Method for forming a sole shape for footwear and for a cup insole, and article

Abstract

A sole includes a closed cell resin foam of a low-density polyethylene (A), ethylene-vinyl acetate copolymer (B), filler (C), foaming agent (D), and cross-linker (E), wherein a mass ratio of the low-density polyethylene (A) and the ethylene-vinyl acetate copolymer (B) equals (A)/(B) within a range 90/10 to 95/5. The resin foam, molded into a predetermined middle padding member, is deformable by an external force. An elastic covering member covers the middle padding member and is configured to follow the deformation of the middle padding member abutting the covering member configured to be abutted against a foot. Weight applied to the sole crushes, and deforms a plurality of bubbles formed in the resin foam along the shape of the sole.

Description

BRIEF DESCRIPTION OF THE DRAWING

FIG. 1 is a schematic cross sectional view of a resin foam that may be used to form a sole shape for footwear and a sole shape for a cup insole;

FIG. 2 is a perspective view of the footwear using the resin foam according to FIG. 1;

FIG. 3 is a longitudinal sectional view taken along line 3-3 in FIG. 2;

FIG. 4 is a horizontal sectional view taken along line 4-4 in FIG. 3;

FIGS. 5( a) and 5(b) are longitudinal sectional views showing usage states of the footwear in FIG. 2, wherein FIG. 5(a) is a view showing the state where the footwear is put on, and FIG. 5(b) is a view showing the state where the footwear is taken off;

FIGS. 6( a) and 6(b) are longitudinal sectional views taken along line 6-6 in FIG. 2, wherein FIG. 6(a) is a view showing the state where the footwear is unused and FIG. 6(b) is a view showing the state where the footwear is used;

FIGS. 7( a) and 7(b) are longitudinal sectional views taken along line 7-7 in FIG. 2, wherein FIG. 7(a) is a view showing the state where the footwear is unused, and FIG. 7(b) is a view showing the state where the footwear is used;

FIGS. 8( a) and 8(b) are views showing the cup insole of an embodiment according to the formation method for the sole shape for the cup insole of the present invention, wherein FIG. 8(a) is a perspective view of the cup insole, and FIG. 8(b) is a longitudinal sectional view taken along line 8(b)-8(b) in FIG. 8(a);

FIG. 9 is a perspective view wherein a part of the footwear of another embodiment according to the method for forming the sole shape for the footwear of the present invention, is cut off;

FIGS. 10( a) and 10(b) are longitudinal sectional views taken along line 10-10 in FIG. 9, wherein FIG. 10(a) shows unused footwear, and FIG. 10(b) shows the footwear when used;

FIG. 11 is another embodiment of the insole of the footwear in FIG. 9, and illustrates a perspective view wherein a part of the insole is cut off;

FIGS. 12( a) and 12(b) are longitudinal sectional views showing another example of the embodiment in FIG. 9, wherein FIG. 12(a) shows an example where a blocking member is provided between a middle padding member and a supporting member, and FIG. 12(b) shows an example where the blocking member is provided between the supporting member and an out sole;

FIG. 13 is a perspective view wherein a part of the cup insole of another embodiment according to the method for forming the sole shape for the cup insole of the present invention, is cut off;

FIGS. 14( a) and 14(b) are longitudinal sectional views taken along line 14-14 of the cup insole in FIG. 13 placed in the footwear, wherein FIG. 14(a) shows the unused cup insole, and FIG. 14(b) shows the cup insole when used;

FIG. 15 is a perspective view of another embodiment of the cup insole in FIG. 13, wherein a part of the cup insole is cut off; and

FIGS. 16( a) and 16(b) are longitudinal sectional views showing another embodiment of the cup insole in FIG. 13, wherein FIG. 16(a) shows the unused cup insole where the blocking member is provided between the middle padding member and the supporting member, and FIG. 16(b) shows the unused cup insole where the blocking member is provided on the underside of the supporting member.

Claims

1. A method for forming a sole shape in a cup insole, comprising: producing a closed cell resin foam formed of a foamed resin composition including low-density polyethylene (A), ethylene-vinyl acetate copolymer (B), filler (C), foaming agent (D), and cross-linker (E), a mass ratio of the low-density polyethylene (A) and the ethylene-vinyl acetate copolymer (B) being such that (A)/(B) is within a range of 90/10 to 95/5;molding the resin foam into a predetermined shape to form a middle padding member deformable by an external force; andcovering the middle padding member with an elastic covering member configured to follow deformation of the middle padding member that abuts the covering member;wherein the covering member is configured to be abutted against a foot, and weight on a sole allows a plurality of bubbles formed in said resin foam to be crushed for plastic-deformation thereof so that the resin foam is deformed along a shape of the sole.

2. A method for forming a sole shape according to claim 1, further comprising: inserting a sheet supporting member under the middle padding member for supporting the same, said supporting member having a shape of the middle padding member and being harder than said middle padding member; andadhering an abutting surface between said middle padding member and said supporting member.

3. A method for forming a sole shape according to claim 1, further comprising: inserting a sheet supporting member under the middle padding member for supporting the same, said supporting member having a shape of the middle padding member and being harder than said middle padding member;wherein the covering member covers an upper surface of said middle padding member and further comprises a rim turned back and located on an undersurface of said supporting member; andadhering the turnback of the covering member and said supporting member at an abutting surface therebetween.

4. A method for forming a sole shape according to claim 2, further comprising: providing a blocking member projecting toward said covering member for blocking movement of a heel at a site corresponding to a border between the heel and an arch between said middle padding member and said supporting member, or under the supporting member.

5. A method for forming a sole shape according to claim 3, further comprising: providing a blocking member-projecting toward said covering member for blocking movement of a heel at a site corresponding to a border between the heel and an arch between said middle padding member and said supporting member, or under the supporting member.

6. A method for forming a sole shape according to claim 1, wherein the closed cell resin foam is prepared such that a ratio between total mass of the low-density polyethylene (A) and mass of the ethylene-vinyl acetate copolymer (B); and mass of the filler (C) is produced according to ((A)+(B))/(C) within a range (70/30)-(80/20).

7. A method for forming a sole shape for footwear, comprising: preparing the middle padding member with the elastic covering member according to claim 1, to thereby form an insole, andproviding the insole on an outsole,wherein when the foot is put on the covering member and weight on the sole is applied on the covering member, a plurality of bubbles formed in said resin foam is crushed for plastic-deformation so that the resin foam is deformed along a shape of the sole.

8. A sole for an insole, comprising: a middle padding member comprising resin foam; anda covering member for covering the middle padding member;wherein said resin foam is a foamed resin composition including low-density polyethylene (A), ethylene-vinyl acetate copolymer (B), filler (C), foaming agent (D), and cross-linker (E), and a mass ratio of the low-density polyethylene (A) and ethylene-vinyl acetate copolymer (B) is set such that (A)/(B) is within a range 90/10 to 95/5; andthe covering member is configured to be abutted against a foot, and weight on a sole allows a plurality of bubbles formed in said resin foam to be crushed for plastic-deformation so that the resin foam is deformed along a shape of the sole.

9. A sole according to claim 8, further comprising: a sheet-like supporting member having a shape of said middle padding member and being harder than said middle padding member, said supporting member being located under said middle padding member and supporting said middle padding member;wherein the covering member covers at least an upper surface of said middle padding member, and an abutting surface between said middle padding member and said supporting member is adhered.

10. A sole according to claim 8, further comprising: a sheet supporting member inserted under the middle padding member for supporting the same, said supporting member having a shape of the middle padding member and being harder than said middle padding member,wherein the covering member covers an upper surface of said middle padding member and further comprises a rim turned back and located on an undersurface of said supporting member, the turnback of the covering member and said supporting member being adhered at an abutting surface therebetween.

11. A sole according to claim 9, further comprising: a blocking member projecting toward said covering member for blocking movement of a heel at a site corresponding to a border between the heel and an arch between said middle padding member and said supporting member, or between the supporting member and an outer sole.

12. A sole according to claim 10, further comprising: a blocking member projecting toward said covering member for blocking movement of a heel at a site corresponding to a border between the heel and an arch between said middle padding member and said supporting member, or between the supporting member and an outer sole.

13. A sole according to claim 8, wherein the closed cell resin foam includes a ratio of total mass of the low-density polyethylene (A) and mass of the ethylene-vinyl acetate copolymer (B) relative to mass of the filler (C), ((A)+(B))/(C) being within a range (70/30)-(80/20).

14. A sole according to claim 8, wherein the sole is adapted for a cup insole.

15. A sole according to claim 8, wherein the sole is adapted for footwear including an insole provided on an outsole.