Sole structure with complex waterproof and gas-permeable material and manufacturing method thereof
A sole structure with complex waterproof and gas-permeable material and a manufacturing method thereof. A plane blank having a through with a pattern of an array is provided. At least one waterproof and gas-permeable film is combined with the plane blank to cover the through hole. The plane blank with the film is located in a predetermined position inside a sole mold. Then a molten plastic material is filled into the mold to associate the plane blank and the film with the plastic material to form an integral large substrate of the sole. The sole provides waterproof and gas-permeable effect to prevent water from tarrying between the large substrate and middle substrate.
The present invention is related to a waterproof and gas-permeable sole structure and a manufacturing method thereof, and more particularly to an improved sole structure which overcomes the problem that the vapor tarries between the large substrate and the middle substrate (or insole) of the conventional gas-permeable shoe.
The conventional waterproof gas-permeable film such as Gore-Tex film (so-called century fabric) is composed of two kinds of unique polymers. One of the polymers is a nearly thermoplastic polyurethane (TPU) material which provides high stiffness. The other is ePTFE which provides waterproof and gas-permeable effect. Nine billion micro-voids are distributed over each square inch area of such material. The size of such void is two hundred millionth the size of liquid water molecule. However, the size of such void is seven hundred times the size of vapor. Therefore, the water molecule cannot pass through the voids, while the vapor is permitted to be exhausted through the voids. The waterproof gas-permeable film such as Gore-Tex can be attached to inner side of nylon and other fabric for making clothes, shoes, gloves, etc. to achieve windproof, waterproof and gas-permeable characteristics. A user wearing such clothes or shoes can keep dry, warm and comfortable.
In the above structure, the waterproof and gas-permeable film 40 is adhered to the sole 10 to isolation of water and exhaustion of vapor of a user's feet. However, such structure fails to overcome the problem that the water tarries between the large substrate 11 and the middle substrate 12. The melting point of the large substrate 11 is about 180° C. The melting point of the waterproof and gas-permeable film 40 is about 120° C. In addition, these two materials are incompatible with each other. As a result, during the molding procedure, when filling the material of higher temperature into the sole, the waterproof and gas-permeable film 40 is often previously molten or unexpectedly damaged. Therefore, it is hard to associate the waterproof and gas-permeable film 40 with the large substrate 11. This obstructs the waterproof and gas-permeable film 40 from successfully associating with the large substrate 11.
SUMMARY OF THE INVENTIONIt is therefore a primary object of the present invention to provide a sole structure with complex waterproof and gas-permeable material and a manufacturing method thereof. The sole provides waterproof and gas-permeable effect to prevent water from tarrying between the large substrate and middle substrate of the sole. A plane blank having a through with a pattern of an array is provided. A waterproof and gas-permeable film made of a material identical to or compatible with the material of the plane blank is combined with the plane blank to cover the through hole. The plane blank with the film is located in a predetermined position inside a sole mold. Then a molten plastic material is filled into the mold to associate the plane blank and the film with the plastic material to form an integral sole.
According to the above object, the sole structure includes a large substrate and a middle substrate overlaid on an inner face of the large substrate. The plane blank combined with the waterproof and gas-permeable film is disposed in a predetermined position on inner face of the large substrate. The water on outer side of the large substrate is isolated and prevented from getting into the shoe through the through hole of the large substrate. However, the air can pass through the waterproof and gas-permeable film into the shoe to achieve gas-permeable and humidity proof effect. The area of the plane blank is larger than that of the film. The molten plastic material at high temperature is fused with the peripheral section of the plane blank. However, by means of a mold core, the plastic material is isolated from the film without contacting and damaging the film.
In the above structure, multiple fixing holes are formed along the peripheries of the plane blank. When the plastic material is filled into the mold, the plastic material can fill into the fixing holes to form a key structure for firmly associating the plane blank with the plastic material.
In addition, a sheet material such as a mesh tissue sheet or porous sheet with high stiffness (such as TPU sheet) is associated with at least one face of the film to reinforce the film and prolong using life of the film.
The present invention can be best understood through the following description and accompanying drawings wherein:
BRIEF DESCRIPTION OF THE DRAWINGS
Please refer to
A plane blank 16 combined with waterproof and gas-permeable film 40 is laid on the inner face 111 of the large substrate 11 to correspondingly cover the through holes 14, 15. The plane blank 16 is made of a material identical to or compatible with the material of the waterproof and gas-permeable film 40. The plane blank 16 is formed with an array-type through hole 17 corresponding to the through hole 14 or 15 of the large substrate. In this embodiment, the array-type through hole 17 has an array of multiple oblique slats arranged as a blind. Such array prevents alien articles from directly getting into the shoe through the through hole 17. The film 40 is fixedly combined with the plane blank 16 by means of pressing, high frequency or ultrasonic wave. The film 40 at least covers the through hole 17 of the plane blank 16. In principle, the area of the plane blank 16 is larger than the area of the film 40. In a preferred embodiment, a sheet material 22 such as a mesh tissue sheet or reinforcing sheet made of stiffer material (such as TPU sheet) is associated with at least one surface of the film 40. The sheet material 22 is attached to the film 40. In another embodiment, the position relationship between the film 40 and the sheet material 22 and the number thereof are exchangeable and variable. In other words, the sheet material 22 can be arranged between the large substrate 11 and the film 40 (not shown) or between the film 40 and the middle substrate 12. Alternatively, the sheet material 22 can be laid on both the upper and lower faces of the film 40.
Referring to
In step (b), the plane blank 16 associated with the film 40 and the sheet material 22 is located in a predetermined position inside a sole mold 20. An isolating section or pile 21 is used to just cover the peripheral area of the through hole 17 of the blank 16.
In step (c), a plastic (softened) material 30 is filled or placed into the mold 20 for integrally molding the large substrate 11. The plastic material 30 is integrally associated with the periphery of the plane blank 16. In the molding procedure, the plastic material 30 is isolated from the section of the film 40 corresponding to the through hole 17 by the mold 20. Therefore, the plastic material 30 will not contact with or damage the section of the film 40.
In order to solve the problem existing in the prior art that the water tends to tarry inside the large substrate 11 or between the large substrate 11 and the middle substrate 12, the present invention has the following structural characteristics:
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- 1. The large substrate 11 is formed with through holes 14, 15 in predetermined positions. A plane blank 16 combined with a film 40 is located on inner surface 111 of the large substrate 11 corresponding to the position of the through hole 14.
- 2. The plane blank 16 is formed with an array-type through hole 17 corresponding to the through hole 14. The film 40 at least covers the array-type through hole 17, permitting the vapor of the foot to be exhausted from the large substrate through the through hole 17 of the film 40. However, the water on outer side of the sole is isolated by the film 40 and prevented from getting into the shoe through the sole.
- 3. The area of the plane blank 16 should be larger than that of the film 40. In step (b), the isolating section or pile 21 presses the plane blank 16 to cover the film 40. Therefore, the filled high temperature plastic material 30 will flow to associate with the peripheral area of the plane blank 16, while the plastic material 30 will not contact with and damage the section of the film 40 corresponding to the through hole 17.
According to the above arrangement, the present invention can truly solve the problem existing in the conventional sole that the external water gets into shoe through the sole and tarries or accumulates on inner side of the large substrate 11 or between the large substrate 11 and the middle substrate 12.
The above embodiments are only used to illustrate the present invention, not intended to limit the scope thereof. Many modifications of the above embodiments can be made without departing from the spirit of the present invention.
Claims
1. A sole structure with complex waterproof and gas-permeable material, comprising a sole including a large substrate and an insole overlaid on an inner face of the large substrate, said sole structure being characterized in that:
- the large substrate is formed with at least one through hole; and
- a plane blank is laid on the inner face of the large substrate, the plane blank being formed with at least one through hole corresponding to the through hole of the large substrate, the plane blank being combined with a waterproof and gas-permeable film at least at the through hole, the plane blank being disposed at the through hole of the large substrate to cover the through hole thereof, whereby the waterproof and gas-permeable film achieves a waterproof and gas-permeable effect.
2. The sole structure with complex waterproof and gas-permeable material as claimed in claim 1, wherein the through hole of the plane blank has a pattern of an array of multiple oblique slats as a blind.
3. The sole structure with complex waterproof and gas-permeable material as claimed in claim 1, wherein a sheet material such as a mesh tissue sheet or porous sheet with high stiffness is associated with at least one face of the waterproof and gas-permeable film.
4. The sole structure with complex waterproof and gas-permeable material as claimed in claim 2, wherein a sheet material such as a mesh tissue sheet or porous sheet with high stiffness is associated with at least one face of the waterproof and gas-permeable film.
5. The sole structure with complex waterproof and gas-permeable material as claimed in claim 1, wherein a sheet material such as a mesh tissue sheet or porous sheet with high stiffness is associated between the waterproof and gas-permeable film and the plane blank.
6. The sole structure with complex waterproof and gas-permeable material as claimed in claim 2, wherein a sheet material such as a mesh tissue sheet or porous sheet with high stiffness is associated between the waterproof and gas-permeable film and the plane blank.
7. The sole structure with complex waterproof and gas-permeable material as claimed in claim 1, wherein the waterproof and gas-permeable film is made of TPU material.
8. The sole structure with complex waterproof and gas-permeable material as claimed in claim 2, wherein the waterproof and gas-permeable film is made of TPU material.
9. The sole structure with complex waterproof and gas-permeable material as claimed in claim 3, wherein the waterproof and gas-permeable film is made of TPU material.
10. The sole structure with complex waterproof and gas-permeable material as claimed in claim 4, wherein the waterproof and gas-permeable film is made of TPU material.
11. The sole structure with complex waterproof and gas-permeable material as claimed in claim 5, wherein the waterproof and gas-permeable film is made of TPU material.
12. The sole structure with complex waterproof and gas-permeable material as claimed in claim 6, wherein the waterproof and gas-permeable film is made of TPU material.
13. The sole structure with complex waterproof and gas-permeable material as claimed in claim 3, wherein the porous sheet with high stiffness is made of TPU material.
14. The sole structure with complex waterproof and gas-permeable material as claimed in claim 4, wherein the porous sheet with high stiffness is made of TPU material.
15. The sole structure with complex waterproof and gas-permeable material as claimed in claim 5, wherein the porous sheet with high stiffness is made of TPU material.
16. The sole structure with complex waterproof and gas-permeable material as claimed in claim 6, wherein the porous sheet with high stiffness is made of TPU material.
17. The sole structure with complex waterproof and gas-permeable material as claimed in claim 1, wherein two faces of the plane blank are respectively associated with mesh tissue sheet and porous sheet with high stiffness.
18. The sole structure with complex waterproof and gas-permeable material as claimed in claim 2, wherein two faces of the plane blank are respectively associated with mesh tissue sheet and porous sheet with high stiffness.
19. The sole structure with complex waterproof and gas-permeable material as claimed in claim 1, wherein the waterproof and gas-permeable film is combined with the plane blank by means of high frequency or ultrasonic pressing.
20. The sole structure with complex waterproof and gas-permeable material as claimed in claim 2, wherein the waterproof and gas-permeable film is combined with the plane blank by means of high frequency or ultrasonic pressing.
21. The sole structure with complex waterproof and gas-permeable material as claimed in claim 3, wherein the waterproof and gas-permeable film is combined with the plane blank by means of high frequency or ultrasonic pressing.
22. The sole structure with complex waterproof and gas-permeable material as claimed in claim 4, wherein the waterproof and gas-permeable film is combined with the plane blank by means of high frequency or ultrasonic pressing.
23. The sole structure with complex waterproof and gas-permeable material as claimed in claim 5, wherein the waterproof and gas-permeable film is combined with the plane blank by means of high frequency or ultrasonic pressing.
24. The sole structure with complex waterproof and gas-permeable material as claimed in claim 6, wherein the waterproof and gas-permeable film is combined with the plane blank by means of high frequency or ultrasonic pressing.
25. The sole structure with complex waterproof and gas-permeable material as claimed in claim 7, wherein the waterproof and gas-permeable film is combined with the plane blank by means of high frequency or ultrasonic pressing.
26. The sole structure with complex waterproof and gas-permeable material as claimed in claim 8, wherein the waterproof and gas-permeable film is combined with the plane blank by means of high frequency or ultrasonic pressing.
27. The sole structure with complex waterproof and gas-permeable material as claimed in claim 17, wherein the waterproof and gas-permeable film is combined with the plane blank by means of high frequency or ultrasonic pressing.
28. The sole structure with complex waterproof and gas-permeable material as claimed in claim 18, wherein the waterproof and gas-permeable film is combined with the plane blank by means of high frequency or ultrasonic pressing.
29. The sole structure with complex waterproof and gas-permeable material as claimed in claim 1, wherein the through hole of the large substrate is arranged on at least a part of bottom face of the sole.
30. The sole structure with complex waterproof and gas-permeable material as claimed in claim 2, wherein the through hole of the large substrate is arranged on at least a part of bottom face of the sole.
31. The sole structure with complex waterproof and gas-permeable material as claimed in claim 1, wherein a middle substrate is additionally disposed between the large substrate and the insole.
32. The sole structure with complex waterproof and gas-permeable material as claimed in claim 2, wherein a middle substrate is additionally disposed between the large substrate and the insole.
33. The sole structure with complex waterproof and gas-permeable material as claimed in claim 3, wherein a middle substrate is additionally disposed between the large substrate and the insole.
34. The sole structure with complex waterproof and gas-permeable material as claimed in claim 4, wherein a middle substrate is additionally disposed between the large substrate and the insole.
35. The sole structure with complex waterproof and gas-permeable material as claimed in claim 5, wherein a middle substrate is additionally disposed between the large substrate and the insole.
36. The sole structure with complex waterproof and gas-permeable material as claimed in claim 6, wherein a middle substrate is additionally disposed between the large substrate and the insole.
37. The sole structure with complex waterproof and gas-permeable material as claimed in claim 7, wherein a middle substrate is additionally disposed between the large substrate and the insole.
38. The sole structure with complex waterproof and gas-permeable material as claimed in claim 8, wherein a middle substrate is additionally disposed between the large substrate and the insole.
39. The sole structure with complex waterproof and gas-permeable material as claimed in claim 17, wherein a middle substrate is additionally disposed between the large substrate and the insole.
40. The sole structure with complex waterproof and gas-permeable material as claimed in claim 18, wherein a middle substrate is additionally disposed between the large substrate and the insole.
41. The sole structure with complex waterproof and gas-permeable material as claimed in claim 1, wherein the peripheral sections of the plane blank and the sheet material are formed with corresponding fixing holes.
42. The sole structure with complex waterproof and gas-permeable material as claimed in claim 2, wherein the peripheral sections of the plane blank and the sheet material are formed with corresponding fixing holes.
43. A method for manufacturing a sole structure with complex waterproof and gas-permeable material, comprising steps of:
- step (a): preparing a plane blank having through hole and combining a waterproof and gas-permeable film with the plane blank, the film at least sealing one side of the through hole;
- step (b): locating the plane blank in a predetermined position inside a sole mold, an isolating section covering a section of the plane blank fully including the through hole of the blank; and
- step (c): filling a plastic material into the mold, the plastic material being integrally associated with the periphery of the plane blank, which is free from the isolation of the isolating section to form an integral large substrate.
44. The method for manufacturing a sole structure with complex waterproof and gas-permeable material as claimed in claim 43, wherein the through hole of the plane blank has a pattern of an array.
45. The method for manufacturing a sole structure with complex waterproof and gas-permeable material as claimed in claim 44, wherein the film at least covers the through hole with array pattern of the plane blank.
46. The method for manufacturing a sole structure with complex waterproof and gas-permeable material as claimed in claim 43, wherein in step (a), a porous sheet material is overlaid on the plane blank.
47. The method for manufacturing a sole structure with complex waterproof and gas-permeable material as claimed in claim 46, wherein the porous sheet material is associated between the plane blank and the film.
48. The method for manufacturing a sole structure with complex waterproof and gas-permeable material as claimed in claim 46, wherein the porous sheet material is associated with upper and lower sides of the film.
49. The method for manufacturing a sole structure with complex waterproof and gas-permeable material as claimed in claim 43, wherein the isolating section just covers the through hole of the plane blank.
50. The method for manufacturing a sole structure with complex waterproof and gas-permeable material as claimed in claim 43, wherein multiple fixing holes are formed along the peripheries of the plane blank and the sheet material combined with the film, whereby when the plastic material is filled into the mold, the plastic material can fill into the fixing holes to firmly associate the plane blank, film and sheet material.
Type: Application
Filed: May 24, 2004
Publication Date: Jun 16, 2005
Inventor: Huei-Ling Wu (Taichung City)
Application Number: 10/851,173