US20100192421A1

US20100192421A1 - Composite sole

Info

Publication number: US20100192421A1
Application number: US12/697,206
Authority: US
Inventors: Mark Kerns; Christopher J. King; Kurtis Sakai; Tony L. Torrance; Philip Majure
Original assignee: DashAmerica Inc
Current assignee: Pearl Izumi USA Inc
Priority date: 2004-07-14
Filing date: 2010-01-29
Publication date: 2010-08-05

Abstract

The invention relates to a composite sole for a shoe, more particularly to an insert adhesively laminated to one or both of opposing upper and lower component to form the sole of an athletic shoe. The insert is adhesively incompatible with the upper and lower sole components and an adhesion promoter may be positioned between the insert and at least one of the upper and lower sole components to adhesively bond the insert to at least one or both of the upper and lower sole components.

Description

CROSS REFERENCE TO RELATED APPLICATION

This application is a continuation-in-part of U.S. patent application Ser. No. 12/176,883, filed on Jul. 21, 2008, which is a continuation of U.S. patent application Ser. No. 10/710,476, filed on Jul. 14, 2004 now U.S. Pat. No. 7,401,424 both entitled “Composite Outsole.” Each of these patents is hereby incorporated by reference in its entirety.

FIELD OF INVENTION

The present invention relates to a composite sole for a shoe, more particularly to an insert component laminated to one or both of opposing upper and lower sole components.

BACKGROUND OF THE INVENTION

Shoe soles have been improved and specialized for years. Currently, specialized shoe soles are provided for many athletic shoes, such as running, tennis, cycling, football, golf, track and field, baseball, walking, cross-training, shoes for use in inclement weather, etc. Accordingly, the sole of a shoe is typically designed for the intended use of the shoe. For example, running shoes are designed with vibration absorbing soles, while cycling shoes are fabricated to include rigid soles, which are designed for efficient energy transfer from the foot of the cyclist to the bicycle.
Despite previous improvements in sole construction and specialization, methods for addressing sole construction and for making the same continue to improve. For example, in the area of cycling, a continued need exists for lighter weight, more rigid cycling soles and efficient and effective ways of making these soles and the cycling shoes that include these soles. Thus, an improved cycling shoe sole that increases sole rigidly and/or reduces sole weight is desirable.
Embodiments of the present invention describe such improved soles for cycling shoes and cycling shoes incorporating the improved soles.

SUMMARY OF INVENTION

The present invention is directed generally to a composite sole for shoes, and preferably for athletic shoes, and most preferably for bicycling shoes.
It is one aspect of the present invention to provide a composite sole comprising incompatible first and second materials that differ in composition. More specifically, by “incompatible” it is meant that it is substantially difficult to adhesively bond the first and second materials together.
It is another aspect of the present invention to provide a composite sole comprising an insert, an upper material, and a lower material. The upper and lower materials differ in composition from the insert. The compositions of the insert and the upper and lower materials substantially differ, such that an adhesion promoter is used to bond the insert to one or both of the upper and lower materials to form a composite sole.
More specifically, a preferred embodiment of the present invention is a composite sole comprising an insert positioned between upper and lower materials, wherein the insert is adhesively incompatible with the upper and lower materials and the upper and lower materials are adhesively bonded together. An adhesion promoter is positioned between the insert and at least one of the upper and lower materials to bond the insert to at least one of the upper and lower materials. The composite sole further comprises opposing interior and exterior surfaces. The insert also optionally comprises interior and exterior portions. The optional exterior portion of the insert may form at least a portion of the exterior surface of the composite sole. Preferably, the insert is chemically and/or mechanically bonded to one or both of upper and lower materials and the upper material is chemically and/or mechanically bonded to the lower material. More preferably, the adhesion promoter is chemically and/or adhesively bonded to the insert and at least one of the upper and lower materials.
In a preferred embodiment, the composite sole comprises the insert adhesively bonded to the upper and lower materials. Furthermore, the upper and lower materials may be bonded together. The composite sole may be formed by adhesively bonding at least some of the insert between the upper and lower materials. That is, in this embodiment, the composite sole has at least some of the insert positioned between the upper and lower materials. The portion of the insert positioned between upper and lower materials forms an interior portion of the insert, while a portion of the insert that is not positioned between the upper and lower materials forms an exterior portion of the insert.
In some of these embodiments of the present invention, the insert has a perimeter comprising one or more tabs. The one or more tabs may extend radially from the insert in the form of arms. The one or more tabs may be positioned substantially uniformly around the entire perimeter of the insert. In some related configurations, the one or more tabs may extend from some portions of, but not the entire perimeter of, the insert. In yet other related configurations, the one or more tabs may extend from the insert in a manner resembling a symmetrical arrangement (given the asymmetrical nature of the sole of a shoe). Preferably, the one or more tabs are positioned between the upper and lower materials. More preferably, the one or more tabs are positioned between the upper and lower materials and the portion of the insert that is free of tabs forms an exterior portion of the insert.
In some of these embodiments, the exterior portion of the insert may comprise at least some, if not most, of the exterior portion of the composite sole and the insert may optionally contain one or more vent ports. Preferably, the exterior portion of the insert contains some, if not most or all of the one or more vent ports. The one or more vent ports comprise voids and traverse the insert. Optionally, at least some, if not all, of the one or more vent ports may comprise voids that traverse the composite sole. The insert may optionally also contain one or more cleat interconnecting elements for attaching one or more cleats to the composite sole. It can be appreciated that a single cleat may require the one or more cleat interconnecting elements to connect the cleat to the composite sole (such as in the case of a cycling cleat) or that each of several cleat interconnecting elements will accept a single cleat (as in the case of a football shoe).
The insert may comprise without limitation, a metal or metal alloy (such as, but not limited to titanium and its alloys, iron and its alloys, magnesium and its alloys, aluminum and its alloys), a polymeric material (such as, without limitation, rubber, poly(acrylonitrile, butadiene styrene), polyvinyl chloride, ethylene vinyl acetate, polyurethane), and/or a polymeric laminate (such as, without limitation, laminates comprising one or more of carbon fibers, Kevlar™, aluminum, steel, and/or fiberglass with an epoxy, polyester, vinyl ester, and/or nylon resin). In a preferred embodiment, the insert comprises a metal or a metal alloy. In a more preferred embodiment, the metal comprises titanium or a titanium alloy. In another embodiment, the insert comprises a polymeric laminate. In a preferred embodiment, the insert comprises a substantially rigid material. In a more preferred embodiment, the insert comprises a light-weight material having substantial rigidity. The rigidity of insert can be expressed in terms of one or more of yield strength, tensile strength and/or modulus of elasticity, while the light-weight character of the insert can be expressed in terms of density.
The yield strength of the insert can range from about 100 MPa to about 1200 MPa. Preferably, the yield strength can range from about 200 MPa to about 1000 MPa. More preferably, the yield strength can range from about 400 MPa to about 900 MPa.
The tensile strength of the insert can range from about 100 MPa to about 10,000 MPa, preferably from about 300 MPa to about 8000 MPa. More preferably, the tensile strength of the insert can range from about 800 MPa to about 7000 MPa.
The modulus of elasticity of the insert can range from about 3 GPa to about 450 GPa. Preferably, the modulus of elasticity can range from about 40 GPa to about 120 GPa. Even more preferably, the modulus of elasticity of the insert can range from about 100 GPa to about 115 GPa.
The density of the insert can range from about 1 g/cc to about 5 g/cc. Preferably, the density of the insert is from about 1.5 g/cc to about 4 g/cc. More preferably, the density is from about 2 g/cc to about 4 g/cc. Even more preferably, the density is about 4 g/cc.
The upper and lower materials may comprise without limitation, a polymeric material (such as, without limitation, rubber, poly(acrylonitrile, butadiene styrene), polyvinyl chloride, ethylene vinyl acetate, polyurethane), and/or a polymeric laminate (such as, without limitation, laminates comprising one or more of carbon fibers, Kevlar™, aluminum, steel, and/or fiberglass with an epoxy, polyester, vinyl ester, and/or nylon). The polymeric material may comprise one of a thermosetting resin, a thermoplastic resin, or a combination thereof.
In a preferred embodiment, the upper and lower materials comprise a polymeric laminate. In a more preferred embodiment, the polymeric laminate comprises a fiber-reinforced laminate comprising carbon fibers and a resin. Preferably, the fiber-reinforced laminate comprises an A- and/or B-staged thermosetting resin. That is, the fiber reinforced laminate is not completely C-staged. However, in a preferred embodiment of the present invention, the upper and lower materials of the composite sole comprise at least mostly, if not completely, C-staged thermosetting resins.
Preferably, the upper and lower materials have substantially similar compositions. More preferably, the upper and lower materials have substantially identical compositions. That is, the upper and lower materials substantially comprise the same fiber-reinforced laminates having substantially similar, if not identical, fiber reinforcements and resins. In other embodiments, one or both of the fiber reinforcements and/or resins of the upper and lower materials are different.
In yet other embodiments, one of the upper or lower materials may comprise a fiber laminate, while the other of the upper or lower materials can comprise a polymeric material lacking fiber reinforcement. The resins comprising the upper and lower materials can be the same or different resins.
In a preferred embodiment, the upper and lower materials comprise thermosetting resins that chemically react to at least substantially cross-link and/or chemically bond the upper and lower materials together. That is, the upper and lower materials bond, one to the other, without the use of adhesive. Stated another way, the bond of the upper material to the lower material is substantially free of an adhesive. The composite sole of these embodiments comprises thermosetting upper and lower materials that at least mostly, if not completely, cross-link, one with the other. Preferably, the upper and lower materials comprise C-stage thermosetting materials that are substantially, if not completely, cross-linked together. Furthermore, one or both of the upper and lower materials are one or both of chemically and/or mechanically bonded to at least some of the insert. The chemical and/or mechanical bond linking one or both of the upper and lower materials with the insert comprises the reaction product of the adhesion promoter with the insert and one or both of upper and lower surfaces. Similarly, the chemical and/or mechanical bonding of the insert with one or both of the upper and lower materials further comprises the chemical and/or mechanical interaction of the insert with one or both of upper and/or lower materials. In a preferred embodiment, the upper and lower materials comprising the composite sole are chemically cross-linked together, and to the insert, to form a single adhesively-bonded composite sole. Furthermore, the insert is chemically and/or mechanically bonded to the cross-linked upper and lower materials.
In another embodiment, one or both of the upper and lower materials can comprise a thermoplastic material. The one or more thermoplastic upper and lower materials can be adhesively bonded together by flowing and/or intermixing together when heat and/or pressure are applied during the adhesive bonding process. Furthermore, the insert can be adhesively bonded to the one or more thermoplastic materials by the adhesion promoter in at least one of a chemical and/or mechanical adhesion process. That is, when at least one of the upper and lower materials comprises a thermoplastic material, the upper and lower materials bond, one to the other, without the use of adhesive. Stated another way, the bond of the upper material to the lower material is substantially free of an adhesive.
It is another aspect of the present invention to provide a method for bonding first and second materials together to form a composite sole. In these embodiments, a first material, comprising one of the insert, upper material or lower material, and a second material, comprising one of the insert, upper material or lower material, are adhesively bonded to form a composite sole. More specifically, the method comprises adhesively bonding the insert and the upper and/or lower materials together to form the composite sole. Preferably, the adhesive bonding process further comprises an adhesion promoter. The adhesion promoter modifies one or more of the insert, upper material and lower material to facilitate bonding of at least one of the insert, upper material, and/or lower material without the use of an adhesive. That is, the adhesion promoter chemically and/or mechanically modifies one or more of the insert, the upper material and lower material to achieve bonding of the insert, upper material and lower materials together, substantially free of an adhesive. Stated another way, the adhesion promoter modifies at least one of the insert, upper material, and lower material, such that the least one of the insert, upper material, and lower material may bond with at least one of another of the insert, upper material, and lower material.
In a preferred embodiment related to this aspect of the invention, the adhesion promoter is positioned adjacent to and/or between the first and second materials. The adhesion promoter modifies at least one of the first and second materials such that at least one of the first and second materials may bond to the other of the first and second materials to form an adhesive assembly having an adhesive bond strength that is greater with the adhesion promoter than without the adhesion promoter. The adhesion promoter may be applied to one or both of the first and second materials prior to and/or simultaneously with contacting of the first and second materials. More preferably, the adhesive bonding process further comprises a lamination process comprising applying one or both of heat and pressure to an assembly comprising the insert and the upper and lower materials.
In one embodiment, the adhesion promoter chemically reacts with one or both of the first and second materials to chemically bond the first and second materials together. That is, the first material and the second materials are at least partially bonded together by a chemical process comprising a reaction product formed by the chemical reaction between the adhesion promoter with one or both of the first and second materials.
In another embodiment, the adhesion promoter interacts with one or both of the first and second materials to increase adhesive bond strength by one or more of a mechanical (such as, but not limited to mechanical interlocking), chemical (such as, but not limited to chemical bonding) and/or physical (such as, but not limited to electrical, van der Waals and/or London forces) processes. It can be appreciated that the adhesion promoter may refer to a composition of matter (such as, but limited to silane, titanate, or zirconate coupling agents), to a process (such as abraiding, ionizing or chemically functionalizing one or both of the first and second material surfaces), or a combination of both.
In a preferred embodiment, the adhesion promoter comprises a chemical entity described by the following chemical formula:
X—R—Y (1)
wherein, X depicts a chemical entity that chemically reacts with the insert to form a chemical bond with the insert. A non-limiting example of the chemical entity X is a silicon or polysiloxane entity comprising one or more —Si—O— entities. While not wanting to be limited by theory, it is believed that the one or more —Si—O— can chemically react with a titanium surface to form a Ti—O—Si— linkage. X may also comprise —Ti—O— and/or —Zr—O— entities that respectively form linkages comprising Ti—O—Ti— and/or Ti—O—Zr—. In a similar manner, the X entity can react with the insert surface to form a linkage substantially comprising one of —Si—O-insert, —Ti—O-insert, and/or —Zr—O-insert linkages.
Y depicts a chemical entity that chemically reacts and/or interacts with one or both of the upper and lower materials to form a chemical bond with one or both of the upper and lower materials. It can be appreciated that the Y entity can vary depending on the chemical composition of the upper and/or lower materials. For example, if one or both of the upper and lower materials comprise an epoxy, the Y entity would preferably comprise an epoxy cross-linking entity, such as, but not limited to, amine and/or mercapto functionalities.
R depicts a hydrocarbon entity. The hydrocarbon entity can be linear, branched, and/or cyclic. Furthermore, the hydrocarbon can be saturated or unsaturated, the unsaturated hydrocarbon can be conjugated, non-conjugated, or a combination thereof.
Non-limiting examples of suitable adhesion promoters having the chemical formula of X—R—Y are: vinyl silianes, epoxy silianes, methacryl silianes, amino silianes, mercapo silianes, ureido silianes, monoalkoxy titanates, chelate titanates, quaternary titanates, neoalkoxy titantes, cycloheteroatom titanates, coordination zirconates, neoalkoxy zirconates, zirconium propionates, zirconaluminates, zirconium acetylacetones, zirconium methacrylates and mixtures thereof.
In a related embodiment, the adhesion promoter may comprise a composition that forms one or more of the following on the insert surface: hydroxyapatite-containing coating, a sol-gel-containing coating, a phosphate-containing coating, and/or an acetylacetone-containing coating. Such coatings can improve the adhesion of the insert to one or both of the upper and lower materials.
Another aspect of the present invention is a shoe comprising the composite sole embodiments described above. More specifically, a shoe comprising an upper interconnected to a composite sole comprising an insert positioned between upper and lower materials, wherein the insert is adhesively incompatible with the upper and lower materials, wherein the upper and lower materials are adhesively bonded together. In one embodiment, an adhesion promoter is positioned between the insert and at least one of the upper and lower materials to bond the insert to at least one of the upper and lower materials. In a preferred embodiment, the shoe comprises an athletic shoe having the composite sole of the present invention. In a more preferred embodiment, the shoe comprises a cycling shoe having the composite sole of the present invention. In an even more preferred embodiment, the cycling shoe further comprises a titanium insert. Optionally, these embodiments may include cleat interconnecting elements for attaching one or more cleats to the composite sole of the shoe.
Another aspect of the present invention is a method of making a composite sole comprising: a) providing an insert and upper and lower sole materials, wherein the insert is adhesively incompatible with the upper and lower materials; b) treating at least one of the insert, the upper material and lower material with an adhesion promoter; c) positioning in registration, at least some of the insert between the upper and lower materials in a mold, wherein the insert positioned in registration with upper and lower materials forms a composite sole assembly; d) applying at least one of heat and pressure to the composition sole assembly to adhesively bond the insert to at least one of the upper and lower materials to form a composite sole; and e) removing the composite sole from the mold. Preferably, the applied heat and/or pressure are sufficiently affective to at least mostly, if not completely, C-stage the thermosetting resin.
As use herein, “polymeric material” means any homopolymer, copolymer and/or polymer alloy comprising one or more of polyolefins, polystyrenes, polyvinyls, polyacrylics, polyhalo-olefins, polydienes, polyoxides, polyesthers, polyacetals, polysulfides, polythioesters, polyamides, polythioamides, polyurethanes, polythiourethanes, polyureas, polythioureas, polyimides, polythioimides, polyanhydrides, polythianhydrides, polycarbonates, polythiocarbonates, polyimines, polysiloxanes, polysilanes, polyphosphazenes, polyketones, polythioketones, polysulfones, polysulfoxides, polysulfonates, polysulfoamides, polyphylenes, and combinations and/or mixtures thereof.
As used herein, “A-stage” means an early stage in the reaction of certain thermosetting resins in which the resin is fusible and still soluble in certain liquids.
As used herein, “B-stage” means an intermediate stage in the reaction of certain thermosetting resins in which the resin softens when heated and swells when in contact with certain liquids, but may not entirely fuse or dissolve.
As used herein, “C-stage” means the final stage in the reaction of certain thermosetting resins in which the material is relatively insoluble and infusible.
As used herein, a “thermosetting resin” is usually in an uncured stage when in the A- and/or B-stage and the thermosetting resin is fully cured when in the C-stage.
As used herein, “bond strength” means the unit load applied in one or more of tension, compression, flexure, peel, impact, cleavage, or shear, required to break an adhesive assembly with failure occurring in or near the adhesive bond comprising the adhesive assembly.
As used herein, the term “a” or “an” entity refers to one or more of that entity. As such, the terms “a” (or “an”), “one or more” and “at least one” can be used interchangeably herein. It is also to be noted that the terms “comprising”, “including”, and “having” can be used interchangeably. The terms “at least one”, “one or more”, and “and/or” are open-ended expressions that are both conjunctive and disjunctive in operation. For example, each of the expressions “at least one of A, B and C”, “at least one of A, B, or C”, “one or more of A, B, and C”, “one or more of A, B, or C” and “A, B, and/or C” means A alone, B alone, C alone, A and B together, A and C together, B and C together, or A, B and C together.
The preceding is a summary of the invention to provide an understanding of some aspects of the invention. This summary is neither an extensive nor exhaustive overview of the invention and its various embodiments. It is intended neither to identify key or critical elements of the invention nor to delineate the scope of the invention but to present selected concepts of the invention in a simplified form as an introduction to the more detailed description presented below. As will be appreciated, other embodiments of the invention are possible utilizing, alone or in combination, one or more of the features set forth above or described in detail below.

BRIEF DESCRIPTION OF DRAWINGS

The accompanying drawings, which constitute a part of this specification, illustrate embodiments of the present invention, and together with the description, serve to explain the principles thereof. Like items in the drawings are referred to using the same numerical reference.

FIG. 1 is a side elevation view of a composite sole consistent with an embodiment of the present invention;

FIG. 2 is a bottom plan view of the composite sole of FIG. 1 consistent with an embodiment of the present invention;

FIG. 3 is a side-by-side exploded view of the lower material and the insert of the composite sole of FIG. 1 consistent with an embodiment of the present invention;

FIG. 4 is a cross-sectional view the composite sole of FIG. 1 consistent with an embodiment of the present invention; and

FIG. 5 depicts a process for making a composite sole of an embodiment of the present invention.

DETAILED DESCRIPTION

The present invention will now be described with reference to FIGS. 1-5. While the present invention is described with reference to a composite sole, a person of ordinary skill in the art will recognize on reading this disclosure, that the composite sole could be used with other shoes, such as, for example, track and filed shoes, baseball shoes, football shoes, snow and/or ice shoes, soccer shoes, golf shoes, therapy shoes, or other such shoes. The examples of other shoes are exemplary and non-limiting.
A composite sole 300 is depicted in FIGS. 1, 2 and 4. The composite sole 300 comprises an insert 304 and upper 301 and lower 302 materials. The composite sole 300 further has opposing interior 320 and exterior 325 surfaces and may optionally have one or more studs 306 extending from the exterior surface 325. The one or more studs 306 may be formed in the composite sole during forming of the composite sole 300 or may be attached to composite sole 300 by any technique well known within the art. The one or more studs 306 may be attached to insert 304 and/or to the upper 301 and/or lower 302 materials.
In one embodiment, the upper 301 and lower 302 materials individually and separately comprise a homopolymer, copolymer and/or polymer alloy selected from the group of polymers consisting of polyolefins, polystyrenes, polyvinyls, polyacrylics, polyhalo-olefins, polydienes, polyoxides, polyesthers, polyacetals, polysulfides, polythioesters, polyamides, polythioamides, polyurethanes, polythiourethanes, polyureas, polythioureas, polyimides, polythioimides, polyanhydrides, polythianhydrides, polycarbonates, polythiocarbonates, polyimines, polysiloxanes, polysilanes, polyphosphazenes, polyketones, polythioketones, polysulfones, polysulfoxides, polysulfonates, polysulfoamides, polyphylenes, and combinations and/or mixtures thereof.
The composite sole 300 can be contoured similar to a conventional shoe sole. Preferably, the composite sole 300 is contoured similar to a conventional bicycling shoe sole. More preferably, the composite sole 300 is contoured similar to bicycling sole selected from the group of bicycling soles consisting of mountain bicycling soles and road bicycling soles.
The composite sole 300 may optionally have one or more vent ports 402. The one or more vent ports 402 comprise voids. The voids may traverse the insert 304. In another embodiment, the one or more vent ports 402 may optionally traverse the composite sole 300 and extend from the interior 320 to the exterior 325 surfaces. That is, the one or more vent ports extend through the upper 301 and lower 302 materials and the insert 304. The one or more vent ports 402 can be located anywhere on the composite sole 300. Preferably, the one or more vent ports 402 are located on the insert 304. The vent ports may have any shape. Moreover, the one or more vent ports 304 can vary in size. That is, the size of the one or more vent ports 402 can differ from one another.
The composite sole 300 may have one or more cleat interconnecting elements for attaching one or more cleats to the composite sole. It can be appreciated that, one or more cleat interconnecting elements may be required to attach a single cleat to the composite sole 300. While in other configurations of the present invention, each of the one or more cleat interconnecting elements each accepts a single cleat. Furthermore, it can be appreciated that the location of the one or more interconnecting elements on the composite sole 300 depends on the use and function of the composite sole 300. For example, the placement and number of the one or more interconnecting elements for a cycling composite sole 300 differ in the placement and number of the one or more interconnecting elements for a football, or golf, or inclement weather composite sole 300.
In a preferred embodiment, the insert 304 has a perimeter 514 having one or more tabs 502 extending radially from the insert 304. The one or more tabs 502 are in the form of arms extending from the insert 304. The one or more tabs 502 may be positioned substantially uniformly around the perimeter 514 of the insert 304. The one or more tabs 502 may extend from some portions but not other portions of the perimeter 514.
Reference is now made to FIG. 5 which depicts a process for making a composite sole. In step 1, an insert is provided. The insert may or may not have been treated with an adhesion promoter treatment. If the insert lacks an adhesion promoter, step 1 may optionally include treating at least some of the insert with an adhesion promoter. Preferably, at least some of the insert may be treated with an adhesion promoter. Preferably at least most, if not all, of the one or more tabs may be treated with the adhesion promoter. As described above, the adhesion promoter may comprise a chemical composition that chemically reacts with the insert. Furthermore, the adhesion promoter may comprise one or more of a chemical element and/or a physical process that increases the adhesive bond strength between the insert and one or both of the upper and lower materials by a chemical (such as for example, by one or more of covalent, hydrogen, and/or ionic bonds and/or by electrostatic and/or dispersive forces and/or interactions, such as, van der Waals and/or London forces) and/or a mechanical (such as for example by mechanical interaction) processes.
In step 2, the upper and lower materials are provided. When at least some of the insert forms a portion of the exterior surface, the lower material has a void substantially corresponding in shape and area to the portion of the insert forming the exterior surface. The upper and lower may comprise two separate entities or may comprise a single entity that folds over on itself and/or has a void for accepting the insert.
In step 3, the upper and lower materials and the insert are positioned substantially in registration with one another in a mold. The insert and the upper and lower materials can be positioned in the mold sequentially or substantially simultaneously. The insert is positioned between, and in contact with, the upper and lower materials. When the lower material contains one or more voids, the insert is contacted substantially in registration with the void(s). In one configuration, the insert and the upper and lower materials are contacted in registration prior to positioning within the mold.
In step 4, one or both of heat and pressure are applied to the insert and upper and lower materials positioned within the mold. One or both of heat and pressure are applied for a substantial period of time to adhesively bond the insert to the upper and lower materials and to adhesively bond the upper and lower materials to one another.
In step 5, the composite sole is removed from the mold. The composite sole may be removed from the mold while still hot from the heat applied in step 4. In another embodiment, the composite sole may be cooled before removing from mold. In one embodiment, the composite sole may be attached to a shoe upper to form a shoe. In another embodiment, the composite sole may be provided to a vendor for fabricating a shoe therefrom.
The present invention, in various embodiments, includes components, methods, processes, systems and/or an apparatus substantially as depicted and described herein, including various embodiments, subcombinations, and subsets thereof. Those of skill in the art will understand how to make and use the present invention after understanding the present disclosure. The present invention, in various embodiments, includes providing devices and processes in the absence of items not depicted and/or described herein or in various embodiments hereof, including in the absence of such items as may have been used in previous devices or processes, e.g., for improving performance, achieving ease and\or reducing cost of implementation.
The foregoing discussion of the invention has been presented for purposes of illustration and description. The foregoing is not intended to limit the invention to the form or forms disclosed herein. In the foregoing Detailed Description for example, various features of the invention are grouped together in one or more embodiments for the purpose of streamlining the disclosure. The features of the embodiments of the invention may be combined in alternate embodiments other than those discussed above. This method of disclosure is not to be interpreted as reflecting an intention that the claimed invention requires more features than are expressly recited in each claim. Rather, as the following claims reflect, inventive aspects lie in less than all features of a single foregoing disclosed embodiment. Thus, the following claims are hereby incorporated into this Detailed Description, with each claim standing on its own as a separate preferred embodiment of the invention.
Moreover, though the description of the invention has included description of one or more embodiments and certain variations and modifications, other variations, combinations, and modifications are within the scope of the invention, e.g., as may be within the skill and knowledge of those in the art, after understanding the present disclosure. It is intended to obtain rights which include alternative embodiments to the extent permitted, including alternate, interchangeable and/or equivalent structures, functions, ranges or steps to those claimed, whether or not such alternate, interchangeable and/or equivalent structures, functions, ranges or steps are disclosed herein, and without intending to publicly dedicate any patentable subject matter.

Claims

1. A composite sole, comprising an insert positioned between upper and lower materials, wherein the insert is adhesively incompatible with the upper and lower materials, wherein the upper and lower materials are adhesively bonded together, wherein an adhesion promoter is positioned between the insert and at least one of the upper and lower materials to adhesively bond the insert to at least one of the upper and lower materials.

2. The composite sole of claim 1, wherein the upper and lower materials comprise a polymer material and wherein the insert comprises a metal or metal alloy.

3. The composite sole of claim 2, wherein the insert comprises one of: titanium, a titanium alloy, magnesium, a magnesium alloy, aluminum, or aluminum alloys.

4. The composite sole of claim 2, wherein the polymeric material comprises one of a thermosetting and/or thermoplastic resin.

5. The composite sole of claim 3, wherein the thermosetting resin is substantially at least mostly, if not completely, a C-staged thermosetting resin.

6. The composite sole of claim 1, wherein the upper and lower materials are carbon fiber laminates.

7. The composite sole of claim 1, wherein the insert is chemically and/or mechanically adhesively bonded to one or both of upper and lower materials and wherein the upper material is chemically and/or mechanically adhesively bonded to the lower material.

8. The composite sole of claim 7, wherein the adhesion promoter is chemically and/or adhesively bonded to the insert and at least one of the upper and lower materials.

9. The composite sole of claim 1, wherein individually and separately the upper and lower materials comprise a homopolymer, copolymer and/or polymer alloy selected from the group of polymers consisting of polyolefins, polystyrenes, polyvinyls, polyacrylics, polyhalo-olefins, polydienes, polyoxides, polyesthers, polyacetals, polysulfides, polythioesters, polyamides, polythioamides, polyurethanes, polythiourethanes, polyureas, polythioureas, polyimides, polythioimides, polyanhydrides, polythianhydrides, polycarbonates, polythiocarbonates, polyimines, polysiloxanes, polysilanes, polyphosphazenes, polyketones, polythioketones, polysulfones, polysulfoxides, polysulfonates, polysulfoamides, polyphylenes, and combinations and/or mixtures thereof.

10. The composite sole of claim 1, further comprising one or more of:

a) one or more vent ports;

b) one or more cleat interconnecting elements; and

c) one or more studs.

11. The composite sole of claim 1, wherein the insert further comprises one or more tabs extending radially from the insert.

12. The composite sole of claim 11, wherein the composite sole further comprises opposing interior and exterior surfaces, wherein insert further comprises interior and exterior portions, wherein the interior portion of the insert comprises the one or more tabs positioned between the upper and lower materials and wherein the exterior portion of the insert comprises the portion of the insert forming at least a portion of the exterior surface of the composite sole.

14. A shoe, comprising an upper interconnected to a composite sole comprising an insert positioned between upper and lower materials, wherein the insert is adhesively incompatible with the upper and lower materials, wherein the upper and lower materials are adhesively bonded together, wherein an adhesion promoter is positioned between insert and at least one of the upper and lower materials to adhesively bond the insert to at least one of the upper and lower materials.

13. A method for making a composite sole, comprising:

a) providing an insert and upper and lower sole materials, wherein the insert is adhesively incompatible with the upper and lower materials;

b) treating at least one of the insert, the upper material and lower material with an adhesion promoter;

c) positioning in registration, at least some of the insert between the upper and lower materials in a mold, wherein the insert positioned in registration with upper and lower materials forms a composite sole assembly;

d) applying at least one of heat and pressure to the composition sole assembly to adhesively bond the insert to at least one of the upper and lower materials to form a composite sole; and

e) removing the composite sole from the mold.

13. The method of claim 12, wherein the insert comprises one of: titanium, a titanium alloy, magnesium, a magnesium alloy, aluminum, or aluminum alloys and wherein the polymeric material comprises one of a thermosetting and/or thermoplastic resin.

14. The method of claim 13, wherein the applied heat and/or pressure are sufficiently affective to at least mostly, if not completely, C-stage the thermosetting resin.

15. The method of claim 12, wherein the upper and lower materials are carbon fiber laminates.

16. The method of claim 12, wherein the adhesion promoter is chemically and/or adhesively bonded to the insert and at least one of the upper and lower materials.

17. The method of claim 12, wherein individually and separately the upper and lower materials comprise a homopolymer, copolymer and/or polymer alloy selected from the group of polymers consisting of polyolefins, polystyrenes, polyvinyls, polyacrylics, polyhalo-olefins, polydienes, polyoxides, polyesthers, polyacetals, polysulfides, polythioesters, polyamides, polythioamides, polyurethanes, polythiourethanes, polyureas, polythioureas, polyimides, polythioimides, polyanhydrides, polythianhydrides, polycarbonates, polythiocarbonates, polyimines, polysiloxanes, polysilanes, polyphosphazenes, polyketones, polythioketones, polysulfones, polysulfoxides, polysulfonates, polysulfo amides, polyphylenes, and combinations and/or mixtures thereof.

18. The method of claim 12, wherein the insert has one or both of a) one or more vent ports and b) one or more cleat interconnecting elements; and wherein one or more studs are formed on the composite sole during the step d).

19. The method of claim 12, wherein the insert further comprises one or more tabs extending radially from the insert.

20. The method of claim 19, wherein the composite sole further comprises opposing interior and exterior surfaces, wherein insert further comprises interior and exterior portions, wherein the interior portion of the insert comprises the one or more tabs positioned between the upper and lower materials and wherein the exterior portion of the insert comprises the portion of the insert forming at least a portion of the exterior surface of the composite sole.