Shock absorbing innersole and method for preparing same

Claim 2

In a method of manufacturing a shock-absorbing, molded innersole for insertion in footwear, which method comprises: (a) introducing an expandable, polyurethane into a mold; and (b) recovering from the mold an innersole which comprises a contoured heel and arch section composed of a substantially open-celled polyurethane foam material, the improvement which comprises: (i) placing an elastomeric insert material into the mold, the insert material having greater shock-absorbing properties and being less resilient than the molded, open-celled polyurethane foam material, and the insert material having sufficient surface tack to remain in the placed position in the mold on the introduction of the expandable polyurethane material so as to permit the expandable polyurethane material to expand about the insert material without displacement of the insert material; and (ii) recovering a molded innersole with the insert material having a tacky surface forming a part of the exposed bottom surface of the recovered innersole.

Claim 3

The method of claim 1 which includes: (a) providing a mold composed of male and female sections to define a contoured mold cavity, the mold sections adapted to be placed in an open position and a closed postion; (b) introducing the expandable polyurethane material and placing the insert material into the mold cavity when the mold is in the open position; (c) closing the mold to permit the expansion and reaction of the polyurethane material; and (d) opening the mold to obtain a molded, open cell polyurethane material with the tacky insert therein.

Claim 4

The method of claim 1 which includes cutting the recovered molded innersole to the desired shoe form and size.

Claim 5

The method of claim 1 which includes placing the tacky insert material onto a surface of the mold prior to the introduction of the expandable polyurethane material.

Claim 6

The method of claim 1 which includes: (a) placing a flexible sheet material in the mold; and (b) placing the tacky insert material on the flexible sheet material prior to introducing the expandable polyurethane material.

Claim 7

The method of claim 1 wherein the insert material comprises a cellular material having a density of greater than about 10 pounds per cubic foot.

Claim 8

The method of claim 1 wherein the insert material is characterized by an elongation at break of at least 500%.

Claim 9

The method of claim 1 wherein the insert material is characterized by a recovery delayed after compression of at least 0.7 seconds.

Claim 10

The method of claim 1 which includes molding a molded polyurethane material which comprises a full innersole form.

Claim 11

The method of claim 1 wherein the polyurethane foam material has a foam density ranging from about four to twenty pounds per cubic foot and a compressive strength of greater than about 15 psi and a low compression set of less than about 20%.

Claim 12

The method of claim 1 which includes introducing a flexible sheet material into the mold and directly bonding the flexible sheet material as a top surface sheet material to the open-celled, polyurethane foam material.

Claim 13

The method of claim 11 wherein the flexible sheet material comprises a fabric sheet material, a foam sheet material or a solid sheet material or combinations thereof.

Claim 14

The method of claim 11 wherein the flexible sheet material comprises a layer of open cell foam material and wherein the expanding polyurethane material is forced into the open cell surface of the open cell foam layer to form a strong bond between the open cell foam material and the molded polyurethane material.

Claim 15

The method of claim 11 which includes molding a molded polyurethane material which comprises a half innersole form the mold polyurethane tapering into the top surface flexible sheet material.

Claim 16

The method of claim 1 wherein the insert material comprises a solid elastomeric, polymeric material.

Claim 17

The method of claim 15 wherein the polymeric material comprises a polyurethane polymeric material.

Claim 18

The method of claim 1 wherein the insert material is precut from a polymeric sheet material in a particular shape and size for use as a shock material which includes placing the insert material in the mold, either before or after the introduction of the expandable polyurethane material.

Claim 19

The method of claim 1 wherein the insert material is placed in a mold in the heel or ball or both sections of the innersole.

Claim 20

The method of claim 1 wherein the insert material is placed in the mold to form a heel section surrounded by the foamable polyurethane material in the innersole.

Claim 21

The method of claim 1 wherein the insert material is placed to extend across a substantial portion or all of the ball section of the innersole.

Claim 22

The method of claim 1 which includes precutting the insert material from a flat sheet material of from about one-eighth to one-quarter inch in thickness.

Claim 23

The method of claim 1 wherein the insert material comprises a non-cellular polyurethane having a Shore hardness on a scale of zero-zero of ten to eighty.

Claim 24

The method of claim 1 wherein the insert material is placed so as to form a shock-absorbing section in the heel section of the innersole and which insert material forms a generally hourglass-type shape and extends generally to or substantially toward the outer edge of the innersole material.

Claim 25

The molded innersole produced by the method of claim 1.

Claim 26

In the method of manufacturing a molded innersole for use in footwear, which method comprises: (a) introducing an expandable, reactable, low compression set polyurethane material into a mold cavity; (b) introducing a flexible top sheet material into the mold cavity for direct bonding to the expandable polyurethane material and permitting the introduced polyurethane material in the mold cavity to expand and react to form an elastomeric, open-celled polyurethane foam innersole body comprising a heel and arch sectio and a relatively flat ball and toe section, the urethane foam material directly bonded to the flexible top sheet material; and (c) recovering a full-sole molded innersole, the improvement of which comprises: (i) inserting a preformed, solid elastomeric polyurethane insert material into the mold cavity in a position to provide for a shock-absorbing heel or in the ball or both sections of the whole body innersole prior to the introduction of the expandable polyurethane material and the flexible top sheet material, the insert material having greater shock-absorbing properties than the polyurethane foam material and having a greater surface tack than the polyurethane foam material, the surface tack sufficient to permit the insert material to remain in place in the mold cavity on the introduction of the expandable polyurethane material; and (ii) recovering a molded, full-sole innersole, the insert material having the tacky surface forming an exposed part of the bottom surface of the innersole.

Claim 27

In the method of manufacturing a molded innersole for use in footwear, which method comprises: (a) introducing an expandable, reactable, low compression set polyurethane material into a mold cavity; (b) introducing a flexible top sheet material into the mold cavity for direct bonding to the expandable polyurethane material and permitting the introduced polyurethane material in the mold cavity to expand and react to form an elastomeric, open-celled polyurethane foam innersole body comprising a heel and arch sectio and a relatively flat ball and toe section, the urethane foam material directly bonded to the flexible top sheet material; and (c) recovering a full-sole molded innersole, the improvement of which comprises: (i) inserting a preformed, solid elastomeric polyurethane insert material into the mold cavity in a position to provide for a shock-absorbing heel or in the ball or both sections of the whole body innersole prior to the introduction of the expandable polyurethane material and the flexible top sheet material, the insert material having greater shock-absorbing properties than the polyurethane foam material and having a greater surface tack than the polyurethane foam material, the surface tack sufficient to permit the insert material to remain in place in the mold cavity on the introduction of the expandable polyurethane material; and (ii) recovering a molded, full-sole innersole, the insert material having the tacky surface forming an exposed part of the bottom surface of the innersole.

Claim 28

The method of claim 25 wherein the insert material comprises an elastomeric polyurethane having a compression set of about less 15% and a Shore hardness of about 10 to 80.

Claim 29

The molded innersole produced by the method of claim 25.