Boots – shoes – and leggings – Sole-attaching means – Rubber
Reexamination Certificate
2001-04-17
2003-07-01
Kavanaugh, Ted (Department: 3728)
Boots, shoes, and leggings
Sole-attaching means
Rubber
C036S0170PW, C036S02200A, C036S068000, C012S1420MC
Reexamination Certificate
active
06584705
ABSTRACT:
BACKGROUND OF THE INVENTION
1. Technical Field
The present invention relates to shoe construction. More specifically, the present invention relates to methods and apparatus for a shoe having a simplified construction for providing improved waterproofing capability of the shoe, a rigid counter component for keeping the heel portion firm, and for providing support to the heel of the foot and shape to the shoe, cushioning that provides both shock absorption and stability, and for eliminating insole breakdown, reducing manufacturing cost and improving efficiency.
2. Background Art
The relevant prior art is directed to methods and apparatus for constructing shoes, including the heel portion of a shoe that comprises the interface between the upper leather portion and counter component with the outsole.
There are many methods known in the prior art for constructing shoes including dress, casual and athletic shoes. Most shoes include an upper leather portion and an inner lining that cover the top of the foot, a counter placed between the upper leather portion and the lining to provide rigidity at the heel, an insole upon which the foot rests, an outsole which contacts the ground surface and possibly a filler portion that is positioned between the insole and outsole. These specific terms and others typically used in conventional or traditional shoe construction whether the shoe is stitched or glued will now be defined. The term “upper leather portion or layer” refers to the visibly perceivable upper external portion of the shoe. The “inside lining” refers to a fabric layer employed for supporting the counter component, reinforcing the upper leather portion, and providing comfort to the foot. The “counter component” refers to a piece of plastic sheet positioned between the upper leather portion and the inside fabric lining in the heel region of the shoe. The function of the “counter component” is to keep the heel firm, support the foot, and provide shape to the shoe. The “midsole” refers to a piece of material such as rubber or leather that is glued to the inside fabric lining, upper leather portion, and the counter component to hold the construction together. The “filler” refers to a material the serves to fill a space formed between the midsole and the outsole when the midsole is glued to the inside lining, upper leather portion and the counter component. The “filler” which is glued in position can be comprised of the same material as the midsole or to the chemical compound ethylene vinyl acetate often referred to as “EVA”. The “outsole” refers to the bottom portion of the shoe that contacts the ground or floor surface which can be comprised of leather, rubber or any of several suitable synthetic materials. The outsole is typically glued to the “filler”. The “forepart” refers to that portion of the shoe or sole forward of the heel. The “last” refers to a form or mold which simulates the shape of a foot and which is employed to shape and size a shoe.
One of the several methods of shoe construction known in the art is referred to as the side stitch method. In the side stitch method, the upper leather portion, inner lining and counter components of the shoe and the outsole are machine stitched together along a side interface thereof. In some cases, cement may also be used to help secure the insole and inner lining to the outsole. After joining the upper leather portion and the outsole, the stitching remains visible along the side of the shoe. The side stitch method of shoe construction is often employed in outdoorsman and workman type shoes. A second method of shoe construction includes exclusively a cementing process (i.e., no stitching) in which the bottom of the upper leather portion and the outsole of the shoe are machine glued and pressed tegether. Typically, the upper leather and inner lining layers (and possibly a filler layer) are cemented between an insole and an outsole. The cementing method of shoe construction is commonly utilized for athletic footwear.
A third method of shoe construction known in the prior art is the “slip lasted” method. In the “slip lasted” method, the upper leather portion and the outsole are vertically machine stitched together all the way around the shoe. The outsole may have vertical slots formed in the bottom thereof so that the vertical stitching can pass through the upper leather portion and through that portion of the outsole positioned above the vertical slots. The “slip lasted” method is often used for oil tan leather shoes (such as moccasins) which cannot be glued because of the oil tan treatment applied to the leather.
A fourth method of shoe construction is identified as the “stitch and turn” method. In the “stitch and turn” method, the upper leather portion is stitched to the outsole on the side of the shoe. The outsole is typically a single molded unit and the upper leather portion is machine stitched thereto in a known manner. During initial construction, the stitching is accomplished in such a manner that the smooth or top side of the upper leather portion is facing downward and the rough side of the leather is facing upward when the upper leather portion is extended outward from the side of the shoe. After the upper leather portion has been stitched to the side of the outsole, it is turned over the top of the outsole so that the smooth side of the upper leather portion is reversed and faces upward, i.e., exterior, as in a finished shoe. However, the rough side of the leather then faces downward, i.e., toward the interior part of the shoe.
Many problems exist with conventional or traditional shoe construction of the prior art. For example, if the side stitch method is employed to construct the shoe, it is not possible to incorporate a firm counter component therein. This is because the firmness or stiffness of the counter component prevents the successful side stitching of the shoe by the stitching machinery. Further, use of the side stitching method of construction prevents proper waterproofing of the shoe at the interface of the upper leather portion and the outsole. The waterproofing problem exists because the machine stitch holes pass completely through each layer of shoe material, i.e., upper leather portion, counter component and inside lining, and thus cannot prevent the entry of moisture. The problems associated with the inability to provide a firm counter component and proper waterproofing of the shoe also exist with the “slip-lasted” and “stitch and turn” methods of shoe construction.
One prior art method of providing a firm counter component was to stitch the upper leather portion, counter component and inside fabric lining to the midsole. Thereafter, the midsole, filler and outsole were glued together. Waterproofing of the shoe could be achieved in this manner but this prior art method was time consuming and expensive. In an alternative prior art method, the counter component was installed between the upper leather portion and the inside fabric lining typically from above the shoe. The top ends of the upper leather portion and inside fabric lining were stitched together while the bottom ends were cemented to the bottom of the midsole. Then, the bottom of the midsole was glued to the outsole with the filler in between. In addition to bonding the components together, the cement also served as a means for closing the machine stitch holes. This assembly procedure required several steps and was time consuming and expensive because mistakes were common. Further, cemented components often separate after being successfully bonded together, for example, the separation of the upper leather portion from the outsole.
Another problem that exists in prior art methods of manufacturing shoes occurs, for example, with “stitch and turn” construction. In the “stitch and turn” shoe construction method, the insole sits on top of the outsole wall. The insole is typically comprised of soft material, . However, the outsole wall is comprised of hard material and is cube-shaped. Thus the corners of the outsole wall form 90 degree angles. Further, the i
Christopher John S.
Kavanaugh Ted
LandOfFree
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