An item of footwear

Abstract

An item of footwear 1 comprising an inner sole 2 and an outer sole 3 which are detachable by means of complementary protrusions 4 and recesses 5 in the lower surface of the inner sole and upper surface of the outer sole. The protrusions may be studs which fit complementary recesses. The protrusions and recesses may also be formed of ridges and valleys. The inner and outer soles may be formed of different materials which can be recycled in different manners after removal of the outer sole. A layer of fabric material (6, figure 7) may be sandwiched between the inner and outer soles and this may be in the form of a sock which extends at least partially over a portion of the sides of the inner sole.

Description

Field The present invention relates to an item of footwear, such as a shoe, and to a removeable sole which is readily removed when the shoe becomes damaged or worn to facilitate recycling of component parts of the item of footwear. More particularly the invention relates to reuse of materials that form the shoe and enables them to be recycled for regenerative purposes. Background Manufacturing footwear is a complex process, involving several steps and products as there are often many different components required to form a shoe. One of the main components is the sole. Conventionally components are non-com postable and the shoe itself is typically made from synthetic polymer chemicals as well as natural products, such as leather. The is a need to reduce landfill dramatically worldwide. Currently the soles of a shoe or trainer are glued or stitched to the bottom of the shoe. This makes it difficult to detach them at end of their useful life or when shoes become worn or damaged. It is reported that the costs to disassemble a shoe to its component parts can outweigh the price of the shoe / trainer. There is therefore a need for a simpler item of footwear which is robust, reliable and easier to recycle. The present invention arose in order to overcome the aforementioned problems and seeks to provide a recyclable r sole and a recyclable shoe. Summary of the Invention According to a first aspect of the invention there is provided an item of footwear including an upper portion, the upper portion including an inner sole (portion) and an outer sole, wherein the outer sole and the inner sole are connectable and detachable by means of either location lugs / protrusions or recesses in the outer or lower surface of the inner sole and complementary recesses or protrusions in the upper portion of the outer sole. Typically, most footwear manufactured today includes polymer materials, which are mainly found in training and sports shoes, the invention aims to re-use or re-grind and to make the compounds used to make shoes, regenerative and recyclable. One aspect of the invention therefore relates to reuse of materials that form the shoe and enables them to be recycled for regenerative purposes, for example as another shoe or a different item made from the recycled materials. Recycling involves breaking up the sole and recycling some of the materials that are used to make the shoe, for example by using a combination of grinding and an injection moulding process. In some embodiments of the footwear item the protrusions are formed on the outer surface of the inner sole and recess are formed in the upper portion of the outer sole. In some embodiments the protrusions are formed as studs and the recesses are defined by complementary size and shaped recesses. In some embodiments the protrusions and recesses are defined by, or formed as, ridges and valleys. In some embodiments the upper sole and lower sole are formed from dissimilar materials. Optionally a layer of fabric material is sandwiched between the lower and upper soles. The fabric material is in the form of a sock which extends at least partially over a portion of the sides of the inner sole. In some embodiments the outer sole includes a circumferential ridge on the upper surface so as to form a recess. Advantageously the lower portion of the sole is fitted or located within an outer sole recess. The outer sides of the upper sole and / or the inner portion of the circumferential ridge of the outer sole include protrusions or recesses, or have an undulating, saw-tooth or jagged profile. Preferably the protrusions or recess are ridges and valleys or are formed as a jagged edge. In some embodiments the outer sides of the upper sole, and the inner portion of the circumferential ridge of the outer sole, aid include protrusions or recesses and the protrusions and recesses on the outside of the upper sole are complementary to protrusions or recesses to the inner portion of the circumferential ridge of the outer sole. An example of the invention will now be described, with reference to the drawings, in which: Brief Description of the Drawings Figures 1Ato 1D show representations of a footwear item according to one example; Figure 2 shows a cross-sectional view of the footwear item of Figure 1; Figure 3 shows a cross-sectional view of the sole of Figure 2; Figure 4 shows a view of one example of the lower portion of the inner sole of the example of Figure 1 to 3; Figure 5 shows a representation of a cross-section through the footwear item and how the grip or connection is achieved Figure 6 shows a representation of a footwear item according to another example of the invention; Figure 7 shows an underside view of the inner sole of one embodiment with a sewn in sock; Figure 8 shows a view of the sole portion, shown in Figure 7, with a grip; Figure 9 shows the end portion of the inner sole; Figure 10 is a view of an example of an item of footwear, showing inner and outer soles; and Figures 11 to 14 shows representations of a further examples of the item of footwear. Detailed Description of Preferred Embodiments of the Invention In one embodiment of the invention a push on sole portion is clipped into place and is readily removed by unclipping clips which are preferably positioned at an acute angle with respect to the sole. Thus, saving time and can be then recycled through grinding into small parts which in turn is regenerated into new soles. Referring to Figures 1 Ato 1D, 2, 3, 4, 5, 6 there are shown various views of a footwear item 1 comprising an upper footwear portion 10 which includes an inner sole (portion) 2, a top portion 11, and also an outer sole (portion) 3. The inner sole 2 is inserted integrally within the top portion 11 during manufacture. Figures 2, 9, 10, 11, 12 and 13 shows examples where the inner sole 2 is formed inside the top portion 11 Importantly the inner sole (portion) 2 and the outer sole (portion) 11 are detachable from another. For the purpose of the present application, the term “detachable” means that for example, at any time during or after use of the footwear, the inner sole and outer sole can be detached one from another, preferably easily by the wearer. This allows recycling for example of these two components and moreover the recycling can be according to the type of material from which the inner and outer soles are made. In the examples described, the inner sole 2 and outer sole 3 are made from different materials. Thus, the two portions being detachable allows for selective recycling of the inner sole portion 2 and the outer sole portion 3. This is particularly advantageous where the recycling regimes for the two materials are different. Furthermore, when the outer sole wears out, a replacement can be fixed to the inner sole, thus prolonging the use of the upper sole and the top portion of the item of footwear. The various materials that form the inner sole and lower sole are typically recycled in different ways according to the nature of each type of material. For example, the inner and lower sole portions, shown in Figure 1, after having been ground into granules and kept as separate waste streams, so that the different types of granules can be regenerated and used in the manufacture of new soles or other items. As can be seen in the Figures, the upper, inner sole (portion) has studs 4 extending from the bottom thereof, and the outer sole portion has complementary recesses 5 to receive the studs 4. The studs are slightly larger than the recesses, so when pressed together create a firm join. In this way the inner and outer sole portions can be pressed together to form a single component. It will also be appreciated that different stiffnesses may be imparted to each of the two portions thereby enabling the overall comfort and resilience of the shoe to be tailored to suit a specific use, sport, shoe size or user. The stud and or the outer sole can be made from resilient material to allow the outer and inner sole portion not to detach during use or without significant effort. However, in examples, adequate force by a human can be used to separate outer and inner soles after they have been pressed together, without machinery and once clips have been undone or retainers detached. This is done for example using a reversing angle to make it acute and then the release is apparent. It should also be noted that in alternative embodiments the studs may be provided on the outer sole and the inner sole may be provided with the complementary recesses. It should also be noted that rather than studs and recess, any corresponding protrusions and (complementary) recesses which inter-engage can be used. For example, ridges and grooves may be used alternatively. Also, the stud holes in the lower sole may act also as a location point. In enhanced embodiments there is also provided a sock 6, which is sewn into the shoe and a sock formed therewith or attached to the inner sole with or without adhesive. An example of the sock is shown in Figures 7 and 14 and is depicted as being attached to the inner sole or the outer sole. Alternatively, the sock 6 may be sandwiched between the outer and inner soles. In Figure 7 the sock is shown attached to the inner sole. The sock has a number of orifices or holes to allow the studs form extending form the inner sole to protrude through the part 3 stud locking system on the inner sole through part 3 sewn in sock. The sock may be formed from a material or fabric which is stitched or glued around the whole upper sole portion to create a seal. To recap the holes in this material, hold the studs which protrude therethrough. The sock may alternatively be a flexible or woven material sandwiched between upper and lower soles. One advantage of the sock / sandwiched in this manner is that the upper soles and lower soles portions can be more easily detached after usage, because after prolonged periods of use, the upper and lower soles may become fixed or bonded to each other, and thus difficult to separate especially if both are formed from rubber and / or synthetic rubber and / or an elastomeric material and / or a polymeric material. The outer sole component depicted in Figure 8, shows its form in one embodiment. The outer sole component includes a ridge 9 on the upper portion which may form a circumference or along a circumferential ridge. The ridge allows the inner sole to be pressed into the recess of the outer sole formed by the circumferential ridge and such that the outer and inner soles form a grip in the region of the ridges. In order to enhance the grip, the inner surface of the ridge portion may be provided with a number of inner ridges 7a and valleys 7b to improve gripping. The inner ridges 7a and valleys 7b may be enhanced with any form of protrusion like studs, on or along recesses of the inner surface of the ridge. In order to further enhance the grip and to ensure the outer and inner soles are kept together in use, there may also preferably be corresponding complimentary protrusions (ridges and valleys) on the (lower) perimeter portion of the inner sole. An example of this is shown in Figure 9 which shows the inner soles where the periphery has a number of ridges 8a and valleys 8b around the circumference which cooperate with the ridges 7a and valleys 7b on the outer sole. So, the Figures show the ridges which are part of the locking system on the bottom sole. Thus, is provided the inner sole jagged grip which when pressed into the (outer) sole, grips the sole inside grip to lock the two parts together. The shoe or item of footwear is a completely new type of sole attachment design. The shoe sole is different to any other shoe sole attachment process as it is not attached by using glue or stitching or by an injection moulding process. The sole is attached in a two-part process where the inside part which is the shape of the sole has protruding spigot type prongs which are placed through the underside of the upper via location holes. This part also has a clip / claw locking system around the edge. When the upper and the inside part is pressed into the bottom part sole, they lock together by the locking system (spigot type) which is pressed into holes to create tight fit and the edge clip system in turns locks the upper of the shoe around the edges. An advantage is that at the end of life of the product both parts of the sole can be detached, by use of force or by way of a pull cord fitted to the inside of the shoe, in order to release the two parts and enable them to be fully recycled and ground back into granules and used again. In summary, the flexible synthetic plastic inner sole, which is inside of the upper and protruding through the stud access holes of the sewn in sock material at the bottom of the upper sole. These studs are aligned with holes in the soles which when fully pressed together act as a very tight bond which makes the bond difficult to pull apart. Along with the studs there is also around the innersole, any jagged edge is hidden by a thin flexible sewn in sock material. Also, as a mirror image the same reversable jagged edge is provided on the inside of the sole wall. Together when pressed the inner sole studs lock into the holes on the inside of the sole. This action also pushes both jagged edges past each other to create a lock around the sole. The invention has been described by way of examples only and it will be appreciated that variation may be made to the embodiments described, without departure from the scope of the invention, as defined in the claims.

Claims

1. A footwear item including an upper portion, the upper portion including an inner sole (portion) and an outer sole, wherein the outer sole and the inner sole are detachable by means of either protrusions or recesses in the outer or lower surface of the inner sole and complementary recesses or protrusions in the upper portion of the outer sole.

2. A footwear item as claimed in claim 1 wherein the protrusions are formed in the outer surface of the inner sole and recess are formed in the upper portion of the outer sole.

3. A footwear item as claimed in claims 1 or 2 where the protrusions are formed of studs and the recesses are formed of complementary recesses.

4. A footwear item as claimed in claims 1 to 3 wherein the protrusions and recesses are formed of ridges and valleys.

5. A footwear item as claimed in claims 1 to 4 wherein the upper sole and lower sole are formed of different materials.

6. A footwear item as claimed in claim 5 wherein the different materials are formed of materials which are recycled in a different manner.

7. A footwear item as claimed in claim 1 to 6 including a layer of fabric material sandwiched between the lower and upper soles.

8. A footwear item as claimed in claim 7 wherein the fabric is in the form of a sock which extends at least partially over a portion of the sides of the inner sole.

9. A footwear item as claimed in claims 1 to 8 wherein the outer sole includes a circumferential ridge on the upper surface so as to form a recess.

10. A footwear item as claimed in claim 9 wherein the lower portion of the sole is fitted or located within the outer sole recess.

11. A footwear item as claimed in claims 1 to 10 wherein the outer sides of the upper sole and / or the inner portion of the circumferential ridge of the outer sole includes protrusions or recesses, or have an undulating, saw-tooth or jagged profile.

12. A footwear item as claimed in claim 11 wherein the protrusions or recess are ridges and valleys or form a jagged edge.

13. A footwear item as claimed in claim 9 to 12 wherein both the outer sides of the upper sole and the inner portion of the circumferential ridge of the outer sole includes protrusions or recesses and the protrusion and recess on the outside of the upper sole being a are complementary to protrusion or recesses on the inner portion of the circumferential ridge of the outer sole.

14. An outer sole for use with a footwear item of any preceding claim includes protrusions or recesses on the upper surface.

Images