阅读说明：本技术 一种用于制作鞋类物品的方法及鞋类物品 (Method for manufacturing footwear and footwear ) 是由 K·利利 于 2020-03-31 设计创作，主要内容包括：本发明涉及一种用于制作鞋类物品(100)的方法以及鞋类物品(100)。特别地,所述鞋类物品(100)是由硫化橡胶制成的靴子,例如惠灵顿靴子。一种用于制作鞋类物品(100)的方法,该方法包括以下步骤：提供由具有第一抗压强度的第一橡胶材料所制成的鞋底部件(2),该鞋底部件(2)包括位于鞋底部件(2)的鞋跟区域的上表面(2A)中的空腔(4)；将插入件(6)设置于空腔(4)中,所述插入件(6)具有低于第一抗压强度的第二抗压强度；而后在第一温度下进行硫化,从而将由第二橡胶材料制成的上部(8)附接至鞋底部件(2),其中,所述插入件(6)由在第一温度下为固体的材料制成。(The invention relates to a method for manufacturing an article of footwear (100) and to an article of footwear (100). In particular, the article of footwear (100) is a boot made of vulcanized rubber, such as a hulington boot. A method for making an article of footwear (100), the method comprising the steps of: providing a sole element (2) made of a first rubber material having a first compressive strength, the sole element (2) comprising a cavity (4) in an upper surface (2A) of a heel region of the sole element (2); -providing an insert (6) in the cavity (4), the insert (6) having a second compressive strength lower than the first compressive strength; and then vulcanising at a first temperature, thereby attaching an upper (8) made of a second rubber material to the sole element (2), wherein the insert (6) is made of a material that is solid at the first temperature.)

1. A method for making an article of footwear, the method comprising the steps of:

(a) providing a sole component made of a first rubber material having a first compressive strength, the sole component including a cavity in an upper surface of a heel region of the sole component;

(b) disposing an insert in the cavity, the insert having a second compressive strength that is lower than the first compressive strength; then the

(c) Vulcanizing at a first temperature to attach an upper made of a second rubber material to the sole component,

wherein the insert is made of a material that is solid at the first temperature.

2. The method defined in claim 1, wherein step (a) includes molding the sole component to form the cavity.

3. The method of claim 1 or 2, wherein the first rubber material comprises about 4% to about 6% by weight synthetic rubber and about 40% to about 50% by weight natural rubber based on the total weight of the first rubber material, and/or the second rubber material comprises about 4% to about 6% by weight synthetic rubber and about 40% to about 50% by weight natural rubber based on the total weight of the second rubber material.

4. The method of claim 3, wherein the first rubber material and/or the second rubber material consists essentially of:

the natural rubber is prepared from natural rubber,

the rubber is synthesized by the rubber compounding agent,

silica and/or calcium carbonate, and

one or more of zinc oxide, a promoter and an antioxidant.

5. The method of any of claims 1-4, wherein the insert comprises a plurality of air pockets or channels disposed within the insert.

6. The method of claim 5, wherein the air pockets or channels are regularly disposed within the insert.

7. A method according to claim 5 or 6, wherein the air pockets or channels form a honeycomb structure.

8. The method according to any one of claims 5 to 7, wherein the insert is made of a thermoplastic, preferably a thermoplastic polyurethane.

9. The method according to any one of claims 1 to 8, wherein the cavity extends at least 50% of a depth of the sole element in a surrounding area, and the insert is sized and shaped complementarily to the cavity.

10. The method according to any one of claims 1-9, wherein the cavity extends across at least 50% of a width of the sole element, and the insert is sized and shaped complementarily to the cavity.

11. A method according to any of claims 1 to 10, wherein the article of footwear is a boot having a height of at least 100mm, preferably at least 150mm, most preferably at least 200 mm.

12. An article of footwear produced according to the method of any of claims 1 to 11.

13. An article of footwear, comprising:

a sole component made of a first rubber material having a first compressive strength, the sole component including a cavity in a heel region;

an insert disposed in the cavity, the insert having a second compressive strength that is lower than the first compressive strength; and

an upper made of a second rubber material attached to the sole element,

wherein the insert is made of a material having a melting temperature above 140 ℃.

14. The article of footwear of claim 13, wherein the first rubber material comprises about 4% to about 6% by weight synthetic rubber and about 40% to about 50% by weight natural rubber based on a total weight of the first rubber material, and/or the second rubber material comprises about 4% to about 6% by weight synthetic rubber and about 40% to about 50% by weight natural rubber based on a total weight of the second rubber material.

15. The article of footwear according to claim 14, wherein the first rubber material and/or the second rubber material substantially comprises:

the natural rubber is prepared from natural rubber,

the rubber is synthesized by the rubber compounding agent,

silica and/or calcium carbonate, and

one or more of zinc oxide, a promoter and an antioxidant.

16. The article of footwear of any of claims 13-15, wherein the insert includes a plurality of air pockets or channels disposed therein.

17. The article of footwear of claim 16, wherein the air pockets or channels are regularly disposed in the insert.

18. The article of footwear of claim 16 or 17, wherein the air pockets or channels form a honeycomb structure.

19. The article of footwear according to any of claims 13 to 18, wherein the cavity extends at least 50% of a depth of the sole element in a surrounding area, and the insert is sized and shaped complementarily to the cavity.

20. The article of footwear according to any of claims 13 through 19, wherein the cavity extends across at least 50% of a width of the sole element, and the insert is sized and shaped complementarily to the cavity.

21. The article of footwear of any of claims 13 to 20, wherein the article of footwear is a boot having a height of at least 100mm, preferably 150mm, most preferably 200 mm.

Technical Field

The invention relates to a method for manufacturing an article of footwear and an article of footwear. In particular, the article of footwear is a boot formed of vulcanized rubber, such as a hulington boot (Wellington boot).

Background

Methods of manufacturing such boots are generally well known and involve vulcanizing a rubber material to shape such material into the boot, thereby attaching a sole component to the upper of the boot. Vulcanization is the process of curing the elastomer, and the terms vulcanization and curing are sometimes used interchangeably. Traditionally, the sole components of a vulcanized shoe are made from a solid piece of rubber material. Such rubber materials are very heavy and can be uncomfortable for the user to wear in view of the natural characteristics of the rubber. In other articles of footwear, conventional materials used to enhance comfort often cannot withstand the vulcanization process.

Accordingly, there is a need for an improved method for making an article of footwear and an article of footwear.

Disclosure of Invention

According to claim 1, a method for making an article of footwear according to the invention is provided. The method allows for the formation of a vulcanized rubber article of footwear while enhancing comfort and reducing the weight of the article of footwear.

Step (a) may comprise moulding the sole element to form the cavity. Molding is a particularly effective method of forming rubber materials.

The first rubber material may comprise about 4% to about 6% by weight of synthetic rubber and about 40% to about 50% by weight of natural rubber, based on the total weight of the first rubber material, and/or the second rubber material comprises about 4% to about 6% by weight of synthetic rubber and about 40% to about 50% by weight of natural rubber, based on the total weight of the second rubber material.

The first rubber material and/or the second rubber material may consist essentially of: natural rubber, synthetic rubber, silica and/or calcium carbonate, and one or more of zinc oxide, accelerators and antioxidants.

The insert may include a plurality of air pockets or channels disposed within the insert. These air pockets or channels serve to reduce the compressive strength of the material. In particular, materials whose compressive strength is too great to be buffered as a solid block can be changed to a buffer material by introducing these air pockets or channels. This also reduces the weight of the insert.

The air pockets or channels may be regularly arranged within the insert. Regularly arranged air pockets or channels distribute the compressive strength evenly over the entire insert.

The air pockets or channels may form a honeycomb structure. Honeycomb is an effective mode of these air pockets or channels.

The insert may be formed of a thermoplastic, preferably a thermoplastic polyurethane. This material can withstand high temperature vulcanization. They typically have too much compressive strength to be used as cushioning inserts, but air pockets or channels enable them to cushion.

The cavity may extend at least 50% of the depth of the sole element into the surrounding area, and the insert is sized and shaped to be complementarily formed with the cavity. This allows the insert to have a particularly pronounced cushioning effect.

The cavity may extend across at least 50% of the width of the sole element and the insert may be sized and shaped to be complementarily formed with the cavity. This allows the insert to contact the wearer's sole of the foot over a substantial portion of the wearer's heel.

The article of footwear may be a boot having a height of at least 100mm, preferably at least 150mm, and most preferably at least 200 mm. Boots of this size are usually made of such rubber materials.

An article of footwear according to the invention produced according to the method of any one of claims 1 to 11. This is an article of vulcanized rubber footwear having enhanced comfort and reduced weight.

According to claim 12, an article of footwear according to the invention is provided. This is an article of vulcanized rubber footwear having enhanced comfort and reduced weight.

The first rubber material may comprise about 4% to about 6% by weight of synthetic rubber and about 40% to about 50% by weight of natural rubber, based on the total weight of the first rubber material, and/or the second rubber material comprises about 4% to about 6% by weight of synthetic rubber and about 40% to about 50% by weight of natural rubber, based on the total weight of the second rubber material.

The first rubber material and/or the second rubber material may mainly comprise natural rubber, synthetic rubber, silica and/or calcium carbonate, and one or more of zinc oxide, accelerators and antioxidants.

The insert may include a plurality of air pockets or channels disposed within the insert. These air pockets or channels can reduce the compressive strength of the material. In particular, materials whose compressive strength is too great to be buffered as a solid block can be changed to a buffer material by introducing these air pockets or channels. This also reduces the weight of the insert.

The air pockets or channels may be regularly arranged within the insert. Regularly arranged air pockets or channels distribute the compressive strength evenly over the entire insert.

The air pockets or channels may form a honeycomb structure. Honeycomb is an effective mode of these air pockets or channels.

The cavity may extend at least 50% of the depth of the sole element into the surrounding area, and the insert is sized and shaped to be complementarily formed with the cavity. This results in a particularly pronounced damping effect of the insert.

The cavity may extend across at least 50% of the width of the sole element and the insert may be sized and shaped to be complementarily formed with the cavity. This allows the insert to contact the wearer's sole of the foot over a substantial portion of the wearer's heel.

The article of footwear may be a boot having a height of at least 100mm, preferably 150mm, and most preferably 200 mm. Boots of this size are usually made of such rubber materials.

Drawings

The invention will now be described with reference to the accompanying drawings, in which:

FIG. 1 shows a longitudinal cross-section of an article of footwear according to the present invention;

FIG. 2 shows a plan cross-sectional view of the article of footwear of FIG. 1;

FIG. 3 illustrates a bottom view of the article of footwear of FIG. 1;

FIG. 4 illustrates a transverse cross-sectional view of the article of footwear along line H-H of FIG. 1;

FIG. 5 shows a schematic view of one possible configuration of an insert for the article of footwear of claim 1; and

FIG. 6 illustrates a flow chart of a method for making an article of footwear according to the present invention.

Detailed Description

Fig. 1 shows an article of footwear 100 according to the present invention. Article of footwear 100 includes sole element 2. Sole element 2 may be formed from one or more elements of a sole structure. In particular, the sole element 2 may be an outer sole, a mid sole or an inner sole. In a preferred embodiment, the sole element 2 may be an outsole or midsole. Sole element 2 may be configured to contact the ground during use of article of footwear 100. Sole element 2 is made of a first vulcanized rubber material and is generally shaped to conform to a human foot. Such a first vulcanized rubber material will have a first compressive strength.

The first rubber material (prior to being vulcanized to form the first vulcanized rubber material) may comprise natural rubber and/or synthetic rubber. In one embodiment, the first rubber material comprises at least 5%, preferably at least 25%, more preferably at least 35%, most preferably at least 45% by weight of natural and/or synthetic rubber, based on the total weight of the first rubber material. In one embodiment, the first rubber material may comprise at most 95% by weight of natural and/or synthetic rubber, preferably at most 75%, more preferably at most 65%, most preferably at most 55% by weight of natural and/or synthetic rubber, based on the total weight of the first rubber material. In a preferred embodiment, the first rubber material comprises from about 35% to about 65%, more preferably from about 45% to about 55%, by weight of natural and/or synthetic rubber. In a preferred embodiment, the first rubber material comprises about 50% by weight of natural rubber and/or synthetic rubber. Preferably, the first rubber material comprises natural rubber and synthetic rubber.

In one embodiment, the amount of natural rubber in the first rubber material is at least 15%, preferably at least 25%, more preferably at least 35%, most preferably at least 40% by weight based on the total weight of the first rubber material. In one embodiment, the amount of natural rubber in the first rubber material is at most 75%, preferably at most 65%, more preferably at most 55%, most preferably at most 50% by weight. In a preferred embodiment, the amount of natural rubber in the first rubber material is from about 35% to about 55%, preferably from about 40% to about 50%, most preferably about 45% by weight based on the total weight of the first rubber material.

In one embodiment, the amount of synthetic rubber in the first rubber material is at least 1%, preferably at least 2%, more preferably at least 3%, most preferably at least 4% by weight based on the total weight of the first rubber material. In one embodiment, the amount of synthetic rubber in the first rubber material is at most 20%, preferably at most 15%, more preferably at most 10%, even more preferably at most 8%, most preferably at most 6% by weight. In a preferred embodiment, the amount of synthetic rubber in the first rubber material is from about 3% to about 7%, preferably from about 4% to about 6%, most preferably about 5% by weight based on the total weight of the first rubber material.

In a preferred embodiment, the first rubber material comprises about 40% to about 50% natural rubber and about 4% to about 6% synthetic rubber. In a most preferred embodiment, the first rubber material comprises about 45% natural rubber and about 5% synthetic rubber.

The first rubber material may further comprise one or more fillers. Suitable fillers are known in the art. Preferably, the first rubber material comprises silica and/or calcium carbonate, preferably silica and calcium carbonate. In a preferred embodiment, the total amount of the one or more fillers is from about 35% to about 55%, preferably from about 40% to about 50%, most preferably about 45% by weight, based on the total weight of the first rubber material.

The first rubber material may further comprise one or more additives to improve strength, heat resistance and/or stability to ultraviolet radiation. Suitable additives are known in the art. Preferably, the first rubber material comprises one or more of zinc oxide, an accelerator and an antioxidant, preferably the first rubber material comprises zinc oxide, an accelerator and an antioxidant. In a preferred embodiment, the total amount of one or more of zinc oxide, accelerator and antioxidant is from about 3% to about 7%, preferably from about 4% to about 6%, most preferably about 5% by weight, based on the total weight of the first rubber material.

In a preferred embodiment, the first rubber material comprises by weight about 40% to about 50% natural rubber, about 4% to about 6% synthetic rubber, about 40% to about 50% silica and calcium carbonate, and about 4% to about 6% zinc oxide, accelerators and antioxidants.

Preferably, the first rubber material comprises natural rubber, synthetic rubber, silica and/or calcium carbonate, and one or more of zinc oxide, accelerators and antioxidants, each present in the amounts described herein.

"synthetic rubber" means any synthetic elastomer. Typically, these are polymers synthesized from petroleum by-products. Exemplary synthetic rubbers include styrene-butadiene copolymers, nitrile rubber, neoprene rubber, ethylene-propylene-diene-monomer rubber, silicone rubber, and butyl rubber.

"Natural rubber" refers to rubber obtained from non-petroleum sources. Generally, natural rubber is a biosynthetic polymer which is obtained in the form of an aqueous solution from a tree known as "hevea brasiliensis". Natural rubber is predominantly poly-cis-isoprene, which typically contains up to about 5% by weight of other materials such as proteins, fatty acids, resins, and inorganic salts.

Any accelerator or antioxidant known in the art may be used in the rubber material according to the invention. Exemplary accelerators that may be used include accelerators formed from sulfenamides, thiazoles, thiurams, and dithiocarbamates. Exemplary antioxidants that may be used include antioxidants derived from phenols, secondary aromatic amines, and benzimidazoles.

Sole element 2 further includes an upper surface 2A having a cavity 4 formed therein. Cavity 4 is generally formed in the heel area of article of footwear 100. That is, the area that is arranged to contact the heel of a user's foot in use. The cavity may extend at approximately 50% of the depth of sole element 2 at the heel region.

An insert 6 is arranged in the cavity 4. An insert 6 is disposed within the cavity 4 and may be retained therein by any suitable method. For example, the insert 6 may be retained within the cavity 4 by way of an interference fit or by applying an adhesive to one or both of the insert 6 or the cavity 4. The insert 6 has a second compressive strength. This second compressive strength is lower than the first compressive strength of sole element 2. That is, the insert 6 is softer than the sole element 2. In this way, insert 6 may be perceived as more comfortable to a user of article of footwear 100. Insert 6 is generally sized and shaped to complement cavity 4 of article of footwear 100. That is, insert 6 is arranged to fill substantially all of the void and form a substantially continuous upper layer 2A of sole element 2.

Article of footwear 100 further includes upper 8. The upper portion 8 may be a shoe upper or may be any sub-component thereof. Upper 8 is formed from a second rubber disulfide material and is attached to sole element 2 through a vulcanization process. The second vulcanized rubber material may have the same composition as described herein with respect to the first vulcanized rubber material. In one embodiment, the second vulcanized rubber material may be the same as the first vulcanized rubber material. Alternatively, the first vulcanized rubber material and the second vulcanized rubber material may be of different compositions, selected for their mechanical properties that are more suitable for their respective tasks.

Vulcanization is a chemical process used to harden rubber. Traditionally, this has involved the use of sulfur to treat natural rubber, but now extends to the hardening of other synthetic and natural rubbers by various methods. Typically, the vulcanization process is carried out at a temperature in the range of 140 ℃ to 180 ℃. The insert 6 is thus made of a material which is solid at least 140 c, preferably at least 180 c. That is, the material has a melting temperature above 140 ℃, preferably above about 180 ℃. Thus, during vulcanization to attach upper 8 to sole element 2, insert 6 does not melt. One example of a suitable material for the insert 6 is a thermoplastic. In particular, Thermoplastic Polyurethane (TPU) may be suitable as material for the insert 6.

However, such materials capable of withstanding vulcanization may be less comfortable than other insert materials that are unstable at these temperatures. Thus, the insert 6 may then preferably not be a solid block. Instead, the insert 6 may comprise a structure made of this material.

For example, fig. 5 shows an exemplary insert 6. The insert 6 is formed of a material that includes a plurality of air pockets or channels 42. The air pocket or channel 42 may be an open end as shown in fig. 5, or may have a closed end. There may also be a lateral closure within the air pocket or channel 42. These air pockets or channels 42 may be regularly arranged within the insert 6. For example, as shown in fig. 5, air pockets or channels may be provided to form a honeycomb structure. I.e. a hexagonal damascene structure as shown in fig. 5. Alternatively, any other arrangement is possible. In particular, other tessellation arrangements may be suitable. Each air pocket or passage 42 need not have the same shape. The shape of the air pockets or channels 42 selected may be complementary to impart specific characteristics to the insert 6. For example, certain arrangements may provide the insert 6 with a higher or lower compressive strength. In some embodiments, insert 6 may be selected to provide specific characteristics that a user desires article of footwear 100 to have. In some arrangements, the air pockets or channels may be irregularly arranged and/or shaped to facilitate changing a characteristic of the insert 6, such as compression resistance.

As shown in FIG. 2, insert 6 generally conforms to the shape of the user's heel located in the heel region of article of footwear 100. The insert 6 may extend across at least 50% of the width of the sole element 2. Preferably, the insert may extend across at least 70% of the width of the sole element 2. The bottom surface of article of footwear 100 is shown in fig. 3, and a cross-section taken along line H-H in fig. 1 is shown in fig. 4. Figure 4 re-illustrates the extent of depth and width that insert 6 extends within sole element 2.

According to the present invention, there is also provided a method for making an article of footwear 100 according to the present invention. The method is shown in figure 6 and comprises a first step 601 of providing a sole element 2 made of a first rubber material. The first vulcanized rubber material has a first compressive strength. The sole element 2 includes a cavity 4 located in an upper surface 2a of the heel region of the sole element 2. In step 603, an insert 6 is disposed in the cavity 4 of the sole element 2. The insert 6 has a second compressive strength which is lower than the first compressive strength of the rubber material of the sole element 2. In step 605, sole element 2 and insert 4 are then vulcanized, thereby attaching upper 8 to sole element 2. The upper part 8 is made of a second rubber material, which may be the same or different from the first rubber material. The sulfurization is carried out at a first temperature. The first temperature may be in the range of 140 ℃ to 180 ℃. The insert 8 is made of a material that is solid at this first temperature. That is, the insert 8 is made of a material having a melting temperature higher than the first temperature.

A first step 601 may include molding sole element 2 to form cavity 4. That is, the mould for the sole element 2 may include a protrusion to prevent the first rubber material from filling the area of the cavity 4. Alternatively, the cavity 4 may be formed by removing material from the already moulded sole element 2.

As discussed above with respect to article of footwear 100, insert 6 may generally be formed to enhance the comfort of a user of article of footwear 100. To further enhance this comfort, the insert 6 may be formed as a structure including a plurality of air pockets or channels 42. These air pockets or channels 42 may be regularly arranged within the insert 6, for example, to form a plurality of generally tessellated shapes. These shapes may all be the same, for example in a honeycomb structure, or the structure may comprise a structure having different shapes.

Any feature described in relation to any one embodiment of the invention may be incorporated into other embodiments. Article of footwear 100 may be a boot having a height of at least 100mm, preferably at least 150mm, and most preferably at least 200 mm. In particular, the article of footwear 100 may be a Whington boot (Wellington boot). I.e. boots generally made of rubber (natural or synthetic) designed to be waterproof and made by a vulcanization process.