Hands-free molded shoes

Abstract

Hands-free molded shoes may include uniformly molded slip-on shoes that have features to facilitate hands-free wearing. Such features may include using a high-hardness plastic for the heel counter portion of the shoe and a low-hardness plastic for the upper and / or sole portion of the shoe. The heel counter portion may be configured to deform into a new configuration by the load of the user's foot when the user's foot enters the opening, and return to its original configuration when the foot enters the inside of the shoe. The heel counter portion may have an S-shaped vertical cross-section at its rearmost position. The manufacturing method of HFMS may include using an upper insert and a sole insert together with a heel insert having a fixing mechanism for fixing the heel insert to the core of the shoe last.

Description

Technical Field

[0001]

[0001] The disclosure document of this patent application describes aspects of inventions that include various innovative features (hereinafter, "this disclosure") and includes materials that are subject to protection by copyright, mask work, and / or other intellectual property rights. Each owner of intellectual property rights reserves all rights other than those, without objection from anyone, to facsimile reproductions of this disclosure published in the public files / records of the Patent Office.

[0002] (Priority Claim and Related Applications)

[0002] This application is a non-provisional application with Attorney Docket No. 160283 - 7001 (P002Z) of U.S. Provisional Patent Application Serial No. 63 / 636,403, titled "HANDS-FREE MOLDED SHOE," filed on April 19, 2024, and claims priority under 35 U.S.C. § 119. The content of the above application is hereby incorporated by reference in its entirety into this specification.

Background Art

[0003] (Field of the Disclosure)

[0003] This innovation generally relates to footwear and, more specifically, includes hands-free molded shoes ("HFMS").

Summary of the Invention

[0004]

[0004] Embodiments of hands-free molded shoes may include uniformly molded slip-on shoes that have features to facilitate hands-free wearing. Such features may include using a high-hardness plastic for the heel counter portion of the shoe and a low-hardness plastic for the upper and / or sole portion of the shoe. The heel counter portion may be configured to deform into a new configuration by the load of the user's foot when the user's foot enters the opening, and return to its original configuration when the foot enters the inside of the shoe. The heel counter portion may have an S-shaped vertical cross section at its rearmost position. The manufacturing method of HFMS may include using an upper insert and a sole insert together with a heel insert having a fixing mechanism for fixing the heel insert to the core of the shoe mold.

[0005]

[0005] In one embodiment, the article relating to footwear described herein may comprise a sole structure and a heel cup uniformly molded with the sole structure and extending from the sole structure to at least a portion of the heel collar at the rear of the upper, the heel cup uniformly molded with an upper, a middle, and a lower portion, wherein the upper is shorter in the inward and outward length than the middle portion, and the middle and lower portions form a concave structure configured to receive the heel, the upper having a first configuration and being able to deform into a second configuration by the load of the user's foot when the user puts on the footwear, in the second configuration, at least a portion of the upper being lower than the first configuration, and the upper being able to return to the first configuration after the load of the user's foot is removed.

[0006]

[0006] In another embodiment, the footwear article described herein may comprise a uniformly molded upper, sole, and heel cup, the heel cup being made of a first plastic and the upper being made of a second plastic having a different hardness than the second plastic.

[0007]

[0007] In another embodiment, the footwear article described herein may comprise a uniformly molded sole and heel cup, the heel cup being made of a first plastic and the sole being made of a second plastic having a different hardness than the second plastic.

[0008]

[0008] In another embodiment, the method for manufacturing an article relating to footwear described herein may include placing a base material insert with a heel insert in a first shoe last, providing a first plastic to the first shoe last to produce a base material, placing the base material and an overmolded insert in a second shoe last, and providing a second plastic to the second shoe last to produce a shoe, wherein the first plastic is harder than the second plastic.

[0009]

[0009] In another embodiment, the manufacturing apparatus for an article relating to footwear may include a shoe last, an upper insert, a sole insert, and a heel insert having a fixing mechanism for attaching the heel insert to the core of the shoe last. [Brief explanation of the drawing]

[0010]

[0010] The attached appendices and / or drawings illustrate various non-limiting exemplary embodiments of the invention relating to this disclosure.

[0011] [Figure 1]

[0011] An example of a shoe in one embodiment of HFMS is shown, which may be uniformly molded from one or more plastic materials and may include a sole and an upper. [Figure 2]

[0012] This shows the upper, sole, and heel counter portion of one embodiment of the HFMS. [Figure 3]

[0013] This example shows a configuration in which the heel counter and sole of an HFMS are made of a plastic material that is harder than the plastic material used for the upper. [Figure 4]

[0014] An example is shown where, in one embodiment of the HFMS, the heel counter is composed of a plastic material harder than the plastic materials used for the upper and the sole. [Figure 5]

[0015] A front view of a compressible heel cup in one embodiment of the HFMS is shown. [Figure 6]

[0016] A perspective view of the compressible heel cup of FIG. 5 is shown. [Figure 7]

[0017] A side view of the compressible heel cup of FIG. 5 is shown. [Figures 8A-8B]

[0018] A perspective view showing the compressible heel cup of FIG. 5 in a compressed configuration (8A) and an uncompressed configuration (8B) side by side is shown. [Figure 8C-8D]

[0019] A top view showing the compressible heel cup of FIG. 5 in a compressed configuration (8C) and an uncompressed configuration (8D) side by side is shown. [Figure 9]

[0020] A front view of a heel cup configured to have a series of beams intersecting in a cross is shown. [Figure 10A]

[0021] A cross-sectional view of the arc length of the rearmost portion of the heel cup of FIG. 5 is schematically shown. [Figure 10B]

[0022] A cross-sectional view taken along line 6-6 of the heel cup of FIG. 5 is shown. [Figure 11A]

[0023] A side view of a heel counter having a heel cup inside the heel counter. [Figure 11B]

[0024] A top view of the heel counter of FIG. 11A. [Figure 11C]

[0025] A perspective view of the heel counter of FIG. 11A. [Figure 11D]

[0026] A cross-sectional view of a heel counter incorporating a rigid heel cup. [Figure 12]

[0027] An example of the logic flow of a method for manufacturing HFMS in some embodiments is shown. [Figures 13A-13B]

[0028] An example of an insert that can be used in the molding process of HFMS in some embodiments is shown. [Figures 14A-14B]

[0029] An example of a top view of a heel insert used in some embodiments of HFMS is shown. [Figure 15]

[0030] An example of an embodiment of a heel brace baby mold 1501 in some embodiments of HFMS is shown. [Figure 16]

[0031] An example of an embodiment of a heel brace baby mold located above the heel collar region in some embodiments of HFMS is shown. [Figures 17A-17B]

[0032] An example of an alternative embodiment of a heel brace baby mold located below the heel collar region in some embodiments of HFMS is shown. [Figures 18A-18B]

[0033] An example of an embodiment of an open-back heel brace baby mold attached to a midsole platform in some embodiments of HFMS is shown. [Figures 19A-19B]

[0034] An example of an embodiment of a closed-back heel brace baby mold attached to a midsole platform in some embodiments of HFMS is shown. [Figures 20A-20F]

[0035] An example of a uniformly molded sole and heel cup configured to correspond to an upper composed of one or more different materials in some embodiments of HFMS is shown. [Figures 21A-21B]

[0036] An example of a shoe having a uniformly molded sole, a heel cup, and an upper composed of a mesh fabric in some embodiments of HFMS is shown.

Best Mode for Carrying Out the Invention

[0012]

[0037] The hands-free molded shoes ("HFMS") and methods for manufacturing the same disclosed herein, in various embodiments, comprise a uniformly molded shoe, footwear, and / or other that temporarily deforms under the weight of the wearer's foot to enable hands-free insertion of the foot.

[0013]

[0038] In some embodiments, the HFMS comprises a uniformly molded upper, sole, and heel cup, the heel cup being constructed of a plastic having a different (e.g., higher) durometer, elasticity, stiffness, density, and / or hardness than either or both of the upper and sole. By using different plastics for these different parts of the HFMS, different colors and / or other material properties may be achieved.

[0014]

[0039] In some embodiments, the heel cup of the HFMS may be configured to deform from a first configuration to a second configuration due to the load of the user's foot when the user wears footwear. When the user's foot is inserted into the shoe, the heel cup may return to an uncompressed state.

[0015]

[0040] In some embodiments, the rearmost portion of the heel cup of the HFMS may have a vertical cross-sectional shape that is generally similar to that of the S wave. In some embodiments, the amplitude and / or width of the upper arc of the S wave may differ from the amplitude and / or width of the lower arc of the S wave. In some embodiments, the S wave may exhibit thickness variation such that the cross-sectional thickness is thicker at the upper and / or lower ends than in the middle portion (e.g., at or near the inflection point of the S wave) in the vertical direction.

[0016]

[0041] In some embodiments, the method for manufacturing the HFMS may include co-injection molding, overmolding, and / or foam molding processes using homogeneous or dissimilar elastic / hardness plastics and dissimilar molds, baby molds, and / or others to fuse in the molding process. For example, the method may include providing three separate baby molds for the sole, upper, and / or the instep and heel cup, respectively, in the injection molding process. In alternative embodiments, to supply one or more plastics in the HFMS, the HFMS may include a pellet injection process.

[0017]

[0042] HFMS and / or HFMS manufacturing processes may include, but are not limited to, ethylene vinyl acetate (EVA), compression-molded EVA (CMEVA), Pylon®, polyester thermoplastic elastomer (TPEE), thermoplastic polyurethane (TPU), RB foam, rubber, and / or other thermoplastic materials, elastomers, thermoplastic elastomers, and / or others, and / or combinations thereof. For example, in one embodiment, the heel cup and / or outsole portion of the HFMS may be made of TPEE. In another embodiment, the midsole portion of the HFMS may be made of EVA, CMEVA, and / or others. In another embodiment, the outsole portion and / or heel cup portion may be made of TPU. In another embodiment, the outsole portion may be made of a mixture of RB foam and EVA (e.g., about 84.8% RB foam and about 15.2% EVA).

[0018]

[0043] Figure 1 shows an example of a shoe that may be uniformly molded from one or more plastic materials and may include a sole and an upper. This is further illustrated in Figure 2, which shows the upper 200, sole 205, and heel counter 210. The sole 205 may include an outsole, midsole, and / or integrally formed outsole and midsole. The upper 200 may include a toe cap, toe cap, tongue, inner waist, outer waist, and heel counter 210. The shoe has a forefoot, posterior, medial and lateral sides. The upper may include an outer layer, inner layer or internal structure and / or lining. The upper may form an opening that can receive the wearer's foot when the wearer puts on the shoe.

[0019]

[0044] The heel counter or the rear of the upper may have one or more structures that facilitate the insertion of the foot into the opening. These one or more structures may also assist in facilitating the removal of the foot from the shoe. The heel counter or the rear of the upper may expand further instantaneously when the user puts on or takes off the shoe. The expansion of the opening may be initiated by the user applying load to the heel counter or the rear of the upper, which can be applied by the user's foot with minimal or no assistance from the user's hand. In other embodiments of the present invention, the heel counter may be compressible when sufficiently loaded and return to an uncompressible state. Lowering the heel counter may also facilitate the insertion of the user's foot. Once the foot is inserted into the shoe, the heel counter may have a compressible layer, such as a foam component, to secure or enhance the foot's securement while the user is normally wearing the shoe.

[0020]

[0045] In various embodiments, the heel counter and / or heel cup may be made of a plastic material with a different hardness (e.g., harder than either or both of the upper and / or sole) than the upper and / or sole. For example, Figure 3 shows an embodiment in which the heel counter and sole 300 are made of a plastic material that is harder than the plastic material used for the upper 305. In some embodiments, one or more parts of the shoe may be made of other materials and / or not made of plastic at all. For example, in one embodiment, the upper may be made of mesh fabric, synthetic fabric, nylon, suede, and / or others, while the sole and heel cup may be made of uniformly molded plastic.

[0021]

[0046] As another example, Figure 4 shows an embodiment in which the heel counter 400 is made of a plastic material that is harder than the plastic material used for the upper and sole 405. The relative hardness or softness of the plastic material may be characterized according to, but is not limited to, various metrics including elasticity, stiffness, density, and / or durometer readings, values, and / or measurements.

[0022]

[0047] In various embodiments, the plastic material used for the upper, sole, and / or heel counter may consist of one or more polymer foams. Polymer foams, also called foamed, expanded, or sponge plastics, may in some embodiments consist of at least two phases: a solid polymer matrix and a gas phase conventionally derived from a foaming agent. The solid polymer phase may be inorganic, organic, or organometallic. The solid polymer phase may include one or more solid phases, which may consist of a polymer blend based on two or more polymers, an interpenetrating polymer network which may consist of at least two crosslinked polymer networks, or a pseudo-interpenetrating polymer network which may consist of a combination of at least one linear polymer and a crosslinked polymer that is not covalently linked. Examples of polymer foams include, but are not limited to, ethylene vinyl acetate (EVA) foam, low-density polyethylene (LDPE) foam, nitrile rubber (NBR) foam, polychloroprene foam, polyimide foam, polypropylene (PP) foam, polystyrene (PS) foam, polyurethane (PU) foam, polyethylene foam, polyvinyl chloride (PVC) foam, silicone foam, and microcell foam.

[0023]

[0048] Polymer foams can be flexible or rigid, which may depend on whether their glass transition temperature (Tg) is lower or higher than room temperature. Tg depends on the chemical composition, crystallinity, and degree of crosslinking. Polymer foams can be described as closed-cell or open-cell foams. In closed-cell foams, the foam cells are separated from each other, and the cavities are enclosed by complete cell walls. In open-cell foams, the cells are connected. The geometry, size, and shape of the cells affect the properties of the foam.

[0024]

[0049] Polymer foam has a density of approximately 1.6 kg / m². 3 From 961 kg / m 3It can be manufactured at various densities up to a certain level. Foam density is generally proportional to its mechanical strength properties. EVA foam (for example, sometimes used as a component of soles) has a density of 0.033 g / cm³. 3 From 0.28 g / cm³ 3 It has a density in the range of 15 to 80, and the Asuka C hardness can range from 15 to 80. Of the EVA foam used in the components of these soles, some have elasticity of 40% to 60%.

[0025]

[0050] Polymer foams can be manufactured by mechanical, chemical, or physical means. Chemical blowing agents may include reactive species that decompose during the foaming process, releasing large volumes of gas. Examples include azodicarbonamides, 5-phenyltetrazole, and triazoles. Physical blowing agents may include inert gases or low-boiling point liquids that volatilize during the foaming process. Examples of inert gases used include argon, nitrogen, and carbon dioxide. Examples of low-boiling point liquids include compounds containing alkanes (butane, pentane), chlorine, and / or fluorine. Additives may be added to promote nucleation of the blowing agent and / or to promote a more uniform pore / cell size distribution. Various methods involving the use of blowing agents may be incorporated into the injection Phylon process.

[0026]

[0051] Using supercritical fluids (SCFs) containing compounds that do not participate in atmospheric photochemical reactions as physical blowing agents offers several advantages. One advantage of using such photochemically unreactive SCFs is their reduced environmental impact compared to the use of volatile organic compounds (VOCs) and ozone-depleting substances (ODSs). SCFs offer a more cost-effective and safer alternative to other blowing or extracting agents. Using SCFs in the foam molding process improves the impact strength and toughness of the resulting foamed products. The resulting foamed products may also exhibit improved surface appearance, lower dielectric constant, improved thermal insulation, and superior mechanical properties. Such foam molding can contribute to both material savings and weight reduction. SCFs also have a higher diffusivity compared to conventional blowing agents.

[0027]

[0052] Three-dimensional foams with larger pre-expansion sizes or thicknesses using SCF expansion can cause variations in cell curing and non-uniform expansion within the material. This can result in a variety of sole components in terms of hardness, density, elasticity, and bonding with other components, which may be desirable in some embodiments but detrimental in others. Such physical properties can be further altered by post-compression molding. Furthermore, three-dimensional SCF foams may be combined with other components to manufacture composite footwear.

[0028]

[0053] Referring to embodiments in Figures 5 to 10B, the heel counter 32 may include a compressible heel cup 52, which is a heel counter and / or internal component thereof and may be connected to the upper, such that the heel cup 52 is in contact with the foot.

[0029]

[0054] Referring to the exemplary embodiments in Figures 5 to 8D, the heel cup 52 may have a shape substantially corresponding to the heel cover in various embodiments, for example, a pear-shaped contour. The inward and outward width of the heel cup may be narrower than the inward and outward width of the lower part 54 near the heel cup collar 84, as shown in Figures 5 to 6.

[0030]

[0055] As shown in Figure 6, the inner wall 66 of the upper part 64 of the heel cup at the rearmost portion of the heel cup may be inclined downward, for example, between 0 and 90 degrees, with respect to a vertical line 86 perpendicular to the horizontal plane 88 of the floor. In this exemplary embodiment, the upper part 66 may have a 30-degree downward inclination. The inner wall 66 of the upper part 64 of the heel cup 52 may also have a convex curve toward the opening 48. The apex of the convex curve has a 30-degree downward inclination Al. The lower part of the convex curve extends just above a portion of the heel cup 52 that receives the heel. The lower part of the convex curve is smaller than the downward inclination Al and gradually decreases as it approaches the same inclination as the vertical line 86. The heel cup 52 may have a concave curve surrounding the rear of the heel. The medial and lateral sides of the heel cup 52 may also extend to form support toward a portion of the waist and even to the toe cap. The thickness of the heel cup 52 may be thinned in various places. The upper edge line 88 may have tapered inner and outer surfaces of the heel cup 52. The heel cup 52 may have a thickness T1 that increases along other peripheries, such as 2 to 3 mm. In another exemplary embodiment, the thickness T1 may be reduced in certain areas to increase the flexibility of the heel cup 52 when putting on or taking off shoes. In one embodiment, the thickness T1 of the heel cup 52 may gradually decrease from the peripheral portion 70 that constitutes the periphery region of the heel cup 52 toward the central portion or region 50 of the intermediate portion 58. In one embodiment, the minimum thickness TI in the central region 50 of the intermediate portion 58 may be, but not limited to, approximately 1 / 4 to 1 / 6 the thickness of the thickest part at the periphery of the heel cup 52, such as 0.5 to 1 mm. The thickest region at the top may be thicker than the thickest region at the bottom. The thinner thickness Tl in the central region of the intermediate portion 58 may allow the heel cup 52 to be compressed under sufficient load. In alternative embodiments, the thickness TI may be thinner over multiple regions, such as the middle portion 58 and / or the upper portion 64, or over the entire inward and outward direction. Thinner regions may increase the flexibility and flexibility of the heel cup 52, which provides compressibility under the load of the user's foot, such as when putting on shoes.Such compression can cause the upper part 64 and / or middle part 58 of the heel cup 52 to move backward, widening the opening 48 and making it easier to insert the foot. The heel cup 52 may deform from its original first configuration to a second configuration due to the weight of the user's foot when the user puts on the footwear. For example, the heel cup 52 may be partially compressed so that the upper part 64 and / or middle part 58 of the heel cup 52 is sufficiently lowered, allowing the user's foot to be inserted. Once the user's foot is inserted into the shoe, the heel cup 52 may return to its uncompressed configuration.

[0031]

[0056] Furthermore, in this embodiment, when the user puts on the shoe, the heel counter is compressed as shown in Figure 8A, causing the top of the convex curve of the heel cup 52 of the shoe or the uppermost segment of the heel counter to lower and extend backward away from the foot. This action reduces the degree of plantarflexion, making it possible to insert the user's foot into the opening 48. When the heel cup 52 is compressed, a portion of the heel cup 52 may move forward toward the forefoot. The deformation of the heel cup 52 may include the heel counter expanding as the medial and lateral sides of the heel cup move outward, thereby widening the opening of the shoe. The widening of the opening 48 in the inward and outward directions makes it easier to put on the shoe, such as by making it easier to insert the forefoot of the user's foot. In one exemplary embodiment, a 7.5 cm opening can widen by up to 4 cm or about 50%. See Figures 8C to 8D. This widening may vary depending on the shoe size and the flexibility of the heel cup. Depending on the shoe, the desired widening may be smaller or larger depending on the need for fixation and application.

[0032]

[0057] As shown in Figures 5 to 8D, in exemplary embodiments of the heel cup 52, the thickness T1 of the heel cup 52 may range from 0.4 mm to 4 mm. The range of the heel cup thickness T1 may be thinner or thicker in various regions depending on the elastic and durable properties of the desired material. For example, as shown in Figure 10B, the intermediate region may be thinner than the surrounding region, and the central part in particular may be thinner. The central part is spaced apart from the inner and outer edges, and the periphery may be thicker. Other suitable materials may include, but are not limited to, ethylene vinyl acetate (EVA), compression molded EVA (CMEVA), Pylon®, thermoplastic polyester elastomer (TPEE), thermoplastic polyurethane (TPU), RB foam, rubber, and / or other thermoplastic materials, elastomers, thermoplastic elastomers, and / or other polymers for imparting the compressive properties of the heel cup.

[0033]

[0058] In another embodiment, the heel cup may be configured to have a series of beams intersecting in a cross shape, forming an egg-box-like structure. Figure 9 shows an embodiment with diagonally arranged beams. In an alternative embodiment, the beams may be arranged longitudinally and transversely. The openings between the beams may be of substantially uniform size. The beams may be uniform in dimensions but may vary in thickness and width. Thinner or narrower beams may be used to increase flexibility and compressibility at a given location, while thicker or wider beams provide support of varying degrees of rigidity. For example, the beams may be thinner in the middle section, particularly in the center of the middle section spaced away from the edges. The surrounding beams may be thicker than the central section. The central section may be made more flexible to deform under load.

[0034]

[0059] In one embodiment, the rearmost portion of the heel cup 52 may have a vertical cross-sectional shape that is generally similar to an S shape overall, as shown in the cross-sectional view of Figure 10A. The upper and lower parts of the S wave may be distinguished by a point P1 via a horizontal plane, for example, a center line 90, drawn between the upper and lower arc ends of the S wave and intersecting the heel counter 52 and the inflection point of the S wave. The amplitude (A) and width (WU) of the upper arc of the S wave may be different from the amplitude (A) and width (WL) of the lower arc of the S wave. In an exemplary embodiment, WU is about 0.44 times WL. A is about 1 / 3 of A. In one possible embodiment, WU is about 2 centimeters and BL is about 4.5 centimeters. Au is about 3 millimeters and A is about 9 millimeters. The S-shaped configuration may consist only of the lower arc along the medial and lateral sides of the heel cup 52, with both AU / AL and WU / WL decreasing in the cross-section of the region extending from the cross-section of the rearmost part of the heel cup 52. The measurements of the rearmost part of the heel cup 52 in the exemplary embodiment are intended to be illustrative. In some embodiments, the vertical thickness variation of the heel counter and / or heel cup may include thicker portions above and below the S-wave and thinner portions near the inflection point.

[0035]

[0060] The central region of the heel cup midway may have a single opening or multiple openings. The central region of the heel cup midway may be constructed with less material than the maximum thickness of the collar and / or the base, and may also be constructed with greater flexibility than its periphery. The effect of a central region with a single opening, multiple openings, thinner thickness, and / or more flexible material is that it facilitates the insertion and removal of the user's foot from the shoe.

[0036]

[0061] Furthermore, in exemplary embodiments, as shown in Figures 11A to 11D, the heel cup 52 may be integrated with and / or attached to at least the internal foam layer 92. In some embodiments, the foam layer may be molded integrally with the heel cup and / or made from the same plastic as the heel cup. The heel cup 52 may be located inside the heel counter 32 of the upper 16, as shown in Figures 11B to 11D. The foam layer 92 may run along both the inner wall 66 and the outer wall of the heel cup 52. Around the upper and middle portions, the foam layer 92 may extend further, projecting into the opening 48. The foam layer 92 may be thicker at the upper 64 and middle portions 58 of the heel cup 52, or adjacent portions thereof, thereby forming part of the cuff of the opening 48. The thicker foam layer 92 can secure the user's foot because, when the user's foot is inserted into the shoe 12, the foam is above the area of ​​the user's calcaneus and extends to at least a portion of the ankle area. Because the foam is compressible, it is compressed by the heel when the foot is inserted or removed, and when the foot is inserted, it can hold the user's ankle in place.

[0037]

[0062] The heel cup may have a lower portion that forms a heel cup configured to receive the heel of the foot. The lower portion of the heel cup may have a laterally extending portion along both the medial and lateral sides. The heel cup may have an intermediate portion above the lower portion of the heel cup, which may curve inward above the heel bone or may consist of an opening. The heel cup may have an opening at the rear of the heel cup. Furthermore, in this embodiment, the heel cup may be a rigid heel cup made of a material that is substantially incompressible under the load of the foot.

[0038]

[0063] The upper part of the heel cup may consist of a smooth curve that bends downward from the upper edge of the heel cup toward the opening 48. The inner wall of the upper part has an overall downward slope that extends from the curved upper edge toward the interior of the upper 16. The inner wall of the upper part may have dimensions similar to a shoehorn, so that the angle of the smooth curve and downward slope of the upper part allows the heel to slide more easily into the shoe 12. The heel cup may be made of a rigid material that does not compress substantially under the load of the user's foot. In an alternative embodiment, the heel cup may have some flexibility, so that the upper part of the heel cup bends downward and away from the opening, having enough flexibility to widen the opening 48 to facilitate insertion and / or removal of the foot.

[0039]

[0064] As the compressible layer on the inside of the upper 16, foams and one or more optional lining materials known in the art may be used. The foam 76 may be integrally molded and / or bonded to the inner surface of the heel cup 52 to provide cushioning, for example, against a rigid heel cup material. The thickness of the foam may be uniform or vary in certain places depending on the desired cushioning or support for the foot. In one exemplary embodiment, the inner wall 66 of the upper 64 has a thicker foam, which may extend over at least a portion of the inward-outward length of the inner wall 66. Similar to the foam configuration shown in Figure 11D, when the shoe 12 is worn, the foam may be configured to curve over at least a portion of the ankle above the heel. In this embodiment, the foot may compress the foam when the user inserts their foot. After the foot is inserted, the foam may expand until it is completely uncompressible or partially expand, thereby improving the foot's stability within the shoe 12. Other parts of the heel cup 52 may also be lined with thin foam.

[0040]

[0065] Figure 12 shows an example of the logic flow of a method for manufacturing HFMS in several embodiments. First, a base material insert can be placed in a first HFMS mold (1101). In one embodiment, the base material insert may include an upper and / or instep insert. In another embodiment, the base material insert may include both an upper and / or instep insert and a sole insert. Then, a first plastic (for example, having a first hardness, a first color, and / or others) can be injected to form the base material (1105). Next, in one embodiment, the base material insert can be removed from the HFMS mold. Subsequently, the base material and overmolded insert can be placed in the same or different HFMS molds (1110). In embodiments where the base material mold includes an upper and / or instep insert, the overmolded insert may include both a heel insert and a sole insert. In embodiments where the base material mold includes both an upper and / or instep insert and a sole insert, the overmolded insert may include a heel insert. Subsequently, a second plastic (for example, having a second hardness, a second color, and / or other properties) is injected to produce an HFMS (1115). In one embodiment, the second hardness may be higher than the first hardness, as measured, for example, by durometer readings, values, measurements, and / or other means. In an alternative embodiment, the heel insert (with or without a sole insert) may be used first in the mold and the corresponding plastic injected therein, and then the upper and / or instep insert (with or without a sole insert) may be used and the corresponding plastic injected therein.

[0041]

[0066] In alternative embodiments, a process for injecting plastic pellets into one or more molds, baby molds, and / or other components may be employed in connection with the manufacture of HFMS. For example, in one embodiment, the HFMS mold may comprise a middle plate and a bottom plate. The mold may be cleaned, and one or more types of plastic pellets may be injected into each of the middle plate and the bottom plate (e.g., the same pellets may be injected into both, or different pellets may be injected into each). Then, one or more hot pressing steps may be performed (e.g., a first hot press for 30 seconds or less, followed by a second hot press for about 20 minutes) to form the HFMS.

[0042]

[0067] In some embodiments, the upper, heel, and sole may be handled separately and subjected to injection molding, foam molding, pellet injection, and / or other processes. In other embodiments, one or more components of the HFMS (e.g., sole and upper, heel and upper, sole and heel) may be handled together and subjected to injection molding, foam molding, pellet injection, and / or other processes.

[0043]

[0068] In various embodiments, the HFMS may include a single-hardness plastic, a dual-hardness plastic, or a multi-hardness plastic. For example, in one embodiment, the heel may be made of a first-hardness plastic (e.g., about 60C on a Shore C durometer), and the upper and sole may be made of a second-hardness plastic (e.g., about 40C on a Shore C durometer). In another embodiment, the heel may be made of a first-hardness plastic (e.g., about 52C), and the upper and sole may be made of a second-hardness plastic (e.g., about 45C). In yet another embodiment, the entire HFMS may be made of a single-hardness plastic (e.g., about 50C, 55C, or 38-40C).

[0044]

[0069] Figures 13A and 13B show examples of inserts that can be used in the molding process of HFMS in several embodiments. These may include an upper and / or instep insert 1201, a sole insert 1205, and a heel insert 1210. The heel insert may include a fixing feature 1215 for fixing the heel insert to the core of the mold (e.g., the last). In one embodiment, the fixing feature 1215 may include an instep strap configured to extend across and / or around the instep, such as the core or last. In an alternative embodiment, the fixing feature 1215 may include a strap configured to extend across and / or around the core, last, and / or other parts, such as the toe area, the front of the instep, the back of the instep, and / or other parts. In some embodiments, the instep strap may be adjustable by making its length, width, tension, angle relative to the heel, and / or other properties variable. In some embodiments, the instep strap may be made of a different material than the heel portion, such as different plastics (e.g., different hardness, elasticity, and / or others), ribbon material, metal, fabric, polyester, and / or others. In alternative embodiments, the fastening feature 1215 may comprise a partial strap, clip, ribbon, string, fastener, and / or others. Figure 13B shows the upper and / or instep insert 1201, sole insert 1205 and heel insert 1210 assembled to form the shape of the HFMS.

[0045]

[0070] Figures 14A and 14B show examples of top views of heel inserts used in several embodiments of the HFMS. Figure 14A shows a heel insert 1210 with an instep strap 1215. Figure 14B shows another embodiment of a heel insert 1220 with an instep clip 1225 for secure gripping of the core, last, and / or other instep of the HFMS mold.

[0046]

[0071] Regarding the manufacturing method of the HFMS in various embodiments, additional and / or alternative baby molds and / or baby molds with different configurations may be employed. For example, Figure 15 shows an embodiment of the heel brace baby mold 1501 in several embodiments of the HFMS. The heel brace baby mold 1501 may include side portions 1505 configured to be located on both sides of the heel cup of the HFMS and / or between the heel cup and the upper, and a top portion 1510 configured to form the uppermost and rearmost portion of the HFMS. In some embodiments, the heel brace baby mold may consist of a TPEE. Figure 16 shows an embodiment of the heel brace baby mold 1501 located above the heel collar region 1601 of the HFMS. Figures 17A to 17B show an alternative embodiment of the heel brace baby mold 1501 located below the heel collar region 1601. In Figure 17B, the upper beam of the heel brace baby mold is located in a pocket 1701 formed by the plastic (e.g., EVA) portion of the heel collar.

[0047]

[0072] In some embodiments, the heel brace baby mold may be attached and secured to a midsole platform to support the heel and facilitate removal. For example, Figures 18A to 18B show an embodiment of an open-back heel brace baby mold attached to a midsole platform. In Figure 18A, the lower beam 1801 of the heel brace baby mold 1501 is located on the midsole platform 1805. In Figure 18B, the side portion 1505 of the heel brace baby mold 1501 has an extension 1810 configured to rest on the midsole platform 1805. Figures 19A to 19B show an embodiment of a closed-back heel brace baby mold 1501 attached to a midsole platform 1805. Figure 19A shows a rear view, and Figure 19B shows a left side view.

[0048]

[0073] As described above, in some embodiments, the upper may be made of mesh fabric, synthetic fabric, nylon, suede, and / or other materials, while the sole and heel cup may be made of uniformly molded plastic. Figures 20A to 20F show examples of uniformly molded soles and heel cups configured to correspond to an upper made of one or more different materials, including a right side view (Figure 20A), a left side view (Figure 20B), a top view (Figure 20C), a bottom view (Figure 20D), a rear view (Figure 20E), and a front view (Figure 20F). Figures 21A to 21B show an example of a shoe including an upper made of a uniformly molded sole, heel cup 2101, and mesh fabric 2105, in a side view (Figure 21A) and a top view (Figure 21B). In various embodiments, the upper may include at least one elastic material positioned to create tension that enhances the fixation of the foot inserted into the shoe.

[0049]

[0074] The following descriptions of various innovations within the scope of HFMS illustrate further aspects of HFMS and / or the manufacturing process of HFMS in various embodiments.

[0050]

[0075] -

[0080] 1. Sole structure and, A heel cup that is uniformly molded with the sole structure and extends from the sole structure to at least a portion of the heel collar at the rear of the upper, comprising an upper, middle, and lower portion of the heel cup, The upper part is shorter in the inward-outward direction than the middle part, and the middle and lower parts form a concave structure configured to support the heel. The upper part has a first configuration and can deform into a second configuration due to the weight of the user's foot when the user puts on footwear. In the second configuration, at least a portion of the upper part is lower than in the first configuration, and the upper part can return to the first configuration after the user's foot load is removed. Items related to footwear.

[0081] -

[0084] 2. Further equipped with an upper, The upper defines the foot-receiving shoe opening, The heel cup and sole structure are molded uniformly with the upper, relating to the footwear described in Innovation 1.

[0085] 3. An article relating to footwear as described in Innovation 2, wherein the heel cup is made of a first plastic, and the upper is made of a second plastic, and the first plastic has a different hardness than the second plastic.

[0086] 4. An article relating to footwear as described in Innovation 2, wherein the heel cup and sole are made of first-grade plastic, and the upper is made of mesh fabric.

[0087] 5. An article relating to footwear as described in Innovation 1, wherein the heel cup is made of a first plastic and the sole is made of a second plastic, and the first plastic has a different hardness than the second plastic.

[0088] -

[0089] 6. The intermediate portion defines the peripheral portion and the central portion, and the peripheral portion has a first thickness. The central part has a second thickness, The second thickness is thinner than the first thickness; an article relating to footwear as described in Innovation 1.

[0090] -

[0091] 7. An article relating to footwear according to innovation 1, further comprising an internal foam layer integrally molded to the inner wall of the rear side of the heel cup.

[0092] 8. An article relating to footwear according to innovation 1, wherein in a vertical cross-section, the heel cup has an S-shaped wave pattern.

[0093] -

[0096] 9. In the vertical cross-section, the upper part has a first thickness at the first location, In the vertical cross-section, the intermediate portion has a second thickness at a second location. In the vertical section, the lower part has a third thickness at a third location. An article relating to footwear according to innovation 8, wherein the second thickness is thinner than at least one of the first thickness and the second thickness.

[0097] -

[0099] 10. Equipped with a uniformly molded upper, sole, and heel cup, An article relating to footwear, wherein the heel cup is made of a first plastic, and the upper is made of a second plastic, and the first plastic has a different hardness than the second plastic.

[0100] 11. An article relating to footwear as described in innovation 10, wherein the first plastic is harder than the second plastic.

[0101] -

[0102] 12. The heel cup is uniformly molded in an upper, middle, and lower section, with the upper section being shorter in the inward-outward direction than the middle section, and the middle and lower sections forming a concave structure configured to receive the heel. The upper part has a first configuration and is configured to deform into a second configuration by the weight of the user's foot when the user puts on the footwear, as described in innovation 11.

[0103] 13. An article relating to footwear according to innovation 12, wherein in a vertical cross-section, the heel cup has an S-shaped wave pattern.

[0104] -

[0107] 14. In a vertical cross-section, the upper part has a first thickness at a first location, In the vertical cross-section, the intermediate portion has a second thickness at a second location. In the vertical section, the lower part has a third thickness at a third location. An article relating to footwear according to innovation 13, wherein the second thickness is thinner than at least one of the first and second thicknesses.

[0108] -

[0110] 15. Equipped with a uniformly molded sole and heel cup, The heel cup is made of a first type of plastic, and the sole is made of a second type of plastic, with the first type of plastic having a different hardness than the second type of plastic. Items related to footwear.

[0111] 16. An article relating to footwear as described in innovation 15, wherein the first plastic is harder than the second plastic.

[0112] -

[0113] 17. An article relating to footwear according to innovation 16, further comprising an upper uniformly molded with a sole and heel cup.

[0114] -

[0119] 18. Placing a base material insert with a heel insert in the first shoe last, Providing a first plastic to produce a substrate, The base material and overmolded insert are placed in the second shoe last, This includes providing a second plastic to produce shoes, The first plastic is harder than the second plastic. A method for manufacturing articles related to footwear.

[0120] 19. The method of innovation 18, wherein providing a first plastic and providing a second plastic is done by injection molding.

[0121] 20. The method of innovation 18, wherein providing a first plastic and providing a second plastic is done by injecting plastic pellets.

[0122] 21. The heel insert includes an instep strap, as described in innovation 18.

[0123] 22. The method described in Innovation 18, which further includes an overmolded insert and a sole insert.

[0124] 23. The method according to innovation 18, wherein the base material insert includes a sole insert.

[0125] 24. The method according to innovation 18, wherein the first shoe last and the second shoe last are identical.

[0126] -

[0130] 25. Shoe mold and, Upper insert and Sole insert and A heel insert comprising a fixing mechanism for attaching the heel insert to the core of a shoe mold, A manufacturing apparatus for footwear, comprising the following features.

[0131] 26. The device according to innovation 25, wherein the fastening mechanism includes an instep strap.

[0132] 27. The device according to innovation 25, wherein the fixing mechanism includes a clip.

[0133] 28. The apparatus according to innovation 25, wherein, in a vertical cross-section, the rear portion of the heel insert has an S-shaped wave pattern.

[0051]

[0134] To address various challenges and advance the technology, this entire application relating to hands-free molded shoes (including the cover page, title, headings, field, background art, summary of the invention, brief description of the drawings, summary of the invention, claims, abstract, drawings, appendices, etc.) illustrates various embodiments in which the claimed innovation may be implemented. The advantages and features of this application are merely examples of representative embodiments and are not exhaustive and / or exclusive. They are presented solely for the purpose of aiding understanding and teaching the claimed principle. It should be understood that these do not represent all of the claimed innovation. Therefore, specific aspects of this disclosure are not described herein. Where alternative embodiments are not presented for a particular part of the innovation, or where alternative embodiments not described are available for a part, this does not preclude those alternative embodiments. It should be understood that many undescribed embodiments incorporate the same principle as the innovation, and other embodiments are equivalent thereto. Therefore, it should be understood that other embodiments may be utilized without departing from the scope and / or spirit of this disclosure, and that functional, logical, operational, organizational, structural and / or topological modifications may be made. Thus, throughout this disclosure, any examples and / or embodiments are considered non-limiting. Furthermore, no distinction should be made between embodiments described herein and embodiments not described herein, except for the purpose of reducing space and overlap. For example, the logical and / or topological structure of any combination of any process stages and / or feature sets described throughout the drawings and / or is not limited to a fixed operating sequence and / or arrangement; the disclosed order is illustrative, and all equivalents are assumed by this disclosure regardless of the order. Similarly, some features apply to some aspects of this innovation but not to others.Furthermore, this disclosure includes several innovations, including those not currently claimed, and the applicant reserves all rights, including the right to claim these innovations, to file additional applications, continuation applications, continuation-part applications, divisional applications and / or similar applications. Accordingly, it should be understood that the merits, embodiments, examples, functions, features, logic, operation, organization, structure, phase and / or other aspects of this disclosure are not to be considered limitations to the disclosure as defined by the claims or to equivalents of the claims.

Claims

1. Sole structure, A heel cup is uniformly molded with the sole structure and extends from the sole structure to at least a portion of the rear heel collar of the upper, and comprises an upper, middle, and lower portion of the heel cup, The upper part has a shorter length in the inward and outward direction than the intermediate part. The aforementioned middle section and the aforementioned lower section form a concave structure configured to receive the heel, The upper part has a first configuration and can be deformed into a second configuration by the load of the user's foot when the user puts on footwear. In the second configuration, at least a portion of the upper part is lower than that of the first configuration, and the upper part can return to the first configuration after the load of the user's foot is removed. Items related to footwear.

2. With an even more advanced upper, The upper defines the foot-receiving shoe opening, The article relating to footwear according to innovation 1, wherein the heel cup and the sole structure are molded uniformly with the upper.

3. The heel cup is made of a first type of plastic, The upper is made of a second plastic, The article relating to footwear according to innovation 2, wherein the first plastic has a different hardness than the second plastic.

4. The heel cup and sole are made of a first type of plastic. The article relating to footwear according to innovation 2, wherein the upper is made of mesh fabric.

5. The heel cup is made of a first type of plastic, The sole is made of a second plastic, The article relating to footwear according to innovation 1, wherein the first plastic has a different hardness than the second plastic.

6. The aforementioned intermediate portion defines the peripheral portion and the central portion, The peripheral portion has a first thickness, The aforementioned central portion has a second thickness, The article relating to footwear according to innovation 1, wherein the second thickness is thinner than the first thickness.

7. The article relating to footwear according to innovation 1, further comprising an internal foam layer integrally molded with the rear inner wall of the heel cup.

8. An article relating to footwear according to innovation 1, wherein the heel cup has an S-shaped wave pattern in a vertical cross-section.

9. In the aforementioned vertical cross-section, the upper part has a first thickness at a first location. In the aforementioned vertical cross-section, the intermediate portion has a second thickness at a second location. In the aforementioned vertical cross-section, the lower part has a third thickness at a third location. The article relating to footwear according to innovation 8, wherein the second thickness is thinner than at least one of the first thickness and the second thickness.

10. Featuring a uniformly molded upper, sole, and heel cup, The heel cup is made of a first type of plastic, The upper is made of a second plastic, The first plastic has a different hardness than the second plastic. Items related to footwear.

11. The article relating to footwear according to innovation 10, wherein the first plastic has a higher hardness than the second plastic.

12. The heel cup is uniformly molded in its upper, middle, and lower sections. The upper part has a shorter length in the inward and outward direction than the intermediate part. The aforementioned middle section and the aforementioned lower section form a concave structure configured to receive the heel, The article relating to footwear according to innovation 11, wherein the upper part has a first configuration and is configured to deform into a second configuration by the load of the user's foot when the user puts on the footwear.

13. An article relating to footwear according to innovation 12, wherein in a vertical cross-section, the heel cup has an S-shaped wave pattern.

14. In the aforementioned vertical cross-section, the upper part has a first thickness at a first location. In the aforementioned vertical cross-section, the intermediate portion has a second thickness at a second location. In the aforementioned vertical cross-section, the lower part has a third thickness at a third location. An article relating to footwear according to innovation 13, wherein the second thickness is thinner than at least one of the first thickness and the second thickness.

15. Featuring a uniformly molded sole and heel cup, The heel cup is made of a first type of plastic, The sole is made of a second plastic, The first plastic has a different hardness than the second plastic. Items related to footwear.

16. The article relating to footwear according to innovation 15, wherein the first plastic has a higher hardness than the second plastic.

17. An article relating to footwear according to innovation 16, further comprising an upper uniformly molded with the sole and heel cup.

18. The first shoe last is to place a base material insert with a heel insert, To provide a first plastic and generate a base material, The base material and overmolded insert are placed in the second shoe last, This includes providing a second plastic to produce shoes, The first plastic has a higher hardness than the second plastic. A method for manufacturing articles related to footwear.

19. The method of innovation 18, wherein providing a first plastic and providing a second plastic is done by injection molding.

20. The method of innovation 18, wherein providing a first plastic and providing a second plastic is done by injecting plastic pellets.

21. The heel insert is provided by the method of innovation 18, wherein the heel insert includes an instep strap.

22. The method according to innovation 18, wherein the overmolded insert further includes a sole insert.

23. The method according to innovation 18, wherein the base material insert includes a sole insert.

24. The method of innovation 18, wherein the first shoe last and the second shoe last are identical.

25. shoe last and Upper insert and Sole insert and A heel insert comprising a fixing mechanism for attaching the heel insert to the core of the shoe last, A manufacturing apparatus for footwear, comprising the following features.

26. The device according to innovation 25, wherein the fastening mechanism includes an instep strap.

27. The device according to innovation 25, wherein the fixing mechanism includes a clip.

28. The apparatus according to innovation 25, wherein, in a vertical cross-section, the rear portion of the heel insert has an S-shaped wave pattern.

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