Abstract: A method of manufacturing a shoe, provided with a front region and a heel region. The method comprises the steps of stitching an upper to a piece of fabric in order to obtain an inner shoe which is closed at its lower portion, providing a rubber mid-sole having at least one inner cavity or seat and at least one outer cavity or seat, filling the at least one inner cavity with a lightweight filler, coupling said inner shoe with the mid-sole by a peripheral cover band, vulcanizing and placing one or more inserts in the at least one outer cavity or seat.

Abstract: A spike (10) for attachment to baseball shoes has a spike body (11), a leg (14) protruding upright from the spike body and having a distal edge (14a) and an abrasion-resistant tip (20) made of a metal and having a base portion welded to the distal edge of the leg. The base portion (21) has a wedge-shaped ridge (22) pressed to an end face of the distal edge such that the base portion (21) is gripped by and between masses of a once molten and then resolidified material of the distal edge of the leg, so that the spike is abrasion resistant and durable. The distal edge (14a) may have at its middle region a cutout (16) to divide the end face into two parts to which the base portion (21) of the tip are adjoined concurrently and in the same manner.

Abstract: A method of making a sports boot having an upper and a flexible material, an outsole and an insole. The insole having a heel region and forwardly projected portion having an outer edge profile which is stepped inwardly. The lower edges of the upper are folded inwardly and stitched to the inwardly stepped edge profile of the forwardly projecting portion of the insole forming a coplanar assembly of the insole and facing edges, stitching the facing edges to form a boot sub-assembly, applying the boot assembly to a last, folding and securing the lower edges of the upper to the heel region of the insole and securing the outsole to the sub-assembly to complete the formation of the boot.

Abstract: A complex-contoured tensile bladder and method of making same in which a bladder comprises an envelope formed from two outer barrier layers surrounding a tensile element formed of two inner sheets. The inner sheets are attached to one another along selected first attachment portions and include die cuts at certain locations. Each of the outer barrier layers are attached to the inner sheet nearest it at selected second attachment portions which are incoincident with the selected first attachment portions. The outer layers are sealed around the periphery to form the envelope and the bladder is inflated with a gas so that the inner sheets form a tensile member which extends between the selected second portions, and the selected first portions form hinges disposed between the outer layers. When loaded the tensile member compresses at the hinges which readily allow for compression while not interfering with the cushioning properties of the gas.

Abstract: A liner for a sport boot shell and a method for making a custom fitted liner for a sport boot, are disclosed. The liner is designed to be worn inside a boot shell. In a preferred embodiment the liner includes inner and outer of flaps which wrap in opposite directions across a wearer's shin and forms a compound curve in a region in front of the wearer's ankle. The liner including flaps may be made from a single piece of thermoplastic foam material of uniform thickness. The design of the liner prevents the cuff of the liner from loosening around the wearer's shin and calf when the wearer's leg is flexed forward at the ankle. The shell can therefore be worn more loosely than is necessary with a boot liner of conventional design. The liner may be made by making an unfitted liner from a sheet of thermoformable material. The unfitted liner has a forwardly facing opening and wings extending forwardly on either side of opening.

Abstract: Lightweight, inexpensive footwear sole components (14, 18), comprising a midsole portion (14) and an outsole portion (18), are formed by a method that eliminates the need for adhesively attaching the two portions to each other, and comprises the steps of 1) Forming the midsole portion (14) to have a lower surface (17) and at least one opening (26) extending into it through the lower surface (17); 2) Forming the outsole portion (18) on the lower surface (17) of the midsole portion (14) such that the outsole portion has an upper part (28) extending into the opening (26) in the midsole portion; and, 3) Forming a mechanical attachment device (22) between the outsole portion (18) and the midsole portion (14) on an upper end (19) of the outsole portion (18).

Abstract: The present invention is directed to a method of manufacturing a midsole for a shoe and the structure of the resulting midsole. The midsole includes a core of a first plastic material and a peripheral wrap of a second plastic material. The wrap has an outer peripheral surface comprising at least a portion of an outer peripheral surface of the midsole. The method includes the steps of molding a peripheral wrap from a sheet stock of the first plastic material by applying compressive forces on the sheet stock in a direction which is substantially perpendicular with the outer surface of the sheet stock, placing the wrap around the inner peripheral surface of a mold which approximates the shape of the midsole, and pouring the first plastic material in the mold.

Abstract: An athletic shoe (10) having interchangeable components for the customizing to the particular needs of a wearer. The wearer's weight, weight distribution, type and level of activity, and other variables are considered when determining the degree and location of support. The athletic shoe (10) includes a base portion (12) which defines a sole member (14) and an upper (16). A plurality of recesses (24) are defined at selected locations by the sole (14) for the receipt of sole inserts (18). The upper (16) defines a plurality of indicia receiving regions. The sole inserts (18) and the indicators (20) may be permanently attached to the athletic shoe (10) by any selected process such as ultrasonic welding. Additional support members may be placed within the athletic shoe (10) as desired to provide further support for selected portions of the foot, including the ankle and the arch.

Abstract: A shoe sole lamination and method of lamination in which shoe sole portions composed of selected materials and low melting plastic inserts are laminated and then heat embossed. The method includes use of insulating inserts placed strategically in the mold to protect the plastic inserts against the heat and temperatures of embossing.

Abstract: A recreational snowshoe and its method of manufacture are disclosed of the type where a single, homogenous, rigid mass is formed by hardening first and second strands of fiberglass roving impregnated with resin woven to define a frame and webbing. The strands are woven between a first series of removable, spaced pins projecting from the peripheral surface of a jig and around the peripheral surface and across the jig. The webbing includes bracing extending between the tip and rear portions of the snowshoe generally parallel to and spaced from the frame of the sides of the central portion of the snowshoe. The tip portion is upturned such that the bracing is elevated from the sides of the frame, with the bracing been drawn toward the plane of the central portion by lateral bracing to provide a cushion effect.

Abstract: Multi-layer footwear formed of laminated layers of material which are sealed together with a polymeric glue used in the original manufacture of the footwear to secure the various layers of material together. The layers of material held together by polymeric glue are capable of being heated to a degree at which the footwear, when placed in a vacuum bag or compression chamber, is molded to adopt the shape of the foot inside the footwear under atmospheric pressure once pressure inside the bag is reduced or pressure in the compression chamber is increased. The footwear is heated to the point where the synthetic components of the layers of material are flexible under thermoforming conditions, but within a temperature range in which the polymeric glue continues to perform as an adhesive so that the sealed laminated surfaces do not separate.

Abstract: A boot liner, preferably for use with a ski boot of the rear-entry type, including an exterior envelope and an interior sock, having an injection cavity therebetween. Within the injection cavity, a filling product is designed to be injected for retaining the foot of the skier within the boot liner and within the ski boot within which it is adapted to be used. The exterior envelope and the interior sock are sealed along a lower peripheral edge defining a sole portion of the boot liner. The peripheral edge is engageable within a peripheral groove in the internal wall of the exterior envelope to thereby seal the injection cavity from the sole portion of the boot liner to thereby prevent the filling product from flowing beneath the sole of the foot positioned within the boot liner. The injection cavity is defined by respective surfaces of the external envelope and the interior sock.

Abstract: An inner boot for a ski boot which has wall portions that define the body of the inner boot. The wall portions are made from an open cell foam material. A lower portion of the inner boot includes a sealing coating of polyurethane that seals the foot of a skier against moisture and humidity. A process for manufacturing the inner boot includes degreasing the inner boot, soaking the inner boot in a polyurethane solution, removing excess polyurethane and drying the inner boot.

Abstract: A process for applying a flocking fiber to a cloth surface of a shoe includes the step of spraying a clean dry cloth shoe with an adhesive, which adheres to the cloth substrate without excess penetration, which remains pliable, and is not water soluble when set. A short set time is desirable, and then flock fibers suitable for application are carried into a charge in an electrostatic field. A conventional flocking chamber is used, voltage is applied to the electric field, and the flock fibers are applied so that they adhere to the adhesive surface under controlled conditions. The shoe is dried in a drying oven, and then it is ready for use. The flocking process can use adhesives that are colored, flock that is colored, and the flock can be applied in any desired pattern because of the use of the adhesive for causing the flock material to adhere to the cloth surface.

Abstract: The process of molding a component of a sole unit for an athletic shoe comprising the steps of supporting a core of a first plastic material in a cavity of a mold, the core defining an integral part of the component and extending within a heel region toward a forefoot region, supporting at least one rigid plug member within the cavity juxtaposed and in partially surrounding relation to the core, injecting a second plastic material into the cavity to fill the cavity, to form a shell around the core, at least partially curing the injected plastic material, removing the plug member, and injecting a third plastic material which upon curing forms a second resilient plastic material having a hardness (Shore A) greater than that of the material of the core into the cavity to fill the area heretofore occupied by the plug member, the plug member being shaped such that the third plastic material forms a set of posts.

Abstract: Process for filling with foam an inner boot of skiing boot in which the foam or the material to be expanded into a foam is introduced in the lower boot region. The foam or material is directed from the instep region towards the lower heel end and is thus introduced into the skiing boot until it emerges from the heel end. This causes the lateral front region of the inner boot to be filled with foam asymmetrically in relation to the longitudinal central plane.

Abstract: A custom-fit ski boot orthotic which efficiently transfers movement of the foot to the edges of the skis. The orthotic has a substantially rigid base plate attached to a rigid heel post. The base plate has an arch portion 20-40% shallower than the skier's actual arch which permits the limited movement necessary for foot comfort, without any significant loss in transfer efficiency. The base plate also has a heel cup portion to prevent heel roll. The orthotic of the present invention may be used as an insert or be built into the footbed of a ski boot.

Abstract: A stud for a football boot is moulded in two parts. An attachment portion (1;25) moulded in a hard and inflexible material, such as an acetal resin, comprises an externally screw-threaded spigot (3;27) and a body providing a collar (7;29) a flange (5;30) and a central stiffening support. The stiffening support comprises a hub (8;37) supported by spokes (11;38) extending radially from the hub to the collar. A boss (2;26) of the stud is moulded on to the attachment portion and is of a tough but more resilient material, such as a polyurethane. The boss-forming material flows through apertures between the spokes to join up and form a ring (22) or plug (43) which causes the boss to become interlocked with the attachment portion.

Abstract: A canting adjustment for ski boots and a method of canting in which the ski boot contains a plurality of wedge shaped removable innersoles having generally equal and opposite wedge angles to allow a wide range of canting angles.

Abstract: A method of fitting ski boots to a skier by standing the skier in the boots on orthotics with the skier's feet ankles and legs unconfined by the boots, recording the relative lateral locations of the skier's knees and boots, repeating the process with the skier's feet supported on the orthotics and confined by the boots, and adjusting the boots to provide the same relative lateral locations of knee and boot.

Abstract: A shoe patch device and method of preserving and repairing shoes is disclosed wherein a patch member fabricated of a thin, flexible and durable material is formed to be rapidly adhered to the sole and/or upper of the shoe. The patch member is formed in a suitable configuration and includes a plurality of V-shaped notches extending inwardly from its edges to permit the patch member to readily accommodate all shoe sizes and be positioned at differing locations upon the shoe. Due to the lightweight and flexible properties of the patch member, the function and wear characteristics of the shoe are not altered or impaired, nor is it necessary to disturb the original construction of the shoe to effectuate repair or preservation of the shoe.

Abstract: A slipper for a ski boot produced by injection of a foam mixture of plastic material between the walls of two socks placed upon a form set in a mold, the outer of the two socks comprising a very thin, extensible sheet having the same dimensions as the inner sock when the two are in unstressed condition.

Abstract: A ballet dancer's toe dancing ballet shoe is designed and manufactured more simply than conventional ballet toe shoes. A sole supporting shank of the toe shoe has a tip flap at the front thereof which may be folded up to define the front panel of the completed ballet toe shoe. The shank is applied to a male mold member which is inserted into a female mold member cavity and resin is inserted into the space between the mold members for defining a toe box support frame in which the inserted portion of the shank and tip flap are embedded. The shank is comprised of a leather-like material. The completed combination of the shank and toe box support frame are removed from the mold members. A ballet toe shoe upper is fastened to the shank and over the exterior and in the interior, as well, of the toe box support frame.

Abstract: A golf shoe having improved transverse ground traction provided by a novel spike pattern which differs between the right-foot and the left-foot shoes in which the spikes are affixed to the lowermost surface of a specially designed sole and heel assembly. Improved comfort and foot stability can also be provided by use of a cushion pad insert of special configuration having a lateral arch support associated therewith. A first set of ground engaging spikes are arranged adjacent to the leading edges of both the right and the left shoe and at least two spikes in the set are positioned in the instep region of the shoes. A second set of spikes is also provided on the trailing edge of the shoes as defined by the direction of a golf club swing.

Abstract: A process for making a shoe for use in conjunction with various sports. The shoe comprises an upper portion, a walking sole, an intermediate element and at least one projecting portion. The process comprises the steps of integrating the projecting portion together with the intermediate element to form an integral assembly and then integrating the integral assembly with the upper portion and the walking sole to form the shoe.

Abstract: A pliable inner boot for insertion within a rigid outer shell of a ski boot is formed of resinous foam material. The inner boot is bifurcated at the front, and is provided with recesses in the vicinity of the shin region and preferably at the heel pocket. These recesses soften the feel of the inner boot at the shin and ankle regions when it is compressed by closure of the rigid outer shell.A pliable custom fitting reservoir (fit pack) is interposed between the rigid outer shell and the inner surface of the inner boot in the vicinity of the heel pocket and the instep portions of the inner boot. This reservoir may be either integral with or separate from the inner boot. It may include a conduit adapted to receive a liquid resin reaction mixture from a source remote from the ski boot. Alternatively, the fit pack may contain isolated components of a reaction mixture which are mixed by kneading just prior to use.

Abstract: The present invention concerns an article of footwear to be placed inside a ski boot, and the process of its manufacture.The process according to the invention is characterized by the fact that the article of footwear is molded in its open position, thereby permitting the inner core to be conveniently removed from the mold.

Abstract: At least two overlapping portions of plastic material are overmolded successively on a lining formed by a slipper so as to cover the slipper sole and upper at least to a partial extent. The method involves the following successive operations:overmolding of a plastic layer which covers the entire upper of the slipper;overmolding of a plastic stiffening reinforcement having greater rigidity than the previous layer and constituting a shell around the rear counter as well as a thin intermediate sole;addition of an outer wearing sole of molded plastic material.

Abstract: A pliable inner boot for insertion within a rigid outer shell of a ski boot is formed of resinous foam material. The inner boot is bifurcated at the front, and is provided with recesses in the vicinity of the shin region and preferably at the heel pocket. These rcesses soften the feel of the inner boot at the shin and ankle regions when it is compressed by closure of the rigid outer shell.A pliable custom fitting reservoir (fit pack) is interposed between the rigid outer shell and the inner surface of the inner boot in the vicinity of the heel pocket and the instep portions of the inner boot. This reservoir may be either integral with or separate from the inner boot. It may include a conduit adapted to receive a liquid resin reaction mixture from a source remote from the ski boot. Alternatively, the fit pack may contain isolated components of a reaction mixture which are mixed by kneading just prior to use.

Abstract: An ankle pad for use in a ski boot having a shell and a flexible liner disposed within said shell, the ankle pad being less dense than the density of the liner material and being adapted to fit in a recess located in the liner in the area where the ankle joint of a wearer contacts the liner.

Abstract: An ankle pad insert for use in a boot, which covers the ankle of the wearer, including a ski boot, having a relatively stiff shell and a flexible liner disposed within said shell, the ankle pad insert being less dense than the density of the liner material and being adapted to fit in a recess located in the liner in the area where the ankle joint of a wearer contacts the liner.

Abstract: The present invention is directed to a method of manufacturing a midsole for a shoe and the structure of the resulting midsole. The midsole includes a core of a first plastic material and a peripheral wrap of a second plastic material. The wrap has an outer peripheral surface comprising at least a portion of an outer peripheral surface of the midsole. The method includes the steps of molding a peripheral wrap from a sheet stock of the first plastic material by applying compressive forces on the sheet stock in a direction which i substantially perpendicular with the outer surface of the sheet stock, placing the wrap around the inner peripheral surface of a mold which approximates the shape of the midsole, and pouring the first plastic material in the mold.