Shoe and Method of Manufacture
A shoe, and method of manufacture, comprised of (i) a shoe upper having an arrangement of holes in the bottom surface, (ii) an outer sole having an arrangement of holes corresponding to the arrangement of holes in the bottom surface of the shoe upper, and (iii) an inner sole disposed within the shoe upper, the inner sole having a plurality of pegs that extend from its bottom surface that are arranged in alignment with the arrangement of holes in the shoe upper and outer sole when the inner sole is disposed within the shoe upper, each peg extending downwardly through its associated hole in the shoe upper and the outer sole, so that, in the preferred embodiment, the bottom surface of each peg is exposed to, and forms part of, bottom surface of the shoe.
The present invention relates to a new and improved shoe and a novel method of manufacture that is more efficient, less costly and safer than the prior art.
BACKGROUND OF THE INVENTIONShoe manufacturers strive to produce products that are comfortable, lightweight, sturdy, durable, shock absorbent and breathable, yet inexpensive. Incorporating all of these characteristics in a single shoe, however, has been difficult to achieve without employing manufacturing techniques that are expensive, labor intensive and time-consuming, and which sometimes employ hazardous manufacturing materials and methods, such as the use of glues or sealants, which may produce toxic fumes and which require time-consuming cooling during manufacture.
Simpler manufacturing techniques, such as those employed in the manufacture of “flip-flops” (an example of which is disclosed in publication number US 2009/0044423 to Amsterdam) result in reduced manufacturing costs but do not produce a “shoe,” as opposed to a simple beach sandal or the like, which has limited durability and practical use.
SUMMARY OF THE INVENTIONIt is therefore an object of the present invention to produce a relatively high-quality shoe and a novel method of manufacture that is more efficient, less costly and safer than the prior art.
Briefly, the shoe produced in accordance with the preferred embodiment of the present invention includes a shoe upper having an arrangement of holes in the bottom surface, an outer sole having an arrangement of holes corresponding to the arrangement of holes in the bottom surface of the shoe upper, and an inner sole disposed within the shoe upper, the inner sole having a plurality of pegs that extend from its bottom surface that are arranged in alignment with the arrangement of holes in the shoe upper and outer sole when the inner sole is disposed within the shoe upper. In accordance with the preferred embodiment, each peg extends downwardly through its associated hole in the shoe upper and the outer sole, so that the bottom surface of each peg is exposed to the bottom surface of the shoe. Preferably, the bottom surface of each peg is substantially coplanar with the bottom surface of the outer sole. Alternatively, a supplemental outer sole, made from a material similar to the material of the outer sole, may be applied to the bottom surface of the outer sole, if desired.
In accordance with the preferred embodiment, the outer sole and inner sole, including the pegs, are formed of resilient, deformable material. Each peg is configured substantially in the shape of an inverted “T”, and each hole in the outer sole contains a recess that is configured to closely accommodate the configuration of each peg, so that each peg fits snugly within its associated recess. Preferably, each peg and its associated recess have substantially circular cross sections, but other cross sections, such as square, for example, may be used as well.
Various materials preferred for the shoe upper, the inner sole and the outer sole are disclosed, and the materials can be chosen so that the sole, formed by the outer sole and the pegs, can have a substantially uniform surface. The outer sole may be die-cut or molded.
The method for manufacturing a shoe in accordance with the preferred embodiment of the present invention includes the steps of inserting an inner sole having a plurality of pegs extending from its bottom surface into a shoe upper having an arrangement of holes in its bottom surface corresponding to the arrangement of the pegs, inserting each of the plurality of pegs through its corresponding hole on the bottom surface of the shoe upper, providing an outer sole having an arrangement of holes corresponding to the arrangement of holes in the bottom surface of the shoe upper, and inserting each of the plurality of pegs through a corresponding hole in the outer sole, wherein after inserting each of the plurality of pegs through a corresponding hole in the outer sole, the bottom surface of each peg is exposed to and forms part of the bottom surface of the shoe, and preferably is substantially coplanar with the bottom surface of the outer sole. Alternatively, the method may also include the step of applying a supplemental outer sole to the bottom surface of the outer sole.
The resulting manufacture is a shoe that is comfortable, lightweight, sturdy, durable, shock absorbent and breathable, and which is produced using a manufacturing technique that is efficient, inexpensive, and does not require the use of toxic glues or sealants, resulting in production that is safer, more consistent, and which does not require a cooldown process. The resulting flexible inner sole/foot bed is shock absorbent, lightweight and comfortable and may be made of many different kinds of materials. The shoe produced in accordance with the present invention can employ an upper of any conventional style and have an appropriate pull strength to accommodate multiple activities and durability.
These and other objects and aspects of the present invention will be more fully described in accordance with the following detailed description.
With reference to
The particular arrangement of the pegs 22, and corresponding holes 32 and 42, can be as illustrated generally in the drawings, but variations can be made by those skilled in the art to accommodate different styles and sizes so that they can readily accommodate men, women and children, for different activities, as desired, and to avoid placing the pegs at flex and stress points, as may be necessary or desired.
The structure and method of construction of the shoe in accordance with the present invention are illustrated in connection with
In the preferred embodiment, each peg 22 is substantially cylindrical, having a circular cross-section, although other cross sections, such as square (an example of which is shown as peg 22′ in
It will be appreciated that no glues or sealants are required in the construction of the preferred embodiment of the shoe, which is very beneficial, as described herein. Furthermore, and as explained in more detail below, the construction of the shoe, using the upper 30, inner sole 20 and outer sole 40 as shown in the figures, results in a shoe that can be manufactured very quickly and efficiently.
The foregoing construction and assembly is efficient and inexpensive, and can be used advantageously even if a supplemental outer sole, covering the bottom surfaces of the pegs and of the outer sole, is employed. With reference to
It will be appreciated that all of the foregoing constructions result in a shoe that is comfortable, lightweight, sturdy, durable, shock absorbent and breathable. It is produced using a manufacturing technique that is efficient, inexpensive, and, in the preferred embodiment, does not require the use of glues or sealants. The materials required to produce the shoe have been reduced and the amount of labor similarly reduced to thereby significantly shorten the production line process. Although glue or a sealant may be used to bind one or more of the three components to each other, such is not required in the assembly process, and thus production is safer, more consistent, does not require a cooldown process, and cuts down on highly toxic fumes, creating a better work environment.
The shoe produced in accordance with the present invention can employ a footwear upper of any conventional style and have an appropriate pull strength to accommodate multiple activities and durability. The inner sole/foot bed is shock absorbent, lightweight and comfortable.
Because of the efficiency in manufacturing, and minimal labor, the present invention drastically reduces production costs and increases quality. Furthermore, the shoe made in accordance with the present invention may be made of many different kinds of durable materials and will be lightweight and slip resistant. Exemplary materials for the upper include canvas, denim, leather, mesh, neoprene, polyurethane, suede, nubuck, cotton, woven mesh, polyurethane, and synthetic leather; exemplary materials for the inner sole include, rubber, thermoplastic rubbers, ethylene-vinyl acetate, blown ethylene-vinyl acetate, injected molded foam, injection molded rubber, plastic, and polyurethane; and exemplary materials for the outer sole (and supplemental outer sole, if desired), which can be die-cut or molded, include ethylene-vinyl acetate, thermoplastic rubbers, thermoplastic elastomers, blown ethylene-vinyl acetate, blown rubber, leather, injected molded foam, and injection molded rubber. Because the inner and outer soles can be made from the same or similar materials, it will be appreciated that the completed shoe can have a sole, formed by the outer sole and the pegs, that has substantially uniform characteristics throughout its extent. It should be noted that the foregoing materials are exemplary, and other materials may be selected by those skilled in the art to accomplish the goals of the invention set forth herein.
The foregoing preferred embodiments described herein are set forth as exemplary, and it will be appreciated that various modifications may be made without departing from the scope and spirit of the invention which is defined by the following claims.
Claims
1. A shoe comprising:
- a shoe upper having an arrangement of holes in its bottom surface;
- an outer sole having an arrangement of holes corresponding to the arrangement of holes in the bottom surface of the shoe upper; and
- an inner sole disposed within the shoe upper, the inner sole having a plurality of pegs extending from its bottom surface and arranged to align with the arrangement of holes in the shoe upper and outer sole when the inner sole is disposed within the shoe upper, each peg extending downwardly into its associated hole in the shoe upper and outer sole, wherein the bottom surface of each peg is exposed to, and forms part of, the bottom surface of the shoe.
2. The shoe of claim 1, wherein the bottom surface of each peg is substantially co-planar with the bottom surface of the outer sole.
3. The shoe of claim 1, wherein each peg is configured in a substantially inverted ‘T’ shape, and each hole in the outer sole contains a recess that is configured to closely accommodate the configuration of each peg, wherein each peg fits snuggly within its associated recess.
4. The shoe of claim 3 wherein the materials of the inner sole and outer sole are selected so that the sole, formed by the outer sole and the pegs, has substantially uniform characteristics throughout its extent.
5. The shoe of claim 3 wherein each peg and its associated recess have a substantially circular cross-section.
6. The shoe of claim 3 wherein each peg and its associated recess have a substantially square cross-section.
7. The shoe of claim 3 wherein the upper, the inner sole and outer sole are substantially co-extensive and substantially cover the entire sole of the shoe.
8. The shoe of claim 1 wherein the upper is comprised of one of the following materials: canvas, denim, leather, mesh, neoprene, polyurethane, suede, nubuck, cotton, woven mesh, polyurethane, and synthetic leather.
9. The shoe of claim 1 wherein the inner sole is resilient and is comprised of one of the following materials: rubber, thermoplastic rubbers, ethylene-vinyl acetate, blown ethylene-vinyl acetate, injected molded foam, injection molded rubber, plastic, and polyurethane.
10. The shoe of claim 9 wherein the inner sole has at least one of (i) cupped end portions, (ii) a contoured edge, (iii) an arch support region, (iv) massage beads, or (v) perforated knockout holes.
11. The shoe of claim 1 wherein the outer sole is resilient and is comprised of one of the following materials: ethylene-vinyl acetate, thermoplastic rubbers, thermoplastic elastomers, blown ethylene-vinyl acetate, blown rubber, leather, injected molded foam, and injection molded rubber.
12. The shoe of claim 11 wherein the outer sole is die-cut.
13. The shoe of claim 11 wherein the outer sole is molded.
14. A method for manufacturing a shoe, comprising the steps of:
- a. inserting an inner sole having a plurality of pegs extending from its bottom surface into a shoe upper having an arrangement of holes in its bottom surface corresponding to the arrangement of said pegs;
- b. inserting each of the plurality of pegs through its corresponding hole on the bottom surface of the shoe upper;
- c. providing an outer sole having an arrangement of holes corresponding to the arrangement of holes in the bottom surface of the shoe upper;
- d. inserting a tool from the bottom surface of the outer sole through a selected hole in said outer sole;
- e. gripping, with said tool, the peg corresponding to said selected hole;
- f. pulling said corresponding peg through said selected hole;
- g. releasing said corresponding peg from said tool; and
- h. repeating steps (d)-(g) for each remaining peg.
15. A shoe comprising:
- a shoe upper having an arrangement of holes in its bottom surface;
- an outer sole having holes extending completely therethrough in an arrangement corresponding to the arrangement of holes in the bottom surface of the shoe upper;
- an inner sole disposed within the shoe upper, the inner sole having a plurality of pegs extending from its bottom surface and arranged to align with the arrangement of holes in the shoe upper and outer sole when the inner sole is disposed within the shoe upper, each peg extending downwardly into its associated hole in the shoe upper and outer sole; and
- a supplemental outer sole applied to the bottom surface of the outer sole.
16. The shoe of claim 15, wherein each peg is configured in a substantially inverted ‘T’ shape, and each hole in the outer sole contains a recess that is configured to closely accommodate the configuration of each peg, wherein each peg fits snuggly within its associated recess.
17. The shoe of claim 16 wherein the upper, the inner sole and outer sole are substantially co-extensive and substantially cover the entire sole of the shoe.
18. The shoe of claim 16 wherein the inner sole is resilient and is comprised of one of the following materials: rubber, thermoplastic rubbers, ethylene-vinyl acetate, blown ethylene-vinyl acetate, injected molded foam, injection molded rubber, plastic, and polyurethane.
19. The shoe of claim 16 wherein the outer sole is resilient and is comprised of one of the following materials: ethylene-vinyl acetate, thermoplastic rubbers, thermoplastic elastomers, blown ethylene-vinyl acetate, blown rubber, leather, injected molded foam, and injection molded rubber.
20. The shoe of claim 19 wherein the supplemental outer sole is comprised of the same material as the outer sole.
Type: Application
Filed: Oct 18, 2016
Publication Date: Jun 22, 2017
Inventor: Michael K. Douglas (Eatontown, NJ)
Application Number: 15/296,235