1. * GB780017 (A)
Description: GB780017 (A) ? 1957-07-31
Improvements in or relating to methods of providing shoes with moulded shoe
bottom members
Description of GB780017 (A)
COMPLETE SPECIFICATION
Improvements in or relating to methods of Providing Shoes with
Moulded Shoe Bottom Members
We, THE BRITISH UNITED SHOE MACHINERY
COMPANY LIMITED, of Union Works, Belgrave
Road, in the City of Leicester, a British Com- pany registered under
the Companies Acts 1862-1898, do hereby declare the invention (a
communication from United Shoe Machinery Corporation, of Flemington,
in the State of New Jersey, United States of America, a corporation
duly organised under the laws of the said State of New Jersey, and
having a place of business at 140, Federal Street,
Boston, Commonwealth of Massachusetts,
United States of America), for which we pray
that a patent may be granted to us, and the method by which it is to
be performed, to be particularly described in and by the following
statement:
This invention is concerned with improvements in or relating to
methods of providing shoes with moulded shoe bottom members, the term
" shoe " being used herein generically as including outer footwear
generally and also the article in the course of manufacture.
There will be hereinafter described one convenient method provided by
the invention and illustrative thereof, the illustrative method being
a method of moulding a shoe bottom member of plastic material on to
the bottom of a shoe presented bottom downwards.
Various methods of moulding rubber or like soles on to shoe bottoms
are well known and have been practised for a considerable time, but
these generally involve considerable expenditure in moulds as
individual moulds are required for right and left shoes and for
different sizes and shapes of sole. Moreover the application of

2. considerable pressure is 'generally required to cause the material to
fill the mould and enter into bonding engagement with the shoe bottom
and this necessitates the use of pressure applying apparatus which
again involves considerable expense.
It is one of the various objects of the invention to provide an
improved method of moulding shoe bottom members on to shoe bottoms
wherein the need for the use of a large number of expensive moulds is
obviated or at least largely reduced, and wherein the need for the
application of substantial pressure is eliminated or at least
substantially so.
With the above object particularly in mind the illustrative method,
hereinafter described, comprises taking a shoe which presents a wall
member projecting downward below the bottom of the shoe around the
margin thereof, holding the lower edge of the wall member in
substantially fluid-tight engagement with a surface of a moulding
member which closes the cavity peripherally defined by the wall member
and bounded on the side opposite to the moulding member by the shoe
bottom, filling said cavity with dispersion of resin partides heating
said dispersion to solidify it and to bond the solidified dispersion
to the s,hoe bottom and to the wall member to form with said wall
member a moulded shoe bottom member firmly adherent to the shoe, and
finally removing said shoe and adherent shoe bottom member from
engagement with the said surface.
The said dispersion is, preferably a fluid mixture of a consistency
suitable for extrusion of resin particles in a liquid plastidser
having no substantial solvent action on the resin when cool but
capable of combining with the resin when heated to form a solidified
mass. When solidified the dispersion forms a plastic shoe bottom
member adhering firmly to the shoe bottom and, depending on the nature
of the wall member, adhering firmly to, or being integrated with the
wall member. The wall member serves the dual purpose of providing an
accurately placed retaining wall and of spacing the closing surface of
the moulding member from the bottorrrof the shoe to provide the cavity
for the moulding of the resin depression on the shoe bottom. It is
therefore unnecessary to provide for each of the various shoe sizes it
is desired to make side mould members arranged to close together to
grip the shoe between them. Moreover the wall member improves the
union between the sole and the shoe bot tom at the edge portions,
since the wall member may be secured to the shoe by stitching,
cementing, or otherwise to provide an extremely strong union.
In order that the above and others of the various objects of the
invention may become more clear, there will now be given, with
reference to the drawings which accompanied the provisional
specification, a detailed description of the illustrative method above

3. referred to. It is to be clearly understood however that the
illustrative method is selected for description merely by way of
exemplification of the invention and not by way of limitation thereof.
In the drawings:
Figure 1 is a-perspective view of a shoe having a wall member secured
around the periphery of the bottom, and a contoured moulding plate for
use in foaming a tread surface on the shoe;
Figure 2 is an elevation, in section, showing a shoe upper on a last
with a wall member (in accordance with the illustrative method) in
engagement with a contoured moulding plate;
Figure 3 is an elevation similar to Figure 2 showing resin material
solidified to provide a tread surface within the space enclosed by the
wall member, shoe bottom and moulding plate;
Figure 4 is a side elevation partly in section of a shoe~having a wall
member secured around the periphery of the forward portion of the shoe
and a modified contoured moulding plate provided with a step against
which the ends of the wall member abut;
Figure 5 is a fragmentary section taken on the line V-V of Figure 4
showing the step sealing off the space defined by the wall member,
shoe bottom and contoured surface of the moulding plate;
Figure 6 is a fragmentary side view of the heel portion of a completed
shoe made using the moulding plate of Figure 4;
Figure 7 is a fragmentary view in section of a shoe with tread surface
moulded thereon using a second wall member shape;
Figure 8 is a fragmentary view in section of a shoe with tread surface
moulded thereon using a third wall member shape;
Figure 9 is a fragmentary view in section of a shoe with tread surface
moulded thereon using a fourth wall member shape; and
Figure 10 is a fragmentary view in section of a shoe with tread
surface moulded thereon using a fifth wall member shape.
In practising the illustrative method a shoe 10 is mounted on a
suitable form such as a last 12 which will retain it in shape for-the
moulding of a shoe bottom member, hereinafter referred to as a sole,
thereon, For convenience in explanation, the process will be described
first in relation to the formation of a sole on a conventional flat
lasted shoe upper in which the urper has been shaped and
secured to an insole or sock lining 14. A wall
member 16 is permanently secured to the shoe
around the margin of the shoe bottom so as to
project downwardly below the shoe bottom
thus forming a cavity on the bottom of the
shoe. In the shoe shown in Figures 1, 2 and 3,
the wall member 16 is secured to the shoe upper around the margin of
the shoe bottom

4. by a cement bond 18, but stitching or other
known modes of fastening the wall member
may be used. Ordinarily, the wall member 16
will be at the periphery of the shoe bottom and
will define a full sole as shown in Figure 1
or, alternately, a forward portion of the sole
extending toeward from about the breast -line as shown in Figure 4.
This wall member
16 is preferably so constructed and formed as
to simulate a sole edge and may have an
exposed upper surface 20 which may be shaped to simulate stitched
grooved, or otherwise shaped conventional welting. For convenience in
making the necessary bend at the more
sharply curved portions of the shoe such as
at the toe and heel, notches-22 may be pr vided on the inner portions
of the wall mem
ber 16 at such portions. The ends 24 of the wall member 16 are brought
together in fluid
tight engagement just forward of the heel portion of the shoe cn the
inner edge. A fluid-tight joint is conveniently formed by arranging
that the ends of the wall member
form complementary angles, for example a V
shaped notch and a V-shaped projection which
are fitted together as shown in Figure 1.
The wall member may be formed of any strong, tough material such as
those normally used for welting which are capable, or may be treated
to be capable, of bonding strongly to Dlasticised resin. For example,
leather or vinyl welting material may be used. It is how- ever,
preferred to use a strip of plasticised resin similar to the
plasticised resin which is usted when solidified to form the shoe
bottom
member since in this combination the wall member and shoe bottom
member become an integral body and the greatest possible strength
is obtained.
The bottom of the shoe, in this case the
bottom of the insole or sock lining 14, may be coated or lightly
impregnated with a thin fluid, resinous material suitably an aqueous
dispersion of resin particles such as a resin latex. A suitable resin
latex is a 54.6 !. so!ids
polyvinyl chloride latex. Other aqueous dis
persions or latices of resins compatible with
the resin to be moulded on the shoe may be used. When the bottom
surface of the shoe
has been treated with the resinous material, it is dried if necessary

5. and is then ready for the moulding operation. This coating or irr.prw-
nating treatment is likely to give a very strong
bond between the shoe and a sole moulded thereon. It is to be
understood, however, that the treatment may under some conditions at
least be omitted.
A moulding member, shown as a moulding plate 26, (Figure 1) adapted
for cooperating with a shoe bottom 14 and with a wall member 16 for
forming a sole comprises a relatively thick body portion 28 having on
its upper side a moulding surface 30 whose contour is complementary to
the desired contour of the tread surface of the shoe. Since the
outline of the sole member is defined by the wall member 16 attached
to the shoe 10, the contoured plate is usable for moulding a range of
sizes of shoe soles. The sole moulding plate 26 may be of metal or
suitable material capable of being formed to the desired shape and of
withstanding heat and transmitting heat to fluid material in contact
therewith.
The shoe 10 is disposed on the moulding plate 26 with the wall member
16 on the bottom of the shoe 10 held forXexamPle by suitable pad
members 32 (see Figures 2 and 3) in substantially fluid-tight
engagement with the contoured surface 30 of the moulding plate 26.
Peripherally defined by the wall member 16 and bounded on the side
opposite the moulding member 30 by the bottom face of the insole or
sock lining 14 a cavity 34 is provided for the formation of a shoe
bottom member of suitable thickness. Preferably, the distance between
the bottom face of the insole or sock lining 14 and the upper surface
30 of the moulding plate 26 should not be less than '/,, of an inch. A
fluid dispersion of resin particles in a liquid plasticiser is
injected into the cavity either through a temporary opening in the
wall member 16. through a suitable inlet opening 36 in the moulding
plate 26, or through a temporary opening in the insole or sock lining
14. A sufficient quantity of the resin dispersion is introduced to
fill the cavity defined by the bottom of the insole or sock lining 14,
the wall member 16 and the surface 30 of the moulding plate 26 when
the shoe is positioned thereon as shown in Figure 2.
Resin dispersions employed in practising the illustrative method are
fluid to nasty mixtures of from 30% to 70% of thermoplastic resin
particles in from 70ova to 30 /O of a liquid plasticiser having no
substantial solvent action on the resin when cool, but capable of
combining with the resin particles when the dispersion is heated to
form a uniferm solidified mass of plasticised resin. The relative
propertions of resin and plasticiser selected will depend on the
physical troDerties desired in the final tread surface. For example,
high relative proportions of plasticiser will give a softer more
rubbery sole than lower relative proportions within the range.

6. The particle size of the dispersed resin may vary within relatively
wide limits. However, particles of from 275 to 325 microns may be
found satisfactory.
Resin dispersions, fluid or pasty at room temperature, which may be
particularly satisfactory include: a dispersion of particles of a
copolymer of vinyl chloride and vinyl acetate containing from 85 (;;
to 88 '0 of vinyl chloride in a substantially equal quantity by weight
of dioctyl-phthalate; a dispersion of 50 parts of particles of a vinyl
chloride, vinyl acetate copolymer containing 85% to 88'to of vinyl
chloride in 45 parts of dioctyl-phthalate; and a dispersion of 50
parts of vinyl chloride, vinyl acetate copolymer, and 49 parts of an
ester type plasticiser which may be tricresyl phosphate, dibutyl
phthalate or dioctyl phthalate. Dispersions of other resins, including
polymethyl methacrylate and vinyl chloride-vinylidene chloride
copolymers in plasticisers in which they are dissolved or gelled when
heated, may be employed, provided the solidified resin body obtained
on heating the resin dispersion possesses the toughness, hardness and
resilience to render it suitable for use as a shoe sole.
It may be found desirable in certain dispersions at least to use a
stabiliser such as strontium naphthenate.
Limited amounts of fillers may be incorporated in the dispersion prior
to moulding.
Fillers which may be employed include fibres of copolymerised vinyl
chloride and vinyl acetate, sisal fibre, diatomaceous earth and clay.
Other fillers may be used. The percentage of fillers will depend on
the stiffness, strength, or other property desired. The dispersion may
also include any compatible dye or pigment or combination of these.
Where pigment is used it may first be ground into the plasticiser.
In practising Ithe illustrative method the shoe is, as aforesaid, held
with the wall memb-r 16 in substantially fluid-tight engagement with
the moulding plate 26 by any suitable pressure device such as the pad
32; and the assembly of shoe and moulding plate with resin dispersion
in the cavity between them is subject to heating to convert the resin
dispersion to solid condition. The heating may be effected in various
ways such as placing the assembly on a hot plate and maintaining it
there for a period of from 5 to 20 minutes after the resin dispersion
has reached a sufficigently thigh temperature to cause it to solidify,
e.g., a temperature of from 270 to 325 with the vinyl chloride-vinyl
acetate copolymer dispersions referred' to above. Other heating means
may be employed including heating cartridges provided in the moulding
plate such as those shown at 35 (Figure 4), placing the entire
assembly in a heating chamber, or the application of a high frequency
electric field.
After the heat treatment the pad member 32 is disengaged from the shoe

7. and the shoe and adherent sole are removed from the moulding plate.
The edges of the shoe sole 38 thus formed present the appearance of a
shoe having a conventional sole and moreover the shoe is expected to
offer cxceptional resistance to separation of the shoe sole 38 from
the upper by reason of the firm union between the wall member 16 and
thy upper 10 and the strong bond between, or integration of, the wall
member 16 and the sole 38.
In operating on shoes of the flat lasted type, the wall member 16 is
secured to the periphery of the bottom portion of the shoe 10,
preferably by cementing using conventional sole attaching cements.
If it is desired to attach a heel by conventional methods of heel
attaching, a wall member 16I having an exposed upper surface 202 may
extend only part way around the periphery of the bottom portion of a
shoe 101 (see
Figures 4, 5 and 6) for example from approximately the heel breast
line on one side to the heel breast line on the other. With this
arrangement a modified moulding plate 26I is used which is provided
with a step 42 against which the ends 44 of a wall member 16I are
abutted to enclose a cavity between the step 42, the contoured surface
30I of the moulding plate 26t, the wall member 16t and the bottom 141
of the shoe 10I. Resin paste dispersion is introduced into this
enclosed space 34' and solidified by the same procedure as referred to
above in connection with the formation of a sole member over the
entire surface of the shoe bottom. As shown in Figure 6 a special heel
46 is attached to a-shoe 10' having a partial moulded sole 38', a
portion 48 of the heel extending as far as desired over the rearward
end 40 of the sole 38I.
If desired fibrous material inserts may be secured to the bottom of
the insole or sock lining in such a manner that they will be enclosed
within the body of resin moulded on to the bottom of the shoe in
spaced relation to the tread surface. These inserts may be
incorporated by attaching them by any convenient means such as tacks,
nails or adhesive to the bottom surface of the insole of a welt type
shoe or the sock lining of a slip lasted shoe and carrying out
moulding operations as described above.
A variety of different wall members and methods of attaching them to
the shoe may be employed.
Figure 7 shows a wall member 16II having a cross-section particularly
suited for use with pre-welted shoes 1OTI as illustrated, but also
useful with normal welt type shoes. As shown, the wall member 16"
includes an outer portion 50 which provides the sole edge in the fini
shed shoe, a bottom portion which will be flush with the bottom
surface 52 of the sole member 38" to be formed, an inner edge portion
54 which joins with or bonds to the sole member 38Il and a top surface

8. 20" which may simulate
the upper surface of welting. A flexible lip
member 56 extends inwardly at the upper por
tion of the wall member 161t and has a channel
formed therein to receive stitches 58 to hold
the wall member 16tut to the shoe upper 10'I.
This type of wall member 16II is stitched to
the edge of the upper in a prewelt shoe or may be stitched to the rib
of a Goodyear type shoe (not shown). The shoe upper 10Il on a last
121I and with the wall member- 16" secured thereto is placed on a
contoured moulding plate 26 with the wall member 16" pressed in
sealing engagement with the surface 30 of the contoured plate 26. With
this construction and particularly with pre-welt shoes it is
preferable to employ a holddown for the wall member 1BI to insure that
the wall member is held flat against the contoured plate.
The moulding operation is then proceeded with as hereinbefore
described to provide a structure such as shown in Figure 7.
Figure 8 illustrates a wall member 16irk having a cross section
particularly adapted for use with slip lasted shoes. The wall member
16m comprises a body portion having a bottom surface 60 which will be
flush with the bottom surface of the finished sole 38it, an inner edge
portion 64 for union with the main body of the shoe sole 38III and an
edge portion 62 to provide an edge surface for the shoe sole. The
upper portion of the wall member provides a shoulder 66 on which rests
a lip 68 of the upper lOIII which is sewn to a sock lining 14III . The
wall member has an upwardly projecting flange 70 at its outer edge
which serves as an attaching portion through which stitches 72 are
inserted to bind the wall member 16irk to the shoe upper 1OTII and
sock lilt- ing. The moulding of a shoe sole on a shoe of this -
construction follows a procedure similar to that hereinbefore
described and illustrated in Figures 1, 2 and 3.
Figure 9 illustrates an alternative wall member 16IV which differs
from the wall member 16'it of Figure 8 in that the body portion of the
wall member extends outwardly beyond
the upwardly projecting flange 74 to provide an upper face 20ivy to
simulate a welt.
Figure 10 shows a wall member 16V comprising a body portion of which
one face 76 is intended to lie flush with the bottom surface of a shoe
sole 38v to be formed and another surface 78 is exposed at the outer
edge of the shoe sole 38V. This wall member 16V is provided with a
flexible side flange 80 having its exposed surface forming a
continuation of its edge portion 78. In this construction the flange
8C is secured by stitching 82 to the shoe upper 10V with the body
portion of the wall member 16V in inverted position; that is with the

9. flange 80 downward and the face of the wall member 16V which will form
the edge of the shoe sole positioned against the surface of the shoe
upper. Thereafter the flange 80 is bent to bring the wall member
16V to its final position with the flange 80
bent upon itself to give an appearance of a
platform cover at the edge of the shoe sole.
When the wall member 16V has been brought
to this relation, the formation of a shoe sole is carried out as in
the first described method.
What we claim is : -