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  Bonding of an upper and a shell in a shoeUSPTO Application #: 20060005424Title: Bonding of an upper and a shell in a shoe Abstract: A shoe upper and a shoe shell are attached to one another by molding. The upper is placed on a mold core, which includes a portion resembling a foot and a portion on which the upper fits. A flap provided on the upper extends along at least a portion of a bottom rim of the upper and has opposing interior and exterior sides. A mold is provided around the mold core and the flap so as to define a cavity between the mold and the mold core. The flap extends into the cavity so that both the interior and exterior sides of the flap are exposed within the cavity. A shell material is introduced into the cavity so as to mold the shell material directly around the mold core portion resembling a foot and to cohere the shell material to both the interior and exterior sides of the flap. (end of abstract) Agent: Stoel Rives LLP - Portland, OR, US Inventors: Daniel S. Laska, Daniel C. Bennette USPTO Applicaton #: 20060005424 - Class: 036004000 (USPTO) Related Patent Categories: Boots, Shoes, And Leggings, Boots And Shoes, Rubber The Patent Description & Claims data below is from USPTO Patent Application 20060005424. Brief Patent Description - Full Patent Description - Patent Application Claims
TECHNICAL FIELD [0001] This disclosure relates generally to shoes and more particularly to bonding of an upper and a shell in a shoe. BACKGROUND [0002] Shoes provide an important barrier between our feet and the physical world. In many circumstances, such as cold-weather environments, a waterproof shoe is desirable. However, the consumer market for shoes is a highly competitive market, in which buyers demand low prices. Thus, additional shoe features, such as waterproofing, will not lead to commercial success, unless those features can be provided affordably. Because making shoes is a labor-intensive activity, costs are most effectively contained by minimizing the amount of labor needed to add new features to shoes. SUMMARY [0003] According to one method, a shoe shell is attached to a shoe upper by molding. The upper is placed on a mold core, which includes a portion resembling a foot and a portion on which the upper fits. A flap provided on the upper extends along at least a portion of a bottom rim of the upper and has opposing interior and exterior sides. A mold is provided around the mold core and the flap so as to define a cavity between the mold and the mold core. The flap extends into the cavity so that both the interior and exterior sides of the flap are exposed within the cavity. A shell material is introduced into the cavity so as to mold the shell material directly around the mold core portion resembling a foot and to cohere the shell material to both the interior and exterior sides of the flap. [0004] According to another method, a shoe shell is attached to a shoe upper without stitching. The upper has opposing interior and exterior sides and a bottom periphery rim for attachment to the shell. The shell has a top periphery rim, which coheres to portions of both the interior and exterior sides of the upper in proximity to the bottom periphery rim of the upper. [0005] A shoe may be made in accordance with either method described in the preceding paragraphs. Regardless of its method of manufacture, a shoe comprises an upper and a shell. The upper has opposing interior and exterior sides and a bottom rim. The shell has an upper rim, which coheres to at least portions of both the interior and exterior sides of the upper in proximity to the bottom rim of the upper, without stitching of the upper to the shell. As used herein, the term "shoe" encompasses all types of footwear, including, for example, boots. BRIEF DESCRIPTION OF THE DRAWINGS [0006] FIG. 1 is a side view of a shoe upper on a mold core, according to one embodiment. [0007] FIG. 2 is a side cross-section view of a mold being placed around a portion of the shoe upper and mold core of FIG. 1. [0008] FIG. 3 is a partial cross-section view of a shoe shell formed within the mold of FIG. 2. [0009] FIG. 4 is the shoe of FIG. 3 in the process of being removed from the surrounding mold. [0010] FIG. 5 is cross-section view of toe portion of the shoe, mold core, and mold of FIG. 3, taken along line 5-5 of FIG. 3. [0011] FIG. 6 is an enlarged cross-section view of a bond between the upper and shell of the shoe of FIG. 3, according to a first embodiment. [0012] FIG. 7 is an enlarged cross-section view of a bond between the upper and shell of the shoe of FIG. 3, according to a second embodiment. DETAILED DESCRIPTION OF EMBODIMENTS [0013] With reference to the above-listed drawings, this section describes particular embodiments and their detailed construction and operation. As one skilled in the art will appreciate, certain embodiments may be capable of achieving certain advantages over the known prior art, including some or all of the following: (1) attachment of a shoe shell to an upper without stitching; (2) a waterproof interface between a shoe shell and an upper; (3) simpler and less expensive construction; and (4) greater design freedom by relaxing restrictions on permissible curves and angles imposed by a stitching allowance. These and other advantages of various embodiments will be apparent upon reading the following. [0014] FIGS. 1-4 illustrate steps of a method for assembling a shoe according to one embodiment. Generally, that method comprises placing a shoe upper on a mold core, placing a mold around portions of the upper and mold core, molding a shell material between the mold and the mold core to form a shell cohered to the upper, and removing the mold and mold core after the shell material has solidified in the form of the shell. [0015] As shown in FIG. 1, the first step of the method is to place a shoe upper 100 on a mold core 110. The mold core 110 comprises a top portion 120 generally resembling an ankle and a bottom portion 130 generally resembling a foot. The ankle-like top portion 120 and the foot-like bottom portion 130 may be separate or integral. Although the mold core 110 is preferably solid, that need not be the case; the mold core 110 may be an inflatable bladder, for example. The mold core 110 is preferably formed of metal, such as stainless steel, which can be exposed to high-temperature molding materials without significant deformation or deterioration. [0016] The upper 100 may be any material suitable for a shoe upper, such as natural leather, synthetic leather, a textile, or the like. The upper 100 is preferably waterproof, as the interface between it and a shell (not shown in FIG. 1) below the upper 100 can be made waterproof, as explained below. Examples of waterproof materials suitable for the upper 100 include waterproof leather and textiles with a waterproof membrane or coating, such as, for example, an expanded polytetraflouroethylene membrane commonly sold under the trademarks GORETEX.RTM. and EVENT.RTM., or a polyurethane coating. In one form, the upper 100 is a two-ply material of textile on the exterior side and a waterproof membrane or coating on the interior side (although the waterproof layer can be on the exterior side, if desired). [0017] The upper 100 has two opposing sides: an interior side 140 and an exterior side 150. Along the bottom of the upper 100 is a bottom periphery rim 160. The interior side 140 generally fits snugly against the mold core 110, except along the bottom periphery rim 160, which may be more loosely disposed on the mold core 110. Optionally, jigs, pins, pegs, pinchers and wipers, or the like (not shown) can be fitted between the mold core 110 and the interior side 140 of the upper 100 in the vicinity of the bottom periphery rim 160 to separate the upper 100 from the mold core 110 along the bottom periphery rim 160 or portions thereof. Alternatively or additionally, the bottom periphery rim 160 is or comprises a flap of the upper 100. As will be described in greater detail below, that flap is an area of attachment of the upper to a shell (not shown in FIG. 1), which goes around the bottom portion of the mold core 110. The flap may be a stitch flange (although it is not attached by stitching) provided on the interior side 140 of the upper 100 and may extend downward about 8 millimeters (mm), for example. [0018] A next step is shown in FIG. 2, which is a side cross-section view of a mold 200 being placed around a portion of the shoe upper 100 and the mold core 110. In most cases the mold 200 comprises two pieces, such as a front mold piece 210 and a rear mold piece 220, as shown in FIG. 2. Other arrangements for a two-piece mold are possible, e.g., top and bottom pieces, left and right side pieces, etc. Although a two-piece mold offers the advantage of being separable while minimizing the number of joints between pieces, a mold can be formed with three or more pieces. As shown, the front mold piece 210 is moved over the toe portion of the mold core 110 and the rear mold piece 220 is moved over the heel portion of the mold core 110 until mating surfaces 230 abut and preferably engage in a more-or-less sealing contact. Ideally, the mating surfaces 230 are built with sufficient precision to fit together and seal against each other. The mating surfaces may have complementary tongue-in-groove or other surface features to enhance their seal. [0019] When the front mold piece 210 and the rear mold piece 220 contact, they define an interior chamber, in which is typically disposed the mold core 110, or a portion thereof, clad with the upper 100. The interior cavity is defined by an interior wall 240 of the mold 200. A bottom portion of the interior chamber is slightly larger than the foot-like bottom portion 130 of the mold core 110. Thus, when the mold 200 is fully engaged around the mold core 110, there is a cavity or space between the interior wall 240 of the mold 200 and the mold core 110. It is in that cavity where the shell will be formed, as described in further detail below. Continue reading... Full patent description for Bonding of an upper and a shell in a shoe Brief Patent Description - Full Patent Description - Patent Application Claims Click on the above for other options relating to this Bonding of an upper and a shell in a shoe 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 Bonding of an upper and a shell in a shoe or other areas of interest. ### Previous Patent Application: Sole structure of goodyear's dual-intake air-capsule shoes Next Patent Application: Elastic overshoe with modular sole pads Industry Class: Boots, shoes, and leggings ### FreshPatents.com Support Thank you for viewing the Bonding of an upper and a shell in a shoe patent info. 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