MXPA06012875A

MXPA06012875A - Novel vamp, and injection moulding process for forming a vamp.

Info

Publication number: MXPA06012875A
Application number: MXPA06012875A
Authority: MX
Inventors: Alan Roy Gerrand; Norbert Fechter
Original assignee: Imagine Sports Pty Ltd
Priority date: 2004-05-07
Filing date: 2005-05-09
Publication date: 2007-04-30
Also published as: EP1793695A1; NZ551831A; BRPI0510728A; CN100479685C; EP1793695A4; US20070245596A1; WO2005107509A1; CN101014259A

Abstract

A composite vamp includes a first, relatively softer layer (12) shaped and dimensioned to define a periphery of the vamp and the profile of an upper surface of the vamp, and a second, relatively harder layer (14) bonded to the first layer, which second layer is adapted to overlie the instep region of a foot and shaped to match the instep region of the foot.

Description

NOVEDOSA SHOE SHOULDER AND MOLDING PROCESS BY INJECTION TO FORM A SHOE SHOE FIELD OF THE INVENTION This invention relates generally to footwear and more particularly to a shoe shoe composite and to an injection molding process for the manufacture of a shoe blade. The invention is applied to footwear for sporting use, especially footwear used in kicking a ball or something similar and protective footwear. Through this specification the "instep" is the upper part of the foot between the ankle and the toe, or the corresponding part of the footwear, and the "arch" is used in its conventional sense of the part under the arched foot. The term "shoe shovel" is used to describe the front part of the upper part of a shoe or boot. BACKGROUND OF THE INVENTION In sports where a ball is kicked by a player, it is normal to use a shoe or boot to protect the foot of the person who kicks the ball. In different sports, the nature of the shoe or boot varies to take into account the way in which the ball is kicked and the nature of the ball that is kicked. However, in all cases the shoe or boot pretends to follow the inherent form of a human foot. When playing a ball game such as soccer, the player will tend to use various parts of the foot to perform different kicking actions. For example, the side of the ball of the foot, the toe, and the outside of the ball of the foot are usually used to "pass" and other small kicks that do not require much power but require more control. In all these parts of the foot, there is a relatively greater sense of feeling and therefore the player will have more control. When a full kick is required it is usually the instep of the foot that is used, since it allows more power when kicked, particularly in view of the solid nature of this part of the foot and the overall bony structure under the skin. This structure provides a relatively hard surface under the shoelaces or cords so that a solid kicking surface is provided to impart maximum kicking energy to the ball in order to project it as far away as possible. However, the kick with the instep is only used for a small proportion of the total kicks because the players find it less predictable, that is, the control and precision decrease in relation to, for example, the middle or internal kick. . Given the shape of the human foot portion that makes the kicking generally does not correspond to the shape of the ball, it is known to introduce an insert into the shoe or boot, or manufacture the shoe or boot blade adjacent to the instep of the wearer's foot, to modify the surface of the shoe or boot that the ball contacts. The concept of the modification of the shoe upper of a shoe to improve the kick is disclosed in EP 359081, which describes a shoe upper with side flanges to enable improving the guidance of a ball by the foot and by means of this improving the kicking precision International Patent Publication No. WO99 / 00970 by A. Gerrand, describes an insert that assists in obtaining a concave shoe shovel. The insert, which can be joined to or formed integrally with the shoe, serves to provide a surface that complements the shape of the ball that is kicked, effectively "pumping" the ball as it contacts the instep. A pumping effect imparts much more of the kicking energy to the ball, and provides more guidance to the ball. What is referenced here to any specific prior art document or other information is not taken as an admission that the document or information is common general knowledge, whether in Australia or elsewhere. It is an object of the invention to provide an improved shoe upper that can be applied to produce footwear with a modified upper surface, and a method to build a shoe spade. BRIEF DESCRIPTION OF THE INVENTION In one aspect, the present invention provides a composite shoe blade that includes: a relatively soft first layer, shaped and sized to define a blade periphery and a profile of an upper surface of the blade, and a second layer relatively harder, bonded or attached to the first layer, the second layer of which is adapted to rest on the instep region of a foot and is shaped to engage the instep region of the foot. In a further aspect, the present invention provides a method of forming a composite shoe blade that includes: forming a relatively soft piece of material in a mold; injecting a plastic into said mold or into a second mold into at least one side of the soft material; bind or join the injected material to the soft material; and curing the injected plastic while being shaped by means of the mold to provide a relatively harder layer of adjacent material, bonded or bonded to the soft material that is adapted to rest on the instep region of a foot and conforms to engage the region of the instep of the foot, while the relatively soft material forms a layer that is shaped and sized to define a periphery of the blade and the profile of an upper surface of the blade. An intermediate reinforcing element of a stiffness may be arranged between the layers to facilitate maintenance of the profile. In preferred embodiments, the composite shoe blade may comprise additional layers of material depending on the purpose for which the blade is designed. For a boot blade to be used in the construction industry, the reinforcement element may be a steel insert for increased strength and protection. Advantageously, the composite shoe blade is manufactured as a one-piece component for incorporation into a shoe or boot. In one embodiment, the relatively soft first layer is formed of soft plastic. Alternatively, this layer may be formed of skin or synthetic leather or any other fabric, mesh fabric or full-grain leather, provided in a flat sheet. Said profile preferably includes surface features selected from one or more of concavity, ridges and vertices. This can be preformed in the first layer using chemical and mechanical treatment. The second or relatively harder layer is preferably formed of a harder plastic. This layer is advantageously formed by injection molding. In a particularly preferred embodiment, the second or relatively harder layer has regions of different density, hardness, and / or color chosen according to the different design parameters for various shoe applications, for example, an industrial boot may have different characteristics to a soccer shoe Advantageously, the second layer is chemically bonded or welded to the first layer, for example, using aspects of plastic welding technology. The intermediate reinforcing element is preferably a carbon composite or alternatively a reinforced plastic, a reinforced preformed textile and the like.

Preferably, the composite shoe blade has at least one front surface substantially triangular in shape. More preferably, the front surface is concave, the front surface having a radius of curvature that is substantially the same as or slightly larger than the radius of the curvature of the balloon. More preferably, the front surface has a vertex or upper vertices and / or a vertex or posterior vertices. In addition, the composite shoe blade may have a side surface that is also concave or flat, the radius of curvature of the side surface preferably being the same as or slightly larger than the radius of the curvature of the ball. In one embodiment, the composite shoe spade is integral with the shoe. Alternatively, the composite shoe can be formed separately and can be releasably or insattably attached to the shoe. In one embodiment, the composite shoe upper is approximately M-shaped. In an alternate embodiment, for example, when the upper is constructed for use in sturdy shoes, the composite shoe upper may be approximately W-shaped, or Include a series of longitudinal flanges or projections designed to absorb shocks. BRIEF DESCRIPTION OF THE DRAWINGS The invention will now be described by way of example only with reference to the accompanying drawings in which: Figure 1 is a final perspective view of a composite shoe upper constructed in accordance with an embodiment of the invention and designed for incorporation into a soccer shoe or boot. Figure 2 is an enlarged perspective view separately showing the components of the composite shoe upper of Figure 1; and Figure 3 is a longitudinal sectional view of an insert for a secure boot formed in accordance with a further embodiment of the invention. DESCRIPTION OF THE PREFERRED MODALITIES The composite shoe 10 of Figures 1 and 2 comprises a first upper layer 12 formed of a relatively soft material, a second lower layer 14 formed of a relatively harder material, and a reinforcing layer 16 provided intermediate to the first and second layers. These three layers are shown separated in the enlarged view of Figure 2. The upper layer 12 is shaped and sized in a mold to provide a valley 18 of generally concave cross-section, preferably having a radius of curvature substantially equal to, or slightly greater than, the radius of the curvature of a selected ball, for example, a soccer ball. The valley 18 is flanked by two flanges 20, 22, which extend along the total length of the shoe upper 10. A vertex 24 is provided on each of the sides towards the front edge 34 of the upper and shoulders 20, 22 and the flanges 20, 22 taper forward, downward in two directions from the apex 24. The first of these tapered flange sections is generally designed as the 26 and taper outwardly to meet the lower edge 28 of that side of the shoe blade 10. The other tapered flange section section is generally designed as the 30 and tapers downward but towards the center of the valley 18. This therefore creates a triangular area 32 which is facing somewhat towards front and something to the side. This is of great advantage when you want to kick a ball in order to provide a high level of spin but without the need for much energy. In this way, the ball can curve. The triangular surface 32 is generally concave in configuration, with the radius of the curvature preferably being substantially equal to, or slightly greater than, the radius of the curvature of the balloon. Naturally, this is repeated on both sides of the shoe upper 10. The "floor" of the valley 18 - that portion between the two flanges 20, 22 - is preferably of relatively low thickness so that the front edge 34 is of thickness minimum. The second layer 14 and the strengthening layer 16 are shaped to help achieve this, as will be discussed later. The relatively soft upper layer 12 is preferably formed of a soft polyurethane, synthetic leather or any other fabric, mesh fabric or full-grain leather, provided in a flat sheet. To build the top layer, the fabric sheet is located in a mold (not shown) and compressed to form a three-dimensional shape using chemical and mechanical treatment. This formation process enables the formation of concave shapes, ridges, vertices and projections as already described. Advantageously, the three-dimensional shape is achieved without sewing or gluing the shoe upper. Therefore, it will be appreciated from FIGS. 1 and 2 that the upper layer 12 is shaped and sized to define a periphery of the blade and the profile of an upper surface of the shoe upper. The second relatively hard layer 14 is formed in a second stage of the manufacturing process. This step of the process involves synchronized injection molding which includes the simultaneous injection molding of the top and bottom of the piece of preformed cloth 12, either in the mold also used to form the piece 12, in a separate mold . The fabric 12 advantageously projects into the mold thereby providing a flexible fit by means of which the composite blade 10 can be attached to the rest of the shoe. During the course of injection molding, layers 12 and 14 are joined or bonded by conventional chemical bonding or welding techniques. The injection molding process advantageously allows the formation of regions of different density, hardness and color chosen according to the different design parameters for various shoe applications. This multi-density injection allows the selection of various combinations of soft and hard polyurethane for the injection molded layer, or alternate color combinations as desired. Density and hardness variations can be selected to support the designed concave shapes and curves as required.

As illustrated in FIG. 2, the relatively harder injection molded layer 14 is formed as a substantially U-shaped part, which gives a reinforced force. The upper surface of the layer 14 is shaped and sized to maintain the surface characteristics of the shoe upper. The side 15 below the layer 14 is advantageously formed as a convex shape to rest and fit more evenly to the instep region of the wearer's foot. In one embodiment, the underside of the layer 14 is provided with a pre-molded backing clay, which responds to the temperature. In the illustrated embodiment, the layer 14 is shaped so as to secure and support the shoulders 20, 22 of the blade 10. The central region of the layer 14 has been left open at 17 to assist in the maintenance of a concave upper surface of the shovel, and to reduce the thickness of the valley floor 18 of the shovel. It will be appreciated that this process allows for the inclusion of other materials that include but are not limited to foams, elastomeric plastics, reinforced and low density plastics, and cushioning plastics and that absorb rebound shocks. A strengthening layer 16 is preferably integrated in the blade 10 during the injection molding step. In the embodiment illustrated in Figures 1 and 2, the reinforcement layer 10 comprises a single component part, although in some embodiments more than one component may be provided. The strengthening layer 16 serves to provide additional force to the composite blade 10 and aids in maintaining the concave shape of the blade 10 and other shaped surface features. The reinforcement 16 is preferably in the form of a carbon composite, or alternatively, reinforced plastic, preformed reinforced textile, or the like. The strengthening layer 16 can also be shaped and sized so as to contribute to the control characteristics of the blade ball. As illustrated, the reinforcing layer 16 is also formed in a substantially U-shaped form, to support the injection molded layer 14 and reduces the thickness of the valley floor 18. It will be appreciated that the molding process of this invention has application to the construction of general footwear, and in particular, is useful in the construction of safe shoes or gowns that are typically formed with a steel insert over the instep and toe region. In one embodiment of the invention, an insert for a shoe or secure boot is constructed using the injection molding process of the invention. An example of a safety boot insert 40 is illustrated in Figure 3. The insert 40 shown comprises an upper layer 42 of soft fabric that is molded according to the invention, a layer 44 of relatively harder plastic, and a reinforcement 46 of a carbon composite provided between the two layers 42, 44, and incorporated during the injection molding step. It can be seen that this component 40 is shaped to extend forward and downward generally on the toe region of a shoe or boot, so that in this case the upper includes a reinforced toe section 46. In a further embodiment of the invention (not illustrated), the blade 10 can be constructed with an integrated link system. For example, the injection molding process may include the addition of eyelets, cords and buckles. One or more of the contact surfaces of the paddle ball may have surface treatments such that low groove patterns improve contact with the ball, especially in more adverse play conditions. It will be appreciated that the invention enables the construction of a shoe blade composed of a single piece, without the use of any sewing or gluing of the blade. The composite blade includes features of concavity, flanges, and vertices, which are known as advantageous in sports footwear in particular, while having the advantage of current material technology to provide a blade that has selected density and hardness characteristics. .

Claims

CLAIMS 1. A composite shoe blade that includes: a relatively soft first layer, shaped and dimensioned to define a periphery of the blade and the profile of an upper surface of the blade, and a relatively harder second layer, attached or bonded to the first layer, whose second layer is adapted to rest on the instep region of a foot and is shaped to engage the instep region of the foot, characterized in that the relatively harder second layer is injection molded around the first layer, relatively softer.
2. A composite shoe blade according to claim 1, characterized in that it also includes an intermediate reinforcing element, disposed between said layers and a -rigidity to facilitate the maintenance of said profile.
3. A composite shoe blade according to claim 2, characterized in that said intermediate reinforcing element is a composite carbon element.
4. A composite shoe blade according to claim 2, characterized in that said intermediate reinforcing element is a preformed reinforced textile.
5. A composite shoe blade according to claim 2, characterized in that said intermediate reinforcing element is a reinforced plastic element.
6. A composite shoe upper according to claim 2, characterized in that said intermediate reinforcing element is a steel insert.
A composite shoe upper according to any of claims 1 to 6, characterized in that it comprises a one-piece component to be incorporated in a shoe or boot.
A composite shoe blade according to any of claims 1 to 6 and 8, characterized in that said first layer is a plastics material.
A composite shoe upper according to any of claims 1 to 6 and 8, characterized in that said first layer is a synthetic skin or skin.
A composite shoe blade according to any of claims 1 to 6 and 8 to 10, characterized in that said profile includes selected surface features of one or more of concavity, ridges and vertices.
11. A composite shoe upper according to any of claims 1 to 6, and 8 to 11, characterized in that said second layer is chemically bonded or welded to the first layer.
12. A composite shoe blade according to any of claims 1 to 6, and 8 to 12, characterized in that it includes at least one front surface that is concave and having a radius of curvature substantially equal to or slightly greater than the radius of the curvature of a selected ball.
13. A composite shoe upper according to any of claims 1 to 6 and 8 to 13, formed integrally with a shoe or boot.
A composite shoe upper according to any of claims 1 to 6 and 8 to 14, approximately M-shaped in cross-section.
15. A shoe shoe made according to any of claims 1 to 6 and 8 to 15, characterized in that it has one or more longitudinal ridges or projections.
16. A method of forming a composite shoe shovel, characterized in that it includes: forming a piece of relatively soft material in a mold, injecting a plastic in said mold or in a second mold in at least one side of the soft material, linking or joining the injected material to the soft material, and curing the injected plastic while forming, by means of the mold to provide a layer of adjacent material, relatively harder, bonded or bonded to the soft material which is adapted to rest on the region of the instep of one foot and conformed to engage the instep region of the foot, while the relatively soft material forms a layer that is shaped and sized to define a periphery of the blade and the profile of an upper surface of the blade.
17. A method according to claim 16, characterized in that said relatively soft material is a plastics material.
18. A method according to claim 16, characterized in that said relatively soft material is a skin or synthetic skin.
19. A method according to claim 16, 17 or 18, characterized in that it further includes forming said piece of relatively soft material so that said profile includes surface features selected from one or more of concavity, ridges and vertices.
20. A method according to claims 16 to 19, characterized in that said bonds are by chemical bonding or welding.
21. A method according to any of claims 16 to 20, characterized in that it further includes providing an intermediate reinforcing element between said layers.
22. A method according to claim 21, characterized in that the intermediate reinforcing element is a carbon composite element.
23. A method according to claim 21, characterized in that said intermediate reinforcement element is a preformed reinforced textile.
24. A method according to claim 21, characterized in that said intermediate reinforcement element is a reinforced plastic.
25. A method according to claim 21, characterized in that said intermediate reinforcing element is a steel insert.
26. A method according to any of claims 16 to 25, characterized in that said shoe blade is formed integrally with a shoe or boot.
27. A method according to any of claims 16 to 26, characterized in that it includes forming said blade to have approximately the shape of M in cross section. A method according to any of claims 16 to 27, characterized in that it includes providing the shoe upper with one or more longitudinal shoulders or projections.