Abstract: In a molded composite article formed by directly bonding a resin member comprising a polyamide-series resin to a resin member comprising a thermoplastic polyurethane-series resin, the polyamide-series resin comprises a polyamide block copolymer containing (A) a polyether segment having at least one terminal imino group. The polyamide-series resin may comprise a polyamide-series resin having a free amino group in a concentration of not less than about 10 mmol/kg. The molded composite article is producible, for example, by heating at least one of the polyamide-series resin and the thermoplastic polyurethane-series resin to bond the former to the latter. Thus obtained molded composite article is suitable for a member of a shoe and an industrial roll. In such a process, the polyamide-series resin member and the thermoplastic polyurethane-series resin member both of which are different in nature from each other can be directly and firmly bonded together.

Abstract: Provided are, among other things, systems, methods and techniques for manufacturing sheet material. In one representative embodiment, a sheet of fabric material is positioned across a patterning template that has a number of openings; and the sheet of fabric material and the patterning template are fed through an extrusion device in which extrusion material coats the fabric material and forces the fabric material into the openings in the patterning template, thereby producing a composite sheet material.

Abstract: According to the invention, a shoe is produced by firstly forming a shoe upper piece (8), made up of an upper (7) and an inner sole (5), sewn to the upper (7), which is bonded to a sole (4) in the assembled shoe. A sole tread (2) is introduced into a casting mould (1) and then filled with a cork/latex mixture in a pasty state. A fillet (9) is then introduced into the shoe upper piece (8) and the unit thus produced, placed from above into the casting mould (1), such that the casting mould (1) is sealed thereby. It is important that only the sole edge (10) rests on the edge of the casting mould (11) and the fillet (7) is fixed internally to the inner sole (5), such that the shoe base material presses the inner sole (5) against the edge of the upper (12), lying on the fillet (9).

Abstract: A method for making a foamed sole includes the steps of: a) preparing a mold having a lower mold part and an upper mold part removably covering the lower mold part, the lower mold part having a top surface and a lower mold cavity recessed from the top surface, the upper mold part having a bottom surface to contact the top surface of the lower mold part, and an upper mold cavity recessed from the bottom surface; b) filling and molding a first molding material in the upper mold part to form a first sole portion; and c) filling and molding a second molding material in the lower mold part to form a second sole portion having a hardness smaller than that of the first sole portion and bonding directly with the first sole portion.

Abstract: A vapor-permeable and waterproof sole for shoes, including a tread including a plurality of through holes, a multilayer pack, arranged superimposed on the region where the through holes are provided and including a membrane, permeable to water vapor and impermeable to liquids, and a protective layer, arranged directly below the membrane. The tread is overmolded onto the pack and further surrounds the edges, the lower perimetric portion, and the upper perimetric portion of the pack to form a perimetric seal adapted to avoid rise of liquids. The pack includes a vapor-permeable or perforated layer element, arranged directly below the protective layer, superimposed on the through holes region. The layer-like element avoids contact of the molding polymeric material with the protective layer during tread molding, and is further associated with the protective layer.

Abstract: A method for making a component of boot body for a skating shoe includes a cutting step, a mold-making step, a coating step and a shaping step. The cutting step cuts a flexible sheet to form a base sheet with at least one predetermined coating area. The mold-making step forms a coating mold with at least one coating slot. The coating step applies epoxy resin to the base sheet to form a layer of epoxy resin coating and applies the epoxy resin to the at least one predetermined coating area through the at least one coating slot to integrally form at least one reinforcement on the base sheet. The shaping step heats and pressurizes the base sheet to form a component of a boot body. The at least one reinforcement provides an improved hardness and impact strength to the boot body and keeps a user's foot from injury.

Abstract: A method for making a shoe includes the steps of: a) placing a foamed sole blank and an upper in a mold, the upper being superimposed on the sole blank and having a last inserted therein; b) heating the mold to a temperature ranging from 110 to 150° C. so that the sole blank is softened and bonded to the upper, and so that the sole blank is formed into a shape of a sole of the shoe; and c) cooling the mold. The sole blank is larger than the sole by a volume of 12-45%.

Abstract: The object of the present invention is to provide a high quality polyester resin having high productivity, stability and safety, a catalyst for polyester production with high catalytic activity, a method for producing the polyester resin with the catalyst, a polyester resin obtained with the catalyst, and a hollow molded container having the polyester resin. The polyester resin of the present invention satisfies specific parameters regarding polymerizability, stability, and metal content. The catalyst for polyester production satisfies specific parameters. The catalyst particularly preferably has: (a) a solid titanium-containing compound which has a maximum solubility in ethylene glycol of 1,000 ppm or more in terms of converted titanium amount when dissolved in ethylene glycol with heating at 150° C.

Abstract: In order to produce a shoe, an outsole is firstly inserted in a hollow mold. This outsole has fixing means, which are formed by upwardly projecting neps and which fix a shoe upper of the shoe inside the hollow mold. The hollow mold is covered on the top by an upper mold, which rests on an upper sole while leaving a free space open between its edge and a lateral wall of the hollow mold. A wedge-shaped element is inserted into said free space from the top. This element leaves a narrow gap open through which a cork-latex mixture can exit during expansion.

Abstract: A shoe including an upper, a lower attached to the upper, and an outsole attached to the lower is presented. In one embodiment, the outsole has a ground contacting surface which includes a first section and a second section, with the first section being formed of a first material and the second section having an outer later formed of a fabric material. The first section is free of the fabric material and is instead formed of other suitable materials, such as rubber, leather, etc. The outsoles and uppers are configured so that they can easily be mixed and matched with one another for assembly of the shoe at time after each of the individual components is separately made.

Abstract: An article of textile-soled footwear and method of making employ a simple fabrication process and apparatus that allows fabrication of the footwear outer shell via a single injection-molding step. The article of footwear has a textile layer at the ground-contacting surface of the outsole, the textile layer being moldably and integrally attached, in a common mold, to the molded outsole as it is being created during the injection process. Fasteners are set along the side of the sole plate of the injection mold to secure the textile layer across the sole plate and prevent it from being moved during injection of the moldable compound to form the outsole. The sole plate and the sidewalls of the injection mold are assembled in place for the injection process. The shoe upper is fitted onto the shoe last and set in place in the mold, the mold is closed, and the moldable compound is injected into the mold.

Abstract: An outsole for a shoe, especially a house slipper, has an outer layer constituted of a fabric material, and a backing layer constituted of a shape-retaining, moldable material. The fabric layer and the backing layer are molded integrally together to provide the outsole with increased slip resistance, quieter usage and increased shape retention.

Abstract: The invention relates to a layered structure comprising a plastic substrate, at least one intermediate metallic layer on top of this plastic substrate and a metal or metal alloy layer on top of this intermediate metallic layer. The metal or metal alloy layer is applied from the melt of a metal or metal alloy. The invention further relates to a method of manufacturing such a layered structure.

Abstract: A system and method for receiving footwear size and past product fit information for a user at a host computer from a client computer over a computer network, such as the Internet, is disclosed. Foot size information for the user (preferably measured in millimeters) is received from the client computer, and a recommended footwear size is determined for the selected footwear model based on the received foot size information, a length adjustment factor for the selected footwear model and past product fit information. Additionally, a width adjustment factor can be used for determining the recommended footwear size.

Abstract: In a method of forming an article of footwear, a shell is formed between at least two die portions. The shell has a flash line defined proximate an interface of the die portions and along a perimeter of the shell. The method may include coupling a component directly to the shell so that the flash line is at least in part disposed proximate or below an upper edge of the component, with the component selected from the group consisting of a midsole and an outsole. The flash line may be positioned to coincide with an edge of a ridge on the shell.

Abstract: The present invention relates to a method and apparatus for making an item of footwear (2) and to a last (5) to be used in that method and apparatus. The last (5) includes a body (8) which mimicks the general shape of a foot around which an upper (3) for the item of footwear (2) is formed. The last body (8) has a base (9) corresponding to a sole of the general foot shape and the base is adapted to be heated to facilitate moulding of a rubber sole (4) to the upper (3) while the upper is still positioned on the forming last (5). The last preferably has heating means (16) located inside.

Abstract: A method for making a shoe includes the steps of forming a midsole in an outsole in a first mold, transferring the assembly of the midsole and the outsole into a second mold, and forming an insole between the midsole and an upper in the second mold.

Abstract: In a method of forming an article of footwear, a shell is formed between at least two die portions. The shell has a flash line defined proximate an interface of the die portions and along a perimeter of the shell. The method may include coupling a component directly to the shell so that the flash line is at least in part disposed proximate or below an upper edge of the component, with the component selected from the group consisting of a midsole and an outsole. The flash line may be positioned to coincide with an edge of a ridge on the shell.

Abstract: The shoe is obtained by depositing wedge (2), with or without a midsole (1), under the last incorporating cut (5), sewn to a gridded insole (6) and so that the top surface of the closure ring (4.1), a single one per size, of semimould (4) of outsole or sole (3) to be injected meets the top edge of wedge (2), then injecting the plastic of outsole or sole (3), which is of the same family as that of wedge (2), so that they fuse together, to which resulting set may or may not be later added the lower skid.

Abstract: A method for preparing a wear-resisting outsole for a shoe, which mixes polyol polyurethane oligomer and prepolymer isocyanate together to form a mixed material. Then, the mixed material is poured into a shaping mold and coagulated by heating to form a TPU polymer outsole. Lastly, a substrate covers the mold and is bonded with the TPU outsole by a heat-pressure forming process to achieve a wear-resisting outsole.

Abstract: An outsole for a shoe, especially a house slipper, has an outer layer constituted of a fabric material, and a backing layer constituted of a shape-retaining, moldable material. The fabric layer and the backing layer are molded integrally together to provide the outsole with increased slip resistance, quieter usage and increased shape retention.

Abstract: A method for forming an outsole of an article of footwear includes the steps of placing an upper and an insert in a mold cavity, filling the mold cavity and a gap between the upper and the insert with a foamable material, and closing the mold cavity and subjecting the foamable material to expansion and molding so as to form the outsole with the insert inlaid therein.

Abstract: A method of integrally forming shoe with multiple material employs a set of molds which include a lower mold, a middle mold and an upper mold. The lower and middle mold have respectively a lower cavity and a middle cavity. The method includes the steps of: blending, melting and injecting, secondary injecting, positioning and pouring. The contact surface of the outsole will be melted slightly when a coupling agent is injected thereby to bond the TPU and outsole made from rubber. A vamp may be placed over the middle mold to receive the PU for forming a midsole thereby to enable the vamp, midsole and lower sole formed integrally.

Abstract: A method for making a shoe includes the steps of preparing an outsole, an upper having an insole, a cover strip, and a mold, placing the outsole, the upper, and the cover strip in the mold cavity such that the outsole and the insole are interconnected by the cover strip to confine an inner space thereamong, closing the mold, filling a foamable material into the inner space, and permitting the foamable material to expand to form a foamed midsole that is enclosed by and that is bonded to the outsole, the insole, and the cover strip.

Abstract: A method of manufacturing a multi-layer, composite footwear upper having a three-dimensional geometry includes the steps of forming a substantially planar composite sheet from two or more layers, heating the composite sheet, and compression molding the composite sheet into the three-dimensional geometry of the footwear upper. The composite sheet is formed by laminating a first layer of thermoplastic foam to a second layer of thermoplastic urethane (TPU), preferably in the form of a TPU film. A third layer of mesh fabric can be interposed between the first and second layers. The composite sheet is compressed after heating in a mold cavity to achieve the desired three-dimensional geometry. The composite sheet can be compression molded into separate sections which are assembled after molding to form the footwear upper. Alternatively, the composite sheet can be compression molded into a seamless, unitary footwear upper that requires minimal, if any, assembly for completion.

Abstract: An article of textile-soled footwear and method of making employ a simple fabrication process and apparatus that allows fabrication of the footwear outer shell via a single injection-molding step. The article of footwear has a textile layer at the ground-contacting surface of the outsole, the textile layer being moldably and integrally attached, in a common mold, to the molded outsole as it is being created during the injection process. Fasteners are set along the side of the sole plate of the injection mold to secure the textile layer across the sole plate and prevent it from being moved during injection of the moldable compound to form the outsole. The sole plate and the sidewalls of the injection mold are assembled in place for the injection process. The shoe upper is fitted onto the shoe last and set in place in the mold, the mold is closed, and the moldable compound is injected into the mold.

Abstract: A fabric-covered shoe welt, and methods of making such a welt and using it to make shoes. The welt is an extruded polymer, and has fabric attached to at least one surface. The fabric is then bonded to the sole of the shoe. The fabric is selected to adhere well to both welt and sole, usually by allowing liquid to wick into the fabric before solidification.

Abstract: A method for making a shoe includes the steps of forming a midsole in an outsole in a first mold, transferring the assembly of the midsole and the outsole into a second mold, and forming an insole between the midsole and an upper in the second mold.

Abstract: A method for making a footwear includes the steps of disposing a pad between an upper and an outsole, placing an assembly of the pad, the upper, and the outsole in a mold in such a manner that the assembly forms first, second and third gaps thereamong, and filling and molding a molding material in the first, second and third gaps in the mold to form a midsole bonded to the pad, the upper, and the outsole.

Abstract: A method of manufacturing a multi-layer, composite footwear upper having a three-dimensional geometry includes the steps of forming a substantially planar composite sheet from two or more layers, heating the composite sheet, and compression molding the composite sheet into the three-dimensional geometry of the footwear upper. The composite sheet is formed by laminating a first layer of thermoplastic foam to a second layer of thermoplastic urethane (TPU), preferably in the form of a TPU film. A third layer of mesh fabric can be interposed between the first and second layers. The composite sheet is compressed after heating in a mold cavity to achieve the desired three-dimensional geometry. The composite sheet can be compression molded into separate sections which are assembled after molding to form the footwear upper. Alternatively, the composite sheet can be compression molded into a seamless, unitary footwear upper that requires minimal, if any, assembly for completion.

Abstract: In a method for making a shoe, an insole blank having a peripheral portion is prepared. An outsole which has an adhesive applied to the top thereof is positioned in a mold assembly including at least two opposite side mold parts that have forming patterns for forming the peripheral portion of the insole blank. The insole blank is placed in the mold assembly adjacent to the top of the outsole while the insole blank is being softened by heat to a plastic state. The insole blank is pressed against and is bonded to the outsole, and the peripheral portion of the insole blank is pressed and patterned via the side mold parts. The bonding of the insole blank and the outsole and the patterning of the peripheral portion of the insole blank are carried out simultaneously by closing the mold assembly.

Abstract: The invention relates to a method of manufacturing a shoe sole, in particular for a sports shoe, wherein a preform of the sole is first produced from a first material and at least one second material in a common mold by injection molding and wherein subsequently the preform is vulcanized to obtain the finished sole.

Abstract: A process for manufacturing an article of waterproof footwear such as a boot is provided. The bottom of the lower where the sole is attached is initially left open so that any seams can be sealed watertight and any additional features, such as insulation and liners, can be added in an easier and more precise manner. The present method also makes it easier to custom fit footwear and make footwear in half sizes by taking the guesswork out of determining the actual inner dimensions of the footwear because these dimensions can be directly observed.

Abstract: A method of integrally forming shoe with multiple material employs a set of molds which include a lower mold, a middle mold and an upper mold. The lower and middle mold have respectively a lower cavity and a middle cavity. The method comprising the steps of: blending, melting and injecting, secondary injecting, positioning and pouring. The contact surface of the outsole will be melted slightly when a coupling agent is injected thereby to bond the TPU and outsole made from rubber. A vamp may be placed over the middle mold to receive the PU for forming a midsole thereby to enable the vamp, midsole and lower sole formed integrally.

Abstract: A method of compression moulding an article from rubber moulding material incorporating hollow inserts avoids damage to the inserts. Where compression moulding takes place in an enclosed mould at an elevated pressure, the pressure can distort and damage the hollow inserts especially if they are of plastics. In order to avoid such distortion and damage, the method compresses during moulding creating a pressure in a cavity of the insert which substantially balances the pressure exerted on the exterior of the insert by the rubber moulding material in the mould. The pressure in the cavity is preferably produced by introducing some rubber moulding material into the cavity of the insert. This material becomes pressurised during moulding and supports the interior of the insert.

Abstract: A method for integrally manufacturing a shoe with different materials is disclosed. The main bottom is formed by covering a main template upon a left template. By the groove like a main bottom in the two template, molding material is injected into the shoe groove. For the middle bottom, a right template covers on the main template. By the groove like a middle bottom in the two templates, molding material is injected into the shoe groove. For the shoe pad above the middle bottom, a lower template covers on the main template. In the two templates, a shoe groove like a pad corresponding to the main bottom is formed. Then, molding material is injected into the shoe groove. For a time period, the left templates is opened, and the shoe pad, middle bottom, and main bottom are combined together.

Abstract: A footwear construction and method for manufacturing the same. The sole include a rigid flexplate suspended within the midsole. The flexplate extends along substantially the entire length and width of the sole. The sole also preferably includes a rear stabilizer molded in place about the heel region of the midsole. Further, the footwear may include a dual-density collar disposed about the ankle region of the upper. The collar includes a relatively soft inner layer that permits the collar to be stitched to the upper and a relatively rigid outer layer that provides the desired level of stability. The sole is preferably manufactured using the general steps of (a) providing a mold with a plurality of flexplate locating pins, (b) positioning a flexplate within the mold, (c) injecting the midsole material into the mold about the flexplate, and (d) attaching an outsole to the midsole. The rear stabilizer is preferably molded prior to and retained within the mold during the midsole molding step.

Abstract: A method of compression moulding an article from rubber moulding material incorporating hollow inserts avoids damage to the inserts. Where compression moulding takes place in an enclosed mould at an elevated pressure, the pressure can distort and damage the hollow inserts especially if they are of plastics. In order to avoid such distortion and damage, the method compresses during moulding creating a pressure in a cavity of the insert which substantially balances the pressure exerted on the exterior of the insert by the rubber moulding material in the mould. The pressure in the cavity is preferably produced by introducing some rubber moulding material into the cavity of the insert. This material becomes pressurised during moulding and supports the interior of the insert.

Abstract: A mould (14) for manufacturing an article of footwear comprises two mould halves (16); a hollow last (20) which includes a cylindrical downwardly open opening (30) at its foot end (26); and a first sole plate (34) which includes a projection (32) having a head portion (36) which is arranged to extend into the opening (30) in the last (20) in order to restrict movement of the last within the mould. Polyurethane is injected into cavity (44) defined between the last and mould halves (16)/sole plate (34) to form an inner sole of an article of footwear having a hole in it in a position where projection (32) cooperated with opening (30). This opening may then be plugged prior to the formation of an outer sole using a second sole plate (which does not include a projection (32) instead of the first sole plate.

Abstract: A method for manufacturing a shoe, which includes the steps of:arranging an upper-insole assembly about a last;coupling an intermediate member comprising a toe portion and a heel portion to a lower region of the upper-insole assembly arranged about the last; andarranging the intermediate member in a mold and introducing plastic material into the mold so as to form an injected plastic material member which surrounds the intermediate member and which is integrally connected with both the intermediate member and the upper-insole assembly.

Abstract: In methods and apparatus for the production of molded laminated articles a thin layer of a first moldable heat curable material is placed in the mold cavity of a heated mold and thereafter a second polymerisable material is injected to fill the remainder of the cavity, so that the materials are in intimate contact and form the laminate. The polymerisation of the second material is exothermic and the curing of the first material is facilitated by heat from this reaction. Preferably the second material is also foamable and the foaming generates pressure that molds the first material against the mold surface while it is being cured. Preferably the layer of first material is brought in contact with the mold surface, and air that would otherwise be trapped between them, is removed by drawing a vacuum between the layer and the surface. A preferred first material is epoxidised bondable uncured vulcanisable rubber and a preferred second material is foamable polymerisable polyurethane.

Abstract: Method for producing soles for shoes, which initially includes the production, by molding, of a sole that has a perimetric ridge that protrudes downwards. The sole is then placed on a plunger of a mold that has a head which is shaped complementarily with respect to the lower surface of the sole and with respect to the ridge and in which there is a recess for containing the ridge and a gap for the intended flow of a second material to be injected. The last step consists in trimming the flash, which has an intended consistency.

Abstract: A method of making a sock liner for insertion in footwear comprising providing a sock liner member having a cavity in an underside thereof, filling the cavity with a fluid which is curable to an elastomeric condition, and allowing the fluid to cure to the elastomeric condition.

Abstract: A shoe that conforms to foot contours and provides cushioning is comprised of a shoe sole and a shoe upper attached to the shoe sole. The shoe upper is comprised of an outer layer, an inner layer and a conforming layer therebetween, wherein a first portion of the conforming layer is comprised of viscoelastic gel and a second portion of the conforming layer is comprised of environmentally-responsive gel. The environmentally-responsive gel is preferably a temperature-responsive gel that will react to the heat emanating from a foot inserted into the shoe to express a liquid. The viscoelastic gel is preferably a soft, flowable gel that conforms to foot contours.

Abstract: A method of making an article of footwear includes the steps of constructing an upper having an inner surface material and an outer surface material which define an upper formation cavity, disposing the upper on a mold core, positioning the mold core and the upper in a base portion of a mold such that the upper formation cavity is accessible from above when the mold cavity is open, pouring a plastic foam material into the upper formation cavity of the upper, closing a top portion of the mold onto the base portion of the mold to thereby sealingly close the mold and the upper formation cavity, curing the plastic foam material within the upper formation cavity of the upper to form a molded article of footwear upper, and opening the top portion of the mold and removing the article of footwear upper.

Abstract: A process of making a shoe includes bonding a flat structure to an upper layer of the shoe to form a bonded structure. The flat structure has a melting temperature T.sub.2 and provides stability to a shape of the upper layer. The bonded structure is positioned into a mold so that an underside of the bonded structure faces the mold. A liquid sole material at a temperature T.sub.1 which is greater than T.sub.2 is sprayed into the mold, thereby contacting and melting the flat structure. The sole material cools and solidifies to form a shoe. The flat structure has a melting temperature T.sub.2 and provides stability to a shape of the upper layer.

Abstract: A mold device for making a safety shoe includes a last and a post secured on a board. The last includes a number of spacers and a number of cone-shaped supports formed on top for engaging with a protector and for spacing the protector from the last. Two mold pieces are pivotally coupled to the post and each includes a mold cavity for engaging with the last. A cover is pivotally coupled to the post. The spacers and the supports may space the protector from the last and the mold pieces and the cover for allowing the protector to be engaged in the safety shoe.

Abstract: A method of forming a shoe sole having a co-molded anti-skid insert is provided. Raw unvulcanized rubber sheet material for the insert, and raw unvulcanized rubber sheet material for the main portion of the sole are placed in a mold and heated to fuse them together, to vulcanize the rubber, and to produce an anti-skid pattern on the insert. The material of the insert is preferably substantially the same as that of the main portion of the sole, except for its color; however, it has the appearance and texture of a separate insert.

Abstract: The present invention is a method of making a molded part having a sheet metal portion and at lease one fastener coupled to the sheet metal portion. The fastener has a body portion and an annular barrel portion which extends from the body portion. The body portion has a free open end and a bore extending therethrough in generally coaxial alignment with the opening in the barrel portion. The barrel portion free end is driven into the sheet metal to pierce the sheet metal and form a slug from the sheet metal. The barrel is also deformed radially outwardly in mechanical interlocking relation with the panel. The slug which is formed is wedged into the opening of the barrel portion to seal the barrel portion. The sheet metal and barrel portion can then be surrounded with molding material with the slug preventing the molding material from flowing into the bore.

Abstract: In a sandal, lateral parts are produced without a separate cementing process in a hollow mold in a single operation as a show sole is made by foaming. To this end the hollow mold has lateral pockets in which the strap parts are fixed by a holding frame reaching partially over the bottom end of each strap part before plastic is placed in the hollow mold and the mold is closed for foaming.