Patent Abstract:
Improvements in shoe constructions are provided that provide ground contacting surfaces of multiple materials that resist separation from one another and which provide traction and tariff benefits.

Full Description:
TECHNICAL FIELD 
   The present invention relates generally to a shoe and more specifically, relates to a shoe having a fabric material disposed on at least a portion of the outsole and to a manufacturing process thereof. 
   BACKGROUND OF THE INVENTION 
   A shoe is generally formed of an upper, a lower attached to the upper, and an outsole attached to the lower. The outsole of the shoe is the exposed portion of the sole that contacts the ground or other supporting surface. The outsole provides many characteristics of the shoe such as the shoe&#39;s traction and stability with respect to the intended supporting surface. For example, the outsole of the shoe may be provided with some type of traction elements arranged in a pattern to provide a gripping action between the outsole and the ground or supporting surface. The outsole should also be manufactured so that it offers extended wear to permit the shoe to be worn for a lengthy period of time. 
   Often, the outsole of the shoe is formed of a rubber material or leather in designer shoes and the like. In men&#39;s and women&#39;s shoes, the outsole is very often substantially smooth and this can cause traction problems. For example, such outsoles are often very slippery because of their smooth texture and this increases the chances that the user may accidently slip or slide during normal use. The risk of slipping and sliding is increased significantly when the surface or supporting surface is wet or otherwise in a slippery state. 
   The outsole is an important component of the shoe for an additionally entirely unrelated reason which has gone unrecognized in the art of shoe sole construction. As the economies of most countries become more and more internationalized, international commercial transactions invoke national customs tariffs that generally must be paid when goods are shipped. Under the Harmonized Tariff Schedules of each country, goods are classified under various categories. For example, most footwear is classified under Chapter 64 of the United States Harmonized Tariff Schedules which covers the importation of goods into the United States. Within this chapter, the following major headings are recited for footwear: 
                                                6401    Waterproof Rubber or Plastic Footwear;           6402   Other Footwear with Uppers and Outersoles of               Rubber or Plastic;           6403   Footwear with Uppers of Leather and Outersoles               Of Rubber, Plastic, Leather, or Composition Leather;           6404   Footwear with Uppers of Textiles and Outersoles of               Rubber, Plastic, Leather, or Composition Leather; and           6405   Other Footwear.                        
Accordingly, footwear is generally classified in a given heading based upon the material of the upper and the material of the outersole. Consequently, the outsole plays an important role in determining the rate of duty which is to be applied to the specific footwear article. Depending upon the material which is used to manufacture the upper and the sole, the rate of the duty may vary significantly. For example, the rate of duty may range from 37.5% ad valorem for many common types of footwear to 3% ad valorem for certain types of sandals and similar footwear. In determining the applicability of a particular section of one chapter of the United States Harmonized Tariff Schedules, knowledge of specific details of the material is necessary. For example, a classification may be based on the type of material that is present on 50% or more of the bottom surface of the shoe (outersole) that contacts the ground.
 
   Over many years, manufacturers have focused their attention on improving the traction properties of shoe outsole construction, but have not recognized that a price advantage can be had by combining materials in the outer shoe sole construction. 
   What is needed in the art and has heretofore not been available is an outsole and method of manufacture thereof which offers slip resistance and other desirable properties in addition to providing a competitive advantage to the manufacturer based on its construction. 
   SUMMARY OF THE INVENTION 
   According to the present invention, a shoe including an upper, a lower attached to the upper, and an outsole attached to the lower is presented. In one embodiment, the outsole has a ground contacting surface which includes a first section and a second section, with the first section being formed of a first material and the second section having an outer later formed of a fabric material. The first section is free of any fabric material and is instead formed of other suitable materials, such as rubber, leather, etc. 
   In another embodiment, the ground contacting surface substantially consists of a shaped fabric member having the fabric material disposed on an outer surface thereof. The shaped fabric member extends below other surrounding sections of the outsole which do not contain a fabric material, so as to form a ground contacting surface of the outsole. 
   According to the present invention, the outsole is preferably formed using a molding process and, more specifically, is formed using a two stage molding process. The fabric material is not just layered over an existing outsole construction but rather forms an integral part of the outsole construction itself. In one embodiment, a shaped fabric member having the fabric material disposed on an outer surface thereof is formed during a first molding process and then the shaped fabric member is disposed in a second mold. A second molding process is conducted and the remaining portion of the outsole is formed around the shaped fabric member which becomes an integral part of the outsole. The result is that an integral outsole is produced in which a substantial amount of the ground contacting surface of the outsole is defined by the fabric material. Preferably, greater than 50% of the ground contacting surface of the outsole includes the fabric material. 
   In accordance with the present invention, the outsole provides increased slip resistance, is durable, and provides a competitive manufacturing advantage. 
   Other features and advantages of the present invention will be apparent from the following detailed description when read in conjunction with the accompanying drawings. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The foregoing and other features of the present invention will be more readily apparent from the following detailed description and drawings of illustrative embodiments of the invention in which: 
       FIG. 1  is a bottom perspective view of one exemplary type of shoe having an outsole in accordance with one embodiment of the present invention; 
       FIG. 2  is a bottom plan view of the shoe of  FIG. 1 ; 
       FIG. 3  is a cross-sectional view taken along the line  3 — 3  of  FIG. 1 ; 
       FIG. 4  is a bottom plan view of the shoe of  FIG. 1  showing a fabric portion of the outsole peeled back to expose a backing portion of the outsole; 
       FIG. 5  is a bottom perspective view of another exemplary type of shoe having an outsole in accordance with the present invention; 
       FIG. 6  is a bottom plan view of shoe of  FIG. 1 ; 
       FIG. 7  is a cross-sectional view taken along the line  7 — 7  of  FIG. 6 ; 
       FIG. 8  is a bottom perspective view of another exemplary type of shoe having an outsole in accordance with the present invention; 
       FIG. 9  is a bottom plan view of the shoe of  FIG. 8 ; 
       FIG. 10  is an exploded perspective view of a first mold including first and second dies; 
       FIG. 11  is perspective view of a shaped fabric member formed during a process using the first mold of FIG.  10  and for use in an outsole in accordance with the present invention; and 
       FIG. 12  is a perspective view of a second mold in an open position, the second mold including first and second dies, with the shaped fabric member of  FIG. 11  being placed in one of the first and second dies. 
   

   DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
   The present invention will be first described with reference to  FIGS. 1 through 4 .  FIG. 1  illustrates one exemplary type of shoe  10  having an upper  20 , a lower  30  attached to the upper  20 , and an outsole  40  attached to the lower  30 . The shoe  10  is of a style which is commonly worn by women in both workplace settings and social settings. The style and nature of shoe  10  is merely exemplary and it will be understood that the present invention applies to a wide range of types of shoes, including but not limited to men&#39;s, women&#39;s, and children&#39;s shoes. 
     FIG. 3  is a cross-sectional view of the shoe  10  showing its construction in greater detail. The upper  20  includes a soft cushioned material, such as a fabric-backed foam  22  at an interior portion of the shoe  10  for resiliently engaging a wearer&#39;s foot. The fabric-backed foam  22  thus serves to cushion the wearer&#39;s foot during use and reduce impact between the foot and the surrounding environment. The upper  20  also includes an exterior cover  24 , such as a high pile fabric, coupled to the fabric-backed foam  22 . For example, the exterior cover  24  may be stitched to the fabric-backed foam  22 . It will be appreciated that the upper  20  may be formed of a number of different materials and foam and high pile fabric are merely exemplary materials. For example, the exterior cover  24  may be formed of leather or the like or velvet or the like, especially for women&#39;s shoes. 
   The lower  30  includes a base material  32  at the interior of the shoe  10  for engaging the wearer&#39;s foot. Typically, the base material  32  is formed of a foam or a fabric and may be formed of multiple layers. For example, the base material  32  of the exemplary shoe  10  actually includes a thin top layer  34  which may be formed of any number of materials, including a fabric and a suitable plastic material. Underneath the top layer  34  is a cushion element  35  which preferably has an identical shape as the top layer  34 . The cushion element  35  is preferably formed of a soft cushioned material, such as a foam. It will be appreciated that the top layer  34  and cushion element  35  may be formed as a single integral piece. 
   Underneath the cushion element  35 , a support layer  36  is provided. 
   The support layer  36  is also preferably similarly or identically shaped as the top layer  34  and the cushion element  35  and is designed to act as a backbone of the lower  30 . The support layer  36  is formed of a rigid material so that it maintains its shape under application of force, such as the weight of the wearer. The support layer  36  may be formed of any number of rigid materials, such as a rigid plastic, a rigid reinforced cardboard member, etc. The cushion element  35  is coupled to the support layer  36  using any number of techniques, including applying an adhesive to a backside of the cushion element  35  and then applying the cushion element  35  to a topside of the support layer  36 . 
   The upper and lower  20 ,  30  of the shoe are attached to one another using any number of techniques. For example and as shown in the cross-sectional view of  FIG. 3 , a portion of the upper  20 , and more specifically a portion  26  of the exterior cover  24 , is tucked underneath an edge of the lower  30  to secure the upper  20 . The exterior cover  24  may be secured to the lower  30  by applying an adhesive or the like to the area where the exterior cover  24  and the lower  30  meet. 
   In accordance with the present invention, the outsole  40  is made of a rigid material so as to provide support to the outsole  40  and includes an outer surface  42 . The outsole  40  may have any number of shapes depending upon the type of shoe  10 . For example, shoe  10  is a typical women&#39;s shoe and therefore includes a prominent heel  50 . When shoe  10  has a heel, such as heel  50 , the heel  50  may be formed as a separate member from the outsole  40  or the heel  50  may be integrally formed as part of the outsole  40 . In the exemplary shoe  10 , the heel  50  is a separate member which is coupled to the outsole  40  using known techniques. Preferably, an upper portion of the heel  50 , in the form of a lip  51 , extends around a heel portion of the exterior cover  24 . This lip portion  51  is coupled to the adjacent heel portion of the exterior cover  24  using an adhesive or the like. A bottommost portion  53  of the heel  50  engages the ground or support surface and therefore may be formed of a suitable material for such wear. For example, the bottommost portion  53  may be formed of the same material as the other portions of the heel  50  or may be formed of a different material. The major portion of the heel  50  is preferably formed of a rigid material, such as a rigid plastic or wood. The bottommost portion  53  may be formed of this type of material or may be in the form of a shaped rubber pad which is coupled to the other portions of the heel  50 , as shown in  FIGS. 1-2 . 
   As is known in the art, different portions of the outsole  40  of shoe  10  are referred to differently. The outsole  40  of shoe  10  includes the heel  50  formed at one end and includes a ball portion  49  formed generally at an opposite end of the shoe  10 . The ball portion  49  is the portion of the outsole  40  which primarily contacts the ground during normal use of the shoe  10 . Between the ball portion  49  and the heel  50 , the outsole  40  includes a shank  55  which does not contact the ground during wear of the shoe  10 . The shank  55  is thus angled upwardly away from the ground surface when the ball portion  49  and the heel  50  are seated against the ground. The height of the heel  50  determines the angle between the shank  55  and the ground surface. 
   In accordance with the present invention, the outsole  40  also includes a shaped fabric member  60  which forms a part of the outsole  40  and has a predetermined shape. As best shown in  FIG. 3 , the shaped fabric member  60  includes a thin, flexible, fabric sheet material  62  and a backing layer  64 . Preferably, the fabric sheet material  62  is formed of a non-woven fabric, such as polyester fibers mixed with cotton. Thus, the fabric sheet material  62  is not produced using a weaving process but rather is produced using other suitable techniques for forming a non-woven fabric. For example, the polyester fibers may used to form a needle felt which is then impregnated with a material before being dried and pressed. It will be appreciated that the shaped fabric member  60  may have any number of shapes and sizes depending upon the shoe design and other parameters such as the amount of contact between the outsole  40  and the ground or support surface. 
   In accordance with the present invention, the shaped fabric member  60  is disposed on a significant and preferably substantial portion of the outsole  40  which engages the ground or support surface during normal use. More specifically, the shaped fabric member  60  preferably occupies an area which is at least greater than 50% of the area of the outsole  40  which contacts the ground. In the exemplary shoe  10  shown in  FIGS. 1-3 , the ground contacting portion of the outsole  40  includes the bottommost portion  53  of the heel  50  and the ball portion  49 . It will be appreciated that the percent of the ground contacting surface of the shoe  10  that includes the shaped fabric member  60  will depend upon a number of factors, including but not limited to the type of shoe  10  (i.e., high heel or not) and the area of ground contacting surface as a percentage of the total area of the outsole  10 . For example, the shaped fabric member  60  preferably occupies greater than 50% to about 90% of the entire ground contacting surface of the outsole  40 . 
   In the shoe  10 , the shaped fabric member  60  is disposed within the outsole  40  and more preferably is disposed within the ball portion  49  of the outsole  40 . Preferably, the shaped fabric member  60  is integrally formed as part of the outsole  40  as will be described hereinafter. The bottommost portion  53  of the heel  50  is formed of a rubber or other suitable material. A gap  63  is formed between the fabric sheet material  62  and a surrounding edge  71  of the outer surface  42  of the outsole  40 . As shown in the figures, the outer surface  42  of the outsole  40  surrounds the shaped fabric member  60 . When the shaped fabric member  60  is disposed within the outsole  40 , an outer face of the fabric sheet material  62  is preferably substantially planar to the surrounding outer surface  42  of the outsole  40  so that during use, the outsole  40  engages the ground in a relatively uniform manner. 
   The backing layer  64  is preferably formed of a shape-retaining material, for example, a rubber or plastic material. The backing layer  64  and the fabric sheet material  62  are integrally connected to one another by any number of techniques, including using a molding process as will be described in greater detail hereinafter. In addition, the surrounding outsole  40  and the backing layer  64  may be formed of the same material or may be formed of different materials. In one exemplary embodiment, both are formed of a thermoplastic. In another embodiment, both are formed of a material that is referred to herein as a thermoplastic rubber. 
   The shaped fabric member  60  along with the surrounding outsole  40  provide the shoe  10  with a slip-resistance, shape-retaining partially fabric outsole  40 . It is also contemplated that the outer surface  42  and/or the backing layer  64  may have a tread pattern formed thereon for a decorative purpose, a functional purpose, or both. For example, the surface  42  and the layer  64  can have a tread pattern, and in the case of the backing layer  64 , the fabric sheet material  62  can closely conform to the pattern, e.g., follow the contour thereof. 
   The use of the shaped fabric member  60  also has another associated advantage: the provision of the fabric sheet material  62  on greater than 50% of the ground contacting surface area of the outsole  40  enables the shoe  10  to be classified under a different section of the United States Harmonized Tariff Schedules and therefore permits the manufacturer of the shoe  10  to pay a different, lower rate of tariff duty. In other words, the classification of the shoe  10  for tariff purposes depends, in part, on the constituent material of the upper  20  and the constituent material of the outsole  40  (based upon the greatest surface area in contact with the ground). In the exemplary shoe  10 , the upper  20  is formed of a textile material and the constituent material of the outsole  40  is also a textile material because the material which occupies the greatest surface area in contact with the ground is the fabric sheet material  62  (a material classified as a textile). 
   By having both the upper  20  and the outsole  40  formed of a textile material, the shoe  10  can be classified under “Other Footwear, with uppers of textile materials, Other” which has a lower rate of duty than footwear having a textile upper and an outersole formed of rubber, plastic, leather, or composition leather. Under the current United States Harmonized Tariff Schedules, the shoe  10  of the present invention is classifiable under subheading 6405.20.90, which carries a 12.5% rate of duty so long as greater than 50% of the ground contacting surface area of the outsole  40  is occupied by the fabric sheet material  62 . This is significantly lower than a 37.5% rate of duty applied to many types of footwear with outersoles of rubber, plastics, leather or composition leather and uppers of textile materials. Thus, associated costs for the overall manufacturing and delivering process can be significantly reduced by decreasing the rate of duty which is applied to the footwear (shoe  10 ). This results in a competitive advantage. 
   The manufacture of shoe  10  and more specifically, the outsole  40  will now be described in greater detail with reference to  FIGS. 1-3  and  10 - 12 . A two step molding process is preferably used to manufacture the outsole  40 . In a first molding process, the shaped fabric member  60  is formed. Initially, a piece of the fabric sheet material  62  is cut to a predetermined shape and size. 
   Preferably, the fabric sheet material  62  is a non-woven fabric, such as polyester fibers with cotton. This cut piece of the fabric sheet material  62  is then inserted into a first mold  100 . The first mold  100  is a conventional mold having a first shaped die  102  and a second shaped die  104 . The first and second dies  102 ,  104  have one or more cavities formed therein which define the shape of the shaped fabric member  60  and are generally shaped so as to be accommodated in the ball portion  49  of the outsole  40 . The cut piece of fabric sheet material  62  is held in place again the first shaped die  102 . 
   The first and second dies  102 ,  104  are heated to a predetermined temperature which permits the molding process to proceed without damaging or destroying the fabric sheet material  62 . The predetermined temperature which is required for the molding process will depend upon a number of factors, including the type of thermoplastic resin used in the molding process. In one exemplary embodiment, the first and second dies  102 ,  104  are heated to a temperature of about 120° C. when a thermoplastic rubber is used to form the backing layer  64 . The first and second dies  102 ,  104  are pressed together with the fabric sheet material  62  being held in place against the first die  102  and then the thermoplastic rubber is injected into the first mold  100  after the thermoplastic rubber has been melted to a softened state by being exposed to a sufficient temperature (120° C.). 
   Because the thermoplastic rubber is in a softened state, it is able to flow throughout a cavity formed by the first and second dies  102 ,  104 . The thermoplastic rubber forms the shape of the backing layer  64  once the thermoplastic rubber cools after a predetermined time period in which the temperature of the first mold  100  is reduced. The result is that the shaped fabric member  60  is formed and the thermoplastic rubber and the fabric sheet material  62  are bonded to one another by the heating process of the molding operation. Once the shaped fabric member  60  has sufficiently cooled down, the first and second dies  102 ,  104  are opened and the shaped fabric member  60  is removed therefrom. Excess fabric sheet material  62  is cut off from the shaped fabric member  60  to provide for the shaped fabric member  60  shown in FIG.  11 . As previously discussed, the shaped fabric member  60  includes the fabric sheet material  62  bonded to the backing layer  64 . 
   In a second molding operation, the shaped fabric member  60  is placed into a second mold  200 , shown in FIG.  12 . The second mold  200  includes a first die  202  and a second die  204 . The first and second dies  202 ,  204  define a cavity which is generally in the shape of the outsole  40 . It will be appreciated that the cavity may not necessarily define the entire heel structure  50  of the outsole  40  but will likely define the remaining portions, e.g., the shank  53  and the ball portion  49 . The shaped fabric member  60  ( FIG. 11 ) is inserted into the first mold  202  with the fabric sheet material  62  facing a bottom section  203  of the first die  202 . Consequently, the backing layer  64  faces the second die  204  when the second die  204  is closed. 
   The first and second dies  202 ,  204  are heated to a predetermined temperature and are closed with respect to one another. Once again, the predetermined temperature is a temperature at which the first and second dies  202 ,  204  will not damage the fabric sheet material  62  but will permit (1) the thermoplastic rubber forming the backing layer  64  to resoften and (2) permit a second thermoplastic rubber material to soften sufficiently so that it may be injected into the second mold  200 . Preferably, the predetermined temperature of the second mold  200  is greater than the predetermined temperature of the first mold  100 . In one exemplary embodiment, the predetermined temperature of the second mold  200  is from about 160° C. to about 170° C. It will be appreciated that suitable molding temperatures will vary depending upon a number of parameters, such as the operating conditions and the type of thermoplastic rubber being used. 
   The second thermoplastic rubber material is injected into the second mold  200  so that if flows within the cavity formed by the first and second dies  202 ,  204 . Because the backing layer  64  is softened, the heated, injected second thermoplastic rubber material may bond with the backing layer  64 . In one embodiment, the thermoplastic rubber material used in both the first and second molds  100 ,  200  is the same material. It will be appreciated that the thermoplastic rubber material used in the first and second molds  100 ,  200  may be different materials. After heating the materials in the second mold  200  for a sufficient time period, the molds  202 ,  204  are cooled causing the resultant outsole  40  to cool. After a sufficient cooling period, e.g., several minutes (i.e. 6 or more minutes), the first and second molds  202 ,  204  are opened and the outsole  40  is removed. 
   The outsole  40  preferably has the shaped fabric member  60  integrally formed as a part thereof due to the bonding between the backing layer  64  and the surrounding outsole  40 . Preferably, the second mold  200  is configured so that the fabric sheet material  62  is not in contact with the second thermoplastic rubber that is injected into the second mold  200 . In the shoe  10 , the gap  63  separates the fabric sheet material  62  from the surrounding outer surface  42  of the outsole  40 . In other words, the outsole  40  is formed around the shaped fabric member  60  so that the ground contacting surface of the outsole  40  is formed of the fabric sheet material  62  and a portion of the outer surface  42  with both components being preferably generally planar with one another and exposed to contact the ground. 
   After having formed the outsole  40  using the above-described method, the outsole  40  is then incorporated into the shoe  10  by attaching the outsole  40  to the lower  30  to form the shoe  10 . 
   As shown in  FIG. 4 , the outsole  40  and the corresponding manufacturing process may be modified so that a pattern  230  is formed as part of the shaped fabric member  60 . This pattern  230  may be decorative in nature and also provides some functionality as it may be designed to increase the gripping action of the outsole  40 . In one embodiment, a bottom of the first die  102  is modified by forming the pattern  230  thereon. For example, small diamond shaped objects may be formed on the first die  102  ( FIG. 10 ) and the fabric sheet material  62  is laid over the first die  102 . During the first molding process, the pattern  230  is transferred onto the shaped fabric member  60  as a result of the injection and pressing action of the thermoplastic rubber. The resultant shaped fabric member  60  thus includes a textured surface defined by the pattern  230 . 
     FIGS. 5-7  show another embodiment of the present invention. In this embodiment, a shoe  300  is presented and is generally in the form of a women&#39;s shoe having an open aired toe. The shoe  300  includes an upper  310 , a lower  320  attached to the upper  310 , and an outsole  330  attached to the lower  320 . 
   Because of the open toe nature of shoe  300 , the upper  310  is formed of a toe strap  312  and an ankle strap  314 . The toe and ankle straps  312 ,  314  may be formed of any number of suitable materials and in one embodiment, the straps  312 ,  314  are formed of a backing layer  316  and an exterior cover  318 . The backing layer  316  may comprise a fabric backed foam or the like with the exterior cover  318  being attached to the backing layer  316  using known techniques, such as stitching, etc. The exterior cover  318  may be formed of any number of materials, including a high pile fabric. In this embodiment, the ankle strap  314  also includes a buckle assembly  319  for securing the ankle strap  314  around a wearer&#39;s ankle. The toe strap  312  is designed to extend across the upper portion of the foot near the wearer&#39;s toes to secure the front portion of the foot within the shoe  300 . The toe strap  312  should be flexible so as to accommodate foots of different sizes. 
   The lower  320  includes a fabric-backed foam  322  and a support member  324 . The fabric-backed foam  322  provides a cushioned surface for the wearer to place his/her foot. The support member  324  serves to provide a support platform for the wearer&#39;s foot and therefore is formed of a rigid material. For example, the support member  324  may be formed of a rigid reinforced cardboard member, a plastic member, a wooden member, etc. so long as the support member  324  retains its shape and provides adequate support to the wearer&#39;s foot. 
   The upper  310  is attached to the lower  320  using conventional techniques, including stitching or securing ends of the straps  312 ,  314  to the lower  320  and more specifically, by tucking these ends between the support member  324  and the outsole  330 . An adhesive or other material may be used to secure the straps  312 ,  314  to at least one of the support member  324  and the outsole  330 . 
   The outsole  330  in this embodiment includes a shaped fabric member  340  formed as part of the outsole  330  and a heel  360 . The outsole  330  also includes an outer surface  332 . As best shown in  FIGS. 5 and 7 , the shaped fabric member  340  is disposed in a ball portion  331  of the outsole  330  and protrudes below the surrounding portions (outer surface  332 ) of the outsole  330  such that the shaped fabric member  340  is the ground contacting portion of the outsole  330 . During normal wear, the wearer contacts the ground surface with the shaped fabric member  340  because it extends below the surrounding sections of the outsole  330 . 
   The heel  360  is attached to the outer surface  332  using conventional techniques, e.g., use of an adhesive, and a bottommost portion  362  of the heel  360  preferably includes a rubber or plastic piece which reduces wear of the heel  360  and provides a gripping surface. A shank portion  363  of the outsole  330  is formed between the heel  360  and the ball portion  331 . The shank portion  363  is defined by the outsole  330  and does not include the shaped fabric member  340 . The shaped fabric member  340  is thus only provided on sections of the outsole  330  which contact the ground surface during normal wear. 
   As best shown in  FIG. 7 , the shaped fabric member  340  is formed of a fabric sheet material  343  and a fabric backing layer  345 . As will be described hereinafter, the backing layer  345  is preferably integrally bonded to the material forming the outsole  330  and preferably, the layer  345  and the outsole  330  are formed of the same material so that it will appear to the wearer that the fabric sheet material  343  is simply attached to a particular section of the outsole  330 . The backing layer  345  is the material lying immediately underneath the fabric sheet material  343  and serves to define a platform extending downwardly from the surrounding sections of the outsole  330 . In this manner, the fabric sheet material  343  is only in contact with the backing layer  345  and not the surrounding sections of the outsole  330 . 
   In this embodiment and in accordance with the present invention, greater than 50% (as measured in terms of area) of the ground contacting sections of the shoe  300  includes the shaped fabric member  340 . In the exemplary shoe  300  shown in  FIGS. 5-7 , the ground contacting surface of the outsole  330  includes the bottommost portion  362  of the heel  360  and the ball portion  331 . More specifically, besides the heel portion  362 , the only other portion of the outsole  330  which contacts the ground surface is the shaped fabric member  340 . Thus in this particular embodiment, the shaped fabric member  340  comprises a substantial portion of the ground contacting surface of the outsole  330  as the outer surface  332  does not contact the ground surface. 
   The manufacture of the shoe  300  is preferably done in a similar or the same manner as the manufacture of the shoe  10  described in reference to  FIGS. 10-12 . More specifically, the manufacture is preferably a two stage molding process using the first and second molds  100 ,  200 . In this embodiment, the bonding between the backing layer  345  and the outsole  330  is clearly shown in the cross-sectional view of FIG.  7 . After forming the shaped fabric member  340  using the first mold  100 , the member  340  is then placed in the second mold  200  to form the outsole  330  illustrated in  FIGS. 5-7 . During the second molding process, the fabric sheet material  342  is not in contact with the second thermoplastic rubber that is added to the second mold  200  to form the remaining sections of the outsole  330  but rather the second thermoplastic rubber is disposed over and around the heated fabric backing layer  344  (preferably a thermoplastic rubber also). 
   Now referring to  FIGS. 8-9  which illustrate yet another embodiment of the present invention. In this embodiment, a shoe  400  is presented and generally includes an upper  410 , a lower  420 , and an outsole  430 . The shoe  400  is in the form of a walking or leisure type shoe instead of the more formal shoes shown in  FIGS. 1-7 . The upper  410  and lower  420  have conventional constructions and are attached to one another using conventional techniques. The outsole  430  is also attached to the lower  420  using conventional techniques. 
   According to the present invention, the outsole  430  includes a shaped fabric member  440  and a surrounding outsole surface  450 . The shaped fabric member  440  has a fabric sheet material  442  disposed on an outer surface thereof so that the fabric sheet material  442  contacts the ground surface or the like during normal wear of the shoe  400 . Bottom portions (surface  450 ) of the outsole  430  surrounding the shaped fabric member  440  are formed of any number of suitable materials including but not limited to plastic and rubber materials. The bottom portions of the outsole  430  are preferably generally planar with respect to the shaped fabric member  440  to define a substantially planar ground contacting surface of the outsole  430 . In this embodiment, the shoe  400  includes two shaped fabric members  440 , one disposed proximate a heel portion  402  of the shoe  400  and the other disposed proximate to a toe portion  404  of the shoe  400 . A gap  444  is formed between the fabric sheet material  442  and the outer surface  432  of the outsole  430  in one exemplary embodiment. 
   According to the present invention, the shaped fabric members  440  occupy an area which is at least greater than 50% of the area of the outsole  430  which contacts the ground surface. Preferably, the shaped fabric members  440 occupy greater than 50% to about 90% of the entire ground contacting surface of the outsole  430 . The shaped fabric members  440  may have any number of shapes and sizes so long as the shaped fabric members  440  occupy greater than 50% of the surface of the outsole  430  which contacts the ground surface during normal wear. 
   The shoe  400  is preferably formed using the manufacturing process described herein with reference to  FIGS. 10-12 . In other words, the shaped fabric members  440  are formed using a first molding process and then are inserted into the second mold  200  ( FIG. 12 ) where a second molding process is conducted. During the second molding process, the outsole  330  is formed having the shaped fabric members  440  as integral parts thereof. The result is that the outsole  430  of the shoe  400  is partially covered with fabric sheet material  442 , while surrounding portions of the outsole  430  do not contain the fabric sheet material  442  and are formed of suitable materials. It will be appreciated that while thermoplastic rubbers are preferred for use in the molding process, other types of materials may be used so long as they produce the shaped fabric member having the characteristics described herein with reference to the various embodiments of the present invention. 
   The present invention thus provides an outsole and a manufacturing process thereof which present an outsole having a ground contacting surface, wherein the ground contacting surface has a portion thereof which is defined by a fabric sheet material. Advantageously, the outsole of the present invention is slip-resistant, durable, and offers a competitive advantage to the manufacturer. 
   While the invention has been particularly shown and described with reference to preferred embodiments thereof, it will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the spirit and scope of the invention.

Technology Classification (CPC): 0