Fabric footwear outsole and method of manufacturing same

Abstract

The method for fabricating the fabric footwear outsole begins by forming a rubber outsole base with an unfinished exterior surface section. A non-woven fabric sheet and an unvulcanized rubber sheet are separately formed and joined together. The sheets are cut to the shape of the unfinished exterior surface section of the base to form a fabric member. The fabric member is joined to the unfinished exterior surface section of the base by glue. Thereafter, the rubber outsole base and the fabric member assembly are heated to vulcanize the rubber sheet and to securely and permanently attach the fabric member to the outsole.

1 . A method of fabricating an outsole comprising the steps of:
 (a) forming a rubber outsole base with an unfinished exterior surface section;   (b) forming a non-woven fabric sheet;   (c) forming an unvulcanized rubber sheet;   (d) joining the sheets;   (e) cutting the joined sheets to the shape of the unfinished exterior surface section to form a fabric member;   (f) joining the fabric member to the unfinished exterior surface section of said base to form an assembly; and   (g) heating the assembly to vulcanize the rubber sheet and permanently secure the fabric member to said base to form the outsole.   
     
     
         2 . The method of  claim 1  wherein the step of forming the rubber outsole base comprises the step of forming the rubber outsole base with a finished exterior surface section. 
     
     
         3 . The method of  claim 1  wherein the step of forming the rubber outsole base comprises the step of forming the rubber base with a finished exterior surface section proximate the unfinished exterior surface section. 
     
     
         4 . The method of  claim 1  wherein the step of joining the rubber sheet and the fabric sheet comprises the step of cementing the sheets together. 
     
     
         5 . The method of  claim 1  wherein the step of joining the rubber sheet and the fabric sheet comprises squeezing the sheets together. 
     
     
         6 . The method of  claim 4  wherein the step of joining the rubber sheet and the fabric sheet further comprises squeezing the sheets together. 
     
     
         7 . The method of  claim 1  wherein the step of forming an unvulcanized rubber sheet comprises the step of forming an unvulcanized rubber sheet approximately 1 mm in thickness. 
     
     
         8 . The method of  claim 1  wherein the step of forming an unvulcanized rubber sheet comprises the step of squeezing unvulcanized rubber into a sheet. 
     
     
         9 . The method of  claim 1  wherein the steps of forming an unvulcanized rubber sheet and forming the fabric sheet take place simultaneously. 
     
     
         10 . The method of  claim 1  further comprising the step of embossing the surface of the non-woven fabric. 
     
     
         11 . The method of  claim 1  further comprising the step of buffing the surface of the unfinished exterior surface section prior to joining the fabric member thereto. 
     
     
         12 . The method of  claim 1  wherein the step of joining the fabric member to the unfinished exterior surface section comprises the step of cementing the fabric member to the unfinished exterior surface section. 
     
     
         13 . The method of  claim 1  wherein the step of joining the fabric member to the unfinished exterior surface section comprises the step of cementing the fabric member to the unfinished exterior surface section with rubber glue. 
     
     
         14 . A method of fabricating footwear with a fabric outsole comprising the steps of:
 (a) forming a rubber outsole base with an unfinished exterior surface section;   (b) forming a non-woven fabric sheet;   (c) forming an unvulcanized rubber sheet;   (d) joining the sheets;   (e) cutting the joined sheets to the shape of the unfinished exterior surface section to form a fabric member;   (f) joining the fabric member to the unfinished exterior surface section;   (g) heating the assembly to vulcanize the rubber sheet and permanently secure the fabric member to said base to form the outsole;   (h) forming an upper; and   (i) attaching the upper to the outsole.   
     
     
         15 . The method of  claim 14  wherein the step of forming the rubber outsole base comprises the step of forming a rubber outsole base with a finished exterior surface section. 
     
     
         16 . The method of  claim 15  wherein the step of forming the rubber outsole base comprises the step of forming a rubber outsole base with a finished exterior surface section proximate the unfinished exterior surface section. 
     
     
         17 . The method of  claim 14  wherein the step of joining the rubber sheet and the fabric sheet comprises the step of cementing the sheets. 
     
     
         18 . The method of  claim 14  wherein the step of joining the rubber sheet and the fabric sheet comprises squeezing the sheets together. 
     
     
         19 . The method of  claim 18  wherein the step of joining the rubber sheet and the fabric sheet comprises squeezing the sheets together. 
     
     
         20 . The method of  claim 14  wherein the step of forming an unvulcanized rubber sheet comprise the step of forming an unvulcanized rubber sheet 1 mm in thickness. 
     
     
         21 . The method of  claim 14  wherein the step of forming an unvulcanized rubber sheet comprises the step of squeezing unvulcanized rubber into a sheet. 
     
     
         22 . The method of  claim 14  wherein the step of forming an unvulcanized rubber sheet and the fabric sheet take place simultaneously. 
     
     
         23 . The method of  claim 14  further comprising the step of embossing the surface of the fabric. 
     
     
         24 . The method of  claim 14  further comprising the step of buffing the surface of the unfinished exterior surface section prior to joining the fabric member thereto. 
     
     
         25 . The method of  claim 14  wherein the step of joining the fabric member to the unfinished exterior surface section comprises the step of cementing the fabric member to the unfinished exterior surface section. 
     
     
         26 . The method of  claim 14  wherein the step of joining the fabric member to the unfinished exterior surface section comprises the step of cementing the fabric member to the unfinished exterior surface section with rubber glue. 
     
     
         27 . An outsole with a fabric member comprising a rubber outsole base with an exterior surface comprising an unfinished section of a given shape and size; a fabric member substantially of said given shape and size comprising a fabric layer and a rubber layer, and means for joining said fabric member to said unfinished section of said base. 
     
     
         28 . The outsole of  claim 27  wherein said base and said fabric member are heated to vulcanize said rubber sheet subsequent to being joined. 
     
     
         29 . The outsole of  claim 27  wherein said rubber layer is unvulcanized prior to forming said fabric member.