finally pressing the periphery of the heated foamed insole blank 32 so as to form knurls on the periphery of the foamed insole blank 32, thereby forming a final shoe product. The method further comprises the steps of: providing a pair of pivotally connected mold clamps 40 to press the periphery of the foamed insole blank 32 for forming knurls on the periphery of the foamed insole blank 32; providing a corrugated peripheral profile 45 on a top edge 46 of each of the pair of mold clamps 40 as shown in Fig. 11; providing two side mold bases 37 to press the foamed insole blank 32 for forming knurls on the periphery of the foamed insole blank 32; and providing a corrugated peripheral profile 36 on a bottom edge of each of the two side mold bases 37 and mating the corrugated peripheral profile 45 of the top edge 46 of each of the pair of mold clamps 40 so as to precisely form knurls on the periphery of the foamed insole blank 32 as shown in Fig. 12. Referring to Figs. 14-17, in accordance with a further embodiment of the present invention, a method for manufacturing foamed sandal shoes comprising the steps of: (a) providing a shoe tree 49; (b) providing a heated foamed insole blank 54 on the shoe tree 49 and having two opposite sides; (c) providing two connecting pieces 55 on each of the two opposite sides of the foamed insole blank 54; (d) providing a sole 56 coated with glue on the foamed insole blank 54; (e) providing a bottom mold base 48 on the sole 56; (f) placing the sole 56 and the foamed insole blank 54 between the bottom mold base 48 and the shoe tree 49 for pressing and bonding the sole 56 and the foamed insole blank 54 together by a hydraulic or pneumatic cylinder; (g) pressing a periphery of the heated foamed insole blank 54 so as to form knurls on the periphery of the foamed insole blank 54; and (h) bonding a sandal vamp 50 (see Fig. 17) to the connecting pieces 55 of the foamed insole blank 54, thereby forming a final shoe product. The method further includes providing two side mold bases 57 to press the foamed insole blank 54 for forming knurls on the periphery of the foamed insole blank 54. Referring to Figs. 18-21, in accordance with a further embodiment of the present invention, which is similar to the embodiment as shown in Fig. 14-17, the method further comprises the steps of: providing a plurality of slots 53 in the periphery of the foamed insole blank 54; providing a plurality of connecting plates 51 on a periphery of the sandal vamp 50; providing a pull line 52 on each of the connecting plates 51; moving each of the connecting plates 51 to extend through each of the slots 53 of the foamed insole blank 54; bending each of the connecting plates 51 to press a bottom of the foamed insole blank 54; and tightening the pull line 52 of each of the connecting plates 51 for securing the foamed insole blank 54 and the sandal vamp 50 together as shown in Fig. 21. The method further includes providing a pair of pivotally connected mold clamps 60 to press the periphery of the foamed insole blank 54 for forming knurls on the periphery of the foamed insole blank 54 as shown in Fig. 20. As shown in Fig. 22, a cushion 59 can be mounted on the top of the foamed insole blank 54. Accordingly, according to the present invention, the foamed insole blank is integrally formed with the ornamental strips or plates, thereby greatly increasing the entirety of the shoes, and reinforcing the structure of the shoes so as to overcome the shortcoming of the conventional shoes of the prior art. It should be clear to those skilled in the art that further embodiments may be made without departing from the scope of the present invention, as defined by the appended claims.

Claims: A method for manufacturing shoes with foamed soles comprising the steps of: (a) providing a foamable mixture; (b) heating and foaming said foamable mixture to form a foamed insole blank; (c) providing a sole (17); (d) providing a shoe tree (19); (e) providing a vamp (18) on said shoe tree (19); (f) placing said sole (17) coated with glue, said foamed insole blank coated with glue, said vamp (18), and said shoe tree (19) into a pressing mold for pressing and bonding them together; (g) heating an outer periphery of said foamed insole blank locally; and (h) pressing said outer periphery of said foamed insole blank so as to form knurls on said outer periphery of said foamed insole blank, thereby forming a final shoe product. The method in accordance with claim 1, further comprising the step of: pressing a shock absorbing pad (15) into a recess (14) defined in said foamed insole blank. The method in accordance with claim 1, further comprising the step of: pressing a plurality of ornamental plates (151) onto said outer periphery of said foamed insole blank. The method in accordance with claim 1, wherein said step (b) further includes heating and foaming said foamable mixture to form an elongated flat foamed body (10), and then cutting said foamed body (10) into a plurality of foamed insole blank (11). The method in accordance with claim 1, wherein said step (b) further includes forming said foamable mixture into an insole blank (12) with a scale-down size, and then heating and foaming said insole blank (12) into a foamed insole blank (13). The method in accordance with claim 1, further comprising the step of: filling a thermoplastic foamable material made of polyurethane P.U. between said foamed insole blank and said vamp (18). The method in accordance with claim 1, wherein said heated foamed insole blank can also be placed in a pattern generating mold so that said heated foamed insole blank can be pressed into a foamed insole semi-product by a pattern pressing process. The method in accordance with claim 1, wherein said foamed insole blank can also be made with a hollow air cell structure so that when said insole blank is placed in said pattern generating molds, said air cells are inflated and pressed to form an inflatable foamed insole. A method for manufacturing shoes with foamed soles comprising the steps of: providing a foamable mixture of ethylene vinyl acetate E.V.A., a foaming component, in particular blowing agent, and a binder, in particular cross-linking agent, which are prepared and stirred; heating and foaming said foamable mixture to form a heated foamed insole blank; said foamed insole blank being processed by an initial pattern generating step for facilitating embedding a shock absorbing pad in a recess defined in the top edge of said foamed insole blank; providing a sole (17); providing a shoe tree (19); providing a vamp (18) fitted on said shoe tree (19); placing said sole (17) coated with glue, said foamed insole blank coated with glue, said vamp (18), and said shoe tree (19) into a set of pressing molds which are upward and downward slidable relative to each other for vertically pressing and bonding them together so that said shoe parts are integrally bonded and pressingly formed; heating an outer periphery of said foamed insole blank locally by a heating machine; and pressing said outer periphery of said foamed insole blank by two side pattern generating molds horizontally moving toward each other so as to form knurls on said outer periphery of said foamed insole blank, thereby forming a final shoe product. A method for manufacturing shoes with foamed soles comprising the steps of: (a) providing a vamp (20, 30) on a shoe tree; (b) providing a bottom pad (21, 31) on said vamp; (c) providing a heated foamed insole blank (24, 32) on a bottom of said vamp; (d) providing a peripheral flange (25, 33) on a periphery of said foamed insole blank (24); (e) providing a sole (26, 35) coated with glue on said foamed insole blank (24, 32); (f) providing a bottom mold base (28, 38) on said sole; (g) placing said sole (26, 35), said foamed insole blank (24, 32), and said vamp (20, 30) between said bottom mold base (28, 38) and said shoe tree for pressing and bonding said sole, said foamed insole blank, and said vamp together; and (h) pressing said periphery of said heated foamed insole blank (24, 32) so as to form knurls on said periphery of said foamed insole blank, thereby forming a final shoe product. The method in accordance with claim 10, wherein said step (h) further includes providing two side mold bases (27) to press said foamed insole blank for forming knurls on said periphery of said foamed insole blank. The method in accordance with claim 10, further comprising the steps of: providing an ornamental strip (22) bonded on a periphery of said vamp; providing a pull line (23) around a periphery of said ornamental strip (22); mounting said peripheral flange of said foamed insole blank between said vamp and said ornamental strip (22); and tightening said pull line (23) such that said ornamental strip (22) securely encompass said foamed insole blank. The method in accordance with claim 10, further comprising the steps of: providing a leading guard (261) on a first end of said sole; and providing a trailing guard (262) on a second end of said sole. The method in accordance with claim 10, wherein said step (h) further includes the steps of: providing a pair of pivotally connected mold clamps (40) to press said periphery of said foamed insole blank for forming knurls on said periphery of said foamed insole blank; providing a corrugated peripheral profile (45) on a top edge (46) of each of said pair of mold clamps (40); providing two side mold bases (37) to press said foamed insole blank for forming knurls on said periphery of said foamed insole blank; and providing a corrugated peripheral profile (36) on a bottom edge of each of said two side mold bases (37) and mating said corrugated peripheral profile (46) of said top edge of each of said pair of mold clamps (40) so as to precisely form knurls on said periphery of said foamed insole blank. A method for manufacturing shoes with foamed soles comprising the steps of: (a) providing a shoe tree (49); (b) providing a heated foamed insole blank (54) on said shoe tree (49) and having two opposite sides; (c) providing two connecting pieces on each of said two opposite sides of said foamed insole blank (54); (d) providing a sole (56) coated with glue on said foamed insole blank (54); (e) providing a bottom mold base (48) on said sole (56); (f) placing said sole (56) and said foamed insole blank (54) between said bottom mold base (48) and said shoe tree (49) for pressing and bonding said sole (56) and said foamed insole blank (54) together; (g) pressing a periphery of said heated foamed insole blank (54) so as to form knurls on said periphery of said foamed insole blank (54); and (h) bonding a sandal vamp (50) to said connecting pieces of said foamed insole blank (54), thereby forming a final shoe product. The method in accordance with claim 15, wherein said step (g) further includes providing two side mold bases (57) to press said foamed insole blank (54) for forming knurls on said periphery of said foamed insole blank (54). The method in accordance with claim 15, wherein said step (g) further includes providing a pair of pivotally connected mold clamps (60) to press said periphery of said foamed insole blank (54) for forming knurls on said periphery of said foamed insole blank (54). The method in accordance with claim 15, further comprising the steps of: providing a plurality of slots (53) in said periphery of said foamed insole blank (54); providing a plurality of connecting plates (51) on a periphery of said sandal vamp (50); providing a pull line (52) on each of said connecting plates (51); moving each of said connecting plates (51) to extend through each of said slots (53) of said foamed insole blank (54); bending each of said connecting plates (51) to press a bottom of said foamed insole blank (54); and tightening said pull line (52) of each of said connecting plates (51) for securing said foamed insole blank (54) and said sandal vamp (50) together.

Inventors: CHI CHENG-HSIAN, CHI, CHENG-HSIAN
Applicants: CHI CHENG-HSIAN, CHI, CHENG-HSIAN
Application year: 2000
Main classification: B29D31
IPC codes: A43B3, A43B13, B29D35