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AU783483B2 - Method for making a footware having a midsole surrounded by a cover sheet - Google Patents
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AU783483B2 - Method for making a footware having a midsole surrounded by a cover sheet - Google Patents

Method for making a footware having a midsole surrounded by a cover sheet Download PDF

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AU783483B2
AU783483B2 AU44410/02A AU4441002A AU783483B2 AU 783483 B2 AU783483 B2 AU 783483B2 AU 44410/02 A AU44410/02 A AU 44410/02A AU 4441002 A AU4441002 A AU 4441002A AU 783483 B2 AU783483 B2 AU 783483B2
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Australia
Prior art keywords
mold
outsole
insole
cover strip
cover sheet
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AU44410/02A
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AU4441002A (en
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Cheng-Hsian Chi
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Priority to AU44410/02A priority Critical patent/AU783483B2/en
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  • Footwear And Its Accessory, Manufacturing Method And Apparatuses (AREA)

Description

AUSTRALIA
Patents Act 1990 COMPLETE SPECIFICATION STANDARD PATENT Applicant: CHENG-HSIAN CHI Invention Title: METHOD FOR MAKING A FOOTWEAR HAVING A MIDSOLE SURROUNDED BY A COVER SHEET The following statement is a full description of this invention, including the best method of performing it known to me/us: 1a METHOD FOR MAKING A FOOTWEAR HAVING A MIDSOLE SURROUNDED BY A COVER SHEET This invention relates to a method for making a footwear, more particularly to a method for making a footwear having an outsole, an upper, and a midsole that is surrounded by a cover sheet.
Fig. 1 illustrates a conventional method for making a shoe including an upper 4, an outsole 3, and a midsole 5 interconnecting the upper 4 and the outsole 3. The midsole 5 has a base portion 51 in contact with and bonded to the outsole 3, and an upper flange portion 52 extending upwardly from the base portion 51 and bonded to a bottom portion 41 of the upper 4. The method employs a mold 10 including an upper mold part with a last 12, a bottom mold part 11, and side mold parts, which define a mold cavity 13. The midsole 5 is formed by filling a foamable material into an inner cavity 130 that is confined by the outsole 3, the upper 4, and inner walls of the side mold parts.
The midsole 5 normally includes filler (not shown) in the form of pellets which are disposed on the outsole 3 in the mold cavity 13 before the closing of the mold parts and which are enclosed by the midsole 5 during the formation of the same.
The aforesaid method for making the shoe is disadvantageous in that the pellets of the filler tend to move in the inner cavity 13 during filling of the foamable material. As a consequence, some of the pellets may protrude outwardly from an outer surface of the upper flange portion 52 of the midsole thereby adversely affecting the appearance of the shoe. Moreover, since the upper flange portion 52 of the midsole 5 is exposed, it tends to deteriorate and discolor.
Fig. 2 illustrates a shoe prepared by a method that is disclosed in European Patent No. 0830935. The method uses an outsole 6 that has a flange portion 601 extending to and cooperating with a peripheral side wall 701 of an upper 7 to confine an inner cavity therebetween. The upper 7 and the outsole 6 are placed in a mold 10. A midsole is formed in the inner 4, cavity 60 by filling a foamable material into the
S
inner cavity 60. A sealing member 8 is employed to S..e press a tip portion 602 of the flange portion 601 against the peripheral side wall 701 of the upper 7 so as to prevent formation of flash on an exterior of the inner cavity 60. The conventional method is disadvantageous in that a precise match between an inner wall of the mold 10 and an outer surface of the flange portion 601 is needed prior to the formation 25 of the midsole in order to permit the flange portion 601 of the outsole 6 to have a shape conforming to the inner wall of the mold 10. Moreover, it is 3 relatively difficult to form a precise pattern on the outer surface of the flange portion 601 of the outsole 6 according to the conventional method.
Therefore, the object of the present invention is to provide a method for making a footwear that is capable of overcoming the aforementioned drawbacks.
The invention provides a method for making a shoe, comprising the steps of: preparing an outsole having an upper surface and a peripheral portion; preparing an upper having a bottom portion that defines an insole having a peripheral portion which is to be disposed over said peripheral portion of said outsole; preparing a cover strip that is to be disposed between and that is to interconnect said outsole and said insole; preparing a mold that has an inner wall defining a mold cavity, an upper mold part with a last, a bottom mold part opposite to said upper mold part, and at least two opposite side mold parts; placing said outsole, said upper, and said cover strip in said mold cavity such that said outsole is mounted on said bottom mold part, that said upper is fittingly sleeved on said last with said insole being 25 disposed over said outsole, and that said peripheral portions of said insole and said outsole are interconnected by said cover strip so as to confine an inner space thereamong; closing said mold; filling a foamable material into said inner space; and permitting said foamable material in said inner space to expand to thereby forcing said outsole, said insole, and said cover strip to press against said inner wall of said mold so as to form a foamed midsole that is enclosed by and that is bonded to said outsole, said insole, and said cover strip.
H:\Luisa\Keep\Speci\44410-02.doc 29/06/04 4 Preferably said outsole and said insole are interconnected by said cover strip before placing in said mold cavity.
Preferably said outsole and said insole are adhesively bonded to said cover strip so as to be interconnected by the same before placing in said mold cavity.
Preferably the method further comprises the step of heating said mold to a molding temperature before the placement of the assembly of said outsole, said insole, and said cover strip in said mold cavity.
Preferably the method further comprises the step of filling a gas into said inner space so as to force said outsole, said insole, and said cover strip to press against said inner wall of said mold before the step of filling said foamable material into said inner space.
Preferably said inner wall of said mold is patterned, said cover strip being pressed against and being heated by said mold upon foaming of said foamable material in said mold so as to be patterned by said mold.
Preferably said cover strip is made of ethylene oo vinylacetate copolymer, and said foamable material is made of polyurethane.
Preferably the method further comprises the step 25 of loading a filler in said inner space before the placement of the assembly of said outsole, said insole, and said cover strip in said mold cavity, said filler being in the form of pellets, and being made of a plastic material selected from a group consisting of ethylene vinylacetate copolymer, rubber, and polyurethane.
Preferably the method further comprises the step of disposing a plurality of cushioning pads in said inner space before the placement of the assembly of said outsole, said insole, and said cover strip in said mold cavity.
Preferably each of said cushioning pads is an air unit.
H:\Luisa\Keep\Speci\44410-02.doc 29/06/04 4a Preferably the method further comprises the step of attaching a pair of flexible strips to said peripheral portion of said upper, said flexible strips having lower end edges surrounding said peripheral portion of said upper, said cover strip having upper edges in abutment with said end edges of said flexible strips.
Preferably the method further comprises the step of applying an adhesive to said upper surface of said outsole before placement of said outsole in said mold.
In the drawings which illustrate an embodiment of the invention, So:o Fig. 1 is a cross-sectional side view to illustrate a conventional method for making a shoe; Fig. 2 is a cross-sectional side view to illustrate another conventional method for making a shoe; Fig. 3 is a block diagram to show consecutive steps of a method embodying this invention for making a footwear; Figs. 4 and 5 illustrate how a midsole of the footwear is formed in a mold according to the method of this invention; Fig. 6 is a fragmentary cross-sectional side view to illustrate cushioning pads which can be optionally 25 embedded in the midsole of Fig. 5 according to the method of this invention; Fig. 7 is a fragmentary cross-sectional side H-\Luisa\Keep\Speci\4441-O-2.doc 29/06/04 view to illustrate the cushioning pads of Fig. 6 in the form of air bag units that can be exposed from the footwear; Figs. 8 to 10 illustrate how a sandal is made according to the method of this invention.
Fig. 3 shows consecutive steps of a method embodying this invention for making a shoe. Figs. 4 to 6 illustrate how a midsole 40 of the shoe is formed according to the method of this invention. The method includes the steps of: preparing an outsole 20 having a peripheral side wall 202; preparing an upper 30 that is vertically aligned with and that is spaced apart from the outsole 20 and that has a peripheral side wall 301; preparing a flexible elongated cover sheet 21 that is disposed between and that interconnects the peripheral side walls 202, 301 of the outsole and the upper 30 so as to confine an inner cavity among the outsole 20, the upper 30, and the cover sheet 21, the cover sheet 21 being expandable outwardly of 20 the inner cavity 90 when an inner pressure in the inner cavity 90 is increased; preparing a mold 100 that has an inner wall 101 defining a mold cavity 102, an upper mold part 111 with a last 110, a bottom mold part 112 opposite to the upper mold part 111, and at least two o "25 opposite side mold parts 113; placing an assembly of the outsole 20, the upper 30, and the cover sheet 21 in the mold cavity 102 such that the outsole 20 is mounted on the bottom mold part 112, that the upper is fittingly sleeved on the last 110, and that the cover sheet 21 confronts the side mold parts 113; and filling a foamable material into the inner cavity by injecting the foamable material from a feeding device 200 through a feeding channel 130 and permitting curing and expansion of the foamable material to take place and to form the midsole bonded to the upper 30, the outsole 20, and the cover sheet 21, which, in turn, increases the inner pressure in the inner cavity 90 to result in expansion of the cover sheet 21, and which permits the cover sheet 21 to press against the inner wall 101 of the mold 100 and to form into a shape that conforms to the inner wall 101 of the mold 100. It is noted that the air in the inner cavity 90 is simultaneously evacuated through vent-holes (not shown and is discharged to an exterior of the mold 100 in such a manner that the inner pressure in the inner cavity 90 is sufficient 20 to press the cover sheet 21 against the inner wall 101 of the mold 100 during the expansion of the foamable material.
S. Preferably, the peripheral side walls 202, 301 of the outsole 20 and the upper 30 are adhesively 25 bonded to the cover sheet 21 so as to be interconnected by the same before placing the same in the mold cavity o. 102. More preferably, the peripheral side wall 202 of the out.sole 20 is adhesively bonded to the cover sheet 21, and the peripheral side wall 301 of the upper is stitched to the cover sheet 21. A pair of sealing strips 140, 150 are used to surround the tip portion of the cover strip 21 so as to seal a seam between the tip portion of the cover sheet 21 and the upper The cover sheet 21 can be made from ethylene vinylacetate copolymer, polyurethane, rubber, resilient cloth, leather, and the like. Preferably, the cover sheet 21 is made from ethylene vinylacetate copolymer, and has a thickness in a range of from to 8.0mm, and more preferably in a range from to 5.0mm. The foamable material preferably is a mixture of polyols and isocyanate so as to form the midsole 40 of polyurethane.
The mold 100 is preferably operated at a molding temperature in a range of from 40 to 120C for forming eo•: the midsole 40 of polyurethane with the cover sheet 21 made from ethylene vinylacetate copolymer. The 20 inner wall 101 of the mold 100 can be patterned so that when the cover sheet 21 is pressed against and is heated by the mold 100 upon foaming of the foamable material in the mold 100, the cover sheet 21 can be patterned as well. Since the cover sheet 21 is pressed against the inner wall 101 of the mold 100, the pattern formed on the cover sheet 21 can precisely conform to that of the inner wall 101 of the mold 100.
Preferably, an inert gas is filled into the inner cavity 90 prior to the injection of the foamable material into the inner cavity 90 so as to enhance the pressing of the cover sheet 21 against the inner wall 101 of the mold 100 during the forming of the midsole 40 in the inner cavity The method of this invention can further include a step of loading a filler 45 (see Fig. 6) in the inner cavity 90 before placing the assembly of the outsole 20, the upper 30, and the cover sheet 21 in the mold cavity 102 so that the filler 45 will be embedded in the midsole 40 after formation of the midsole 40. The filler 45 can be in the form of pellets, and can be made of a plastic material selected from a group consisting of ethylene vinylacetate copolymer, rubber, and polyurethane.
Referring now to Fig. 7, in combination with Fig.
6, the method of this invention can further include a step of disposing a plurality of cushioning pads 20 50, such as air bag units, in the inner cavity 90 before placing the assembly of the outsole 20, the upper and the cover sheet 21 in the mold cavity 102 so that the cushioning pads 50 can be embedded in the midsole 40 after formation of the midsole 40. Each cushioning 25 pad 50 can have extensions 51 extending through the cover sheet 21 so as to be exposed from the cover sheet 21. As such, the inner wall 101 of the mold 100 is a o a.
a a. a a.
oooo oo o o o o ooe ooo o1 go o o provided with positioning holes 103 for receiving the extensions 51 during the formation of the midsole Preferably, the extensions 51 are provided with sleeves 62 which are received in the positioning holes 103 during the formation of the midsole The following Examples illustrate the advantage of using the cover sheet 21 according to the method of this invention.
Example 1 Material of the cover sheet: ethylene vinylacetate copolymer.
Thickness of the cover sheet: 2.0 mm.
Shape of the inner wall of the mold: concave with shallow pattern.
Foamable material: polyols and isocyanate Amount of the foamable material: 133 grams.
Molding temperature: 50 C.
Molding time: 7 minutes.
Result: Density of the midsole is 0.34 g/cm, profile of the cover sheet is consistent with that of the inner wall of the mold, clear pattern is formed on the cover sheet, and no flash is formed 20 on the seam between the cover sheet and the upper.
Example 2 Material of the cover sheet: ethylene vinylacetate copolymer.
Thickness of the cover sheet: 5.0 mm.
Shape of the inner wall of the rold: concave with shallow pattern.
25 Foamable material: polyols and isocyanate Amount of the foamable material: 133 grams.
Molding temperature: .Molding temperature: 70 °C.
Molding time: 7 minutes.
Result: Density of the midsole is 0.34 g/cm 3 profile of the cover sheet is consistent with that of the inner wall of the mold, clear pattern is formed on the cover sheet, and no flash is formed on the seam between the cover sheet and the upper.
Example 3 Material of the cover sheet: ethylene vinylacetate copolymer.
Thickness of the cover sheet: 8.0 nm.
Shape of the inner wall of the mold: concave with shallow pattern.
Foamable material: polyols and isocyanate Amount of the foamable material: 133 grams.
Molding temperature: 120 C.
Molding time: 5 minutes.
Result: Density of the midsole is 0.34 g/cm 3 profile of the cover sheet is consistent with that of the inner wall of the mold, clear pattern is formed on the cover sheet, and no flash is formed on the seam between the cover sheet and the upper.
Example 4 0
S
0 0055 05*0 0
S
S.
55 0 Material of the cover sheet: ethylene vinylacetate copolymer.
Thickness of the cover sheet: 5.0 mm.
Shape of the inner wall of the nold: concave with shallow pattern.
Foamable material: polyols and isocyanate Amount of the foamable material: 133 grams.
Molding temperature: 120 C.
Molding time: 5 minutes.
Result: Density of the midsole is 0.34 g/cm 3 profile of the cover sheet is consistent with that of the inner wall of the mold, clear pattern is formed on the cover sheet, and no flash is formed on the seam between the cover sheet and the upper.
The inventor of this application found that when the thickness of the cover sheet of ethylene vinylacetate copolymer is less than 0.5 mm and the molding temperature is above room temperature, the cover sheet tends to break, which leads to the formation of flash on the seam between the cover sheet and the upper, and that when the thickness of the cover sheet of ethylene vinylacetate copolymer is greater than 9.0mm, the cover sheet is difficult to be shaped during the molding process even at a molding temperature of about 120-C Moreover, when molding proceeds at room temperature, poor profile of and obscure pattern on the cover sheet of ethylene vinylacetate copolymer result due to poor flexibility of the ethylene vinylacetate copolymer under room temperature. The drawback can be overcome by using polyurethane film as the cover sheet, which is 20 relatively soft and flexible under room temperature.
Figs. 8 to 10 illustrate how a sandal is made according to the method of this invention. The sandal includes an outsole 20', an upper 30' with an upper *o* flange 21' disposed over and connected to the outsole 20', a midsole 40' formed according to the method of this invention and enclosed by the outsole 20' and the upper 30', and a strap unit 31 having four end the upper 30', and a strap unit 31' having four end portions 32'. The function of the upper flange 21' is similar to that of the cover sheet 21 shown in Fig. 4.
The outsole 20' is provided with a pair of linking straps 24' having end portions which are stitched onto the end portions 32' of the strap unit 31' The upper 30' is formed with four slits 411' for passage of the end portions of the linking straps 24' Before the formation of the midsole 40', the upper and the outsole 20' are respectively mounted on the upper mold part 111' and the bottom mold part 112', and four positioning sleeves 26' and four support sleeves 25' are provided and are disposed in a manner that the four positioning sleeves 26' extend through the upper mold part 111' and respectively into the slits 411', that the four support sleeves 25' are disposed between the outsole 20' and the upper at the slits 411' and respectively receive the end portions of the linking straps 24', and that the end portions of the linking straps 24' extend outwardly 20 of the upper mold part 111' through the positioning sleeves 26' After the formation of the midsole the positioning sleeves 26' can be removed from the upper mold part 111', and the end portions of the linking straps 24' can be stitched onto the end 25 portions 32' of the strap unit 31' after removal of the upper and bottom mold parts 111' 112' It is noted that the end portions 32' of the strap unit 31' can 9909 9 9 9 9*99 w99* *9.9 99.9 9**9 9 9 *99* .p 9r 9 09 90 9 9 13 be stitched onto the end portions of the linking straps 24' and the thus formed assembly is then disposed in the mold cavity 90' for subsequent processing steps for the formation of the midsole By using the cover sheet 21 according to the method of this invention, the aforesaid drawbacks as encountered in the prior art can be eliminated.
For the purposes of this specification it will be clearly understood that the word "comprising" means [0 "including but not limited to", and that the word "comprises" has a corresponding meaning.
It is to be understood that, if any prior art publication is referred to herein, such reference does not constitute an admission that the publication forms a part of the common general knowledge in the art, in Australia or any other country.
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Claims (12)

1. A method for making a shoe, comprising the steps of: preparing an outsole having an upper surface and a peripheral portion; preparing an upper having a bottom portion that defines an insole having a peripheral portion which is to be disposed over said peripheral portion of said outsole; preparing a cover strip that is to be disposed between and that is to interconnect said outsole and said insole; preparing a mold that has an inner wall defining a mold cavity, an upper mold part with a last, a bottom S 15 mold part opposite to said upper mold part, and at least two opposite side mold parts; ~placing said outsole, said upper, and said cover strip in said mold cavity such that said outsole is mounted on said bottom mold part, that said upper is fittingly sleeved on said last with said insole being disposed over said outsole, and that said peripheral portions of said insole and said outsole are interconnected by said cover strip so as to confine an inner space thereamong; closing said mold; filling a foamable material into said inner space; and permitting said foamable material in said inner space to expand to thereby forcing said outsole, said insole, and said cover strip to press against said inner wall of said mold so as to form a foamed midsole that is enclosed by and that is bonded to said outsole, said insole, and said cover strip.
2. The method of claim 1, wherein said outsole and said insole are interconnected by said cover strip before placing in said mold cavity. H \Luisa\Keep\Speci\44410-02.doc 29/06/04 15
3. The method of claim 2, wherein said outsole and said insole are adhesively bonded to said cover strip so as to be interconnected by the same before placing in said mold cavity.
4. The method of claim 3, further comprising the step of heating said mold to a molding temperature before the placement of the assembly of said outsole, said insole, and said cover strip in said mold cavity.
The method of claim 4, further comprising the step of filling a gas into said inner space so as to force said outsole, said insole, and said cover strip to press 15 against said inner wall of said mold before the step of filling said foamable material into said inner space.
6. The method of claim 5, wherein said inner wall of said mold is patterned, said cover strip being pressed against and being heated by said mold upon foaming of said foamable material in said mold so as to be patterned by said mold.
7. The method of claim 6, wherein said cover strip is made of ethylene vinylacetate copolymer, and said S* foamable material is made of polyurethane.
8. The method of claim 2, further comprising the step of loading a filler in said inner space before the placement of the assembly of said outsole, said insole, and said cover strip in said mold cavity, said filler being in the form of pellets, and being made of a plastic material selected from a group consisting of ethylene vinylacetate copolymer, rubber, and polyurethane.
9. The method of claim 2, further comprising the step of disposing a plurality of cushioning pads in said H; \Lisa\Keep\peci\44410.O2.doc 29/06/04 16 inner space before the placement of the assembly of said outsole, said insole, and said cover strip in said mold cavity.
10. The method of claim 9, wherein each of said cushioning pads is an air unit.
11. The method of claim 1, further comprising the step of attaching a pair of flexible strips to said peripheral portion of said upper, said flexible strips having lower end edges surrounding said peripheral portion of said upper, said cover strip having upper edges in abutment with said end edges of said flexible strips. 15
12. The method of claim 1, further comprising the step of applying an adhesive to said upper surface of said outsole before placement of said outsole in said mold. Dated this 29th day of June 2004 CHENG-HSIAN CHI By their Patent Attorneys ':GRIFFITH HACK Fellows Institute of Patent and 25 Trade Mark Attorneys of Australia H:\Luisa\Keep\Speci\44410-02.doc 29/06/04
AU44410/02A 2002-05-28 2002-05-28 Method for making a footware having a midsole surrounded by a cover sheet Ceased AU783483B2 (en)

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AU44410/02A AU783483B2 (en) 2002-05-28 2002-05-28 Method for making a footware having a midsole surrounded by a cover sheet

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AU783483B2 true AU783483B2 (en) 2005-11-03

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Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US6149852A (en) * 1995-05-30 2000-11-21 Benetton Sportsystem S.P.A. Method for obtaining a shoe, and shoe obtained with said method
US6205683B1 (en) * 1997-05-30 2001-03-27 The Timberland Company Shock diffusing, performance-oriented shoes

Patent Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US6149852A (en) * 1995-05-30 2000-11-21 Benetton Sportsystem S.P.A. Method for obtaining a shoe, and shoe obtained with said method
US6205683B1 (en) * 1997-05-30 2001-03-27 The Timberland Company Shock diffusing, performance-oriented shoes

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