Fabric (woven – knitted – or nonwoven textile or cloth – etc.) – Nonwoven fabric – Including a foamed layer or component
Patent
1998-05-20
1999-11-30
McCamish, Marion
Fabric (woven, knitted, or nonwoven textile or cloth, etc.)
Nonwoven fabric
Including a foamed layer or component
442315, 442370, 442374, 36 26, 36 44, 428 85, 428 86, 428 95, D04H 514, D04H 518
Patent
active
059942452
DESCRIPTION:
BRIEF SUMMARY
FIELD OF THE INVENTION
The present invention relates to a laminated product for use in footwear manufacturing and to a method of manufacturing an insole for a footwear.
BACKGROUND OF THE INVENTION
Different kinds of laminated products using a needling process for bonding two layers of different material are already known in footwear manufacturing. However, a drawback with those products is that they generally do not provide a good rigidity to the finished product and therefore their use is limited to articles which do not require a good rigidity. As a result, they are not very suitable as an insole for footwear.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a laminated product for use in footwear manufacturing which overcomes this drawback. More particularly, an object of the present invention is to propose a laminated product suitable for use in footwear manufacturing comprising:
An upper layer made of a resilient foam material devised to be in contact with the foot; and fibrous mat including: of the upper layer for bounding the bottom layer to the upper layer; and from, the outer face of the fibrous mat to impart rigidity to the product.
Another object of the present invention is to propose a laminated insole for a footwear comprising:
an upper layer made of a resilient foam material and having an outline shaped for incorporation in the footwear; and
a bottom layer made of a fibrous mat and having a shape conforming with the outline of the upper layer, the fibrous mat comprising: of the upper layer for bonding the bottom layer to the upper layer; and
Preferably, the upper layer has an outer surface opposed to the bottom layer, and each of the fibers of the fraction penetrating the foam material emerges from said outer surface and thereby provides a pilosity thereon.
Preferably also, the stiff portion of the bottom layer is obtained by impregnating an outer surface of the fibrous mat with a member selected from the group consisting of a latex, a solution of thermoplastic resin and a solution of thermosetting resin.
Alternatively, the fibrous mat may comprise a plurality of constructive fibers having a given melting point and a plurality of binding fibers having a melting point smaller than the melting point of the constructive fibers; and then the stiff portion of the fibrous mat may be obtained by subjecting an outer surface of the fibrous mat to a temperature greater than the melting point of the binding fibers and smaller than the melting point of the constructive fibers.
A further object is to propose a method of manufacturing a laminated product suitable for use in footwear manufacturing, the method comprising the steps of:
a) needling a layer made of a fibrous mat comprising a multiplicity of fibers to a layer made of a resilient foam material such that a fraction of said fibers penetrates the foam material; and
b) stiffening a portion of the fibrous mat for providing stiffness to the insole.
Advantageously, a laminated product according to the present invention is suitable for use as an insole as well as a slip-in insole in any footwear. As can be appreciated, it takes advantage of the resilient properties of the foam and the stiffness and thermoformability of the fibrous mat and in a preferred version it also takes advantage of the comfort provided by the pilosity covering the upper layer of foam.
A non restrictive description of preferred embodiments will now be given with reference to the appended drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a top view of an insole according to a preferred embodiment of the present invention;
FIG. 2 is a side elevational cross-sectional view of the insole shown in FIG. 1;
FIG. 3 is a side elevational cross-sectional view of a laminated product according to the present invention shown before the needling step of the method;
FIG. 4 is the same view as FIG. 3 showing the product after the needling step;
FIG. 5 is the same view as FIG. 4 showing a layer of textile needled to the upper layer of foam; and
FIG. 6 is the
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Marier Andre
Redfern Barbara
Scheubel Gerard
McCamish Marion
Singh Arti R.
Texel Inc.
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