Abstract:
A method of manufacturing a component for an article of footwear including providing a two-part mold, inserting a first material layer in the mold, pouring a polyurethane layer on the first material layer, placing a piece of a wool pile fabric on the polyurethane layer and closing the mold for a designated period of time for forming a wool pile fabric component such as a footwear insole. After the designated period of time the mold is opened and the molded wool pile fabric component is removed from the mold.

Description:
PRIORITY CLAIM 
       [0001]    The present non-provisional application claims priority to and the benefit of U.S. Provisional Application No. 61/618,470 filed on Mar. 30, 2012, U.S. Provisional Application No. 61/651,922 filed on May 25, 2012, U.S. Provisional Application No. 61/680,608 filed on Aug. 7, 2012 and U.S. Provisional Application No. 61/722,994 filed on Nov. 6, 2012, each of which are hereby incorporated by reference in their entireties. 
     
    
     BACKGROUND 
       [0002]    Shearling is used in a variety of products including footwear, outwear, e.g., coats, gloves and hats, rugs, throws, pillows and car seat covers. It is an excellent insulator and yet breathes naturally. Natural wool fleece is soft, wicks moisture and provides for air circulation. 
         [0003]    The cost associated with natural sheepskin products depends on the quality and the availability of sheepskin. Sheepskin quality varies considerably depending on many factors, including environmental factors. Accordingly, sheepskin is graded based on whether the sheepskin is a higher quality, i.e., little to no imperfections in the leather, or a lower quality, i.e., having many imperfections. Shearling quality and price is also impacted by the types of sheep that the shearling comes from. Certain types of sheep are more desirable because they produce better quality skins and/or softer fleece. Also, the number of the quality sheepskins available to manufacture the above products is limited by the number of sheep that are available. As demand for shearling and natural fleece products grows, the cost associated therewith also grows. 
         [0004]    Accordingly, there is a need for products made from an alternative to shearling that replicates the desirable qualities of sheepskin while reducing the associated material costs. 
       BRIEF SUMMARY 
       [0005]    The present invention provides a method or process of making a footwear component utilizing a sheared wool fabric. More specifically, sheared wool is knitted with a scrim material to form a natural wool, deep pile fabric that closely approximates sheepskin fleece and can be used in lieu of sheepskin in many applications including footwear components. The footwear component may be an insole, a liner or other component. The present method may also be used to manufacture liners and other components for apparel such as coats, gloves, hats, and other apparel products. 
         [0006]    An embodiment of the present method of manufacturing a component part of an article of footwear includes providing a two-part mold, inserting a first material layer in the mold, pouring a polyurethane layer on the first material layer, placing a piece of a wool pile fabric on the polyurethane layer and closing the mold for a designated period of time for forming a wool pile fabric component such as a footwear insole. After the designated period of time the mold is opened and the molded wool pile fabric component is removed from the mold. 
         [0007]    Another embodiment of the present method includes providing a two-part mold, inserting a wool pile fabric piece having a wool fiber side and a scrim side in the mold, pouring a liquid foam on the scrim side of the wool pile fabric piece and closing the mold for a designated period of time for forming a wool pile fabric component. After the designated period of time the mold is opened and the molded wool pile fabric component is removed from the mold. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0008]      FIG. 1  is a perspective view of a lower part of a two-part mold for forming an footwear insole where a first material is inserted in the lower part. 
           [0009]      FIG. 2  is a perspective view of a lower part of a two-part mold of  FIG. 1  where a second material is inserted in the lower part. 
           [0010]      FIG. 3  is a perspective view of the two-part mold forming an embodiment of a footwear insole where the mold is in an open position. 
           [0011]      FIG. 4  is a perspective view of the two-part mold of  FIG. 3  where the mold is in a closed position. 
           [0012]      FIG. 5  is a perspective view of an embodiment of the present footwear insole. 
           [0013]      FIG. 6  is a perspective view of another embodiment of the present footwear insole. 
           [0014]      FIG. 7  is a perspective view of the two-part mold forming another embodiment of a footwear insole where the mold is in an open position. 
           [0015]      FIG. 8  is a perspective view of the two-part mold of  FIG. 7  where the mold is in a closed position. 
       
    
    
     DETAILED DESCRIPTION 
       [0016]    Various embodiments of the invention are described below by way of example only, with reference to the accompanying drawings. The drawings include schematic figures that may not be to scale, which will be fully understood by skilled artisans with reference to the accompanying description. Features may be exaggerated for purposes of illustration. From the preferred embodiments, artisans will recognize additional features and broader aspects of the invention. 
         [0017]    The present disclosure is related to a method of manufacturing a wool pile fabric described in commonly owned U.S. patent application Ser. No. 13/838,551, entitled “Natural Wool Pile Fabric and Method for Making Wool Pile Fabric,” filed on Mar. 15, 2013, which is incorporated herein by reference. 
         [0018]      FIG. 1  shows a lower part  12  of a two-part mold  10  ( FIG. 3 ) used to make a footwear component, and more specifically, a footwear insole  14  for a shoe, boot or other footwear product. The two-part mold  10  may be any suitable mold. In  FIG. 1 , the lower part  12  of the mold  10  includes a recess  16  formed in the shape of the insole  14  where the insole may be for a right or left shoe. Initially, a piece of polyurethane laminated foam  18  is cut to the approximate shape of the recess  16  and placed in the recess in the bottom or lower mold part  12 . The laminated foam  18  may be an Ortholite open-cell polyurethane foam, a memory foam or another suitable foam or foam product. 
         [0019]      FIG. 2  shows the laminated foam  18  in the recess  16  of the lower part  12  of the mold  10  where a layer of polyurethane  20  is poured or otherwise applied to an upper surface  22  of the foam  18  and spread evenly over that surface. Preferably, the polyurethane layer  20  has a thickness of about two millimeters but may be of another suitable thickness. After the polyurethane is poured onto the laminated foam piece  18 , the polyurethane layer  20  is allowed to cure for a designated period of time, and preferably until a dry film or “dry skin” appears on at least the upper surface  23  of the polyurethane layer. 
         [0020]    In  FIGS. 3-4 , a piece of the sheared wool fabric  24  is cut to the approximate size of the insole  14  and placed onto the polyurethane layer  20 . After the sheared wool product  24  is placed on the polyurethane layer, a top or upper part  13  of the mold  10  is pressed onto the lower part  12  of the mold to close the mold and press or mold the laminated foam  18 , polyurethane layer  20  and sheared wool product  24  together. After a designated period of time, the mold  10  is opened, i.e., the lower and upper parts  12 ,  13  of the mold are separated, and the molded insole  14  is removed from the two-part mold. In the illustrated embodiment, the mold  10  is closed for approximately five minutes and then opened to remove the insole  14 . It should be appreciated that the mold  10  may be closed for other time periods as maybe necessary to bond the components. 
         [0021]      FIG. 5  shows the footwear insole  14  made by the above method where the insole includes the foam layer  18 , the polyurethane layer  20  and the sheared wool pile fabric  24 . In one embodiment, the laminated foam layer  18  and the polyurethane layer  20  are yellow and red respectively, but may be any suitable color or combination of colors. Similarly, the sheared wool product  24  is a white or cream color but may be dyed to any desired color or combination of colors. It should also be appreciated that the foam layer  18  and polyurethane layer  20  may be any suitable thickness. 
         [0022]      FIG. 6  shows another footwear insole  26  having a different foam layer  28 , a polyurethane layer  30  and sheared wool fabric layer  32 . In this embodiment, a thicker foam is used for the foam layer where the foam may be the same foam described above or a different foam or combination of foams. It should be appreciated that other suitable foam, such as a laminated foam, may be used in the making of the footwear or apparel component. 
         [0023]      FIGS. 7 and 8  show another embodiment of the footwear component manufacturing process. In this embodiment, a two-part mold  10 ′ having a lower part  12 ′ and an upper part  13 ′ is opened and a piece of the sheared wool pile fabric  31  is cut to the approximate size and shape of the insole (or other footwear component) and placed in the lower part with the wool pile side facing down or towards the bottom of recess  33 . The scrim or backing material side  35  of the sheared wool product piece is facing up or toward the top part  13 ′ of the mold  10 ′. Next, a foam/cushioning material  37 , in a liquid or semi-liquid state, is poured or otherwise applied to the scrim side  35  of the piece of sheared wool product. The liquid foam material  37  at least partially penetrates the backing material and into the wool fibers to create a bond between the foam material or foam material layer  37  and the sheared wool product  31 . Preferably, the foam material  37  is applied to the sheared wool product  31  so that it penetrates the scrim and passes into and bonds with about 0.5 mm to 1 mm of fibers on the fiber side. Applying the liquid foam material in this manner, helps to make the wool fibers stand straighter (instead of laying or matting down in the same direction) to more closely replicate natural sheepskin where the fibers grow in many different directions. Any excess foam material that extends beyond the perimeter of the insole or footwear component can be trimmed. 
         [0024]    In the above embodiments, the footwear component is made using a two-part mold  10  or  10 ′. It should be appreciated that a three-part mold or other suitable molds, such as a press mold or an injection mold, may be used to manufacture the component. 
         [0025]    While particular embodiments of the present method have been described herein, it will be appreciated by those skilled in the art that changes and modifications may be made thereto without departing from the invention in its broader aspects.