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  Injection molded phylon midsoleUSPTO Application #: 20060143950Title: Injection molded phylon midsole Abstract: Disclosed is an injection molded Phylon (foam ethylene vinyl acetate) midsole having distinguished advantages, such as increased productivity, improved quality, decreased manufacturing cost, reduced fraction defective, reduced weight or the like, in relation to a conventional injection molded Phylon midsole. The injection molded Phylon midsole is manufactured by an upper molding and a lower molding. The midsole (10) is formed with a vertical through-groove (11), a horizontal through-groove (11), or a cross through-groove (11). When the midsole (10) is bonded to an outsole (2), the midsole (10) of a proper size within an allowable variation or deviating from the allowable variation widens or constrains the through-groove (11), so that the midsole (10) is exactly bonded to the outsole (2) without deforming the midsole. (end of abstract) Agent: Notaro And Michalos - Orangeburg, NY, US Inventor: Soo-Ho Beak USPTO Applicaton #: 20060143950 - Class: 036097000 (USPTO) Related Patent Categories: Boots, Shoes, And Leggings, Boots And Shoes, With Adjustment Of Shoe Size The Patent Description & Claims data below is from USPTO Patent Application 20060143950. Brief Patent Description - Full Patent Description - Patent Application Claims
TECHNICAL FIELD [0001] The present invention relates to an injection molded Phylon (foam ethylene vinyl acetate) midsole having distinguished advantages, such as increased productivity, improved quality, decreased manufacturing cost, reduced fraction defective, reduced weight or the like, in relation to a conventional injection molded Phylon midsole. BACKGROUND ART [0002] Recently, as shoes are trend toward a high quality, shoe midsoles are made from Phylon having some physical properties comprising light weight, high elasticity and good shock absorption. A conventional Phylon midsole is manufactured in a sheet shape, and is cut by a press moldinging of the same size as that of a midsole to be made. Then, the cut midsole is ground to conform to a correct shape of the wanted midsole. [0003] Since the midsole is cut (punched) by the press molding of the same size as the midsole, a required size variation of the midsole is not large. Therefore, the conventional method may reduce a fraction defective related to the variation. Because material loss is excessive (about 40%) after carrying out the press process, and its productivity is poor, mass production is difficult. For the above reasons, a manufacturing cost is increased, and wasted material should be processed. The method is hardly used at present due to the cumbersome and economical loss. [0004] In order to solve the above problems contained in the conventional method of manufacturing the midsole, a method of manufacturing a Phylon midsole using injection molding has been proposed. Specifically, a volume of a midsole molding consisting of an upper molding and a lower molding is adapted to have 60% size relative to actual size of the midsole. Preheated ethylene vinyl acetate comprising a forming agent is injected into the moldings. After the upper and lower moldings are heated during a predetermined time, when the upper and lower moldings are opened, the midsole expanded in the upper and lower moldings is released from the moldings. The injection molded Phylon midsole is completed by the above process. However, since the midsole is formed in the upper and lower moldings at a high pressure and a high temperature and is expanded at the same time as the open of the upper and lower moldings, a size variation of the completed midsole is serious due to factors such as a compounding ratio of the forming agent, a temperature variation of machines, a temperature variation of worksite, weather, a temperature variation resulted from thermal conductivity of heat transferred from an exterior of the molding to an interior thereof. Therefore, it is impossible to manufacture the midsole of uniform size, and a fraction defective is increased, thereby causing the economical loss and failing a production scheme. [0005] Meanwhile, because the midsole has to be adhered and fixed between an outsole and a shoe upper, each having the same size as the midsole, in an exactly conforming size, the size variation of the midsole is very important factor. In general, since a shoe is made in unit of 5 mm every size, an allowable size variation of the injection molded Phylon midsole used in present is within a range of .+-.2 to 3 mm relation to a standard size. The midsole deviating from the variation range is not actually allowed due to the defective problem, and is not used. Specifically, the midsole deviating from the variation range of +2 to 3 mm falls into disuse. The present invention can manufacture all of midsoles without falling into disuse. [0006] Considering a method of bonding the midsole with an outsole, after an adhesive is applied on a bottom surface of a midsole 1 or an upper surface of an outsole 2, the midsole 1 is bonded to the outsole 2 by carefully bonding edges of them and then forcibly pressing a center portion thereof using a press (referring to FIG. 2). The midsole 1 having a variation of average 2 to 3 mm is forcibly bonded to the outsole 2 to make a shoe, but the completed shoe is almost deformed into a shape shown in FIG. 2. Accordingly, the midsole having a variation of above .+-.3 mm should fall into disuse. [0007] Referring to FIG. 2 to prove the reason, since the bond is started from the edge of the midsole 1 having a size which does not coincide with that of the outsole 2, and the center portion of the midsole is bonded to the center portion of the outsole by the press, the midsole 1 tends to return to its original size. Specifically, since the bottom surface of the midsole 1 is bonded to the upper surface of the outsole, the bottom surface of the midsole cannot be deformed. Force tending to return to its original size acts upon the upper surface and side of the midsole 1. Therefore, side protrusions 1b of the midsole 1 are widened left and right (toward an exterior of the shoe), and the center portion of the midsole convexes to form a center bossed portion 1a. Therefore, the center portion of the outsole 2 is deformed with the midsole 1 to form a center bossed portion 2a and thus make a deformed article. Meanwhile, if the outsole is boned to the midsole of a small size than that of the outsole, a phenomenon contrary to the above description happens. Specifically, the protrusions 1b are moved toward the center thereof, and the center bossed portion 1a are protruded not upwardly but downwardly to a bottom of the midsole 1, i.e., the outsole 2, so that the center portion of the outsole 2 convexes toward the bottom (the ground). These cases must be a defective. [0008] In the case of bonding the conventional midsole 1 and the outsole 2, although the state deformed after the bond is not distinctly depicted in FIG. 2, it will be understood that it may be deformed as shown in FIG. 2 on the basis of the standard. If the midsole deviating from a variation range of .+-.2 mm is used, the defective deformed as shown in FIG. 2 necessarily happen. Therefore, the midsole having a variation range of 3 mm must fall into disuse. Since the shoe is made in unit of 5 mm every size, if the variation of the midsole is close to +5 mm or -5 mm, the interest midsole may be used as a higher size or a lower size. [0009] Therefore, the shoes made from the conventional midsole have a poor landing feeling and cause inconvenience to wearer's feet. Since the side protrusions 1b always tend to be outwardly spread or inwardly shrunk, the bonding force of the midsole to the shoe upper becomes weak, thereby dissatisfying a consumer. In addition, since the Phylon midsole is not reusable, it falls into disuse as an industrial waste, thereby causing an economical loss and going against environmental protection. DISCLOSURE OF THE INVENTION [0010] Therefore, an object of the present invention is to solve the problems involved in the prior art, and to provide an injection molded Phylon midsole. [0011] In order to accomplish the above and other objects, there is provided an injection molded Phylon midsole manufactured by an upper molding and a lower molding, wherein the midsole is formed with a vertical through-groove, a horizontal through-groove, or a cross through-groove, and wherein when the midsole is bonded to an outsole, the midsole of a proper size within an allowable variation or deviating from the allowable variation widens or constrains the through-groove, so that the midsole is exactly bonded to the outsole without deforming the midsole. BRIEF DESCRIPTION OF THE DRAWINGS [0012] The above objects, other features and advantages of the present invention will become more apparent by describing the preferred embodiment thereof with reference to the accompanying drawings, in which: [0013] FIG. 1 is a cross-sectional view illustrating a state prior to that a conventional Phylon midsole is bonded to an outsole. [0014] FIG. 2 is a cross-sectional view illustrating a state of bonding a conventional Phylon midsole to an outsole. [0015] FIG. 3 is a perspective view of an injection molded Phylon midsole according to a preferred embodiment of the present invention. [0016] FIG. 4 is a cross-sectional view taken along a line 100-100 in FIG. 3. [0017] FIG. 5 is a cross-sectional view taken along a line 200-200 in FIG. 3. [0018] FIG. 6 is a cross-sectional view illustrating a state of bonding an injection molded Phylon midsole of the present invention to an outsole. [0019] FIG. 7 is a plan view of an injection molded Phylon midsole according to one preferred embodiment of the present invention. [0020] FIGS. 8, 9 and 10 are plan views of an injection molded Phylon midsole according to alternative embodiments of the present invention. Continue reading... Full patent description for Injection molded phylon midsole Brief Patent Description - Full Patent Description - Patent Application Claims Click on the above for other options relating to this Injection molded phylon midsole 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 Injection molded phylon midsole or other areas of interest. ### Previous Patent Application: Shoelace lockdown system Next Patent Application: Shoe with changeable upper design Industry Class: Boots, shoes, and leggings ### FreshPatents.com Support Thank you for viewing the Injection molded phylon midsole patent info. IP-related news and info Results in 1.38111 seconds Other interesting Feshpatents.com categories: Novartis , Pfizer , Philips , Polaroid , Procter & Gamble , |
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