Shoe comprising an aeration or transpiration system, and corresponding fabrication method

Abstract: A shoe having a top part or upper (2), an inlay sole (14) , an outsole (4, 4A), and an aeration or transpiration system (5-16) comprising: one or more aeration passages (16) defined in said inlay sole (14); a path (7A) for passage of air, which is defined underneath said inlay sole (14) and is able to set in communication said aeration passages 16 with at least one passage way (5) that extends between said path (7A) and the outside of said outsole (4). At least one substantial part of said path (7A) is defined in the body of an insert (6) set underneath said inlay sole (14) and in contact with the latter, said insert (6) being at least partially surrounded by or enclosed in a material constituting said outsole (4, 4A). The outsole can thus be formed by means of injection moulding directly on the ensemble made up of said upper (2), said inlay sole (4) and said insert (6).

Description: The present invention relates to a shoe of the type specified in the preamble of Claim 1 annexed hereto, as well as to the corresponding fabrication method. Currently known to the art are various systems designed to enable air change inside a shoe and/or to prevent footwear from getting saturated with sweat inside. In the simplest solutions, these systems are obtained by providing aeration passages in the upper of the shoe. The said passages may be in the form of simple holes made in the upper as required, or else holes inherent in the structure of special air-permeable materials of which the upper is at least in part made. In other known solutions, the footwear is, instead, provided with a transpiration or aeration system proper, which forms an integral part of the outsole. In a first type of said solutions, the system envisages the use of a special membrane, usually made of Goretex (registered trade mark) or of a similar material, which is set between a rubber outsole and an inner sole or inlay sole for mounting of the shoe. In particular, the inlay sole presents a series of through holes, beneath which the membrane is set, the latter being located in a position corresponding to an imprint or perforated seat, which is defined on the top surface of the outsole. The aforesaid membrane can, in this way, absorb the humidity inside the shoe, through the holes of the inlay sole, and then discharge it outside through the holes present in the imprint of the outsole. By virtue of the characteristics of the material that constitutes the membrane, the latter also prevents entry of water inside the shoe through the holes present in the outsole. From W0 99/26504 a shoe with a transpiration system of the above type including a special membrane is known, having the features of the preamble of claim 1. In a second type of known solutions, the system envisages a series of ducts which are open at the top and are defined within the rubber forming the outsole of the shoe. Provided on top of the outsole is a perforated inlay sole for mounting of the shoe, and the outsole is provided, on one side, with a one-way valve, which is designed to set the aforesaid ducts in communication with the outside environment. The air present inside the shoe can in this way reach, through the holes in the inlay sole, the ducts defined in the outsole, and then be discharged outside through the aforesaid valve. Also in this case, the air extracted is replaced with fresh air that penetrates from the top part of the shoe. From FR-A-2.519.521 a shoe with a transpiration system of the type including a valve is also known, having a composite sole comprising an outsole, a compressible middle sole and an inner cover sole. A network of aerating and venting channels is formed in the midsole, which establish a connection between the spacing inside the shoe and the outside, by means of a valve housed in a hole defined in the ousole, the latter being set to cover midsole and glued to the shoe's upper. In order to produce footwear provided with the aforesaid transpiration or aeration system of the valve type, the outsole must be previously made in the form of a distinct component and then be glued or bonded to the upper of the shoe, and cannot, instead, be obtained by injection moulding directly on the upper, according to a by now customary technique in the field of production of footwear. The above type of construction decidedly complicates the manufacturing process for producing the footwear, the said process necessarily requiring a specific operation of gluing or bonding of the preformed outsole to the upper; this consequently entails also a higher cost of the end product. The purpose of the present invention is to overcome the above-mentioned drawback. In the above framework, a purpose of the present invention is to propose a shoe provided with an aeration or transpiration system integrated in the outsole, in which the outsole itself can be injected or moulded directly onto the upper. A further purpose of the present invention is to propose a shoe of the above type that is simple and inexpensive to make. Yet another purpose of the present invention is to provide a method for making, in a simple and inexpensive way, a shoe of the above-mentioned type. The above and yet other purposes are achieved according to the present invention by an article of footwear and a method having the characteristics specified in the attached claims 1 and 10, respectively, which are intended as forming an integral part of the present description. Further purposes, characteristics and advantages of the present invention will emerge clearly from the ensuing detailed description and from the attached drawings, which are provided purely by way of explanatory and non-limiting example and in which: Figure 1 is a schematic side view of a shoe made according to the present invention; Figure 2 is a schematic side view of an internal component of the shoe of Figure 1; Figure 3 is a schematic cross-sectional view of the component of Figure 2, taken along the line II-II of Figure 2; Figure 4 is a schematic cross-sectional view of the component of Figure 2, taken along the line IV-IV of Figure 3; Figure 5 is a schematic cross-sectional view of the component of Figure 2, taken along the line V-V of Figure 3; Figure 6 is a schematic plan view of an inlay sole of the shoe of Figure 1; Figure 7 is a schematic cross-sectional view of the shoe of Figure 1, taken along the line VII-VII of said figure; Figure 8 is a schematic cross-sectional view of the shoe of Figure 1, taken along the line VIII-VIII of Figure 7; and Figure 9 is a schematic cross-sectional view of the shoe of Figure 1, taken along the line IX-IX of Figure 7. Figure 1 is a schematic side view of a shoe made according to the teachings of the present invention. The said shoe, designated as a whole by the reference number 1, comprises an upper 2, obtained in a way in itself known and provided with a lace 3 for tying the shoe, and an outsole 4, provided with a bottom tread 4A. As will be described in greater detail in what follows, the outsole 4 integrates an aeration or transpiration system, and for this purpose it is equipped with an air-outlet valve 5, made in a way in itself known. According to a primary aspect of the present invention, albeit integrating the aforementioned aeration system, the outsole 4 is obtained by injection or direct moulding of material onto the upper 2, unlike what happens according to the current state of the art as mentioned previously. The above possibility is afforded, according to the present invention, thanks to a particular composite structure of the outsole 4, and in particular by virtue of the fact that an insert or internal component is provided inside the outsole itself, the said insert being hereinafter referred to by the term "midsole". The said midsole is schematically represented in Figures 2-5, where it is designated, as a whole, by the reference number 6. The midsole 6, which is, for instance, made of moulded plastic material, comprises a main body that is shaped for defining a series of internal ducts, designated by 7A in Figures 3-5, which communicate with one another. In particular, in the embodiment exemplified in the figures, the midsole 6 basically presents a single cavity, designated by 7, open at the top. Within the said cavity 7 there is defined a plurality of projections, some of which are designated by 8, 9, 10, and at least one longitudinal wall, designated by 11, said projections and wall being designed to form a labyrinth-like or matrix-like path, which forms the ducts 7A. As may be noted both from Figure 2 and from a comparison between Figures 4 and 5, the thickness of the midsole 6 is greater in the rear portion of the latter, namely the one that is designed to operate in the heel area of the shoe 1. Consequently, also the depth of the ducts 7A is greater in the rear portion of the midsole 6. The reference number 12 designates a through hole, made on one side of the midsole 6, which is designed to house a portion of the valve 5 of Figure 1. Finally, in Figures 3-5 the reference number 13 designated a perimetral base which surrounds the cavity 7 and which is designed to provide a surface for gluing or bonding of the midsole 6 to an inlay sole for mounting of the shoe, on which the upper is mounted, the said inlay sole being designated, as a whole, by 14 in Figure 6. In the case illustrated by way of example in the figures, the inlay sole 14 has a series of holes for aeration and drainage of humidity, which are designated by 15 and 16 and are respectively present in the front portion and in the rear portion of the inlay sole 14. In Figures 7-9, the shoe 1 according to the present invention is represented by means of various cross-sectional views. From the above figures it may be readily seen how the lateral dimensions of the midsole 6 are reduced as compared to those of the outsole 4, in such a way that the material constituting the latter will completely surround the outer perimeter of the former. From the said figures it is also possible to note how the valve 5 is, as a whole, housed in part within the hole 12 (see Figures 3 and 5) of the midsole 6 and in part directly in the outsole 4. In Figures 8 and 9, the reference number 17 designates, as a whole, a steel plate, which is positioned underneath the midsole 6. The said plate 17 constitutes a protective element, which is designed to prevent any foreign bodies, such as nails or similar sharp objects, from coming into contact with the foot of the user, after they have traversed the outsole of the shoe 1. It should, in any case, be borne in mind that the protection plate 17 is to be considered merely optional for the purposes of implementation of the present invention. The manufacturing process for producing the footwear article according to the invention is carried out according to the modalities described in what follows. The midsole 6 is previously made as a separate component, for instance of thermoplastic material, by means of a moulding operation carried out according to modalities in themselves known. The upper 2 is pre-assembled according to known modalities, by associating thereto all the various components required (linings, borders, tongue, eyelets for the laces, etc.). Also the inlay sole 14 for mounting of the shoe, provided with the holes 15 and 16, is formed according to modalities in themselves known. The inlay sole 14 is then fixed to the bottom part of the upper 2 in such a way as to be integral with the latter. The said fixing may be obtained with any known technique, such as bonding, stapling or sewing. The midsole 6, to the hole 12 of which the valve 5 has been previously associated, is then glued on the under surface of the inlay sole 14. In practice, gluing is performed by depositing a layer of adhesive at least along the perimetral base 13 of the midsole 6, and then pressing the midsole itself onto the bottom surface of the inlay sole 14, so as to achieve adhesion between the parts. Possibly, if it is considered necessary for the purpose of improving the adhesion of the midsole 6 to the inlay sole 14, a layer of adhesive can be deposited also on the top surfaces of the various projections 8, 9, 10 and of the wall 11 of the midsole. Following upon gluing, the series of holes 15 and 16 of the inlay sole 14 come to be set in positions corresponding to the underlying ducts 7A of the midsole 6. The semi-finished product thus obtained, made up of the upper 2, the inlay sole 14 and the midsole 6, is then introduced into a corresponding mould which forms part of a piece of equipment, of a type in itself known, designed to perform injection or direct moulding, onto the semi-finished product itself, of the material that is to form the outsole 4, for instance rubber. In the case where the shoe 1 is to be equipped with the protection element 17, the latter may be glued on the bottom surface of the midsole 6, in such a way that into the said mould there may be introduced a semi-finished product which also includes the protection element. The operation of the aeration or transpiration system of the shoe 1 is altogether similar to the one previously mentioned in the introductory part of the present description. In brief, the air present inside the shoe 1 can reach, through the holes 15 and 16 of the inlay sole 14, the ducts 7A defined in the midsole 6. The air is then discharged outwards through the valve 5. Also in this case, the air extracted is replaced by fresh air that penetrates from the top part of the shoe 1. The characteristics of the shoe according to the present invention and of the corresponding fabrication method emerge clearly from the foregoing description, the said characteristics being further specified in detail in the annexed claims. Also the advantages of the present invention emerge clearly from the foregoing description. In particular, it should be emphasized how the solution described makes it possible to build a shoe that is provided with an aeration or transpiration system integrated in the outsole, the latter being injected or directly moulded onto the upper, in a simple way and with evident saving in time and manufacturing and assembly costs as compared to the prior art, which, instead, presupposes a special process of fabrication of the outsole, in the form of an independent component, which is subsequently to be glued to the upper. Of course, without prejudice to the principle of the invention, the details of construction and the embodiments may vary widely with respect to what is described and illustrated herein, without thereby departing from the scope of the present invention as defined in the attached claims. For example, it would be possible to set on top of the inlay sole 14 a further inlay sole inside the shoe, such as an anatomic arch-support, provided with aeration passages in the form of holes or passages inherent in the structure of the material itself that constitutes the said further inlay sole. The aeration system could comprise, if so required, a number of valves, of the type of the one previously designated by 5, in which case the midsole 6 will be provided with a corresponding number of holes 12. The valve 5 could be, at least in part, made of a single piece with the midsole 6.

Claims: A shoe having a top part or upper (2), an inlay sole (14), an outsole (4, 4A), and an aeration or transpiration system (5-16) comprising: one or more aeration passages (15, 16) defined in said inlay sole (14); a path (7, 7A) for passage of air, which is defined underneath said inlay sole (14) and is able to set in communication said aeration passages (15, 16) with at least one passage way (5, 12) that extends between said path (7A) and the outside of said outsole (4), wherein at least a substantial part of said path (7, 7A) is defined in the body of an insert (6) set underneath said inlay sole (14) and in contact with the latter, said insert (6) being at least partially surrounded by, or enclosed in, a material constituting said outsole (4, 4A), the latter being at least in part made of a material directly injected or moulded onto the ensemble made up of said upper (2), said inlay sole (4) and said insert (6), at least a first portion (12) of said passage way (5, 12) is defined within the body of said insert (6), said first portion comprising a hole (12) which traverses a wall of the body of said insert (6), at least a second portion of said passage way (5, 12) is defined within said outsole (4), characterized in that said passage way (5, 12) comprises a valve (5) partially inserted into said first portion (12), said second portion being formed by material constituting said outsole (4, 4A), which surrounds the part of said valve (5) that extends outside the body of said insert (6). The shoe according to claim 1, characterized in that the thickness of said insert (6) and/or the depth of said ducts (7A) is greater in the portion of the insert that is designed to operate in the heel area of the shoe (1), said passage way (5, 12) including said valve (12) being located in said heel area. The shoe according to Claim 1, characterized in that said insert (6) has a cavity (7) that opens in the direction of said inlay sole (14) and that a single intermediate longitudinal wall (11) is formed in said cavity (7) for delimiting two longitudinal ducts (7A) within which there are defined a plurality of projections (8, 9). The shoe according to Claim 1, characterized in that said insert (6) comprises at least one surface (13) in contact with said inlay sole (14). The shoe according to Claim 4, characterized in that said surface comprises a perimetral base (13) which surrounds said path (7A). The shoe according to Claim 1, characterized in that there is further provided a protection element (17), basically in the form of a plate, which is able to prevent any possible foreign bodies from coming into contact with the foot of the user of the shoe (1), after they have traversed the outsole (4) of the latter. The shoe according to Claim 6, characterized in that said protection element (17) is set beneath said insert (6) and is at least in part surrounded by the material of the outsole. The shoe according to one or more of the preceding claims, characterized in that said insert (6) is made of moulded thermoplastic material, and the material constituting said outsole (4) is rubber. The shoe according to claim 1, characterized in that said valve (5) is, at least in part, made of a single piece with said insert (6). A method for producing an article of footwear (1) having a top part or upper (2), an inlay sole (14), an outsole (4), and an aeration or transpiration system (5-16) comprising: one or more aeration passages (15, 16) defined in the inlay sole (14); a path (7A) for passage of air, which is defined underneath the inlay sole (14) and is able to set in communication said aeration passages (15, 16) with at least one passage way (5, 12) that extends between said path (7A) and the outside of said outsole (4), the method comprising the following steps: a) formation of the upper (2); b) formation of the inlay sole (14); c) association of the inlay sole (14) to the upper (2); d) formation of one or more cavities or ducts (5, 7, 7A) in the body of a further component (6) of the shoe (1), designed to form at least a part of said path (7A) and said passage way (12), at least a first portion (12) of said passage way (5, 12) being formed within the body of said insert (6), said first portion comprising a hole (12) which traverses a wall of said further component (6); e) setting the further component (6) underneath the inlay sole (14) and in contact with the latter, in such a way that the cavity or cavities or ducts (7, 7A) are in communication with the aeration passages (15, 16) of the inlay sole (14), f) association of the outsole (4) to the upper (2), wherein step f) is carried out by means of injection or moulding of the material that is to form at least one portion (4) of the outsole (4, 4A) directly onto the bottom part of the ensemble made up of the upper (2), the inlay sole (14) and the further component (6), at least part of the latter in this way being surrounded by, or enclosed in, said material, characterized in that , for the purposes of obtaining said passage way (12), a valve (5) is partially inserted into said first portion (12), at least a second portion of said passage way (5, 12) is formed by material constituting said outsole (4, 4A) which surrounds the part of said valve (5) that extends outside the body of said insert (6).

Inventors: LICO GIANDOMENICO, LICO, GIANDOMENICO
Applicants: DIADORA INVICTA S P A, DIADORA - INVICTA S.P.A.
Application year: 2001
Main classification: A43B7
IPC codes: A43B7