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  Article of footwear and associated of manufactureUSPTO Application #: 20060026862Title: Article of footwear and associated of manufacture Abstract: A method for manufacturing an article of footwear utilizes an insole body. A mask is attached to a lower surface of the insole body so as to cover a substantial portion of the lower surface. A coating is applied to the insole body with the mask attached thereto to cover exposed surfaces of the insole body. Thereafter the mask is removed from the insole body to expose the substantial portion of the lower surface. The insole body is adhesively attached along the lower surface to an upper surface of an outsole. Preferably at least part of the exposed lower surface of the insole body is adhesively attached to the upper surface of the outsole. (end of abstract) Agent: R. Neil Sudol - Bridgeport, CT, US Inventor: Bruce Cagner USPTO Applicaton #: 20060026862 - Class: 036011500 (USPTO) Related Patent Categories: Boots, Shoes, And Leggings, Boots And Shoes, Sandals The Patent Description & Claims data below is from USPTO Patent Application 20060026862. Brief Patent Description - Full Patent Description - Patent Application Claims
BACKGROUND OF THE INVENTION [0001] This invention relates to footwear and a method of manufacture therefor. [0002] Certain types of sandals include an insole bonded to an outsole where the insole and outsole are made of different materials. Typically, the insole is made of a soft or spongy material for purposes of enhancing the comfort of the wearer. The insole functions in part as a shock absorber and in part as a means of instantaneously molding the shoe to the wearer's foot. The outsole is typically made of a harder material for purposes of wear resistance. The outsole protects the wearer and the insole from potential damage caused by irregular ground features. [0003] The material of the insole is typically a porous compressible material. In some sandals of this type, the insole may be provided with a coating of a nonporous material such as polyvinyl chloride exemplarily for aesthetic reasons. A shiny vinyl topcoat provides a visual impact and a smooth textural feel markedly different from that of a spongy porous rubber or thermoplastic resin material. [0004] To apply the coating to the insole, it is cusomtary to dip the entire insole in a vat of liquid vinyl. Thus, the bottom of the insole is coated as well as the top and sides of the insole. The vinyl coating on the bottom surface of the insole body is then cemented to an upper surface of an outsole. OBJECTS OF THE INVENTION [0005] It is an object of the present invention to provide a new method of manufacturing a shoe of the above-described type. [0006] Another object of the present invention is to provide such a method of manufacture that reduces the amount of coating material needed on the insole. [0007] A further object of the present invention is to provide such a method of manufacture that enables a direct bond between the main material of the insole and the upper surface of the outsole. [0008] Yet another object of the present invention is to provide a shoe of novel construction. [0009] These and other objects of the present invention will be apparent from the drawings and descriptions herein. Although every object of the invention is believed to be attained by at least one embodiment of the invention, there is not necessarily any one embodiment that achieves all of the objects of the invention. SUMMARY OF THE INVENTION [0010] A method for manufacturing an article of footwear comprises, in accordance with the present invention, providing an insole body, attaching a mask to a lower surface of the insole body so as to cover a substantial portion of the lower surface with the mask, applying a coating to the insole body with the mask attached thereto to cover exposed surfaces of the insole body, thereafter removing the mask from the insole body to expose the substantial portion of the lower surface, and adhesively attaching the insole body along the lower surface to an upper surface of an outsole. Preferably at least part of the exposed lower surface of the insole body is adhesively attached to the upper surface of the outsole. [0011] Pursuant to another feature of the present invention, the coating is applied by dipping at least a portion of the insole body with the mask attached thereto in a reservoir of liquid coating material. The liquid coating material is preferably a polymeric material such as polyvinyl chloride. [0012] The insole may be dipped in a vertical or a horizontal orientation. In the vertical orientation, the mask on the lower surface of the insole is covered with layer of the coating material. This layer of coating is susbequently removed, either before or simultaneously with the mask. [0013] Where the insole has a horizontal orientation during the dipping process, the mask faces upwardly. Although the mask may be completely covered with a coating layer, it is possible using the horizontal orientation to largely limit the coating to the upper and side surfaces of the insole. Some of the liquid coating material may drift onto the mask. Howwever, the amount of coating material utilized can be reduced, resulting in materials cost savings. [0014] Pursuant to a further feature of the present invention, the manufacturing method additionally comprises cutting at least one hole in the insole body after the dipping of the insole body in the liquid coating material. The hole extends from an upper surface of the insole body to the lower surface. An end portion of a shoe upper is inserted through the hole prior to the adhesive attaching of the exposed substantial portion of the lower insole surface to the upper surface of the outsole. [0015] The dipping of the insole body with the mask attached thereto in the liquid coating material may include inserting at least a portion of the insole body multiple times in the liquid coating material. This technique results in a shiny, even appearance of the polymeric coating. [0016] The insole body is preferably made of a soft or spongy foam material that compresses under pressure of the user's foot. The compressible material may be a rubber or polymeric foam material. In addition, the insole body is cut from a sheet of the compressible material. [0017] Peferably, the mask is attached to the lower surface of the insole via a releasable adhesive layer. Thus, the mask may be removed simply by peeling the mask away from the lower insole surface. The mask may be made of paper or polymeric material. [0018] Preferably, the mask is spaced on all sides from an edge of the lower insole surface. This procedure results in a shoe having an even appearance of coating about the lower periphery of the side surfaces. The aesthetic appeal of the shoe is thereby maintained. [0019] To remove the mask from the insole body, one typically cuts through the coating along an edge of the mask. Thereafter the mask is removed from the lower surface of the insole body. Where the coating extends over the mask, the coating on the mask may be removed from the insole together with the mask or separately prior to removal of the mask. [0020] An article of footwear comprises, in accordance with the present invention, an insole body of compressible material. The insole body has an upper surface, a lower surface, and a perimetrically extending side surface connecting the upper surface and the lower surface. The upper surface and the side surface are provided with a coating of water impervious polymer, while the lower surface being mostly free of the polymer. The lower surface of the insole body is adhered to a top surface of an outsole, while an upper member is attached at least to the outsole. [0021] The insole body is provided with at least one hole extending from the upper surface of the insole body to the lower surface, an end portion the upper member extending through the hole. Continue reading... Full patent description for Article of footwear and associated of manufacture Brief Patent Description - Full Patent Description - Patent Application Claims Click on the above for other options relating to this Article of footwear and associated of manufacture patent application. ###  How KEYWORD MONITOR works... a FREE service from FreshPatents1. Sign up (takes 30 seconds). 2. Fill in the keywords to be monitored. 3. Each week you receive an email with patent applications related to your keywords. Start now! - Receive info on patent apps like Article of footwear and associated of manufacture or other areas of interest. ### Previous Patent Application: Washer/dryer plumbing connection and method Next Patent Application: Shoe system Industry Class: Boots, shoes, and leggings ### FreshPatents.com Support Thank you for viewing the Article of footwear and associated of manufacture patent info. 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