Sole component for an article of footwear and method for making same

Abstract

A sole component having a base, a toe cover and an integral line of articulation permitting the toe cover to be molded in an “open” position and moved into a “closed” position during assembly on the article of footwear. The line of articulation may include a line of reduced thickness extending laterally across the sole. The line of articulation may also include breaks defined in the sidewall of the sole in alignment with the line of reduced thickness. The present invention also provides a method of forming a sole component generally including the steps of providing a mold having bottom and top mold parts shaped to cooperatively define a mold cavity in the shape of a sole component having a toe cover joined to a base along a line of articulation, closing the mold parts, injecting a sole forming material into the cavity, removing the sole component and moving the toe cover about the line of articulation into a closed configuration for use.

Description

BACKGROUND OF THE INVENTION[0001]The present invention relates to a sole component for an article of footwear and a method for making the sole component.[0002]There is an ongoing effort in the footwear industry to produce footwear that provides durability and a high level of comfort, while maintaining a sense of style. As the styles change, so must the methods of manufacturing the shoes. However, such changes can and often do result in manufacturing difficulties.[0003]Many of today's shoes include either a partial or complete toe cover, such that the toe of the shoe in encompassed at least partially by sole material. The primary difficulty with toe cover constructions is how the toe cover can be formed and attached via machinery. For example, in one construction the toe cover is formed as an integral part of the outsole. In this construction, the outsole extends the full length of the shoe and includes a heel cup at the rear of the shoe and a toe cover at the front of the shoe. Give...

AI Technical Summary

Benefits of technology

"The present invention provides a sole component with a toe cover that can be easily molded and moved into a closed configuration during assembly on the article of footwear. The sole component includes a line of articulation that permits the toe cover to be opened and closed. The invention also provides a method for manufacturing the sole component using a conventional mold with only a single moving part. The invention provides an cost-effective solution for manufacturing articles of footwear that provide a desired aesthetic appeal."

Problems solved by technology

However, such changes can and often do result in manufacturing difficulties.

The primary difficulty with toe cover constructions is how the toe cover can be formed and attached via machinery.

Given the undercut nature of the toe cover, this sole cannot be manufactured using a conventional mold with a single moving mold part because the toe cover would entrap a portion of the mold preventing its removal from the mold.

In this construction, the outsole is manufactured using a relatively complex multi-part mold.

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