Patent Application
20130139409
The present invention relates to footwear, especially welted footwear and method of making welted footwear.
Footwear with un-lasted uppers is known in the art. For example, U.S. Pat. No. 7,234,248, which is hereby incorporated herein by reference, discloses a shoe comprised of an upper having a lower marginal edge with a plurality of spaced fingers or tabs extending downwardly from the lower marginal edge, a footbed or sock liner having a plurality of spaced slots or openings therein for receiving the fingers or tabs of the upper, the fingers or tabs being folded under and secured to the lower surface of the footbed, an outsole secured to the lower surface of the footbed and confining the fingers or tabs between the footbed and the outsole, and means extending around the periphery of the footbed and the lower margins of the upper for concealing the connection between the upper and the footbed.
The present invention is an improvement to the unlasted shoe construction shown in U.S. Pat. No. 7,234,248.
In accordance with the invention, an article of footwear comprises an upper, footbed, outsole and welt strip. The upper has a lower marginal edge and a plurality of spaced tabs extending from the marginal edge. A plurality of notches are defined between the tabs, respectively. The footbed has a peripheral edge, the upper surrounding the peripheral edge of the footbed. The outsole is below the footbed. The tabs of the upper are folded over the peripheral edge and under the footbed and are secured in between the footbed and the outsole. The outsole has a peripheral edge that extends beyond the peripheral edge of the footbed to define a welt above the outsole, outside of the lower marginal edge of the upper. The welt strip is positioned on the welt and is cemented to the marginal edge of the upper to substantially seal the notches between the tabs of the upper.
A preferred embodiment of the invention comprises a fabric wrapped welt strip. A footwear upper has a lower marginal edge and a plurality of spaced tabs extending from the marginal edge such that a plurality of notches are defined between the tabs, respectively. The sole structure comprises a footbed, outsole and mid-sole there between. The footbed has a peripheral edge, such that the upper surrounds the peripheral edge of the footbed. The tabs of the upper are folded and cemented in between the footbed and the mid-sole. The mid-sole and outsole extend have substantially co-extensive peripheral edges that extend beyond the peripheral edge of the footbed to define a welt, outside the marginal edge of the upper. The welt strip is covered with a layer of fabric. The fabric wrapped welt strip is positioned on the welt and cemented to the mid-sole and the marginal edge of the upper to substantially seal the notches between the tabs of the upper.
A method of manufacturing an article of footwear in accordance with the invention comprises the steps of forming an upper with a lower marginal edge, molding a footbed, molding an outsole, the footbed and the outsole having substantially co-extensive peripheral edges, removing a peripheral strip from the marginal edges of the footbed, attaching the upper to the footbed, attaching the outsole to the footbed, and cementing the peripheral strip that was removed from the footbed to the lower marginal edge of the upper to form a welt strip above the outsole. Preferably a mid-sole is formed and positioned between the footbed and outsole. Furthermore, it is preferred to wrap the peripheral welting strip with fabric prior to cementing it to the lower marginal edge of the upper. The method of the invention does not require lasting the upper.
Additional features and advantages of the invention will become apparent to those of reasonable skill in the art from the following detailed description, as considered in conjunction with the accompanying drawings.
The following is a detailed description of certain embodiments of the invention presently contemplated by the inventors to be the best mode of carrying out their invention.
Referring to
The upper 12 may be any conventional shoe upper, such as a lace up full shoe upper that covers the toes, instep and heel, a slip-on upper, i.e., without a heel, a loafer upper, a moccasin upper, a slipper upper and even a boot upper. The upper 12 has a lower marginal edge 20 and a plurality of spaced fingers or tabs 22 extending from the edge 20 around the periphery of the edge. A plurality of notches 23 are defined between the tabs 22, respectively.
The footbed or sock liner 14, herein referred to as footbed, may comprise any material customarily used for footbeds and is preferably cushiony material consistent with sandal design and construction, such as molded foam. The footbed has a peripheral edge 24, and may optionally include slots 26 for receiving the tabs 22 of the upper. As shown in
The mid-sole 16, if employed, is preferably comprised of the same material as the footbed. It has a peripheral edge 25 that extends beyond the peripheral edge of the footbed 24. The mid-sole has an upper surface and a lower surface and is adhered at its upper surface to the lower surface of the footbed 14. Preferably the mid-sole includes recesses 32 to receive the folded end portions 28 of the tabs 22, thereby to secure the tab end portions 28 between the footbed and the mid-sole. Alternatively, recesses can be provided in the bottom surface of the footbed. Use of the same materials for the lower surface of the footbed and the upper surface of the mid-sole or outsole ensures a secure bond between the two, and thus a highly reliable securement of the tab end portions within the shoe. This results in a very economical way of securing an upper to a sole structure and eliminates the need for the stitchdown or lasting board required in conventional lasted shoe constructions.
The outsole 18 may be made of any conventional outsole material and has a lower ground engaging surface and an upper surface adhered to the lower surface of the mid-sole 16. If the mid-sole is omitted from the structure, as is permissible, the upper surface of the outsole is preferably comprised of material compatible with the footbed so that they may be cemented or otherwise directly bonded to the lower surface of the footbed 14 and the folded over end portions 28 of the tabs 22 to confine and secure the tabs between the footbed and the outsole. The outsole has a peripheral edge 27 that also extends beyond the peripheral edge 24 of the footbed to form a welt 15. If a mid-sole is employed the mid-sole peripheral edge 25 and outsole peripheral edge 27 are preferably co-extensive and together form welt 15 for receiving a welt strip.
Turning now to
In a preferred embodiment, shown in
The assembly of the shoe 10 comprises the steps of forming the upper 12, molding a footbed 14, optionally forming a mid-sole 16, forming an outsole 18 and attaching welt strip 17. The mid-sole and outsole may be formed by any conventional process, but molding is preferred. Initially, the footbed and the outsole have substantially co-extensive peripheral edges. However, a peripheral strip 17 is removed from the marginal edges 24 of the footbed 14. Next, the upper is attached to the footbed. Although an un-lasted upper is shown as being attached with tabs to the footbed, for the purpose of the method of the invention, any type of upper can be attached in any manner to the footbed. Next, the mid-sole if one is employed and outsole are attached to the footbed. Finally, the peripheral strip 17 that was previously removed from the footbed is cemented to the lower marginal edge of the upper to form a welt strip above the outsole. In a more preferred method of the invention, peripheral welting strip is wrapped with fabric prior to cementing it to the lower marginal edge of the upper.
The assembly produces footwear wherein all of the components are adhered and sealed together in a very efficient, economical and practical manner to produce footwear that are very comfortable, practicable, and usually economical.
The objects and advantages of the invention have therefore been shown to be attained in a convenient, practical, economical and facile manner.
While preferred embodiments of the invention have been herein illustrated and described, it is to be appreciated that various modifications, rearrangements and variations may be made therein without departing from the scope of the invention as defined by the appended claims.
