Source: https://patents.google.com/patent/US20060225305A1/en
Timestamp: 2020-04-01 22:18:58
Document Index: 344132526

Matched Legal Cases: ['arts 220', 'arts 220', 'arts 220', 'art 220', 'art 220', 'art 222', 'art 222', 'arts 220', 'arts 220', 'art 222', 'art 222', 'arts 220', 'arts 220', 'arts 220']

US20060225305A1 - Footwear outsole and method of manufacture - Google Patents
Footwear outsole and method of manufacture Download PDF
US20060225305A1
US20060225305A1 US11/103,857 US10385705A US2006225305A1 US 20060225305 A1 US20060225305 A1 US 20060225305A1 US 10385705 A US10385705 A US 10385705A US 2006225305 A1 US2006225305 A1 US 2006225305A1
US11/103,857
US7313876B2 (en
Wen-Jong Liu
2005-04-12 Application filed by Wolverine World Wide Inc filed Critical Wolverine World Wide Inc
2005-04-12 Priority to US11/103,857 priority Critical patent/US7313876B2/en
2005-04-12 Assigned to WOLVERINE WORLD WIDE, INC. reassignment WOLVERINE WORLD WIDE, INC. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: LIU, WEN-JONG, MORGAN, MARK M.
2006-10-12 Publication of US20060225305A1 publication Critical patent/US20060225305A1/en
2008-01-01 Publication of US7313876B2 publication Critical patent/US7313876B2/en
230000035699 Permeability Effects 0 claims abstract description 6
An outsole construction having an integral display layer. The outsole includes a main body and a plurality of lugs extending from the main body to define a plurality of ground engaging elements. The display layer is disposed at the surface of the main body such that it is visible in the main body of the outsole and is spaced away from the surface of the lugs such that it is not visible on the surface of the lugs. The display layer may include a printed pattern, such as a camouflage pattern. The present invention also provides a method for manufacturing an outsole including the general steps of (a) providing a mold defining a main body and a plurality of lugs extending from the main body, (b) placing a permeable display layer in the mold and (c) injecting sole material into the mold. In this method, the permeability of the display layer and/or the viscosity of the sole material may be selected so that the display layer lies along the surface of the main body of the sole but not the surface of the lugs.
(a) providing a mold defining a cavity having main body region and a plurality of lug regions extending from the main body region,
(b) placing a permeable display layer in the mold,
(c) injecting sole material into the mold, and
(d) permitting the sole material to cure while in intimate contact with the display material thereby providing a one-piece sole having a display layer integral with the outsole; wherein the permeability of the display layer and/or the viscosity of the sole material is selected so that the sole material permeates or flows through the display layer at the lug regions so that the display layer is not visible at the surface of the lugs.
The present invention provides a simple and effective outsole construction that permits a display layer to be placed on the undersurface of an outsole. Because the lugs bear a majority of the ground contact, scuffing, marring and wear have little effect on the display layer. Accordingly, the display layer remains visible in good condition for a relatively long time. The manufacturing process is simple and effective and can be implemented without significant changes to existing tooling or other equipment. In some applications, the display layer may simply be closed between the mold halves without any modification to the mold. In these applications the display layer is gripped between the mold halves, for example, between the shut-off portions of the mold. In other applications, the display layer may be held by pins or not held at all.
(a) providing a mold 200 defining a mold cavity 202 with a main body region 204 and plurality of lug regions 206 extending from the main body region 204 (See FIG. 5),
(b) inserting a permeable display layer 20 into the mold cavity 202 (See FIG. 7) and
(c) injecting sole material 18 into the mold cavity 202; wherein the display layer 20 and/or sole material 18 is selected so that the display layer 20 remains on or embedded in the surface of the material 18 in the main body 12 of the sole 10 and the material 18 passes through the permeable display layer 20 in the lugs 14 so that the display layer 20 is not on the surface of the lugs 14. The present invention is described in connection with a conventional outdoor sole having a plurality of relatively regular, pronounced lugs. It should be understood that the present invention is well-suited for use in soles with other types of lugs, which may include cleats, ribs, bars and other protrusions from the main body 12 of the sole 10.
A boot 100 incorporating the sole 10 is shown in FIG. 2. The boot 100 is shown for disclosure purposes only and is not intended to limit the invention to use with boots. To the contrary, the present invention is well-suited for use with essentially any type of soled footwear. The illustrated boot 100 generally includes an upper 102 and a sole 104 (See FIG. 2). The upper 102 is generally conventional and therefore will not be described in detail. The upper 102 is affixed to the sole 10 using essentially any attachment construction. For example, the sole 10 may be cemented, sewn, welted or directly attached to the upper. In the illustrated embodiment, the boot 100 includes a multilayer sole 104 generally including a footbed 106, a midsole 108 and the outsole 10 (See FIG. 3). The footbed 106 is a generally conventional footbed and may be removably fitted within the upper 102 to directly engage the wearer's foot. The midsole 108 is also generally conventional and may be sandwiched between the outsole 10 and the upper 102. In the illustrated embodiment, the midsole 108 is a relatively thick layer of cushioning material that is fitted within a corresponding recess 22 in the upper surface of the outsole 10. The sole 104 may include other conventional components as desired, such as a shank, heel cushion, support plate. The present invention is not limited in use to multilayer sole constructions, but rather may be incorporated into essentially any sole construction. Accordingly, the construction of sole 104 may vary from application to application as desired.
In the illustrated embodiment, the outsole 10 is molded from conventional outsole materials, such as polyurethane (“PU”). Alternative outsole materials include without limitation thermoplastic resin (“TPR”), ethylene vinyl acetate (“EVA”) and rubber. The outsole material 18 may be opaque and may have a color selected to compliment the display layer 20. For example, if the display layer 20 includes a camouflage pattern, the outsole material 18 may be selected with a color that corresponds with one of the colors in the camouflage pattern. Alternatively, the outsole material 18 may be selected with a color that contrasts with the display layer 20.
The outsole 10 may be manufactured using conventional injection molding equipment. FIG. 5 illustrates a mold 200 capable of operating in accordance with a manufacturing method of the present invention. The mold 200 generally includes a pair of mold parts 220 and 222 that are selectively movable using conventional equipment, such as hydraulic or pneumatic cylinders (not shown). The mold parts 220 and 222 are contoured to cooperatively define a pair of mold cavities 202 in the desired shape of the pair of outsoles 10. The pair of mold cavities are essentially the mirror-image of one another and are shaped to form matching left and right outsoles 10. Given that the two cavities are essentially identical (except of being the mirror image of one another), this discussion will focus only on one of the two cavities. The mold parts 220 and 222 also include marginal portions 224 and 226 that engage one another when the mold 100 is closed. The marginal portions 224 and 226 include the “shut-off” that prevents liquid sole material 18 from flowing out of the cavity 202. As perhaps best shown in FIG. 6, the upper mold part 220 is contoured to correspond in shape with the upper surfaces of the two outsoles 10. In this embodiment, the upper mold part 220 includes a pair of convex surfaces 230 (only one of which is visible in the drawings) that defines the recesses 22 in the top surfaces of the outsoles 10. The lower mold part 222 is contoured to correspond in shape with the lower surfaces of the outsoles 10. More specifically, the lower mold part 222 is shaped to define a main body region 204 and plurality of lug regions 206 extending from the main body region 204 for each of the two outsoles. As shown in FIG. 8, the lug regions 206 are extensions of the main body region 204 so that material injected into the main body region 204 can flow into the lug regions 206.
Manufacture of the outsole 10 using the mold 200 will now be described in connection with FIGS. 5-11 . The process begins with the mold 200 in an open position (See FIGS. 5 and 6). In this position, the mold parts 220 and 222 are spaced far enough apart to permit the display layer 20 to be placed between the mold parts 220 and 222, for example, atop the lower mold 222 covering the mold contours. The display layer 20 may be of sufficient size to extend over the entire extents of the lower mold part 222 or may be smaller covering only portions of the lower mold part 222 (See FIG. 7). In alternative applications, the display layer 20 may include two or more separate portions. For example, the display layer may include a forefoot portion that covers the forefoot region of the sole and a separate heel portion that covers the heel region of the sole (not shown). This option may be desirable when different patterns are desired in the forefoot and heel regions or when the outsole includes separate forefoot and heel parts. In the illustrated embodiment, the display layer 20 includes marginal portions that extend beyond the extents of the mold cavity 202 where the marginal portions of the display layer 20 can be sandwiched between the marginal portions 224 and 226 of the mold parts 220 and 222, respectively (See FIG. 8). In this way, the mold parts 220 and 222 cooperatively hold the display layer 20 reducing the likelihood of the display layer 20 being forced down into the lug regions 206 by the flow of injected sole material 18. In alternative embodiments, the display layer 20 may be held by clamps, pins or other mechanical features incorporated into the mold 200 or structures adjacent to the mold 200. Fabric pins 90 are shown in phantom lines in FIG. 8. The tension or amount of slack in the display layer 20 may vary from application to application. For example, in application with a deep mold cavity 202, it may be desirable to include some slack in the display layer 20. The amount of slack may be selected so that the flow of sole material 18 into the mold cavity 202 is capable of pushing the display layer 20 to the surface of the main body of the outsole 10. On the other hand, it may be desirable in some applications to hold the. display layer 20 without any slack or even under tension. For example, if the display layer 20 is manufactured from a relatively elastic or stretchable material or if the mold cavity is relatively flat or if the lug regions 206 are relatively large in cross-section, it may be beneficial to hold the display layer 20 without slack or under tension. This may be achieved by holding the display layer 20 with the desired degree of tension while the mold is closed either manually or using supplemental mechanical components, such as clamps, teeth or pins mounted adjacent to the mold parts 220 and 222. In some applications, it may not be necessary to hold the marginal edges of the display layer 20 to prevent the display layer 20 from being pushed down to the surface of the lugs 14. For example, if the display layer 20 has sufficient stiffness, the sole material 18 has a sufficiently low viscosity or the lug regions 206 have a sufficiently small cross section, it may not be necessary to hold the display layer 20 to prevent it from being pushed down into the lugs.
a plurality of lugs integral with and extending from said main body, said plurality of lugs extending from said outer surface to define a plurality of ground engaging surfaces;
a display layer integral with the outsole, said display layer extending along said outer surface of said main body whereby said display layer is visible on said outer surface, said display layer being embedded within the outsole above said ground engaging surfaces of said plurality of lugs whereby said display layer is hidden from view above said ground engaging surfaces.
2. The outsole of claim I wherein said display layer is coextensive with the outsole.
3. The outsole of claim 1 wherein said main body and said plurality of lugs are manufactured from an opaque sole material.
4. The outsole of claim 1 wherein said display layer includes a pattern, said pattern being visible on said outer surface of said main body and not being visible on said ground engaging surface of said plurality of lugs.
5. The outsole of claim 1 wherein said display layer is permeable.
6. The outsole of claim I wherein said display layer is a fabric.
7. The outsole of claim I wherein said display layer is a tricot fabric.
8. The outsole of claim 4 wherein said pattern is further defined as a camouflage pattern.
a sole affixed to said upper;
wherein said sole includes a sole component having an integral display layer, said sole component including a main body and a plurality of lugs extending from said main body, said lugs defining a plurality of ground engaging surfaces, said display layer being visible along a surface of said main body and not being visible along said ground engaging surfaces of said plurality of lugs.
10. The article of claim 9 wherein said main body includes an outer surface, said display layer being visible along said outer surface.
11. The article of claim 10 wherein said lugs extend from said outer surface, whereby said display layer is visible on said main body around said plurality of lugs.
12. The article of claim 11 wherein said display layer includes permeable regions at least adjacent said plurality of lugs.
13. The article of claim 11 wherein said display layer is manufactured from a permeable material.
14. The article of claim 13 wherein said display layer is a fabric.
15. The article of claim 13 wherein said display layer is a tricot fabric having a camouflage pattern.
16. The article of claim 11 wherein said display layer is visible along and coextensive with said outer surface of said main body.
17. A method for manufacturing a sole component, comprising the steps of:
(b) placing a display layer in the mold, said display layer being permeable at least in regions adjacent the plurality of lug regions,
(c) injecting sole material into the mold such that the display layer is disposed at a surface of the main body region and spaced from a surface of the plurality of lug regions, and
(d) permitting the sole material to cure while in intimate contact with the display layer to form a one-piece sole having a main body and a plurality of lugs extending from the main body, the display layer being visible on a surface of the main body and being embedded in the lugs and not visible on a surface of the lugs.
18. The method of claim 17 wherein at least one of a permeability of the display layer and a viscosity of the sole material is selected so that the display layer lies along the surface of the main body of the sole while the sole material passes through the display layer at the lugs so that the display layer is not visible at the surface of the lugs.
19. The method of claim 18 wherein said placing step includes positioning the display layer on a surface of a mold party.
20. The method of claim 17 further including the step of closing the mold on a peripheral portion of the display layer, whereby the closed mold holds the display layer in place within the mold.
21. The method of claim 20 wherein said injecting step includes injecting sole material into the mold on a side of the display layer opposite the plurality of lug regions, whereby the sole material pushes the display layer against a mold surface and whereby the sole material flows through the display layer to fill the lug regions.
22. The method of claim 21 wherein the mold includes a pair of mold parts and the display layer includes a marginal region extending around an entire periphery of the display layer; and
23. The method of claim 18 wherein the display layer is a fabric.
24. The method of claim 23 wherein the fabric includes a camouflage pattern and the outsole material is substantially opaque.
US11/103,857 2005-04-12 2005-04-12 Footwear outsole and method of manufacture Expired - Fee Related US7313876B2 (en)
US11/103,857 US7313876B2 (en) 2005-04-12 2005-04-12 Footwear outsole and method of manufacture
US11/938,513 US20080060228A1 (en) 2005-04-12 2007-11-12 Footwear outsole and method of manufacture
US11/938,513 Division US20080060228A1 (en) 2005-04-12 2007-11-12 Footwear outsole and method of manufacture
US20060225305A1 true US20060225305A1 (en) 2006-10-12
US7313876B2 US7313876B2 (en) 2008-01-01
ID=37081765
US11/103,857 Expired - Fee Related US7313876B2 (en) 2005-04-12 2005-04-12 Footwear outsole and method of manufacture
US11/938,513 Abandoned US20080060228A1 (en) 2005-04-12 2007-11-12 Footwear outsole and method of manufacture
US (2) US7313876B2 (en)
WO2010056784A1 (en) * 2008-11-14 2010-05-20 Nike International, Ltd. Decorated sole elements for articles of footwear and processes for making thereof
EP2292113A2 (en) * 2009-09-03 2011-03-09 Michaela Aussieker Sole
KR101474712B1 (en) 2007-04-24 2014-12-19 푸마 에스이 Method for producing a cleat sole
US9931803B2 (en) 2015-03-12 2018-04-03 Nike, Inc. Method of manufacturing sole assembly with camouflage appearance
2005-04-12 US US11/103,857 patent/US7313876B2/en not_active Expired - Fee Related
2007-11-12 US US11/938,513 patent/US20080060228A1/en not_active Abandoned
WO2009148877A2 (en) 2008-05-29 2009-12-10 Nike International Ltd. Article of footwear with a marking system
EP2292113A3 (en) * 2009-09-03 2012-12-19 Michaela Aussieker Sole
US20170340061A1 (en) * 2016-05-27 2017-11-30 JV International S.r.l. Footwear sole
US7313876B2 (en) 2008-01-01
US20080060228A1 (en) 2008-03-13
US20170136689A1 (en) 2017-05-18 Articles and Methods of Manufacture of Articles
EP3114956B1 (en) 2020-02-26 Soles for sports shoes
US10005251B2 (en) 2018-06-26 Decorated sole elements for articles of footwear and processes for making thereof
US8276294B2 (en) 2012-10-02 Vapor-permeable element to be used in composing soles for shoes, sole provided with such vapor-permeable element, and shoe provided with such sole
TWI527525B (en) 2016-04-01 Sole plate assembly and method of making
Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNORS:MORGAN, MARK M.;LIU, WEN-JONG;REEL/FRAME:016468/0470;SIGNING DATES FROM 20050411 TO 20050412