DE2601336A1 - CAST MOLDED SPORTS BOOT AND METHOD OF MANUFACTURING THE SAME - Google Patents

Description

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The Garcia Corporation, Teaneck, II. J. / USA Cast molded sports boot and method of making the same

The invention relates to a molded sports boot and a Process for its manufacture. In particular, the invention relates to a novel construction for a cast-molded red Spcrtsriefel, in which an insert of cloth-like material is embedded or encapsulated in the material for the boot so that strength and rigidity can be obtained in specific areas without a substantial increase in weight or the Thickness of the boot material is present. The new type of boot construction according to the invention is particularly suitable for ski boots and ice skate boots, for example ice hockey shoes.

Sports boots have traditionally been made from synthetic materials such as polyurethane rubber or rubber molded. Those molded boots require additional support in certain boot areas, so that there is sufficient stiffness and rigidity here. So

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ORIGINAL INSPECTED

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some known shaped boots had areas of increased thickness, which provide the additional support required. Such a construction makes the boot excessively heavy and bulky. Other known molded boots use a separate insert element made from a rigid plastic that is mechanically attached to a molded outer shell connected is. An arrangement for attaching the insert element on the outer shell is shown in U.S. Patent 3,807,062. Here, openings are made at specific points on the insert element formed, wherein the outer shell is poured around the insert element, so that the material for the outer shell flows into the openings and thus the insert and shell are coupled together. This arrangement has the disadvantage that the reinforcement insert is close provides maximum stiffness to the wearer's foot and is consequently uncomfortable to wear. Furthermore, the mechanical connection subjected to very high stresses between boots and use. In addition, the stretch that occurs in the boot shell not transferred evenly to the insert.

The aim of the invention, on the other hand, is a sports boot as well to provide a method for its manufacture which circumvents the disadvantages associated with known boots by defining precisely Areas has a high tensile strength and stiffness without local stress concentrations occurring and there is a tendency to be pulled off, it should be possible to manufacture such a boot further in a simple manner.

The inventive solution to this aim is characterized by that the sports boot has a molded outer shell which is designed to encircle a human foot, with a porous insert is embedded from a cloth-like material in the material for the outer shell and is impregnated by the material, so that /. Outer shell and insert are interlocking connected. The material for the insert has a greater modulus of elasticity and a higher strength than the material for the outer shell and is involved dc-r outer shell in such a way that in areas in which the insert is arranged, increased rigidity and strength

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A molding process is used to manufacture the sports boot according to the invention proposed, which is characterized in that a porous sock-like insert arrangement is slipped over a bar, which in turn is enclosed in a form. A castable material, such as polyurethane, is then injected into the mold, to fill the mold interior around the bar and at the same time to impregnate and encapsulate the insert assembly. The insert arrangement shifts slightly away from the bar and is thus embedded and integrated into the material for the molded boot shell in order to obtain the desired strength and rigidity.

According to another feature of the invention is a novel insert assembly intended for use with molded sports boots. This insert arrangement consists of a highly porous, elastic, Sock-like holding and positioning element in which one or more insert elements made of porous material with a high modulus of elasticity are contained. These insert elements are at certain points in the holding and positioning element by sewing, gluing, tack welding or like attached. The holding and positioning element slides over the bar and holds the insert elements during the mold filling process in a suitable position. Nevertheless, the holding and positioning element allows the insert elements to drift away slightly from the mold, see above that the insert elements are completely embedded in the boot material.

Further developments of the invention are listed in the subclaims.

In summary, the invention is a shaped sports boot, a reinforcing insert assembly for a sports boot and a Method for making the boot created. A cloth-like insert is placed on a bar and then one around the bar Closed shape. A castable material, v / ie polyurethane, is injected into the mold so that it impregnates the insert before it solidifies and encapsulated. In this way, a sports boot with high tensile strength and rigidity is formed. The mentioned operational

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arrangement has a porous elastic, sock-like element, which is arranged over the bar. A layer made of a woven or knitted polyamide and a layer made of a non-woven Polyamide is attached to the inside of the sock-like element at specific points.

Exemplary embodiments of the invention are explained in more detail below with reference to the drawing. Show it:

Figure 1 is a perspective view of a molded one

Boot cover embodying the invention,

Fig. 2 is a sectional view along the cutting line

2-2 according to Fig. 1,

FIG. 3 shows a further sectional view along the section line 3-3 according to FIG. 2,

Figure 4 is an exploded perspective view

showing the location of an insert assembly on a ledge as the first step in forming the Boot cover according to Fig. 1,

Fig. 5 is an exploded perspective view

the components of the insert arrangement according to Fig. 4,

Figure 6 is an exploded perspective view

the location of the strip provided with the insert assembly in a mold as a further step in molding the boot cover according to FIG. 1,

Fig. 7 is a sectional side view of the around the bar

closed with the insert assembly attached Shape according to Fig. 6,

FIG. 8 is a view similar to FIG. 7, with the shape

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is filled with a castable material forming the boot, and

Figure 9 is a fragmentary sectional view of one

Another structure for the molded boot shell according to FIG. 1.

In Fig. 1, a sheath 10 is basically a shoe-like shape for shown an ice hockey boot. The sheath 10 is basically with a flat sole 20 is provided, to which a skid, not shown, is attached later. The boot shell 10 also has a reinforced toe area 22, which provides protection against bumps from ice hockey sticks, ice skates and the puck during the game. An open entrance area is also located on the boot cover 10 24, and eyelets 26 are provided along each side to enable the boot to be tied around the foot. The boot cover 10 is also equipped with an upper opening 28 which surrounds the wearer's ankle. In most cases, there will be a 28 on the sides of the boot shell just below the top opening tendon and ankle protectors, not shown, which extend upwardly and protect the tendons and ankles of the wearer.

The boot cover 10 is made of synthetic material such as polyurethane rubber, poured or injected. A suitable polyurethane rubber is available from E.I. du Pont de Nemours & Co. Inc., Wilmington, Delaware, manufactured under the trade name Adipren. The urethane material has sufficient elasticity to fit snugly Adjust the wearer's foot when the boot 10 is tied tightly. This material also has a high degree of wear and tear wear resistance.

When ice skating, as well as other sporting activities the footwear used is subjected to particularly high stresses on its various parts. These stresses work in different directions, depending on the chosen sport. In hockey, for example, the

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Ice-skate boots withstand stresses caused on the one hand by the forces exerted by the foot and on the other hand by the reaction forces transmitted by the skid. These forces generate tensile stresses in the plane of the boot sole , as well as torsional stresses around axes perpendicular to this plane. In order to be able to withstand these stresses and to avoid impermissible stretching as a result of these stresses, the boot sole must have a high modulus of elasticity, ie a high level of rigidity in its own plane. Although the stiffness can be increased to some extent by providing a sole of greater thickness, this would make the boot more expensive and also undesirably increase the overall weight of the boot. With the invention, on the other hand, the modulus of elasticity and the rigidity along the plane of the boot sole can be increased to a substantial extent without this being associated with a significant increase in the total weight of the boot.

The toe area of an ice hockey skate is a different type of stress exposed, notably from the jolts exerted by ice hockey sticks, pucks and other ice skates will. As a result, the toe area must be reinforced against bending stresses in local zones. The invention creates also, as will be discussed below, such local reinforcement against sagging and buckling without an excessive increase in weight or thickness.

From Fig. 2 and 3 it can be seen that the ice hockey boot shell 10 consists primarily of an outer, shaped area 30, in which Material an insert arrangement composed of several layers is embedded. The insert assembly consists of an outer one sock-like holding and positioning layer 32, a woven layer 34 and a non-woven layer 36. As previously indicated, the outer Area 30 preferably made of a polyurethane rubber, such as the material available under the trade name Adipren. The outer portion 30 can also be made of polyether, polyester, or a Polycaprolactam-based polyurethane. To be in the various

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Areas with different tensile strengths to a certain extent, Achieving stiffness and elastic elongation is that Thickness of the outer area 30 is different. On the sole area 20 and on the toe area 22, however, according to the invention, by means of the cooperating The effect of the woven and non-woven layers 34 and 36 creates additional reinforcement.

Both woven and nonwoven layers 34 and 36 are made made of a polyamide fiber such as nylon and preferably of a material sold under the trade name Kevlar by E.I. du Pont de Nemours Se Co. Inc., Wilmington, Delaware. Other Ma Materials include nylon-11, nylon-12, and nylon-13.

The woven layer 34 extends over and around the toe area 22 and along the length of the sole area 20. This woven layer consists of fibers that extend along the plane of the toe and sole area extend. Because of the porosity of the woven layer 34, the layer is impregnated with the material for the outer shell 30 and therein encapsulated; it becomes an integral part of the outer shell. As a result, it creates the modulus of elasticity for the material of the woven layer 34, which is much higher than the elastic modulus of the material for the outer shell 30, a high total modulus of elasticity in the plane of the sole region 20 and in the plane of the Toe area 22, so that these areas without significant stretching can withstand high tensile stresses. In fact, it was found that the elongation of the polyurethane up to its breaking strength is reduced from 200% to less than 5% when the layers 34 and 36 are used can be. This creates resistance to shear and torsional forces, as they occur through the skid during use, created.

The nonwoven layer 36 can be made from the same material as the woven Layer 34 exist. However, the nonwoven layer is felted or braided with its fibers oriented randomly. It should also be pointed out that the non-woven layer is considerably thicker than the woven layer 34. This thickness is used for

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to provide resistance to flexing or denting when impregnated with the outer region 30 material. Thus, a cooperative effect is achieved between the material for the outer sheath 30 _7, which impregnates the fibers of the nonwoven layer 30 and maintains the spacing between the fibers, and the material for the individual fibers themselves, the tensile strength of which in their spaced arrangement creates a resistance against deflection. The extent of this flexural resistance depends on the thickness or volume of the nonwoven layer. The volume should be such that the nonwoven layer occupies 40 to 60%, preferably 45 to 55% of the total volume of the boot area containing the layer.

As shown in Figure 3, the layers 34 and 36 extend upwardly over the upper end of the toe region 22 of the boot _; so that strength and rigidity are achieved over this entire boot area. The layers 34 and 36, however, extend from the toe area only along the sole area 20 to reinforce it to the rear. The remainder of the boot does not contain any reinforcing material, as the specific strength and stiffness requirements in these other areas do not require such reinforcement. Rather, it is important that these other areas remain flexible so that they can accommodate normal foot movements while ice skating. Of course, one or both of the layers 34 and 36 can extend to different boot areas depending on the particular requirements of the boot. For example, ski boots would have reinforcing layers that are arranged in different places than the ice skate boots shown here.

The outer sock-like holding and positioning layer 32 does not perform any noteworthy reinforcing or strength-increasing function. Rather, their task is, the outer layers during the Hold the boot shell in place by shaping it. This outer Layer is made of highly porous elastic material such as stretched nylon. It should not contain any materials that were used during the Forming the material for the outer shell occurring high temperature

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cannot withstand, nor should it contain any material, such as latex, that weakens the outer shell.

From Fig. 2 it can also be seen that the layer 32 is a band-like Includes side portion 32a that extends around the sides of the toe and heel portions of boot 10 and from sole portion 20 protrudes upwards by a length of 2.54 cm, although this is accordingly the type and size of the boots may change. The ply 32 also includes a bottom portion 32b that extends below the woven Location 34 extends. The side portion 32a is preferably made of a material comprised of a stretched nylon wrapped around it Polyurethane core is formed. One such material is sold under the tradename Lycra by E.I. du Pont de Nemours% Co., Inc. Wilmington, Delaware. The bottom area 32b can also consist entirely of stretched nylon. To during the casting and To allow the polyurethane material to flow freely during the molding process, the layer 32 should have a porosity of about 95%.

Fig. 4 shows an insert assembly 38 which is arranged as a first step to form the boot shell 10 of FIG. 1 by a bar 10. The last 10 is designed according to the human foot and its size depends of course on the size of the boot shell to be formed. The insert assembly 38 appears in FIG. 4 as a fabric-like insole that is slightly smaller than the lower end of the bar 40. The outer holding and positioning layer 32, however, consists of stretched material, so that the arrangement can be attached over the strip 40 with a stretch fit and maintains its position on it during the subsequent processing steps.

As shown in the exploded view of FIG. 5, the insert assembly comprises 38 the outer holding and positioning member 32 with the woven and nonwoven layers 34 and 36 attached thereto. Although the shape of the outer holding and positioning element 32 is such that it can be arranged over the strip 40, depending on the The shape of the woven and non-woven layers 34 and 36 depends only on the specific locations on the boot shell where reinforcement

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is to be made, and further the shape of this layer depends on the type of reinforcement required itself. It will be recognized that because the reinforcement material limits the flexibility of the material for the outer shell to some extent, it is not advantageous to provide the reinforcement over the entire shell. The inner layers 34 and 36 can be stitched , glued or otherwise held in position with respect to the outer holding and positioning layer 32.

As shown in FIG. 6, the insert assembly 38 is populated Bar 40 arranged so that it can be enclosed by outer mold halves 42 and 44 which come together around the bar and which Define the extended configuration of the boot shell.

6 and 7, the mold halves 42 and 44 have an inlet channel 46 and pouring and venting passages 48 near the boot heel on, so that the moldable material under pressure in the interior the mold surfaces can be introduced and thereby displaces the air contained therein. To completely remove the air and to ensure penetration of the moldable material, a bottom fillable shape is desirable. Furthermore, in some cases it is preferred that the mold is provided with additional secondary channels, not shown, to the mold cavity, which are shared by a common Lead inlet channel 36 along the boot sole. It can also be seen from FIG. 7 that the insert arrangement 38, although on the strip 40 held elastic, is somewhat loose so that the woven and non-woven layers 34 and 36 can be easily peeled off the bar, so that the moldable material can encapsulate these layers without, however, thereby disrupting the layers in the transverse direction from their desired locations be moved.

From Fig. 8 it can be seen that when the moldable polyurethane is injected or similar material 50 in the form of which the entire insert assembly 38 including each layer 32, 34 and 36 is impregnated. Although the material 50 flowing in at the beginning

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arrangement 38 wants to press against the bar 40, the effect occurs, that further flow of the material 50 through the mold is optional pulls the insert assembly 38 away from the ledge 40 slightly. As a result, only the outer holding and positioning layer 32 touches the Bar 40; and this contact occurs only along the outermost edge of the ply 32. As a result, the woven and nonwoven reinforcing plies become completely encapsulated and therefore integrated into the finished boot. After the injected material has hardened 50 the mold halves are separated from each other ^ and the The molded boot shell 10 with the insert assembly 38 encapsulated therein is removed from the last 40.

It follows that the preformed Einsatζanordnung 38 having disposed therein various woven and non-woven layers, the provision of different types of reinforcement and reinforcement quantities any desired _location> in a molded boots, without the need for complicated manual manipulations are required.

A modification made possible by the invention is shown in Fig. 9, in which a boot 52 is provided with a non-woven reinforcing layer 54 which extends only over the toe area 56 extends, while a woven reinforcement layer 58 extends over both the toe area 56 as well as over the sole area 60. The nonwoven layer 54 and the woven layer 58 are both medium an elastic, porous, outer holding and positioning layer 62. on which they are sewn or glued on, held in their appropriate places.

The invention has been drawn up with reference to preferred embodiments described. It is understood, however, that the skilled person after taking notice the invention can make various changes and modifications without thereby departing from the essence and scope of the Invention is deviated.

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Claims (26)

9601336-12 claims 1. Sports boot, characterized by a molded outer shell which is designed to encircle a human foot _; and by a porous insert which is embedded in the material for the outer shell and encapsulated by the material so that the outer shell and insert interlock, the insert having a higher modulus of elasticity than the outer shell. 2. Boot according to claim 1, characterized in that the porous insert is a cloth-like material which is impregnated with the material for the outer shell. 3. Boot according to claim 1, characterized in that the porous insert consists of at least two layers the cloth-like material, each layer having a different thread arrangement and both layers of the material are impregnated for the outer shell. 4. Boot according to claim 1, characterized in that the outer shell is a polyurethane rubber. 5. Boot according to claim 3, characterized in that one of the layers is woven. 6. Boot according to claim 5, characterized in that the other layer is not woven. 7. Boot according to claim 6, characterized in that the non-woven layer has such a thickness that it occupies between 40 and 60% of the volume of the outer shell in that area which contains the non-woven layer. 8. Boot according to claim 3, characterized in that one of the layers is a woven polyamide and 609831/0273 - 13 - - 13 - 7601336 the other layer is a non-woven polyamide. 9. Boot according to claim 6, characterized in that the woven layer extends along the sole of the Outer shell extends. 10. Boot according to claim 6, characterized in that the non-woven layer is over the toe of the outer shell lies. 11. Boot according to claim 3, characterized in that the porous insert has an outer elastic Contains layer that holds the other layers in place with respect to a shape. 12. Boot according to claim 11, characterized in that the outer layer is a polyurethane-nylon material is. 13. Boot according to claim 11, characterized in that the layers are held together by stitching are. 14. Insert assembly for use in manufacture of a sports boot, characterized by an outer sock-shaped insert element made of flexible, elastic and highly porous material which is loosely but securely attachable around a ledge, the insert assembly further being a reinforcing Has insert element made of at least one layer of cloth-like material, which is attached to the outer insert element. 15. Arrangement according to claim 14, characterized in that that the reinforcing insert element is stitched to the outer insert element. 16. Arrangement according to claim 14, characterized in that g e k e η η - 609831/0273 - 14 - indicates that the outer insert element is a polyurethane-nylon material is. 17. The arrangement according to claim 14, characterized in that g e k e η nz It is assumed that the reinforcing insert member includes first and second cloth-like layers. 18. Arrangement according to claim 1 "7, characterized in that the first layer is a woven polyamide. 19. The arrangement according to claim 18, characterized in that the second layer is a non-woven polyamide is. 20. Process for the production of a sports boot, characterized in that a tucharticje porous insert arrangement is attached to a foot-like shaped bar, placing a mold around the bar and then injecting a pourable rubber-like material into the mold, leaving the space between the mold and the bar is filled and at the same time the insert is impregnated and surrounded, so that a resistant A unitary shell is created that is designed to encircle a human foot. 21. The method according to claim 20, characterized in that the insert arrangement consists of at least one layer a cloth-like material with a higher modulus of elasticity than the castable rubber-like material. 22. The method according to claim 20, characterized in that the castable rubber-like material is polyurethane and the one layer consists of a polyamide material. Is 23. A method according to claim 21, characterized geke η η ζ ei seframe that the insert arrangement comprises at least two plies of cloth-like material, wherein a layer of woven and the subsequent dereni _c ht woven. _{60g831 / 0273} - 15 - 7601336 24. The method according to claim 20, characterized in that g e k e η η, that the insert assembly includes a highly extensible area where the reinforcement layer of cloth-like material is attached and that the highly extensible area is placed over the bar in a straight fit. 25. The method according to claim 20, characterized in that the porous insert arrangement has an outer highly porous, stretchable, sock-like element in which a porous Insert with a higher modulus of elasticity than the castable rubber-like material is included, and that the sock-like element is stretched over the ledge so that the porous insert is in place during the injection of the castable rubber-like material is held. 26. The method according to claim 25, characterized in that the sock-like element is sufficiently elastic is so that the porous insert can drift something away from the ledge during injection and the porous insert in the castable rubber-like material is encapsulated. 609831/0273 Blank page