This application relates to footwear and, in particular, to a shoe that can be worn in activities that take place in wet environments, such as boating.
Traditional footwear manufacturing methods (e.g., Strobel or board lasting) generally include a lasting step. Lasting describes how the upper is attached to the midsole. For example, in the Strobel lasting method, the upper is stitched to an insole or other shoe liner and then the combination is pulled onto a last so that a midsole can be attached. In the board lasting method, an upper is glued to a piece of cardboard or fiberboard, and then the resulting product is subsequently attached to a midsole. Such manufacturing techniques that include an insole or other shoe liner increase the manufacturing costs by increasing the amount of materials and labor required to produce a shoe. In addition, such insoles and liners tend to get waterlogged and uncomfortable when exposed to water, which make such shoes uncomfortable to wear in wet environments.
Attempts to create footwear that does not include an insole or require the lasting methods discussed above have been primarily limited to sandals or other open footwear that does not offer sufficient comfort, support, or protection to the feet of the user, especially when worn in wet conditions.
In one embodiment, a novel method of making a shoe is disclosed. The method includes forming a sole member of EVA and forming an upper member. The sole member has a top side, a bottom side, a lateral side edge, a medial side edge, a toe side edge, and a heel side edge. The sole member has at least one flange member integrally formed with the sole member and extending upwardly from the top side of the sole member. The flange member extends at least substantially around the perimeter of the shoe and is disposed inward of each of the lateral side edge, the medial side edge, the toe side edge, and the heel side edge. The method further comprises forming an upper member that has a foot covering portion and a flange attachment portion. The flange attachment portion is located substantially at a lower edge of the upper member. The upper member is positioned on the top side of the sole member with the flange member disposed inside of the flange attachment portion of the upper member. The flange member is attached to the flange attachment portion.
In one embodiment, the flange member comprises a single, continuous flange member extending completely around the perimeter of the sole member.
In another embodiment, a ledge is formed between the flange member and the lateral side, medial side, toe side, and heel side edges of the sole member. The lower edge of the upper member abuts the ledge when the upper member is positioned on the top side of the sole member.
In another embodiment, the flange member is formed with an inner curved portion. In specific implementations, the inner curved portion varies along the length of the sole member and the inner curved portion can be defined by an inner radius. The inner radius may be larger along the length of the sole member at locations closer to the heel side edge of the sole member than it is at locations closer to the toe side edge. The flange member can also have a thickness that varies along the length of the sole member.
In other embodiments, the attaching of the flange member to the flange attachment portion comprises applying an adhesive between the flange member and the flange attachment portion. In addition, the attachment can include stitching at least a portion of the flange member to the flange attachment portion. The portion that is stitched can comprise portions in a heel area and a forefoot area of the shoe.
In other embodiments, the attaching of the flange member to the flange attachment portion can be achieved by machine stitching. The machine stitching can be performed using a round point needle.
In specific implementations, a pathway on a top side of the sole member can be formed for directing water from the top side of the sole member to one or more of the lateral side, medial side, toe side, or heel side edges. An opening can also be formed in at least one of the lateral side, medial side, toe side, or heel side edges of the sole member. The opening can be in fluid connection with the pathway when water is introduced to the top side of the sole member.
In specific implementations, the shoe is a closed shoe with the foot covering portion of the upper member being configured to substantially cover an upper portion of a foot when the shoe is being worn by a person. The shoe can also be a boat shoe, with the upper member comprising a leather portion or a canvas portion that has been treated to be hydrophobic.
In other embodiments, the EVA sole member is formed by injection molding. In other embodiments, a fabric can be positioned between the flange member and the flange attachment portion of the upper member prior to attaching the flange member to the flange attachment portion.
In other embodiments, a recess is formed on the bottom side of the sole member, and a rubber outsole is formed and positioned in the recess formed on the bottom side of the sole member. The rubber outsole is attached to the sole member.
A novel shoe is disclosed. The shoe comprises a sole member and an upper member. The sole member comprises an EVA material and has a top side, a bottom side, a lateral side edge, a medial side edge, a toe side edge, and a heel side edge. At least one flange member extends upwardly from the top side of the sole member. The flange member is integrally formed with the sole member and extends at least substantially around the perimeter of the shoe. The upper member has a foot covering portion and a flange attachment portion. The flange attachment portion is located substantially at a lower edge of the upper member. The flange attachment portion is attached to the flange member. The upper member is disposed on the top side of the sole member with the flange member disposed inside of the flange attachment portion of the upper member.
In specific implementations, the flange member comprises a single, continuous flange member that extends completely around the perimeter of the sole member. In other implementations, the flange member is disposed inward of the lateral side, medial side, toe side, and heel side edges forming a ledge between the flange member and the lateral side, medial side, toe side, and heel side edges of the sole member. The lower edge of the upper member may abut the ledge.
In other embodiments, the flange member is formed with an inner curved portion. The inner curved portion may vary along the length of the sole member. The inner curved portion can also be defined by an inner radius, with the inner radius being larger along the length of the sole member at locations closer to the heel side edge of the sole member than it is at locations closer to the toe side edge. The flange member can also have a thickness that varies along the length of the sole member. In other specific implementations, the flange member is machine stitched to the flange attachment portion.
In other embodiments, the sole member further comprises a pathway on a top side of the sole member for directing water from the top side of the sole member to one or more of the lateral side, medial side, toe side, or heel side edges; and an opening formed in at least one of the lateral side, medial side, toe side, or heel side edges of the sole member. The opening is in fluid connection with the pathway when water is introduced to the top side of the sole member.
In specific implementations, the shoe is a closed shoe with the foot covering portion of the upper member being configured to substantially cover an upper portion of a foot when the shoe is being worn by a person. The shoe can also be a boat shoe with an upper member that comprises a leather portion or a canvas portion that has been treated to be hydrophobic.
In specific implementations, the EVA sole member is formed by injection molding. In other implementations, the shoe further comprises a recess on the bottom side of the sole member; and a rubber outsole positioned in the recess on the bottom side of the sole member. The rubber outsole is attached to the sole member. In other embodiments, a fabric is disposed between the flange member and the flange attachment portion of the upper member.
The foregoing and other objects, features, and advantages of the invention will become more apparent from the following detailed description, which proceeds with reference to the accompanying figures.
The upper can be constructed of a variety of materials, including, for example, leather, canvas, or mesh. Desirably, the selected material is either naturally hydrophobic or it is chemically treated so that the material acts in a hydrophobic manner. The upper can include laces 16 that pass through eyelets 18 in vamp 20. Sole 14 desirably includes openings 22 that permit water to drain from shoe 10. The upper 12 is stitched directly to sole 14 using stitches 24.
Upper 12 is desirably perimeter stitched to flange member 26 using a stitching machine and a round point needle. Razor edged needles create a slice that is less desirable when working with relatively thin portions of EVA material. Slices formed by razor edged needles may create weaknesses in the EVA material that can introduce or encourage tearing or other failures in the EVA material. Accordingly, it is more desirable to stitch upper 12 to flange member 26 using a needle that creates independent and substantially round holes. The distance between the holes formed during the stitching process is desirably about 0.5 mm. If the holes are formed too close together, flange member 26 may tear or fail; however, if the holes are formed too far apart, the strength of the connection between flange member 26 and the flange attachment portion of upper 12 may be insufficient. In addition, it may be desirable to include an adhesive between the stitched portions of the upper and flange member.
In another embodiment, upper 12 can be bonded to flange member 26 using adhesive alone, or in combination with a portion of the stitching described above and shown in
Desirably, flange member 26 is disposed inward from the outer edge of sole 14, creating a ledge 30. This can be seen clearly in
EVA is known as a midsole material and is used in various running shoes to provide cushioning. EVA has also been used as a material for use with sandals and other “open” footwear. However, it is believed that EVA has not been used as the sole material in a closed shoe design with an upper attaching directly (i.e., without a lasting step) to the EVA sole in the manner discussed below.
Although sole 14 can be constructed of just one type of material, such as EVA, sole 14 desirably also includes a relatively thin stock-fitted rubber outsole 32 that is attached to a recess in a bottom portion of sole 14. Outsole 32 is desirably attached to sole 14 using an industry accepted footwear adhesive. The rubber material of outsole 32 can be a non-marking gum rubber. Since gum rubber provides a “stickier” surface than EVA materials, a gum rubber outsole 32 provides shoe 10 with improved traction when used in wet conditions. In addition, outsole 32 desirably includes treads 34. Treads 34 are indentations or raised markings that further improve the ability of shoe 10 to grip surfaces, including wet surfaces, without slipping.
Flange member 26 is desirably formed integrally with sole 14. Flange member 26 can be formed integrally with the sole using a molding process. This molding process can be, for example, either compression molding or injection molding. Injection molding, however, is more preferred since it is more efficient than compression molding and produces less material waste.
Flange member 26 extends upward and is disposed inward of each of the lateral side, medial side, toe side, and heel side edges of sole 14. Flange member 26 is desirably disposed inward from the edges, thereby forming ledge 30. Ledge 30 extends from flange member 26 to the outer edge of sole 14. Referring to
The top surface of sole 14 is desirably textured to provide a smooth, but non-slippery surface on which the foot can rest. Therefore, texture 36 is provided on the upper surface of sole 14. In addition, water draining pathways 38 are provided to direct water in the shoe to openings 22. Pathways 38 are indentations or depressions in the top surface of sole 14 that function to direct water to holes 40 at the end of pathways 38, which are in fluid connection with openings 22. Thus, if water were to cover the surface of sole 14, the water would be directed through pathways 38 to holes 40, and then out the side of sole 14 through openings 22.
Desirably, the inner radius of flange member 26 varies along the length of the shoe. The inner radius is desirably larger near the heel area and smaller near the toe area. In one embodiment, in a U.S. size 9 shoe, moving from toe to heel, the inner radii vary as follows: R1=5 mm; R2=5 mm; R3=7 mm; R4=13.5 mm; R5=14 mm; R6=14 mm; R7=12 mm. Accordingly, the inner radius of the flange member 26 is desirably at least twice as large at the back as it is at the front. The varying radius of flange member 26 increases the structural stability of the shoe (e.g., the strength of the attachment of flange member to the upper), as well as produces a more ergonomically correct shoe, which increases comfort to the wearer.
Desirably, the thickness of flange member 26 also varies along the length of sole 14. The thickness of the flange at the top portion in
In one embodiment, in a U.S. size 9 shoe, the thickness of the flange member 26 varies as follows: T1=0.8 mm; T2=1.0 mm; T3=1.0 mm; T4=1.0 mm; T5=0.8 mm; T6=0.8 mm; and T7=0.8 mm.
In another embodiment, referring again to FIGS. 8 and 10-16, a U.S. size 7 shoe can have the following radii and thicknesses: R1=4 mm; R2=6 mm; R3=9 mm; R4=12 mm; R5=10 mm; R6=10; R7=8 mm; R8=9 mm; R9=6.5 mm; T1=0.8 mm; T2=0.8 mm; T3=0.8 mm; T4=0.8 mm; T5=0.8 mm; T6=0.8 mm; and T7=0.8 mm.
Flange member 26 is desirably positioned so that the inner side of flange member 26 is just lightly resting against the outside of a wearer's foot. The variation in inner radii, as discussed above, desirably takes into account the anatomy of the wearer's foot.
The novel method of manufacturing a shoe that comprises an upper attached directly to an integral flange on a sole formed of EVA material has numerous advantages. The method eliminates many of the traditional steps required for manufacturing closed form shoes, such as attaching the upper to an insole or other type of shoe liner. Instead, the upper can be stitched directly to the flange, either by hand or machine, without requiring any extra materials or labor-intensive steps.
The reduction of materials can also be significant. First, there is no insole board or sock material associated with the manufacture of the shoe. Thus, that material can be eliminated. In addition, since the upper can be shorter than a traditional upper, the amount of material required to produce an upper is reduced. As noted above, the upper does not wrap around an insole; rather, it sits on a ledge outside of the flange member. As such, less upper material is required to produce a finished product. The elimination of the insole and lasting step also eliminates or greatly reduces the amount of adhesive that is required to manufacture the closed form shoe.
The EVA sole is both comfortable and light-weight. By eliminating the materials discussed above, the overall weight of the shoe can be reduced without sacrificing comfort or stability of the shoe. In addition, EVA has little or no odor, is resistant to UV radiation, and has good barrier properties, which prevents water and other harmful or odorous liquids or vapors from being absorbed by the sole. In addition, EVA is highly resistant to cracks and has good anti-microbial properties.
Various alternatives of the configurations disclosed above are possible without departing from the scope of the invention. For example, the water draining openings, holes, and pathways could be configured differently and located at other locations in the sole.
In view of the many possible embodiments to which the principles of the disclosed invention may be applied, it should be recognized that the illustrated embodiments are only preferred examples of the invention and should not be taken as limiting the scope of the invention. Rather, the scope of the invention is defined by the following claims. We therefore claim as our invention all that comes within the scope and spirit of these claims.