WO2009011896A1 - Integrally molded components - Google Patents

Integrally molded components Download PDF

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Publication number
WO2009011896A1
WO2009011896A1 PCT/US2008/008763 US2008008763W WO2009011896A1 WO 2009011896 A1 WO2009011896 A1 WO 2009011896A1 US 2008008763 W US2008008763 W US 2008008763W WO 2009011896 A1 WO2009011896 A1 WO 2009011896A1
Authority
WO
WIPO (PCT)
Prior art keywords
strap
connector
hole
component
support
Prior art date
Application number
PCT/US2008/008763
Other languages
French (fr)
Inventor
William L. Hearn
Original Assignee
2001 Brands, Inc.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by 2001 Brands, Inc. filed Critical 2001 Brands, Inc.
Publication of WO2009011896A1 publication Critical patent/WO2009011896A1/en

Links

Classifications

    • A—HUMAN NECESSITIES
    • A43—FOOTWEAR
    • A43B—CHARACTERISTIC FEATURES OF FOOTWEAR; PARTS OF FOOTWEAR
    • A43B3/00—Footwear characterised by the shape or the use
    • A43B3/12—Sandals; Strap guides thereon
    • A43B3/122—Sandals; Strap guides thereon characterised by the attachment of the straps
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/0053—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor combined with a final operation, e.g. shaping
    • B29C45/006—Joining parts moulded in separate cavities
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/0081—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor of objects with parts connected by a thin section, e.g. hinge, tear line
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
    • B29D35/00—Producing footwear
    • B29D35/02—Producing footwear made in one piece using a moulding technique, e.g. by injection moulding or casting
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
    • B29D35/00—Producing footwear
    • B29D35/12—Producing parts thereof, e.g. soles, heels, uppers, by a moulding technique
    • B29D35/126—Uppers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C2793/00—Shaping techniques involving a cutting or machining operation
    • B29C2793/0009—Cutting out
    • B29C2793/0018—Cutting out for making a hole
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/0053—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor combined with a final operation, e.g. shaping
    • B29C45/0055—Shaping
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/48—Wearing apparel
    • B29L2031/50—Footwear, e.g. shoes or parts thereof

Definitions

  • aspects of the present invention generally relate to an integrally molded component assembly and methods for production, and more particularly to an integrally molded footwear assembly which includes a strap integrally molded to a strap support forming at least a portion of a shoe.
  • a component of such footwear is formed from a mold which has the desired shape of the component.
  • a material such as plastic, is introduced into the mold to form the footwear component. Once the material hardens or cures, the component is removed from the mold.
  • the footwear style includes more than one molded component, each component is molded separately in different molds, and thereafter the components are assembled together to form the footwear.
  • FIGS. 1-2 illustrate a molded sandal 10.
  • the sandal 10 has a first molded component 20 which includes a sole 22 and footbed 26, each arranged to extend below a wearer's foot, and an upper 24 arranged to extend above a wearer's foot.
  • the sandal 10 also has a second molded component 30 which includes a strap 32.
  • the first molded component 20 is formed in a first mold (not illustrated) and the second molded component 30 is formed in a second mold (not illustrated).
  • fasteners 40, 42 are used to secure the second molded component 30 (strap 32) to the first molded component 20 (sole 22, upper 24 and footbed 26).
  • strap 32 is arranged to secure a wearer's foot to the sole 22 and upper 24.
  • a first fastener 40 secures one end of the strap 32 to the medial side of the upper 24, and a second fastener 42 secures a second end of the strap to the lateral side of the upper 24. Holes may be formed in the strap 32 and the upper 24 to engage each fastener 40, 42 to secure the strap 32 to the upper 24.
  • an integrally molded footwear assembly includes a strap support forming at least a portion of a shoe, a strap constructed and arranged to secure a wearer's foot to the strap support, and a first connector formed between the strap support and the strap.
  • the strap support, the strap and the first connector are integrally molded together, and the first connector is sized and shaped such that a hole forming operation that forms a first hole through the strap and the strap support removes the first connector to allow a fastener to be engaged in the first hole to secure the strap to the strap support.
  • a method for footwear production includes providing an integrally molded footwear assembly including a strap support forming at least a portion of a shoe, a strap constructed and arranged to secure a wearer's foot to the strap support, and a first connector formed between the strap support and the strap. The method further includes forming a first hole through the strap and the strap support to remove the first connector, and engaging a fastener in the first hole to secure the strap to the strap support.
  • a method for footwear production includes providing a mold, the mold having contiguous strap, connector and strap support voids, introducing a molding material into the mold, so as to fill the voids, and forming a shoe, where the shoe has a strap support forming at least a portion of a shoe, a strap constructed and arranged to secure a wearer's foot to the strap support, and a first connector formed between the strap support and the strap.
  • the first connector is sized and shaped such that a hole forming operation that forms a first hole through the strap and the strap support removes the first connector to allow a fastener to be engaged in the first hole to secure the strap to the strap support.
  • an integrally molded assembly in another illustrative embodiment, includes a first component, a second component constructed and arranged to act as a handle to the first component, and a first connector formed between the first component and the second component.
  • the first component, the second component and the first connector are integrally molded together, and the first connector is sized and shaped such that a hole forming operation that forms a first hole through the first and second components removes the first connector to allow a fastener to be engaged in the first hole to secure the first component to the second component.
  • FIG. 1 is a top view of one embodiment of molded footwear
  • FIG. 2 is a rear lateral perspective view of the molded footwear illustrated in FIG.
  • FIG. 3 is a detailed top view of a portion of an integrally molded footwear assembly according to one illustrative embodiment
  • FIG. 4 is a cross-sectional view of an integrally molded footwear assembly according to one illustrative embodiment
  • FIG. 5 is a top view of an integrally molded footwear assembly according to another illustrative embodiment
  • FIG. 6 is a bottom perspective view of the integrally molded footwear assembly illustrated in FIG. 5;
  • FIG. 7 is a side view of the integrally molded footwear assembly illustrated in FIG. 5;
  • FIG. 8 is a detailed partial side view of the integrally molded footwear assembly illustrated in FIG. 5;
  • FIG. 9 is a cross-sectional view of an integrally molded footwear assembly according to yet another illustrative embodiment.
  • FIG. 10 is a cross-sectional view of an integrally molded footwear assembly according to yet another illustrative embodiment
  • FIG. 11 is a side view of an integrally molded footwear assembly according to yet another illustrative embodiment.
  • the present invention is directed to an integrally molded component assembly and methods for production. As discussed in greater detail below, in some embodiments, the assembly is directed to footwear, whereas in other embodiments, the invention is directed to non-footwear integrally molded components, which may include items such as, but not limited to toys, consumer products, clothing, and accessories. In one embodiment, the invention is directed to any expanded foam product with multiple parts that fit together.
  • an integrally molded footwear assembly is provided.
  • the term “footwear assembly” may include an entire shoe, whereas in other embodiments, the term “footwear assembly” may include only a sub-part or a portion of a shoe, as the invention is not so limited.
  • the assembly may be combined with other sub-parts or portions to form an entire shoe.
  • the integrally molded footwear assembly may be used to manufacture molded footwear in a manner that reduces the total number of manufacturing steps.
  • the integrally molded footwear assembly may be used to manufacture molded footwear in a manner that reduces manufacturing costs, and in some embodiments, the integrally molded footwear assembly may be used to manufacture molded footwear in a manner that enhances the ability to automate one or more of the manufacturing steps.
  • a conventional approach to manufacturing a molded footwear as illustrated in FIGS. 1-2 includes forming each component 20, 30 separately in different molds. The components are thereafter assembled to form the molded footwear, such as the sandal 10 shown in FIGS. 1-2.
  • the desired length of the strap 32 may depend upon the length of the shoe sole 22.
  • Applicant recognized that sizing the first component 20 relative to the second component 30 may be difficult and may lead to an increased numbers of manufacturing steps and costs to adjust the relative sizing. Problems associated with the relative sizing of the separately molded components 20, 30 may be exacerbated by the expanding and contracting characteristics of the materials used to form the components 20, 30. After the molding material is injected, or otherwise introduced, into a component mold to form a component and the mold is opened, the material may expand thereby changing the size and shape of the component.
  • the material when using a molding material such as an Ethylene Vinyl Acetate (EVA) foam, the material may both expand and then shrink before reaching a stabilized configuration.
  • EVA Ethylene Vinyl Acetate
  • the molds used to form each component 20, 30 may be different in size than the sizes of the desired finished components. In one embodiment, the mold used to form one component may be approximately 50% smaller than the finished component size.
  • each component 20, 30 may expand at different rates and in different directions because of geometrically induced heating, cooling, and cross-linked plastic curing characteristics.
  • components expand at different rates and/or in different directions it may be difficult to size one component relative to another.
  • sizing one component's mold relative to another component's mold may not result in accurate sizing in the finished components. This may lead to further increased manufacturing steps and costs.
  • aspects of the present invention are directed to reducing and/or eliminating some of the sizing problems associated with manufacturing molded footwear.
  • aspects of the present invention are directed to integrally molded footwear assemblies where two or more components are formed in one mold, so that the variations between the expansion and shrinking of each component during the molding/curing process may be lessened.
  • a "sacrificial" or temporary connector is integrally formed between the two components in the mold. After the molding material cures, this connector may be removed from the assembly to allow a fastener 40, 42 to secure the two components together.
  • the portion of the footwear assembly 50 is constructed similar to the sandal 10 shown in FIGS. 1-2 and includes a strap 60, a strap support 70, and a first connector 80.
  • the first connector 80 is formed between the strap 60 and the strap support 70 such that the strap support 70, the strap 60 and the first connector 80 are integrally molded together.
  • the strap 60 is constructed similar to strap 32 in sandal 10 and the strap support 70 is constructed similar to component 20 in sandal 10.
  • the first connector 80 is sized and shaped such that a hole forming operation that forms a first hole 90 (see FIG. 4) through the strap 60 and the strap connector 70 removes the first connector 80 to allow a fastener 40, 42 to be engaged in the first hole 90 to secure the strap 60 to the strap support 70.
  • the hole forming operation may be performed with a separate punching device 82.
  • the punching device 82 may be removed from the first hole 90 and a fastener 40, 42 may be inserted into the hole 90 to secure the strap 60 to the strap support 70.
  • the hole forming operation may be performed without a separate punching device 82, as the invention is not limited in this respect.
  • the hole 90 may be formed with the fastener itself.
  • the strap support 70 forms at least a portion of a shoe.
  • the strap support 70 is part of a footbed 26 arranged to extend below a wearer's foot.
  • the strap support 70 is also part of an upper 24 arranged to extend above a wearer's foot. In yet another embodiment, the strap support 70 is part of a sole 22 arranged to extend below a wearer's foot. In one embodiment, the strap portion 70 may be configured similar to the first molded component 20 illustrated in FIGS 1-2, and in one embodiment, the strap support 70 is part of an integrally molded shoe including at least a sole 22 constructed and arranged to extend below a wearer's foot and an upper 24 arranged to extend above a wearer's foot.
  • FIGS. 5-9 illustrate another embodiment of an integrally molded footwear assembly 50 according to the present invention. In this particular embodiment, the footwear assembly 50 may only include a sub-part or portion of a shoe.
  • the integrally molded footwear assembly 50 in the embodiment illustrated in FIGS. 5-9 also includes a strap 60, a strap support 70, and a first connector 80.
  • the strap support 70 may be substantially rectangular in shape. In other embodiments, the shape of the strap support 70 may vary as the invention is not so limited.
  • the first connector 80 is sized and shaped such that a hole forming operation that forms a first hole 90 (see FIG. 9) through the strap 60 and the strap connector 70 removes the first connector 80 to allow a fastener 94 to be engaged in the first hole 90 to secure the strap 60 to the strap support 70. In the illustrated embodiment shown in FIG.
  • the fastener 94 is shown in the process of being inserted through both the strap 60 and the strap support 70 by a force F.
  • the fastener 94 forms the first hole 90 and also removes the first connector 80, thereby detaching the strap 60 from the strap support 70.
  • the width Wp of the fastener 94 is greater than the width Wc of the first connector 80.
  • the width W F of the fastener is substantially equal to the width Wc of the first connector 80, and in yet another embodiment, the width Wp of the fastener is less than the width Wc of the first connector 80.
  • the fastener 94 has a sharpened end 96 which may be used to form the hole 90. It should be appreciated that in other embodiments, the fastener 94 may not include a sharpened end, and as discussed above, in other embodiments, a separate punching device 82 may be used to form the hole 90.
  • the fastener is a rivet 100 which includes a rivet head 104 at each end to prevent the rivet 100 from disengagement with the strap 60 and/or strap support 70.
  • One or both of the rivet heads 104 may be removable from the rivet body 100 to facilitate the insertion of the rivet into a hole 92.
  • a washer 106 may be provided to minimize friction along the rivet 100. It should be appreciated that a variety of types of fasteners such as screws, nails, rivets, pins, snaps, etc. may be used, as the present invention is not limited in this respect. As shown in FIG.
  • aspects of the present invention are also directed to embodiments where the integrally molded footwear assembly 50 includes a second connector 200 formed between the strap support 70 and the strap 60 where the second connector 200 is spaced apart from the first connector 80.
  • the strap support 70, strap 60, first connector 80 and second connector 200 are integrally molded together.
  • the second connector 200 is sized and shaped such that a hole forming operation that forms a second hole 92 (see FIG. 10) through the strap 60 and the strap support 70 removes the second connector 200 to allow a fastener to be engaged in the second hole 92 to secure the strap 60 to the strap support 70.
  • the first connector 80 is molded on a medial side of the strap support 70 and the second connector 200 is molded on a lateral side of the strap support 70.
  • the integrally molded footwear assembly 50 may include a first connector 80 formed on the medial side (proximate fastener 40) and a second connector 200 formed on the lateral side (proximate fastener 42).
  • one component of the footwear assembly 50 is configured to move relative to another component of the footwear assembly 50.
  • the second strap component 30 is configured for pivotal movement relative to the first component 20, so that the strap component 30 may rotate about a pivot axis defined by the two fasteners 40, 42.
  • the connectors 80, 200 may be removed to allow insertion of fasteners on each side. These fasteners may pivotally secure the strap 60 to the strap support 70.
  • the first connector 80 is sized and shaped such that a hole forming operation that forms a first hole 90 through the strap 60 and the strap support 70 removes the first connector 80 to allow a fastener to be engaged in the first hole to secure the strap 60 to the strap support 70.
  • the first connector 80 is substantially cylindrical in shape.
  • a cylindrical-shaped connector 80 may be preferred in embodiments having substantially cylindrical shaped fasteners, however, the invention is not so limited.
  • the first connector 80 may be square or rectangular, oblong, and/or irregular in shape.
  • a second connector 200 is provided with a shape similar to the first connector 80, whereas in other embodiments, the second connector 200 may have a shape that is different than the first connector 80.
  • an integrally molded footwear assembly 50 which includes the strap support 70 forming at least a portion of a shoe, a strap 60 arranged to secure a wearer's foot to the strap support 70, and a connector 80 formed between the strap support 70 and the strap 60.
  • the first hole 90 is formed through the strap 60 and strap support 70 to remove the first connector 80.
  • a fastener is engaged in the first hole 90 to secure the strap 60 to the strap support 70.
  • these acts of forming the first hole 90 and engaging a fastener are performed simultaneously, which may help to further reduce manufacturing steps and/or costs.
  • the fastener acts to form the hole 90 while also securing the strap 60 and the strap support 70.
  • this method is performed manually by a user applying the force F, illustrated in FIG. 9.
  • portions of this method may be automated.
  • a robot may be used to perform one or a plurality of steps in the manufacturing process.
  • a robot may be programmed to apply the force F.
  • Another aspect of the present invention is a method for footwear production which includes providing a mold, where the mold has contiguous strap, connector and strap support voids.
  • a molding material is introduced into the mold to fill the voids and a shoe is formed having a strap support 70, a strap 60 arranged to secure a wearer's foot to the strap support 70, and a first connector 80 formed between the strap support 70 and the strap 60.
  • a conventional last having the form of a foot may be used to control the shape of one of more portions of the shoe.
  • the size and shape of the mold depends upon the desired size and shape of the footwear.
  • a variety of types of molding materials may be used in the mold to form the molded footwear assembly 50, as the invention is not limited in this respect.
  • a molding material such as an Ethylene Vinyl Acetate (EVA) foam is used to form the strap 60, connectors 80, 200 and/or the strap support 70.
  • EVA Ethylene Vinyl Acetate
  • other plastic materials such as other types of expanded foam materials, may be used as the molding material. It should be appreciated that any material that expands in at least one of a molding stage, and/or a polymerization stage, and/or a crosslinking stage, and/or a foam expansion stage may be utilized, as the invention is not so limited.
  • a plurality of molding materials may be used to form the strap 60, the strap support 70 and the connectors 80, 200.
  • Multi-shot injection molding of different molding materials is contemplated by the present invention.
  • footwear having a plurality of different colored molding materials may be manufactured.
  • one molding material may be used to form the strap 60 and another material may be used to form the strap support 70.
  • the connectors 80, 200 may be formed using either or both molding materials.
  • the present invention is not limited to footwear.
  • a variety of other types of assemblies may also be made using the above-described techniques. For example, in one embodiment, a suitcase, bucket or pail having a handle may be formed from the same mold as described above.
  • these items may be formed with a first component, such as the pail body, being formed in one mold, with a second component, such as the pail handle, formed in a second mold.
  • these two components may be formed in one mold with a connector formed between the two components.
  • the pail body, the pail handle and the connector may be integrally molded together, and the connector may be sized such that a hole forming operation that forms a first hole through the pail handle and the pail body removes the connector to allow a fastener to be engaged in the first hole to secure the pail body and the pail handle.
  • the handle may be configured to move relative to the pail body.
  • the handle may be configured for rotational movement relative to the pail body.

Abstract

An integrally molded footwear assembly may include a strap support (70) forming at least a portion of a shoe, a strap (60) constructed and arranged to secure a wearer's foot to the strap support and a first connector (80) formed between the strap support and the strap. The strap support, the strap, and the first connector are integrally molded together, and the first connector is sized and shaped such that a hole forming operation that forms a first hole through the strap and the strap support removes the first connector to allow a fastener to be engaged in the first hole to secure the strap to the strap support. Methods of footwear production and an integrally molded assembly are also provided.

Description

INTEGRALLY MOLDED COMPONENTS
FIELD OF INVENTION
Aspects of the present invention generally relate to an integrally molded component assembly and methods for production, and more particularly to an integrally molded footwear assembly which includes a strap integrally molded to a strap support forming at least a portion of a shoe.
DISCUSSION OF RELATED ART A variety of different styles of molded footwear exist. Typically, a component of such footwear is formed from a mold which has the desired shape of the component. A material, such as plastic, is introduced into the mold to form the footwear component. Once the material hardens or cures, the component is removed from the mold. When the footwear style includes more than one molded component, each component is molded separately in different molds, and thereafter the components are assembled together to form the footwear.
One embodiment of molded footwear is shown in FIGS. 1-2 which illustrate a molded sandal 10. The sandal 10 has a first molded component 20 which includes a sole 22 and footbed 26, each arranged to extend below a wearer's foot, and an upper 24 arranged to extend above a wearer's foot. The sandal 10 also has a second molded component 30 which includes a strap 32. The first molded component 20 is formed in a first mold (not illustrated) and the second molded component 30 is formed in a second mold (not illustrated).
After the first and second molded components 20, 30 are separately formed, fasteners 40, 42 are used to secure the second molded component 30 (strap 32) to the first molded component 20 (sole 22, upper 24 and footbed 26). In the illustrated embodiment, strap 32 is arranged to secure a wearer's foot to the sole 22 and upper 24. A first fastener 40 secures one end of the strap 32 to the medial side of the upper 24, and a second fastener 42 secures a second end of the strap to the lateral side of the upper 24. Holes may be formed in the strap 32 and the upper 24 to engage each fastener 40, 42 to secure the strap 32 to the upper 24. SUMMARY OF INVENTION
In one illustrative embodiment, an integrally molded footwear assembly includes a strap support forming at least a portion of a shoe, a strap constructed and arranged to secure a wearer's foot to the strap support, and a first connector formed between the strap support and the strap. The strap support, the strap and the first connector are integrally molded together, and the first connector is sized and shaped such that a hole forming operation that forms a first hole through the strap and the strap support removes the first connector to allow a fastener to be engaged in the first hole to secure the strap to the strap support. In another illustrative embodiment, a method for footwear production includes providing an integrally molded footwear assembly including a strap support forming at least a portion of a shoe, a strap constructed and arranged to secure a wearer's foot to the strap support, and a first connector formed between the strap support and the strap. The method further includes forming a first hole through the strap and the strap support to remove the first connector, and engaging a fastener in the first hole to secure the strap to the strap support.
In yet another illustrative embodiment, a method for footwear production includes providing a mold, the mold having contiguous strap, connector and strap support voids, introducing a molding material into the mold, so as to fill the voids, and forming a shoe, where the shoe has a strap support forming at least a portion of a shoe, a strap constructed and arranged to secure a wearer's foot to the strap support, and a first connector formed between the strap support and the strap. The first connector is sized and shaped such that a hole forming operation that forms a first hole through the strap and the strap support removes the first connector to allow a fastener to be engaged in the first hole to secure the strap to the strap support.
In another illustrative embodiment, an integrally molded assembly includes a first component, a second component constructed and arranged to act as a handle to the first component, and a first connector formed between the first component and the second component. The first component, the second component and the first connector are integrally molded together, and the first connector is sized and shaped such that a hole forming operation that forms a first hole through the first and second components removes the first connector to allow a fastener to be engaged in the first hole to secure the first component to the second component.
BRIEF DESCRIPTION OF DRAWINGS The accompanying drawings are not intended to be drawn to scale. In the drawings, each identical or nearly identical component that is illustrated in various figures is represented by a like numeral. For purposes of clarity, not every component may be labeled in every drawing.
Various embodiments of the invention will now be described, by way of example, with reference to the accompanying drawings, in which:
FIG. 1 is a top view of one embodiment of molded footwear;
FIG. 2 is a rear lateral perspective view of the molded footwear illustrated in FIG.
1;
FIG. 3 is a detailed top view of a portion of an integrally molded footwear assembly according to one illustrative embodiment;
FIG. 4 is a cross-sectional view of an integrally molded footwear assembly according to one illustrative embodiment;
FIG. 5 is a top view of an integrally molded footwear assembly according to another illustrative embodiment; FIG. 6 is a bottom perspective view of the integrally molded footwear assembly illustrated in FIG. 5;
FIG. 7 is a side view of the integrally molded footwear assembly illustrated in FIG. 5;
FIG. 8 is a detailed partial side view of the integrally molded footwear assembly illustrated in FIG. 5;
FIG. 9 is a cross-sectional view of an integrally molded footwear assembly according to yet another illustrative embodiment;
FIG. 10 is a cross-sectional view of an integrally molded footwear assembly according to yet another illustrative embodiment; and FIG. 11 is a side view of an integrally molded footwear assembly according to yet another illustrative embodiment. DETAILED DESCRIPTION
The present invention is directed to an integrally molded component assembly and methods for production. As discussed in greater detail below, in some embodiments, the assembly is directed to footwear, whereas in other embodiments, the invention is directed to non-footwear integrally molded components, which may include items such as, but not limited to toys, consumer products, clothing, and accessories. In one embodiment, the invention is directed to any expanded foam product with multiple parts that fit together.
In one aspect of the invention, an integrally molded footwear assembly is provided. It should be appreciated that in some embodiments, the term "footwear assembly" may include an entire shoe, whereas in other embodiments, the term "footwear assembly" may include only a sub-part or a portion of a shoe, as the invention is not so limited. In embodiments where the footwear assembly includes only a sub-part or portion of a shoe, the assembly may be combined with other sub-parts or portions to form an entire shoe. As discussed in greater detail below, in some embodiments, the integrally molded footwear assembly may be used to manufacture molded footwear in a manner that reduces the total number of manufacturing steps. In some embodiments, the integrally molded footwear assembly may be used to manufacture molded footwear in a manner that reduces manufacturing costs, and in some embodiments, the integrally molded footwear assembly may be used to manufacture molded footwear in a manner that enhances the ability to automate one or more of the manufacturing steps.
As mentioned above, a conventional approach to manufacturing a molded footwear as illustrated in FIGS. 1-2 includes forming each component 20, 30 separately in different molds. The components are thereafter assembled to form the molded footwear, such as the sandal 10 shown in FIGS. 1-2.
Applicant has recognized that there are problems associated with this conventional manufacturing process. In general, the bigger the shoe size, the longer the strap length and also the longer the length of the shoe sole. Therefore, the desired length of the strap 32 may depend upon the length of the shoe sole 22. Applicant recognized that sizing the first component 20 relative to the second component 30 may be difficult and may lead to an increased numbers of manufacturing steps and costs to adjust the relative sizing. Problems associated with the relative sizing of the separately molded components 20, 30 may be exacerbated by the expanding and contracting characteristics of the materials used to form the components 20, 30. After the molding material is injected, or otherwise introduced, into a component mold to form a component and the mold is opened, the material may expand thereby changing the size and shape of the component. For example, when using a molding material such as an Ethylene Vinyl Acetate (EVA) foam, the material may both expand and then shrink before reaching a stabilized configuration. To compensate for the expanding and/or shrinking of the material, the molds used to form each component 20, 30 may be different in size than the sizes of the desired finished components. In one embodiment, the mold used to form one component may be approximately 50% smaller than the finished component size.
Furthermore, each component 20, 30 may expand at different rates and in different directions because of geometrically induced heating, cooling, and cross-linked plastic curing characteristics. When components expand at different rates and/or in different directions, it may be difficult to size one component relative to another. In other words, sizing one component's mold relative to another component's mold may not result in accurate sizing in the finished components. This may lead to further increased manufacturing steps and costs.
Aspects of the present invention are directed to reducing and/or eliminating some of the sizing problems associated with manufacturing molded footwear. Aspects of the present invention are directed to integrally molded footwear assemblies where two or more components are formed in one mold, so that the variations between the expansion and shrinking of each component during the molding/curing process may be lessened. As described in greater detail below, a "sacrificial" or temporary connector is integrally formed between the two components in the mold. After the molding material cures, this connector may be removed from the assembly to allow a fastener 40, 42 to secure the two components together.
Turning now to FIGS. 3-4, a portion of an integrally molded footwear assembly 50 according to the present invention is illustrated. In this particular embodiment, the portion of the footwear assembly 50 is constructed similar to the sandal 10 shown in FIGS. 1-2 and includes a strap 60, a strap support 70, and a first connector 80. The first connector 80 is formed between the strap 60 and the strap support 70 such that the strap support 70, the strap 60 and the first connector 80 are integrally molded together. In this particular embodiment, the strap 60 is constructed similar to strap 32 in sandal 10 and the strap support 70 is constructed similar to component 20 in sandal 10. The first connector 80 is sized and shaped such that a hole forming operation that forms a first hole 90 (see FIG. 4) through the strap 60 and the strap connector 70 removes the first connector 80 to allow a fastener 40, 42 to be engaged in the first hole 90 to secure the strap 60 to the strap support 70.
As shown in FIG. 4, the hole forming operation may be performed with a separate punching device 82. Once the hole 90 is formed, the punching device 82 may be removed from the first hole 90 and a fastener 40, 42 may be inserted into the hole 90 to secure the strap 60 to the strap support 70. As discussed in greater detail below, in other embodiments, the hole forming operation may be performed without a separate punching device 82, as the invention is not limited in this respect. For example, in one embodiment, the hole 90 may be formed with the fastener itself. The strap support 70 forms at least a portion of a shoe. For example, in the embodiment illustrated in FIG. 3, the strap support 70 is part of a footbed 26 arranged to extend below a wearer's foot. In this particular embodiment, the strap support 70 is also part of an upper 24 arranged to extend above a wearer's foot. In yet another embodiment, the strap support 70 is part of a sole 22 arranged to extend below a wearer's foot. In one embodiment, the strap portion 70 may be configured similar to the first molded component 20 illustrated in FIGS 1-2, and in one embodiment, the strap support 70 is part of an integrally molded shoe including at least a sole 22 constructed and arranged to extend below a wearer's foot and an upper 24 arranged to extend above a wearer's foot. FIGS. 5-9 illustrate another embodiment of an integrally molded footwear assembly 50 according to the present invention. In this particular embodiment, the footwear assembly 50 may only include a sub-part or portion of a shoe. Similar to the embodiment illustrated in FIG. 3, the integrally molded footwear assembly 50 in the embodiment illustrated in FIGS. 5-9 also includes a strap 60, a strap support 70, and a first connector 80. As shown in FIGS. 5-6, the strap support 70 may be substantially rectangular in shape. In other embodiments, the shape of the strap support 70 may vary as the invention is not so limited. As illustrated in FIGS. 8-9, the first connector 80 is sized and shaped such that a hole forming operation that forms a first hole 90 (see FIG. 9) through the strap 60 and the strap connector 70 removes the first connector 80 to allow a fastener 94 to be engaged in the first hole 90 to secure the strap 60 to the strap support 70. In the illustrated embodiment shown in FIG. 9, the fastener 94 is shown in the process of being inserted through both the strap 60 and the strap support 70 by a force F. In this particular embodiment, the fastener 94 forms the first hole 90 and also removes the first connector 80, thereby detaching the strap 60 from the strap support 70. In this particular embodiment, the width Wp of the fastener 94 is greater than the width Wc of the first connector 80. In another embodiment, the width WF of the fastener is substantially equal to the width Wc of the first connector 80, and in yet another embodiment, the width Wp of the fastener is less than the width Wc of the first connector 80.
As shown in FIG. 9, in one embodiment, the fastener 94 has a sharpened end 96 which may be used to form the hole 90. It should be appreciated that in other embodiments, the fastener 94 may not include a sharpened end, and as discussed above, in other embodiments, a separate punching device 82 may be used to form the hole 90.
Turning to FIG. 10, another type of fastener is illustrated in greater detail. In this particular embodiment, the fastener is a rivet 100 which includes a rivet head 104 at each end to prevent the rivet 100 from disengagement with the strap 60 and/or strap support 70. One or both of the rivet heads 104 may be removable from the rivet body 100 to facilitate the insertion of the rivet into a hole 92. As illustrated in FIG. 10, in one embodiment, a washer 106 may be provided to minimize friction along the rivet 100. It should be appreciated that a variety of types of fasteners such as screws, nails, rivets, pins, snaps, etc. may be used, as the present invention is not limited in this respect. As shown in FIG. 11, aspects of the present invention are also directed to embodiments where the integrally molded footwear assembly 50 includes a second connector 200 formed between the strap support 70 and the strap 60 where the second connector 200 is spaced apart from the first connector 80. In this embodiment, the strap support 70, strap 60, first connector 80 and second connector 200 are integrally molded together. The second connector 200 is sized and shaped such that a hole forming operation that forms a second hole 92 (see FIG. 10) through the strap 60 and the strap support 70 removes the second connector 200 to allow a fastener to be engaged in the second hole 92 to secure the strap 60 to the strap support 70. In one embodiment, the first connector 80 is molded on a medial side of the strap support 70 and the second connector 200 is molded on a lateral side of the strap support 70. For example, in one embodiment where the strap support 70 is shaped and configured similar to the first component 20 illustrated in FIGS. 1-2, the integrally molded footwear assembly 50 may include a first connector 80 formed on the medial side (proximate fastener 40) and a second connector 200 formed on the lateral side (proximate fastener 42).
In some embodiments, one component of the footwear assembly 50 is configured to move relative to another component of the footwear assembly 50. For example, in the embodiment illustrated in FIGS. 1-2, the second strap component 30 is configured for pivotal movement relative to the first component 20, so that the strap component 30 may rotate about a pivot axis defined by the two fasteners 40, 42. In one embodiment, which includes a first connector 80 positioned on the medial side and a second connector 200 positioned on the lateral side, the connectors 80, 200 may be removed to allow insertion of fasteners on each side. These fasteners may pivotally secure the strap 60 to the strap support 70.
As discussed above, the first connector 80 is sized and shaped such that a hole forming operation that forms a first hole 90 through the strap 60 and the strap support 70 removes the first connector 80 to allow a fastener to be engaged in the first hole to secure the strap 60 to the strap support 70. In one embodiment, the first connector 80 is substantially cylindrical in shape. A cylindrical-shaped connector 80 may be preferred in embodiments having substantially cylindrical shaped fasteners, however, the invention is not so limited. In other embodiments, the first connector 80 may be square or rectangular, oblong, and/or irregular in shape. In some embodiments, a second connector 200 is provided with a shape similar to the first connector 80, whereas in other embodiments, the second connector 200 may have a shape that is different than the first connector 80.
Another aspect of the invention is a method for footwear production. In particular, an integrally molded footwear assembly 50 is provided, which includes the strap support 70 forming at least a portion of a shoe, a strap 60 arranged to secure a wearer's foot to the strap support 70, and a connector 80 formed between the strap support 70 and the strap 60. As shown in FIGS. 4 and 9, the first hole 90 is formed through the strap 60 and strap support 70 to remove the first connector 80. A fastener is engaged in the first hole 90 to secure the strap 60 to the strap support 70.
In one embodiment, these acts of forming the first hole 90 and engaging a fastener are performed simultaneously, which may help to further reduce manufacturing steps and/or costs. For example, as discussed above, in some embodiments, the fastener acts to form the hole 90 while also securing the strap 60 and the strap support 70. In one embodiment, this method is performed manually by a user applying the force F, illustrated in FIG. 9. In another embodiment, portions of this method may be automated. For example, in one embodiment, a robot may be used to perform one or a plurality of steps in the manufacturing process. For example, a robot may be programmed to apply the force F.
Another aspect of the present invention is a method for footwear production which includes providing a mold, where the mold has contiguous strap, connector and strap support voids. A molding material is introduced into the mold to fill the voids and a shoe is formed having a strap support 70, a strap 60 arranged to secure a wearer's foot to the strap support 70, and a first connector 80 formed between the strap support 70 and the strap 60. A conventional last having the form of a foot may be used to control the shape of one of more portions of the shoe. It should be appreciated that the size and shape of the mold depends upon the desired size and shape of the footwear. A variety of types of molding materials may be used in the mold to form the molded footwear assembly 50, as the invention is not limited in this respect. As mentioned above, in one embodiment, a molding material such as an Ethylene Vinyl Acetate (EVA) foam is used to form the strap 60, connectors 80, 200 and/or the strap support 70. In other embodiments, other plastic materials such as other types of expanded foam materials, may be used as the molding material. It should be appreciated that any material that expands in at least one of a molding stage, and/or a polymerization stage, and/or a crosslinking stage, and/or a foam expansion stage may be utilized, as the invention is not so limited.
It is also contemplated that a plurality of molding materials may be used to form the strap 60, the strap support 70 and the connectors 80, 200. Multi-shot injection molding of different molding materials is contemplated by the present invention. In such embodiments, footwear having a plurality of different colored molding materials may be manufactured. For example, in one embodiment, one molding material may be used to form the strap 60 and another material may be used to form the strap support 70. In such embodiments, the connectors 80, 200 may be formed using either or both molding materials. As mentioned above, the present invention is not limited to footwear. A variety of other types of assemblies may also be made using the above-described techniques. For example, in one embodiment, a suitcase, bucket or pail having a handle may be formed from the same mold as described above. Traditionally, these items may be formed with a first component, such as the pail body, being formed in one mold, with a second component, such as the pail handle, formed in a second mold. According to one embodiment of the present invention, these two components may be formed in one mold with a connector formed between the two components.
The pail body, the pail handle and the connector may be integrally molded together, and the connector may be sized such that a hole forming operation that forms a first hole through the pail handle and the pail body removes the connector to allow a fastener to be engaged in the first hole to secure the pail body and the pail handle. It should be appreciated that any of the above mentioned fasteners may be used in this embodiment. Furthermore, in some embodiments, the handle may be configured to move relative to the pail body. For example, the handle may be configured for rotational movement relative to the pail body.
Having thus described several aspects of at least one embodiment of this invention, it is to be appreciated various alterations, modifications, and improvements will readily occur to those skilled in the art. Such alterations, modifications, and improvements are intended to be part of this disclosure, and are intended to be within the spirit and scope of the invention. Accordingly, the foregoing description and drawings are by way of example only. What is claimed is:

Claims

1. An integrally molded footwear assembly comprising: a strap support forming at least a portion of a shoe; a strap constructed and arranged to secure a wearer's foot to the strap support; a first connector formed between the strap support and the strap; wherein the strap support, the strap and the first connector are integrally molded together, and wherein the first connector is sized and shaped such that a hole forming operation that forms a first hole through the strap and the strap support removes the first connector to allow a fastener to be engaged in the first hole to secure the strap to the strap support.
2. The integrally molded footwear assembly of claim 1, wherein the strap support is part of a sole constructed and arranged to extend below a wearer's foot.
3. The integrally molded footwear assembly of claim 1, wherein the strap support is part of an upper constructed and arranged to extend above a wearer's foot.
4. The integrally molded footwear assembly of claim 1, wherein the strap support is part of a footbed constructed and arranged to extend below a wearer's foot.
5. The integrally molded footwear assembly of claim 1, wherein the strap support is part of an integrally formed shoe including at least a sole constructed and arranged to extend below a wearer's foot and an upper constructed and arranged to extend above a wearer's foot.
6. The integrally molded footwear assembly of claim 1, further comprising: a second connector formed between the strap support and the strap, wherein the second connector is spaced apart from the first connector; and wherein the strap support, the strap, the first connector and the second connector are integrally molded together, and wherein the second connector is sized and shaped such that a hole forming operation that forms a second hole through the strap and the strap support removes the second connector to allow a fastener to be engaged in the second hole to secure the strap to the strap support.
7. The integrally molded footwear assembly of claim 6, wherein the first connector is molded on a medial side of the strap support, and the second connector is molded on a lateral side of the strap support.
8. A method for footwear production, comprising: providing an integrally molded footwear assembly including a strap support forming at least a portion of a shoe, a strap constructed and arranged to secure a wearer's foot to the strap support, and a first connector formed between the strap support and the strap; forming a first hole through the strap and the strap support to remove the first connector; and engaging a fastener in the first hole to secure the strap to the strap support.
9. The method for footwear production of claim 8, wherein the acts of forming a first hole and engaging a fastener are performed simultaneously.
10. The method for footwear production of claim 9, wherein the acts of forming a first hole and engaging a fastener are automated acts.
11. The method of footwear production of claim 8, wherein the fastener is constructed and arranged to pivotally secure the strap to the strap support.
12. A method for footwear production, comprising: providing a mold, the mold having contiguous strap, connector and strap support voids; introducing a molding material into the mold, so as to fill the voids; and forming a shoe having: a strap support forming at least a portion of a shoe; a strap constructed and arranged to secure a wearer's foot to the strap support; and a first connector formed between the strap support and the strap, wherein the first connector is sized and shaped such that a hole forming operation that forms a first hole through the strap and the strap support removes the first connector to allow a fastener to be engaged in the first hole to secure the strap to the strap support.
13. The method for footwear production of claim 12, further comprising: forming a first hole through the strap and the strap support to remove the first connector; and engaging a fastener in the first hole to secure the strap to the strap support.
14. The method of footwear production of claim 13 , wherein the fastener is constructed and arranged to pivotally secure the strap to the strap support.
15. An integrally molded assembly comprising: a first component; a second component constructed and arranged to act as a handle to the first component; a first connector formed between the first component and the second component; wherein the first component, the second component and the first connector are integrally molded together, and wherein the first connector is sized and shaped such that a hole forming operation that forms a first hole through the first and second components removes the first connector to allow a fastener to be engaged in the first hole to secure the first component to the second component.
16. The integrally molded assembly of claim 15, wherein the first component is a pail body.
17. The integrally molded assembly of claim 15, further comprising: a second connector formed between the first component and the second component, wherein the second connector is spaced apart from the first connector; and wherein the first component, the second component, the first connector and the second connector are integrally molded together, and wherein the second connector is sized and shaped such that a hole forming operation that forms a second hole through the first and second components removes the second connector to allow a fastener to be engaged in the second hole to secure the first component to the second component.
PCT/US2008/008763 2007-07-19 2008-07-17 Integrally molded components WO2009011896A1 (en)

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WO2014200376A1 (en) * 2013-06-11 2014-12-18 You Can Chance It Internacional, Lda. Method for producing a fastening system for interchangeable sandal straps

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EP0308679A1 (en) * 1987-08-26 1989-03-29 NORKUN Norddeutsche Kunststoffverarbeitung GmbH Plastic container with moulded handle
DE4327175A1 (en) * 1993-08-13 1995-02-16 Jokey Plastik Wipperfuerth Plastic container with moulded-on carrying bar
US20010001350A1 (en) * 1999-04-22 2001-05-24 Santiago J. Aguerre Convertible slide and method
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EP1712146A1 (en) * 2005-04-14 2006-10-18 Patent Production s.r.l. Footwear in plastic made by pressure casting with fastening supports

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