Methods of making lightweight heels

Claim 1

THE METHOD OF MAKING A HEEL FOR A SHOE COMPRISING THE STEPS OF MOLDING A HOLLOW SHELL OF THIN, TOUGH FLEXIBLE THERMOPLASTIC RESIN SHEET MATERIAL TO PRESENT AN EXTERIOR SURFACE IN THE SHAPE OF A HELL, SUPPORTING THE FLEXIBLE WALLS OF SAID SHELL TO PREVENT DISTORTION OF THE SHELL, DEPOSITIONING IN SAID SUPPORTED SHELL A QUANTITY OF A FLUID RESIN MIXING COMPRISING A LIQUID THERMOSETTING RESIN AND PARTICLES OF A THERMOPLASTIC RESIN EXPANDABLE TO CELLULAR FORM, SAID MIXTURE BEING ADHESIVE IN EXPANDED FORM TO THE WALLS OF SAID SHELL, DISPOSING AA MOLDDING SURFACE ON THE TOP OF SAID SHELL TO DEFINE WITH SAID SHELL A CLOSED CHAMBER INCLUDING EDGE PORTIONS OF THIN CROSS SECTION INTO WHICH EXPANDED THERMOPLASTIC PARTICLES CANNOT PENETRATE, INCREASING THE TEMPERATURE TO CAUSE SAID RESIN MIXTURE TO INCREASE IN VOLUME AND CORE TO FORM A MASS OF CELLULAR BODIES SURROUNDED BY AND EMBEDED IN CURED THERMOSETTING RESIN, THE EXPANSION OF SAID THERMOPLASTIC PARTICLES PUSHING THE MIXTURE OUTWARD TO FILL THE SHELL COMPLETELY TO CONFORM AND ADHERE TO THE WALLS OF THE SHELL, SAID EXPANSION SQUEEZINGG SAID THERMOSETTING RESIN INTO THIN CROSS SECTIONS WHICH THE EXPANDED THERMOPLASTIC PARTICLES CANNOT PENETRATE, THE PORTIONS OF SAID MASS IN THIN CROSS SECTIONS OF SAID HEEL SHELL COMPRISING CURED THERMOSETTING RESIN SUBSTANTIALLY FREE FROM SAID CELLULAR BODIES.

Claim 2

THE METHOD OF MAKING A HEEL FOR A SHOE COMPRISING THE STEPS OF MOLDING A HOLLOW SHELL OF THIN, TOUGH FLEXIBLE THERMOPLASTIC RESIN SHEET MATERIAL TO PRESENT AN EXTERIOR SURFACE IN THE SHAPE OF A HELL, SUPPORTING THE FLEXIBLE WALLS OF SAID SHELL TO PREVENT DISTORTION OF THE SHELL, DEPOSITIONING IN SAID SUPPORTED SHELL A QUANTITY OF A FLUID RESIN MIXING COMPRISING A LIQUID THERMOSETTING RESIN AND PARTICLES OF A THERMOPLASTIC RESIN EXPANDABLE TO CELLULAR FORM, SAID MIXTURE BEING ADHESIVE IN EXPANDED FORM TO THE WALLS OF SAID SHELL, DISPOSING AA MOLDDING SURFACE ON THE TOP OF SAID SHELL TO DEFINE WITH SAID SHELL A CLOSED CHAMBER INCLUDING EDGE PORTIONS OF THIN CROSS SECTION INTO WHICH EXPANDED THERMOPLASTIC PARTICLES CANNOT PENETRATE, INCREASING THE TEMPERATURE TO CAUSE SAID RESIN MIXTURE TO INCREASE IN VOLUME AND CORE TO FORM A MASS OF CELLULAR BODIES SURROUNDED BY AND EMBEDED IN CURED THERMOSETTING RESIN, THE EXPANSION OF SAID THERMOPLASTIC PARTICLES PUSHING THE MIXTURE OUTWARD TO FILL THE SHELL COMPLETELY TO CONFORM AND ADHERE TO THE WALLS OF THE SHELL, SAID EXPANSION SQUEEZINGG SAID THERMOSETTING RESIN INTO THIN CROSS SECTIONS WHICH THE EXPANDED THERMOPLASTIC PARTICLES CANNOT PENETRATE, THE PORTIONS OF SAID MASS IN THIN CROSS SECTIONS OF SAID HEEL SHELL COMPRISING CURED THERMOSETTING RESIN SUBSTANTIALLY FREE FROM SAID CELLULAR BODIES.