Abstract:
An outsole for a shoe has a backing layer constituted of a shape-retaining, moldable material and a multitude of fibers flocked thereon to provide the outsole with increased slip resistance and quieter usage. The fibers are resistant to removal during wear.

Description:
CROSS REFERENCE TO RELATED APPLICATION  
       [0001]    This application is a continuation-in-part of U.S. patent application Ser. No. 10/176,430, filed Jun. 19, 2002, now pending. 
     
    
     
       BACKGROUND OF THE INVENTION  
         [0002]    1. Field of the Invention  
           [0003]    The present invention generally relates to a shoe having a slip-resistant, flocked fabric outsole.  
           [0004]    2. Description of the Related Art  
           [0005]    A house slipper is typically designed for maximum comfort and is usually constructed of soft cushioned materials. The upper of the slipper is generally made with fabric-backed foam, and the lower of the slipper generally has foam inserts. The foam provides the desired comfort.  
           [0006]    The outsole of many house slippers is usually entirely constituted of a fabric material. Although generally satisfactory, a slipper with an all-fabric outsole quickly loses its shape, thereby detracting from its appearance. Sometimes, a midsole board is inserted between the upper and the lower of the slipper. However, the midsole board is an extra component and renders the slipper less comfortable.  
           [0007]    Other house slippers and many shoes have outsoles made from rubber or plastic materials. Although generally satisfactory, a slipper or shoe with an all-rubber/plastic outsole is “noisier” during walking as compared to an all-fabric outsole and also tends to have less slip resistance.  
           [0008]    It is also known to adhere a sheet of fabric material to a lower bottom surface of an outsole of a shoe. Although the fabric provides slip resistance, experience has shown that the fabric sheet tends to delaminate and pull away from the outsole over time, especially when the fabric is exposed to wet environments and like harsh conditions.  
         SUMMARY OF THE INVENTION  
       OBJECTS OF THE INVENTION  
         [0009]    Accordingly, it is a general object of this invention to provide an outsole for a shoe that is “quiet” in use, that has an increased slip resistance, and that is durable in use.  
         FEATURES OF THE INVENTION  
         [0010]    In keeping with the above object and others which will become apparent hereafter, one feature of the present invention resides, briefly stated, in a shoe having an upper, and an outsole attached to the upper, the outsole having an outer layer constituted of a flocked fabric material. Relatively short, finely cut fibers are applied to a lower surface of the outsole. The lower surface was previously coated with an adhesive. In accordance with this invention, the outer flocked fabric layer provides the increased slip resistance and the quieter usage, and the individual fibers are less prone to being removed during wear.  
           [0011]    The novel features which are considered as characteristic of the invention are set forth in particular in the appended claims. The invention itself, however, both as to its construction and its method of operation, together with additional objects and advantages thereof, will be best understood from the following description of specific embodiments when read in connection with the accompanying drawings. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0012]    [0012]FIG. 1 is a perspective view on a reduced scale of a slipper having a flocked fabric outsole in accordance with this invention;  
         [0013]    [0013]FIG. 2 is an enlarged, sectional view taken on line  2 - 2  of FIG. 1;  
         [0014]    [0014]FIG. 3 is a perspective view of the slipper of FIG. 1 as seen from below; and  
         [0015]    [0015]FIG. 4 is a block diagram depicting the flocking of the outsole in accordance with this invention. 
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS  
       [0016]    Reference numeral  10  in FIG. 1 generally identifies a shoe, especially a slipper, having an upper  12 , a lower  14  attached to the upper  12 , and an outsole  16  attached to the lower  14 .  
         [0017]    As best seen in FIG. 2, the upper  12  includes a soft cushioned material, such as a fabric-backed foam  18  at the interior of the shoe for resiliently engaging a wearer&#39;s foot, and an exterior cover, such as a high pile fabric  20 , stitched to the fabric-backed foam  18 . The foam  18  and high pile fabric  20  are merely exemplary materials since many other materials can be used to make the upper.  
         [0018]    As also seen in FIG. 2, the lower  14  includes a base material  22  at the interior of the shoe for engaging the wearer&#39;s foot, and a skirt material  24  at the exterior of the shoe. The base and skirt materials are typically constructed of a fabric, and preferably may be made of the same material as the high pile fabric  20 . An upper portion  28  of the skirt material is stitched to a lower portion of the upper, and is also stitched to opposite sides of the base material  22  along a peripheral seam  26 . A lower portion  30  of the skirt material is stitched to the outsole  16 , thereby forming an internal compartment  32  between the outsole  16  and the base material  22 . One or more foam inserts  34 ,  36  are inserted into the compartment  32  to provide cushioning for the wearer&#39;s foot. Again, the described choice of materials for the lower is merely exemplary, since many other materials can be used to make the lower.  
         [0019]    The outsole  16  includes a backing layer  40  constituted of a shape-retaining material, for example, a rubber or a plastic material. The backing layer  40  is preferably an injection-molded part which retains its molded shape.  
         [0020]    The backing layer preferably has a raised and/or recessed tread pattern, as exemplified by the flower-like decorations  42  and diagonal ribs  44  visible on the underside of the shoe in FIG. 3. Other tread patterns, are, of course, contemplated by this invention.  
         [0021]    In accordance with this invention, as depicted in FIG. 4, an adhesive is applied (step  50 ) over a lower, bottom surface of the backing layer  40 . The adhesive can be continuously applied over the entire bottom surface, or over selected portions thereof. The adhesive can be sprayed-on, roller-coated, or brushed-on.  
         [0022]    Thereupon, a multitude of finely cut, relatively short, flock fibers  38  is applied (step  52 ) over the adhesive coating. The flock fibers  38  may be either mechanically or electrostatically applied, or applied by a combination of both techniques. Preferably, the flock fibers are sprayed on in a pneumatic process that propels the flock fibers toward the bottom surface in a stream of air, allowing flocking of contoured shapes. The fibers are oriented in any direction, but primarily in a direction perpendicular to the bottom surface, and are embedded in the adhesive coating. The fibers can be natural or synthetic, especially nylon.  
         [0023]    As opposed to the known technique of glueing a single fabric sheet, which is subject to delamination and peeling, the flocked fibers of this invention are highly resistant to removal since each fiber is individually held in place.  
         [0024]    A finishing treatment (step  54 ) may be performed to the flock fibers. The finishing may include printing graphic markings thereon, such as by silk screening, or embossing graphic markings therein. The finishing may include a waterproofing step by spraying a waterproofing material over the fibers, or a pressing step in which heat and pressure are applied over the fibers to obtain a flattened appearance. A flocked finish may impart friction modification, heat insulation, thermal stability, buffing, polishing, cushioning or a decorative, tactile and visual appeal.  
         [0025]    It will be understood that each of the elements described above, or two or more together, also may find a useful application in other types of constructions differing from the types described above. The flocked fabric outsole is applicable to any footwear.  
         [0026]    While the invention has been illustrated and described as embodied in a shoe with slip-resistant, flocked fabric outsole, it is not intended to be limited to the details shown, since various modifications and structural changes may be made without departing in any way from the spirit of the present invention.  
         [0027]    Without further analysis, the foregoing will so fully reveal the gist of the present invention that others can, by applying current knowledge, readily adapt it for various applications without omitting features that, from the standpoint of prior art, fairly constitute essential characteristics of the generic or specific aspects of this invention and, therefore, such adaptations should and are intended to be comprehended within the meaning and range of equivalence of the following claims.  
         [0028]    What is claimed as new and desired to be protected by Letters Patent is set forth in the appended claims.