GB2533146A

GB2533146A - Improved footwear and method of assembly

Info

Publication number: GB2533146A
Application number: GB1422078.4A
Authority: GB
Inventors: Swift Richard
Original assignee: Britannia Footwear (uk Manufacturing) Ltd
Current assignee: Britannia Footwear (uk Manufacturing) Ltd
Priority date: 2014-12-11
Filing date: 2014-12-11
Publication date: 2016-06-15
Also published as: WO2016092297A4; WO2016092297A3; WO2016092297A2

Abstract

Apparatus 100 for reverting an inside-out upper and sole assembly to a righted upper and sole assembly, the apparatus comprising a clamping arrangement 101 having a first member 102 with a first contact end 103 and a second member 104 with a second contact end 105, both members being arranged end to end along a longitudinal axis A-A and being mechanically operable to move along said longitudinal axis between a first position in which the first and second contact ends are nipped together and a second position in which the first and second ends are distanced from one another. When the ends are in the second position, there is preferably enough distance between them so that an assembly may be placed or removed on either end. The members preferably comprise elongate arms, and the contact ends comprise discs attached to the arms. The mechanical operation may comprise an opposite end (to the contact ends) of at least one of the members attached to a sliding mechanism to facilitate the longitudinal movement of the members between the first and second positions, with the sliding mechanism being a pneumatic cylinder driven ram.

Description

IMPROVED FOOTWEAR AND METHOD OF ASSEMBLY

BACKGROUND Technical Field

The present invention relates generally to the field of manufacturing footwear and footwear constructions. More particularly, but not exclusively, the present invention concerns improvements in soles and improvements in methods of assembly of footwear during a manufacturing process.

Description of the Related Art

Conventional footwear constructs as shown in Figures 1 and 2 show a typical shoe 1 comprising the sole 2 as the bottom part, or walking surface, whilst the upper 6 makes up the part of the shoe 1 that surrounds a foot of a wearer and retains the shoe 1 on the foot. The upper 6 and the sole 2 are joined together. The sole 2 is generally formed from an outsole 3, an insole 4 and occasionally, a midsole 5 (shown here). The outsole 3 is the exposed part of the sole 2 that is contact with the ground and can be made from a variety of materials which provide grip, durability, and water resistance. The insole 4 comprises a layer of material that sits inside the shoe 1 that creates a layer directly under the wearer's foot and typically is formed from a material that adds comfort for the wearer, whilst concealing the join of the upper 6 on the outsole 3 and therefore, the 'feel' of the join. Where a midsole 5 is incorporated, it is typically between the outsole 3 and the insole 4 and is present to impart some shock absorption characteristics to the shoe 1, for example, in a running shoe. For clarification, the upper 6 comprises the entire part of the shoe 1 that covers the wearer's foot. The upper 6 comprises a vamp 6a located at the front of the upper 6 and covering a toe section 1 a and a quarter 6b located at the rear and sides of the upper 6 and covering a heel section 1 b. The vamp 6a and the quarter 6b may be formed from individual pieces of material or formed as a single piece of material. The upper 6 can be formed in very different styles and may incorporate features such as a tongue 7 and/or lacing 8 to aid retention and other decorative features to make a shoe attractive.

In some shoes, a shank (not shown) is inserted between the outsole 3 or midsole 5 and the insole 4 in the region where an arch of the wearer's foot would be located (the waist of the shoe 1). The shank is often formed from a shaped piece of metal to provide an arch support. The sole 2 may comprise a heel 9 to raise a rear of the shoe 1 in relation to a front of the shoe 1. The heel 9 contacts the upper 6 at a heel seat, which is generally shaped to match the form of the upper 6. The toe section la and the heel section lb are each often strengthened with a stiffener, referred to as a puff and a counter respectively (not shown). Most shoes 1 include a lining on the inside of the upper 6 to improve wearing comfort.

The conventional cement or flat lasted method of assembling a shoe 1 comprises a number of time consuming steps briefly comprising: a design and cutting stage to produce the various components of the sole 2 and the upper 6; joining of the insole 4 or midsole 5 to the upper 6 by way of adhesives (hot melt or other) or by tacks; removal of excess upper 6 material away from the underside of the insole 4 or a midsole 5; shaping of the upper 6 usually by heat treatment; and attachment of the outsole 2 to the upper 6, by application of an adhesive or cement to an underside of the insole 4/ midsole 5 on the upper 6 and pressing together with a top surface of the outsole 3.

With the above method, the upper 6 needs to be attached to an insole 4 or midsole 5 and excess material removed before the outsole 3 can be attached. Attachment of the insole 4/ midsole 5 is time intensive, which increases the number of steps in the method and increases the cost of manufacture. The use of adhesives/ cement is required to perform many of the assembly steps, which cause significant mess, which requires further attention to remove or remains an unsightly feature of the shoe I. In addition, even small excesses of adhesive/ cement inside the shoe 1 can cause discomfort to a wearer.

In UK Patent Application No. 1314575.0, a significant improvement to the conventional footwear construct 10 has been devised (Figures 3-5), in which an outsole 13 comprises an upper face 13a for engagement with an insole 14 and a lower face 13b configured to contact the ground in use, wherein the outsole 13 comprises a peripheral outer groove 15 for attachment of an upper 16 therein. The upper 16 likewise comprises an outer face 16a presented outwardly on a finished construct 10 and an inner face 16b presented inwardly on a finished construct 10. Accordingly, the improved method allows for the upper 16 to be turned inside-out (inner face 16b facing outwardly) before it is stitched, or otherwise attached into the groove 15, such that an inverted assembly of the outsole 13 and upper 16 comprises the lower face 13b of the outsole 3 presented temporarily as an inner face and the outer face 16a of the upper 16 is also presented temporarily as an inner face. The inverted assembly is then reverted (or 'righted') such that the upper 16 presents its outer face 16a outwardly and the outsole 13 also presents its lower face 13b outwardly.

This improved method significantly cuts down the number of steps required in manufacture of a construct 10, makes it easier to attach the outsole 13 and the upper 16 as well as providing a strong attachment between the outsole 13 and the upper 16, successfully hides the join between the outsole 13 and the upper 16 and may even avoid the use of adhesives which can be unsightly and subject to deterioration leading to delamination of a construct 10.

However, the reversion process for the inverted assembly is mechanically challenging.

It is an object of the present invention to address one or more of the problems of the prior art as discussed herein or otherwise.

Therefore, it is now desired to provide an apparatus to facilitate the reversion process such an inverted assembly.

It is also desired to provide an improved outsole to provide a greater capacity for shock absorbance characteristics within greater load bearing footwear constructs.

SUMMARY OF THE INVENTION

In a first aspect of the present invention there is provided an apparatus for reverting an inside-out upper-sole assembly to a righted upper-sole assembly, the apparatus comprising a clamping arrangement having a first member with a first contact end and a second member with a second contact end, both members being arranged end-to-end along a longitudinal axis and being mechanically operable to move along said longitudinal axis between a first position in which the first and second contact ends are nipped together and a second position in which the first and second ends are distanced from one another.

By 'upper-outsole assembly', what is meant is a footwear upper attached to a footwear sole to form a basic footwear construct.

By 'inside-out upper-outsole assembly', what is meant is an inverted arrangement of the basic footwear construct, such that an outer face of the upper and a ground-engaging face of the sole are both orientated inwardly within the assembly.

By 'righted upper-sole assembly', what is meant is a typical arrangement of the basic footwear construct, such that an outer face of the upper and a ground-engaging face of the sole are both orientated outwardly within the assembly.

By 'clamping arrangement', what is meant is an assembly in which at least two members (e.g. first and second arms) are brought together to grip something therebetween.

By 'nipped together' what is meant is brought into near contact so as to tightly grip something therebetween.

By 'distanced from one another' what is meant is the contact ends are separated sufficiently such that an assembly is no longer gripped thereby and can be manoeuvred on the apparatus and/or removed from the apparatus.

With this arrangement, the upper-sole assembly can be tightly clamped at a single point allowing an operator to easily and quickly manipulate the assembly from an inside-out orientation to a righted orientation using both hands. In particular, by locating a first member of said clamping arrangement into a cavity of said inside-out upper-sole assembly such that a contact end of said member abuts a toe section of the assembly and clamping the toe section between the two members, an operator can easily manipulate a heel section of the assembly into a righted arrangement and then the sole can be peeled towards the toe section and then beyond the clamping ends until the righted upper-sole assembly is located over the second member. Such a tight clamping arrangement to allow the reversion process is difficult to achieve by hand, or with other conventional clamps, since the hands/ conventional clamps get in the way of the process.

Preferably, the second position comprises a distance between the contact ends that is sufficient to easily manoeuvre an assembly onto and off of each member respectively. The distance may therefore, comprise between approximately 8 cm and approximately 30 cm. Preferably, the distance comprises approximately 10 cm.

Alternatively, the second position comprises a (shorter) distance between the contact ends that is sufficient to release the grip of the toe section. The shorter distance may therefore, comprise between approximately 1cm and approximately 8 cm.

Preferably, the members comprise arms. The arms are preferably elongate and are preferably of a length long enough to easily accommodate a large-sized shoe. The length of each arm may be approximately 10 cm to approximately 20 cm. Preferably, the length of each arm is approximately 18.5 cm. The girth of the arms (apart from the contact ends), are preferably narrow up to approximately 4 cm in width at their widest point. Most preferably, the girth of the arms (apart from the contact ends) is approximately 2 cm at their widest point.

The contact ends are shaped to contact a wide portion (between two sides) of a toe section of an assembly. Preferably, therefore, the contact ends may comprise a substantially arced or semi-circular shape to sit within a toe section. Preferably, the contact ends also comprise a substantially flat plate shaped to contact a shallow portion (between a top and a bottom) of a toe section. Most preferably, therefore, the contact ends comprise a shallow disc attached to the arms. This shape of contact ends provides a decent gripping area facilitated by the shaped width of the contact ends, whilst reducing the obstacle to the reversion of the toe section during turning by the contact ends being shallow in depth.

Preferably, therefore, the contact ends comprise a diameter of approximately between 2 cm and approximately 5 cm, most preferably, approximately 4 cm. Preferably, the contact ends comprise a depth of approximately between 2 mm and approximately 1 cm, most preferably approximately 4 mm.

The arms are preferably configured to lie substantially straight along said longitudinal axis. One or both arms may comprise a jointed section from which a front section of the arm can bend or pivot away from the longitudinal axis. In this arrangement however, the joint is releasably and firmly lockable into said substantial straight position. Accordingly, therefore, the arms may be bent or pivoted from the second position into a third position in which the inside-out assembly can be easily located over one of said arms and the righted assembly can be easily removed from the other arm at the end of the procedure.

With one or more jointed arms it is conceivable that the apparatus length may be reduced, since the distance between the contact ends in the second position may need only be enough to ungrip the toe section, since the third position can provide the space to manoeuvre the assembly onto and off of the arms.

Preferably, the mechanical operation comprises an opposite end (to the contact ends) of at least one of the members attached to a sliding mechanism to facilitate the longitudinal movement of the members between the first and second positions. Alternatively, both members may be attached to a sliding mechanism.

The sliding mechanism may be realised by rotary movement translated into straight line motion, such as in a slide-crank mechanism (lever rotation or wheel), or by otherwise pushing a sliding member along a guidance channel. The sliding mechanism may be manually operated by an operator, or automatically realised.

Preferably, the sliding mechanism comprises a pneumatic cylinder driven ram. The sliding mechanism most preferably operates to move only one of said members, with the other member comprising a fixed position.

Preferably, the sliding mechanism moves said member within a range of between approximately 8 cm and approximately 15 cm, most preferably, approximately 10 cm.

Preferably, the sole in the upper-sole assembly is an outsole. Alternatively, the sole in the upper-sole assembly comprises a midsole (for location inside a footwear construct above an outsole and potentially below an insole), or an intersole (for location partially outwardly of a footwear construct above an outsole and potentially below a midsole or insole).

In a second aspect of the present invention there is provided a method for reverting an inside-out upper-sole assembly using a clamping arrangement, the method comprising: 1) locating a first member of said clamping arrangement into a cavity of said inside-out upper-sole assembly such that a contact end of said member abuts a toe section of the assembly; 2) bringing a second member of said clamping arrangement into end-to-end contact with the first member, with said toe section of the assembly clamped therebetween; 3) manipulating a heel section of the assembly into a righted arrangement; 4) pulling the righted heel section of the assembly towards the contact ends and the clamped toe section to achieve a substantially righted mid-section; and 5) puling the righted heel-section and mid-section beyond the contact ends of the members until the upper-sole assembly substantially lies over the second member to achieve a righted toe section of the assembly.

By 'righted' and 'righted arrangement' what is meant is a typical orientation of the respective sections of the assembly as would be found in a finished footwear construct, such that the relevant sections of an outer face of the upper and ground-engaging face of the sole are both substantially orientated outwardly within the assembly.

Preferably, the method uses the apparatus of the first aspect of the invention.

Preferably, the method comprises a precursor step to step 1) in which the first and second contact ends of the members are move along said longitudinal axis to the second position in which the first and second ends are distanced from one another.

The method may also comprise moving one of said members into the third position prior to step 1) and return to second position prior to step 2).

It will be appreciated that the preferred features described in relation to the first aspect of the invention apply to the second aspect of the invention.

In a third aspect of the present invention there is provided an improved sole for a footwear construct, comprising: a ground-engaging outsole and an intersole, the outsole being configured to attach to the intersole and the intersole comprising a shock-absorbing component, wherein the outsole comprises a cavity to receive a lower part of the intersole.

Since the outsole comprises a cavity to receive a lower portion of the intersole, the intersole can be greater in depth without increasing the overall depth of the sole. This in turn allows a greater depth of shock-absorbing component (up to 25 mm) to be accommodated in the intersole and also serves to reduce the weight of the outsole, impacting on the overall weight of the shoe.

The lower part of the intersole may be retained within the cavity of the outsole using an adhesive or other known bonding mechanism.

Alternatively, the cavity and the lower part of the intersole may comprise cooperable components to retain the lower part of the intersole within the cavity. Preferably, the cavity and the lower part of the intersole comprise interlocking parts. More preferably, the cavity comprises one or more internal peripheral protrusions within the cavity for retaining one or more external peripheral protrusions on the lower part of the intersole within the cavity. Preferably, the peripheral protrusions within the cavity and on the lower part of the intersole are a single continuous protrusion.

The peripheral protrusion(s) of the cavity may be located adjacent a top surface of the outsole, or alternatively part way down the cavity.

The peripheral protrusion(s) of the cavity of the outsole may be shaped to provide a recess/ recesses of a desired profile thereunder. The profile of the recess(es) may match that of the protrusion(s) on the lower part of the intersole. Alternatively, the profile of the recess(es) may match be different to that of the protrusion(s) on the lower part of the intersole.

In either event, the cavity protrusion(s) serve to prevent unintentional lifting of the intersole from the cavity.

The protrusion(s) of the outsole and/or the intersole may comprise resiliently flexible material in order to allow assembly but minimise unintentional disassembly.

Preferably, the intersole comprises a cavity to receive the shock-absorbing component. The shock-absorbing component may be integrally formed with the intersole, but is preferably separately formed. The shock-absorbing component may be permanently retained within the intersole cavity using an adhesive or other known bonding mechanism.

Alternatively, the intersole cavity and the shock-absorbing component may comprise cooperable components to retain the shock-absorbing component within the intersole cavity. Preferably, the intersole cavity and the shock-absorbing component comprise interlocking parts. More preferably, the intersole cavity comprises one or more internal peripheral protrusions for retaining one or more external peripheral protrusions on the shock-absorbing component within the cavity. Preferably, the peripheral protrusions within the intersole cavity and on the shock-absorbing component comprise a single continuous protrusions.

The peripheral protrusion(s) of the intersole cavity may be located adjacent a top surface of the outsole, or alternatively part way down the intersole cavity.

The peripheral protrusion(s) of the intersole cavity may be shaped to provide a recess/ recesses of a desired profile thereunder. The profile of the recess(es) may match that of the protrusion(s) on the shock-absorbing component. Alternatively, the profile of the recess(es) may match be different to that of the protrusion(s) on the shock-absorbing component.

In either event, the intersole cavity protrusion(s) serve to prevent unintentional lifting of the shock-absorbing component from the intersole cavity.

The protrusion(s) of the intersole and/ or the shock-absorbing component may comprise resiliently flexible material in order to allow assembly but minimise unintentional disassembly.

The shock-absorbing component may comprise a porous material and may comprise one of a variety of densities, e.g. a high density for jogging or similar impact activities, a medium density for hiking or similar impact activities, or a low density for trekking or other similar impact activities.

The shock-absorbing component may comprise a memory foam and may comprise one of a variety of memory characteristics from slow memory to fast memory.

The shock-absorbing component preferably fills substantially the whole of the intersole cavity. Alternatively, the shock-absorbing component may only fill a lower portion of the intersole cavity to make room for an insole.

Therefore, the intersole cavity may comprise a further retention means for retaining an insole in engagement with a top surface of the intersole. The retention means may also comprise separate cooperable components to retain the insole within the intersole cavity.

It is to be appreciated that the cooperable components for the insole may comprise features as described above in relation to the intersole and shock-absorbing component.

The outsole may comprise a core of light weight material, for example, ethyl vinyl acetate (EVA). The outsole may comprise an outer skin of suitable shock-absorption material on the ground-engaging face. The skin may therefore, comprise approximately 5 mm to 8 mm of a more suitably denser (when compared with EVA) wear-resistant material.

The intersole may comprise a suitably dense stable material to support the shock-absorbing component therein. The intersole may comprise rubber, such as thermo poly rubber (TPR), Thermoplastic polyurethane (TPU), or a dense EVA.

The shock-absorbing component may comprise a single layer of porous polyurethane. Preferably, the shock-absorbing component comprises a multi-layered construction. The mutilayered component may a base of closed-cell EVA topped by one or more layers of an open-cell (porous) polyurethane. The one or more layers of polyurethane may comprise differing densities Preferably, the intersole comprises an attachment means for an upper. The attachment means may comprise a peripheral outer groove for attachment of an upper therein. The peripheral groove is preferably provided adjacent a top surface of the intersole. Accordingly, the intersole may be assembled with the upper as described in the method of the second aspect of the invention, which may use the apparatus of the second invention.

It will be appreciated that the preferred features described in relation to the first and second aspects of the invention apply to the third aspect of the invention where applicable.

BRIEF DESCRIPTION OF THE DRAWINGS

For a better understanding of the invention, and to show how exemplary embodiments may be carried into effect, reference will now be made to the accompanying drawings in which: Figure 1 is a perspective side view of a conventional shoe according to the prior art; Figure 2 is a vertical cross section across the width of a conventional shoe, where only part of the shoe upper has been shown for clarity; Figure 3 is a vertical cross section across the width of a shoe in a normal orientation according to UK Patent application No.1314575.0; Figure 4 is a vertical cross section across the width of a shoe in an inverted orientation according to UK Patent application No.1314575.0; Figure 5a is a partial side view of an apparatus for reverting an inside-out upper-sole assembly to a righted upper-sole assembly according to a first embodiment of the invention in a primary stage of use (demonstrated by a cross-section through an inside-out upper-sole assembly); Figure 5b is a partial side view of an apparatus for reverting an inside-out upper-sole assembly to a righted upper-sole assembly according to Figure 5 in a later stage of use (demonstrated by a cross-section through a righted upper-sole assembly); Figure 6 is a side view of shoe according to a second embodiment of the invention; Figure 7A is an exploded side view of upper of the shoe according to Figure 6; Figure 7B is an exploded side view of the intersole of the shoe according to Figure 6; Figure 7A is an exploded side view of the outsole of the shoe according to Figure 6; Figure 8 is a vertical cross section across the width of an intersole according to Figure 6; Figure 9a is a side view of the apparatus according to Figure 5a showing the second position; Figure 9b is a partial plan view of the first end of the apparatus according to Figures 9a showing a first position; and Figure 9c is a partial plan view of the second end of the apparatus according to Figures 9a showing the second position.

DETAILED DESCRIPTION OF THE EXEMPLARY EMBODIMENTS

In accordance with Figures 9A to 90 and Figure 5A and 5B, a first embodiment of the invention provides an apparatus 100 for reverting an inside-out upper-sole assembly 120 to a righted upper-solo asscmbly 120', thc apparatus 100 comprising a clamping arrangcmcnt 101 having a first member 102 with a first contact end 103 and a second member 104 with a second contact end 105, both members 102, 104 being arranged end-to-end along a longitudinal axis A-A' and at least one of said members 102, 104 being mechanically operable to move along said longitudinal axis A-A' between a first position in which the first and second contact ends 103, 105 are nipped together (Figure 9B) and a second position in which the first and second ends 103, 105 are distanced from one another (Figures 9A and 9C).

As shown in Figures 5A and 5B, the upper-sole assembly 120 comprises an upper 130 attached along a bottom edge thereof to an outer peripheral wall (not shown) of a sole 140 forming a basic footwear construct 100.

The footwear construct 100 comprises a toe section 125, a mid-section 126 and a heel section (not shown).

The inside-out assembly 120 (figure 5A) is orientated such that an outer face 131 of the upper 130 faces inwardly and a ground-engaging face 141 of the sole 140 faces inwardly, whilst an inner face 132 of the upper faces outwardly and an inner face 142 of the sole 140 faces outwardly.

In contrast, the righted upper-sole assembly 120' (Figure 5B) is orientated such that the outer face 131 of the upper 130 faces outwardly and a ground-engaging face 141 of the sole 140 faces outwardly, whilst an inner face 132 of the upper faces inwardly and an inner face 142 of the sole 140 faces inwardly.

With the apparatus 100 of this embodiment, the inside-out upper-sole assembly 120 can be tightly clamped at a single point allowing an operator to easily and quickly manipulate the assembly 120 from an inside-out orientation to a righted orientation 120' using both hands. In particular, by locating a first member 102 of said clamping arrangement 101 into a cavity of said inside-out upper-sole assembly 120 such that a contact end 103 of said member 102 abuts a toe section 125 of the assembly 120 and clamping the toe section 125 between the two members 102, 104, an operator can easily manipulate a heel section of the assembly into a righted arrangement 120' and then the sole 140 can be peeled towards the toe section 125 and then beyond the contact ends 103, 105 until the righted upper-sole assembly 120' is located over the second member 105. Such a tight clamping arrangement 101 to facilitate the reversion process is difficult to achieve by hand, or with other conventional clamps, since the hands/ conventional clamps get in the way of the process.

Returning to Figures 9A -9C, the apparatus 100 comprises the two members 102, 104 as elongate arms of substantially square cross-section. Each arm is of a length long enough to easily accommodate a large-sized assembly 120 and in a preferred embodiment, each arm comprises a length of approximately 18.5 cm. At one end of each of the arms 102, 104, the contact ends 103, 105 comprise substantially flat circular discs. In a preferred embodiment, the diameter of the discs is approximately 4 cm, whereas the depth of the discs is approximately 4 mm. This shape and size of the contact ends 103, 105 optimises the possible clamping area facilitated by the shaped width of the contact ends 103, 105, whilst reducing the obstacle to the reversion of the toe section 125 during turning by the contact ends 103, 104 being shallow in depth.

The contact ends 103, 105 are partially mounted on a top surface of their respective arm 102, 104, such that the contact ends 103, 105 sit proud of said top surface and protrude laterally therefrom. The lower surface of each arm 102, 104 also tapers upwardly to narrow the depth of the arm 102, 104 as it approaches the contact end 103, 105. This ensures that the transition does not provide any sharp corners.

At ends opposing the contact ends 103, 105, each member is fixed to a support member 106, 107 such that the contact ends 103, 105 oppose one another.

A first support member 106 is fixably mounted on a support plate 108, whereas a second support member 107 is slidably mounted on said support plate 108. Accordingly, the second support member 107 is movable between two positions along the fixed longitudinal axis A-A', towards and away from the first member 106, such that the members 106, 107 can be stationed at a first distance B and a second distance C from one another.

The sliding mechanism comprises a pneumatic cylinder driven ram (not shown) housed within the second support member 107 and connected to a pressured-cylinder. The ram slidably moves the second support member 107 along a guidance channel (not shown) in the support plate 108. The ram is operable to move the second support member 107 and therefore, the second arm 104 approximately 10 cm along the axis A-A'. The boundaries of the first distance B and the second distance C is reinforced by an abutment 110 fixed on the support plate 108.

The ram is operated by a two depressible buttons 111 located on the second support member 106, which are electrically configured to activate the ram and therefore, the second support member 107. For safety reasons, both buttons 111 need to be depressed simultaneously to move the contact ends 103, 105 into the first position and the support members 106, 107 to the first distance B (Figure 9B).

The ram is retracted by a pressure-releasing button 109 located on the first support member 106 to move the contact ends 103, 105 into the second position and the support members 106, 107 to the second distance C (Figure 9A and 9C).

The first distance B of the support members 106, 107 comprises the closest possible distance to one another dictated by the contact ends 103, 105 abutting one another (to provide the first position). The second support member 107 is locked via a at the first distance B so as to ensure that the grip provided between the contact ends 103, 105 in use is sustained until the contact ends 103, 105 are intended to be moved into the second position.

The second distance C of the support members 106, 107 comprises a maximum distance from one another in which the contact ends 103, 105 are substantially spaced from one another (to provide the second position). The second distance C therefore, comprises a distance C' between the contact ends 103, 105 that is sufficient to easily manoeuvre an assembly 120, 120'onto and off of each member 102, 104 respectively.

Although the arms 102, 104 are described to move and lie substantially along said longitudinal axis A-A', one or both arms 102, 104 may comprise a jointed section from which a front section of the arm can bend or pivot away from the longitudinal axis A-A'. In this arrangement however, the joint is releasably and firmly lockable into said substantial straight position. Accordingly, therefore, the arms 102, 104 may be bent or pivoted from the second position into a third position in which the inside-out assembly 120 can be easily located over one of said arms 102, 104 and the righted assembly 120' can be easily removed from the other arm 102, 104 at the end of the procedure.

In use, the second support member 107 of the apparatus 100 is slid to the second distance so as to place the contact ends 103, 105 in the second position (distance C' is approximately 10 cm). An inside-out upper-sole assembly 120 is arranged over the first arm 102, by locating the first member 102 into a cavity of said inside-out upper-sole assembly 120. The assembly 120 is moved along the arm 102 until the contact end 103 abuts a toe section 125 of the assembly 120. The second member 104 is brought into end-to-end contact (the first position) with the first member 102 by sliding the second support member 107 to the first distance B using buttons 111 to activate the pneumatic ram. In this arrangement, the toe section 125 of the assembly 120 is firmly clamped between the contact ends 103, 105 and the sliding mechanism is then locked (as shown in Figure 5a).

In a first stage of the reversion process, the a heel section of the assembly 120 is manipulated into a righted arrangement, wherein the outer face 131 of the upper 130 and the ground-engaging face 141 of the sole 140 in the region of the heel are facing outwardly. Significant force can be applied by the hands of the operator to achieve this, because the assembly 120 is firmly clamped.

In a second stage, the operator can pull the righted heel section of the assembly 120 towards the contact ends 103, 105 and the clamped toe section 125 to achieve a substantially righted mid-section 126. This occurs easily because the upper 130 and the sole 140 in the mid-section 126 want to follow the reverted orientation of the heel section.

In a third stage, the operator pulls the righted heel-section and mid-section 126 beyond the contact ends 103, 105 of the members 102, 104 until the upper-sole assembly 120 substantially lies over the second member 104. Again, the upper 130 and the sole 140 in the toe section 125 want to follow the reverted orientation of the mid-section 126 and the heel section, although force may need to be applied. In doing this, the toe section 125 flips over the contact end 105 of the second member 104 and the assembly is now righted 120' (as shown in Figure 5b).

Finally, the clamping arrangement 101 is released using button 109 to move the support member 107 to the second distance C, thereby moving the contact ends 103, 105 apart to the second position and providing room to remove the assembly 120' from the apparatus 100.

In a second embodiment of the present invention as shown in Figures 6 -8 there is provided an improved sole 202 for a footwear construct 200, comprising: a ground-engaging outsole 230 and an intersole 240, the outsole 230 being configured to attach to the intersole 240 and the intersole 240 comprising a shock-absorbing component 245, wherein the outsole 230 comprises a cavity (not shown) to receive a lower part 241 of the intersole 240.

Since the outsole 230 comprises a cavity to receive a lower portion 241 of the intersole 240, the intersole 240 can be greater in depth without increasing the overall depth of the sole 202. This in turn allows a greater depth of shock-absorbing component 245 to be accommodated in the intersole 240 and also serves to reduce the weight of the outsole 230, impacting on the overall weight of the shoe 200.

The outsole 230 comprises a ground-engaging face 231 which is profiled accordingly with grips and curvature in accordance with a standard footwear construct 200, in this case, a training shoe. The outsole 230 also comprises an upper face 232. The outsole 230 comprises a core 233 of light weight ethyl vinyl acetate (EVA) and an outer skin 234 of suitable shock-absorption material on the ground-engaging face 231, for example, approximately 5 mm to 8 mm of a more suitably denser (when compared with EVA) wear-resistant material.

The intersole 240 comprises the lower part 241, a rib 247 thereabove and an attachment portion 248 above the rib 247. The rib 247 protrudes outwardly of the lower part 241 and the attachment portion 248 and is the only visible part of the intersole 240 from the outside of a footwear construct 200 once assembled.

The lower part 241 of the intersole 240 is retained within the cavity of the outsole 230 using an adhesive or other known bonding mechanism. However, it is to be appreciated that the outsole cavity and the lower part 241 of the intersole 240 may comprise cooperable components to retain the lower part 241 of the intersole 240 within the outsole cavity formed from resiliently flexible interlocking parts. In particular, it is envisaged that the outsole cavity comprises an internal peripheral protrusion within the cavity defining a recess thereunder for retaining an interlocking external peripheral protrusion on the lower part 241 of the intersole 240 within the cavity.

The depth of the whole sole 202 of the footwear construct 200 in the case of a training show can be between 20 mm and 30 mm. Of this depth, the outsole 230 ground-engaging face is usually around 5 mm to allow for wear. Allowing for a short depth of 2-3 mm on the base of the intersole 240, this arrangement can provide an additional 12 -22 mm in depth for the shock-absorbing component 245. Of course, with increased sole depths and/or reduced base walls of the outsole 230 and the intersole 240, greater depths can be achieved.

As shown in Figure 8, the intersole 240 comprises a cavity 242 which extends from a top surface 240a towards the bottom of the lower part 241 along the length of the intersole 240. The shock absorbing component 245 is configured to substantially fill the cavity 242.

The cavity 242 comprises an internal peripheral groove 243 disposed adjacent the top surface 240a of the intersole 240. The shock-absorbing component 245 comprises a cooperating peripheral protrusion 245a. The shock-absorbing component 245 is retained within the intersole 240 by pressing the component 245 into the cavity 242 until the protrusion 245a is deflected into the groove 243 at which point the protrusion 245a resiliently flexes to substantially accommodate the groove 243. This arrangement minimise unintentional disengagement of the component 245 from the cavity 242 of the insole 240, but facilitates intentional removal and replacement of the component 245 if and when required. For example, it may be possible to interchange components 245 comprising different material densities, such as a high density for jogging or similar impact activities, a medium density for hiking or similar impact activities, or a low density for trekking or other similar impact activities.

The shock-absorbing component 245 comprises a compressible porous material, such as memory foam. In a preferred embodiment, the shock-absorbing component 245 comprises a multi-layered construction (construction) comprising a base of closed-cell EVA topped by one or more layers of an open-cell (porous) polyurethane. Where there is more than one layer of polyurethane, they comprise differing densities. However, it is to be appreciated that the shock-absorbing component 245 comprises a single layer of porous polyurethane.

The outer body of the intersole 240 comprises a suitably dense stable material to support the shock-absorbing component therein, for example, rubber, such as thermo poly rubber (TPR), thermoplastic polyurethane (TPU), or a dense EVA, although any suitable material may be used.

Adjacent the top surface 240a of the intersole 240, an external peripheral groove 246 is provided. The groove 246 provides an attachment point for an upper 260 such that a bottom edge 261 of the upper 260 can be stitched into the external groove 246, thereby hiding the groove 246.

Accordingly, the intersole 240 may be assembled with the upper 260 using the apparatus 100 of the first embodiment of the invention as described in the method, in which the inside-out upper 260 is disposed around the periphery of the intersole 240, such that the majority of the upper 260 depends beyond the ground-engaging face 231 of the outsole 230. The edge 261 is then attached into the groove 246 by stitching through the inner face 132 of the upper 260 into the groove 246. The upper-intersole assembly 240-260 is then reverted as described above.

Following assembly and reversion of the upper-intersole assembly 240-260, the outsole 230 can be attached to the intersole 240. The lower part 241 of the intersole 240 is lowered into the outsole cavity until the rib 247 abuts the top face 232 of the outsole 230. The outsole 230 is typically secured with an adhesive, although the alternative interlocking components as described previously may be employed additionally.

The total depth of the sole on a typical training shoe is usually around 15 -25 mm. Of this, the shock absorbing component within a midsole or insole is around 3-4 mm. A greater depth than this would make the sole too deep. However, with the present invention, a greater depth of shock-absorbing component can be ioncorporated by way of the intersole by taking advantage of the depth of the outsole and creating a cavity for the intersole to sit partly therein. Accordingly, a shock-absorbing component of between 15 mm and 20 mm can be incorporated within a typical depth of 25 mm sole.

Although a few preferred embodiments have been shown and described, it will be appreciated by those skilled in the art that various changes and modifications might be made without departing from the scope of the invention, as defined in the appended claims.

Claims

CLAIMS1 An apparatus for reverting an inside-out upper-sole assembly to a righted upper-sole assembly, the apparatus comprising a clamping arrangement having a first member with a first contact end and a second member with a second contact end, both members being arranged end-to-end along a longitudinal axis and being mechanically operable to move along said longitudinal axis between a first position in which the first and second contact ends are nipped together and a second position in which the first and second ends are distanced from one another.
2 The apparatus according to claim 1, wherein the second position comprises a distance between the contact ends that is sufficient to easily manoeuvre an assembly onto and off of each member respectively.
3 The apparatus according to claim 2, wherein the distance may therefore, comprise between approximately 8 cm and approximately 30 cm.
4 The apparatus according to any one of claims 1 to 3, wherein the members comprise elongate arms.
The apparatus according to claim 4, wherein the length of each arm may be approximately 1 cm to approximately 20 cm.
6 The apparatus according to any one of claims 1 to 5, wherein the contact ends are shaped to contact a wide portion (between two sides) of a toe section of an assembly.
7 The apparatus according to any one of claims 1 to 6, wherein the contact ends comprise a shallow disc attached to the arms.
8. The apparatus according to claim 7, wherein the contact ends comprise a diameter of approximately between 2 cm and approximately 5 cm.
9. The apparatus according to any one of claims 7 to 8, wherein the contact ends comprise a depth of approximately between 2 mm and approximately 1 cm.
10. The apparatus according to any one of claims 4 to 9, wherein arms are preferably configured to lie substantially straight along said longitudinal axis.
11. The apparatus according to any one of claims 1 to 10, wherein the mechanical operation comprises an opposite end (to the contact ends) of at least one of the members attached to a sliding mechanism to facilitate the longitudinal movement of the members between the first and second positions.
12. The apparatus according to claim 11, wherein the sliding mechanism comprises a pneumatic cylinder driven ram.
13. The apparatus according to claim 12, wherein the sliding mechanism operates to move only one of said members, with the other member comprising a fixed position.
14. The apparatus according to any one of claims 11 to 13, wherein the sliding mechanism moves said member within a range of between approximately 8 cm and approximately 15 cm.
15. The apparatus according to any one of claims 1 to 14, wherein the sole in the upper-sole assembly is an outsole.
16. The apparatus according to any one of claims 1 to 14, wherein the sole in the upper-sole assembly comprises a midsole (for location inside a footwear construct above an outsole and potentially below an insole),
17. The apparatus according to any one of claims 1 to 14, wherein the sole in the upper-sole assembly comprises an intersole (for location partially outwardly of a footwear construct above an outsole and potentially below a midsole or insole).
18. A method for reverting an inside-out upper-sole assembly using a clamping arrangement, the method comprising: 1) locating a first member of said clamping arrangement into a cavity of said inside-out upper-sole assembly such that a contact end of said member abuts a toe section of the assembly; 2) bringing a second member of said clamping arrangement into end-to-end contact with the first member, with said toe section of the assembly clamped therebetween; 3) manipulating a heel section of the assembly into a righted arrangement; 4) pulling the righted heel section of the assembly towards the contact ends and the clamped toe section to achieve a substantially righted mid-section; and 5) puling the righted heel-section and mid-section beyond the contact ends of the members until the upper-sole assembly substantially lies over the second member to achieve a righted toe section of the assembly.
19. The method according to claim 18, wherein the method uses the apparatus of claims 1 to 17.
20. The method according to any one of claims 18 to 19, wherein the method comprises a precursor step to step 1) in which the first and second contact ends of the members move along said longitudinal axis to the second position in which the first and second ends are distanced from one another.
21. An improved sole for a footwear construct, comprising: a ground-engaging outsole and an intersole, the outsole being configured to attach to the intersole and the intersole comprising a shock-absorbing component, wherein the outsole comprises a cavity to receive a lower part of the intersole.
22. The sole according to claim 21, wherein the lower part of the intersole is retained within the cavity of the outsole using an adhesive or other known bonding mechanism.
23. The sole according to any one of claims 21 to 22, wherein the cavity and the lower part of the intersole comprise cooperable components to retain the lower part of the intersole within the cavity.
24. The sole according to any one of claims 21 to 23, wherein the cavity and the lower part of the intersole comprise interlocking parts.
25. The sole according to claim 24, wherein the cavity comprises one or more internal peripheral protrusions within the cavity for retaining one or more external peripheral protrusions on the lower part of the intersole within the cavity.
26. The sole according to claim 25, wherein the peripheral protrusions within the cavity and on the lower part of the intersole are a single continuous protrusion.
27. The sole according to any one of claims 25 to 26, wherein the protrusion(s) of the outsole and/or the intersole comprise resiliently flexible material in order to allow assembly but minimise unintentional disassembly.
28. The sole according to any one of claims 21 to 28, wherein the intersole comprises a cavity to receive the shock-absorbing component.
29. The sole according to claim 28, wherein the shock-absorbing component is permanently retained within the intersole cavity using an adhesive or other known bonding mechanism.
30. The sole according to claim 28, wherein the intersole cavity and the shock-absorbing component may comprise cooperable components to retain the shock-absorbing component within the intersole cavity.
31. The sole according to claim 30, wherein the intersole cavity and the shock-absorbing component comprise interlocking parts.32 The sole according to any one of claims 30 to 31, wherein protrusion(s) of the intersole and/ or the shock-absorbing component comprise resiliently flexible material in order to allow assembly but minimise unintentional disassembly.33. The sole according to any one of claims 21 to 32, wherein the shock-absorbing component comprises a porous material.34. The sole according to any one of claims 21 to 33, wherein the outsole comprises a core of light weight material, for example, ethyl vinyl acetate (EVA).35. The sole according to any one of claims 21 to 34, wherein the outsole comprises an outer skin of suitable shock-absorption material on the ground-engaging face.36. The sole according to any one of claims 21 to 35, wherein the intersole comprises a suitably dense stable material to support the shock-absorbing component therein.37. The sole according to any one of claims 21 to 36, wherein the shock-absorbing component comprises a single layer of porous polyurethane.38. The sole according to any one of claims 21 to 37, wherein the shock-absorbing component comprises a multi-layered construction.39. The sole according to claim 38, wherein the multi-layered component comprises a base of closed-cell EVA topped by one or more layers of an open-cell (porous) polyurethane.40. The sole according to any one of claims 21 to 39, wherein the intersole comprises an attachment means for an upper.41. The sole according to any one of claims 21 to 40, wherein the intersole is assembled with the upper as described in the method of claims 18 -21 using the apparatus of claims 1-17.Amendments to the claims have been filed as follows:CLAIMS1 An apparatus for reverting an inside-out upper-sole assembly to a righted upper-sole assembly, the apparatus comprising a clamping arrangement having a first member with a first contact end and a second member with a second contact end, both members being arranged end-to-end along a longitudinal axis and being mechanically operable to move along said longitudinal axis between a first position in which the first and second contact ends are nipped together and a second position in which the first and second ends are distanced from one another, wherein the mechanical operation comprises an opposite end (to the contact ends) of at least one of the members attached to a sliding mechanism to facilitate the longitudinal movement of the members between the first and second positions and the sliding mechanism comprises a pneumatic cylinder driven ram.2 The apparatus according to claim 1, wherein a first support member is fixably mounted on a support plate, whereas a second support member is slidably mounted on said support plate.3 The apparatus according to claim 2, wherein the ram is operated by a two depressible buttons located on the second support member, which are electrically configured to activate the ram and therefore, the second support member.4 The apparatus according to any one of claims 2 to 3, wherein the ram is retracted by a pressure-releasing button located on the first support member to move the contact ends into the second position.The apparatus according to claim 1, wherein the second position comprises a distance between the contact ends that is sufficient to easily manoeuvre an assembly onto and off of each member respectively.o 6 The apparatus according to claim 2, wherein the distance may therefore, comprise between approximately 8 cm and approximately 30 cm.7 The apparatus according to any one of claims 1 to 3, wherein the members comprise elongate arms.8 The apparatus according to claim 4, wherein the length of each arm may be approximately 1 cm to approximately 20 cm.9 The apparatus according to any one of claims 1 to 5, wherein the contact ends are shaped to contact a wide portion (between two sides) of a toe section of an assembly.10. The apparatus according to any one of claims 1 to 6, wherein the contact ends comprise a shallow disc attached to the arms.11. The apparatus according to claim 7, wherein the contact ends comprise a diameter of approximately between 2 cm and approximately 5 cm.12. The apparatus according to any one of claims 7 to 8, wherein the contact ends comprise a depth of approximately between 2 mm and approximately 1 cm.13. The apparatus according to any one of clams 4 to 9, wherein arms are configured to lie substantially straight along said longitudinal axis.14. The apparatus according to any one of claims 11 to 13, wherein the sliding mechanism moves said member within a range of between approximately 8 cm and approximately 15 cm.15. The apparatus according to any one of claims 1 to 14, wherein the sole in the upper-sole assembly is an outsole.16. The apparatus according to any one of claims 1 to 14, wherein the sole in the upper-sole assembly comprises a midsole (for location inside a footwear construct above an outsole and potentially below an insole), 17. The apparatus according to any one of claims 1 to 14, wherein the sole in the upper-sole assembly comprises an intersole (for location partially outwardly of a footwear construct above an outsole and potentially below a midsole or insole).18. A method for reverting an inside-out upper-sole assembly using a clamping arrangement, the method comprising: 1) locating a first member of said clamping arrangement into a cavity of said inside-out upper-sole assembly such that a contact end of said member abuts a toe section of the assembly; 2) bringing a second member of said clamping arrangement into end-to-end contact with the first member, with said toe section of the assembly clamped therebetween; 3) manipulating a heel section of the assembly into a righted arrangement; 4) pulling the righted heel section of the assembly towards the contact ends and the clamped toe section to achieve a substantially righted mid-section; and 5) puling the righted heel-section and mid-section beyond the contact ends of the members until the upper-sole assembly substantially lies over the second member to achieve a righted toe section of the assembly.19. The method according to claim 18, wherein the method uses the apparatus of claims 1 to o 17.20. The method according to any one of claims 18 to 19, wherein the method comprises a precursor step to step 1) in which the first and second contact ends of the members move along said longitudinal axis to the second position in which the first and second ends are distanced from one another.21. An improved sole for a footwear construct, comprising: a ground-engaging outsole and an intersole, the outsole being configured to attach to the intersole and the intersole comprising a shock-absorbing component, wherein the outsole comprises a cavity to receive a lower part of the intersole.22. The sole according to claim 21, wherein the lower part of the intersole is retained within the cavity of the outsole using an adhesive or other known bonding mechanism.23. The sole according to any one of claims 21 to 22, wherein the cavity and the lower part of the intersole comprise cooperable components to retain the lower part of the intersole within the cavity.24. The sole according to any one of claims 21 to 23, wherein the cavity and the lower part of the intersole comprise interlocking parts.25. The sole according to claim 24, wherein the cavity comprises one or more internal peripheral protrusions within the cavity for retaining one or more external peripheral protrusions on the lower part of the intersole within the cavity.26. The sole according to claim 25, wherein the peripheral protrusions within the cavity and on the lower part of the intersole are a single continuous protrusion.27. The sole according to any one of claims 25 to 26, wherein the protrusion(s) of the outsole and/or the intersole comprise resiliently flexible material in order to allow assembly but minimise unintentional disassembly.28. The sole according to any one of claims 21 to 28, wherein the intersole comprises a cavity to receive the shock-absorbing component.29. The sole according to claim 28, wherein the shock-absorbing component is permanently retained within the intersole cavity using an adhesive or other known bonding mechanism.30. The sole according to claim 28, wherein the intersole cavity and the shock-absorbing component may comprise cooperable components to retain the shock-absorbing component within the intersole cavity.31. The sole according to claim 30, wherein the intersole cavity and the shock-absorbing component comprise interlocking parts.
32. The sole according to any one of claims 30 to 31, wherein protrusion(s) of the intersole and/ or the shock-absorbing component comprise resiliently flexible material in order to allow assembly but minimise unintentional disassembly.
33. The sole according to any one of claims 21 to 32, wherein the shock-absorbing component comprises a porous material.
34. The sole according to any one of claims 21 to 33, wherein the outsole comprises a core of O light weight material, for example, ethyl vinyl acetate (EVA).
35. The sole according to any one of claims 21 to 34, wherein the outsole comprises an outer skin of suitable shock-absorption material on the ground-engaging face.
36. The sole according to any one of claims 21 to 35, wherein the intersole comprises a suitably dense stable material to support the shock-absorbing component therein.
37. The sole according to any one of claims 21 to 36, wherein the shock-absorbing component comprises a single layer of porous polyurethane.
38. The sole according to any one of claims 21 to 37, wherein the shock-absorbing component comprises a multi-layered construction.
39. The sole according to claim 38, wherein the multi-layered component comprises a base of closed-cell EVA topped by one or more layers of an open-cell (porous) polyurethane.
40. The sole according to any one of claims 21 to 39, wherein the intersole comprises an attachment means for an upper.
41. The sole according to any one of claims 21 to 40, wherein the intersole is assembled with the upper as described in the method of claims 18 -21 using the apparatus of claims 1-17.