Title:
Footwear with finished platform
Kind Code:
A1


Abstract:
A method for making footwear using a finished platform. The method includes providing a finished platform having a peripheral side region; providing an outsole unit; and providing an upper attached to the peripheral side region of the finished platform. The finished platform includes an insole, a sock lining unit, having a peripheral portion for seaming and stitching, which is attached to an upper surface of the insole, and a wrapper covering the peripheral side region of the finished platform, the wrapper seamed to the peripheral portion of the sock lining unit. The present method provides the advantage of having a finished platform which can readily receive an upper. This allows a simple and economical attachment of the upper to a finished platform, efficiently streamlining manufacturing and production of completed shoes, making a simple and cost-favorable shoe production possible.



Inventors:
Issler, David C. (North Andover, MA, US)
Application Number:
10/014030
Publication Date:
06/12/2003
Filing Date:
12/10/2001
Assignee:
ISSLER DAVID C.
Primary Class:
Other Classes:
36/24.5, 36/18
International Classes:
A43B3/10; A43B9/02; A43B13/41; A43B23/22; (IPC1-7): A43B9/02
View Patent Images:
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20110283560MULTIPLE RESPONSE PROPERTY FOOTWEARNovember, 2011Portzline et al.
20090133288FOOTWEAR WITH TWO-PLATE SYSTEMMay, 2009Gallegos
20080104777HEEL CONSTRUCTION METHOD FOR INJECTION MOLDED ARTICLE OF FOOTWEARMay, 2008Vitulli
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20150128447MODULAR FOOTWEAR PLATFORMMay, 2015Verona
20150305434Shoe with Divided Ground Contact SurfacesOctober, 2015Santos



Primary Examiner:
KAVANAUGH, JOHN T
Attorney, Agent or Firm:
ST. ONGE STEWARD JOHNSON & REENS LLC (STAMFORD, CT, US)
Claims:

What is claimed is:



1. A method for making footwear comprising: providing a finished platform having a peripheral side region, the platform including: an insole having an upper surface; a sock lining attached to the upper surface of the insole, having a peripheral region; a wrapper covering the peripheral side region of the finished platform; and, stitching the wrapper for seaming to the peripheral region of the sock lining; attaching an upper having a vamp to the peripheral side region of the finished platform subsequent to completing the finished platform; and, attaching an outsole unit to the finished platform.

2. The method of claim 1, wherein the insole of the finished platform further comprises a foam insole cover, a fiber tuck, and a steel shank.

3. The method of claim 1, wherein the outsole unit includes a heel having a height, and wherein the method further includes molding the finished platform on the basis of the height of the heel.

4. The method of claim 2, further comprising attaching the foam insole cover to the upper surface of the insole.

5. The method of claim 4, wherein the wrapper forms a bottom cover having an outsole region marked for attachment of the outsole unit and a shank area for joining the bottom cover.

6. The method of claim 5, further comprising positioning the outsole region marked for attachment in the forepart of the bottom cover and cementing and stitching the outsole unit to the outsole region marked for attachment.

7. The method of claim 5, further comprising seaming or stitching the bottom cover in the shank area of the bottom cover.

8. The method of claim 5, further comprising adhesively attaching the bottom cover to the peripheral side region of the finished platform.

9. The method of claim 8, further comprising hand-sewing the upper around the entire periphery of the finished platform with stitches against the peripheral side region of the finished platform, thereby joining the upper to the finished platform.

10. The method of claim 9, further comprising adhesively attaching the sock lining to the foam insole cover, wherein the sock lining comprises a sock forepart and a skeleton sock backpart.

11. The method of claim 10, further comprising positioning a heel in a heel portion of the underside region of the finished platform.

12. The method of claim 10, wherein the sock lining unit further comprises a sock lining pad placed over a heel portion of the finished platform, covering the skeleton sock backpart.

13. The method of claim 5, wherein the bottom cover is made of the same material as the upper.

14. The method of claim 9, wherein the stitches are Opanka stitch series.

15. The method of claim 1, wherein the insole is made of molded rubber material.

16. The method of claim 1, further comprising providing a plurality of cavities in an underside region of the finished platform for reducing the weight of the platform and giving elasticity to the platform.

17. The method of claim 1, further comprising providing an insole cavity in the upper surface of the insole for attaching the sock lining unit.

18. The method of claim 1, wherein the wrapper is a strip made from a same material as the upper, the wrapper attached to the sock lining unit by Opanka stitch series.

19. The method of claim 1, further comprising providing an outsole cavity in the outsole unit to accommodate the finished platform and providing a shank cavity to fix a steel shank cavity in the outsole cavity, wherein the outsole unit is made of molded rubber.

20. The method of claim 1, further comprising marking the upper for with Opanka stitch series for placement of awl.

21. The method of claim 1, further comprising pre-punching the upper with dots for hand-sewing.

22. The method of claim 17, further comprising placing the foam insole cover in the insole cavity and adhesively attaching the foam insole cover to the insole cavity.

23. The method of claim 18 and 22, wherein the wrapper stitched to the sock lining forms an opening for the placement of the insole, the wrapper adhesively fixed to a side and a bottom periphery region of the insole.

24. The method of claim 23, further comprising hand-sewing the upper to the sock lining unit by Opanka stitch series simultaneously stitching the finished platform to the sock lining.

25. The method of claim 23, wherein a sole cement is applied to the underside region of the finished platform and an upper surface of the outsole unit for adhesively attaching the finished platform to the outsole unit.

26. A method for making footwear comprising: attaching an insole to a sock lining unit having a peripheral portion for seaming and stitching; providing and securing a wrapper covering an underside region of the insole, the wrapper seamed to the peripheral portion of the sock lining unit, wherein the wrapper attached to the insole form a finished platform having a peripheral side region; securing an upper to the peripheral side region of the finished platform subsequent to completing the finished platform; and subsequently attaching the finished platform to an outsole unit.

Description:

TECHNICAL FIELD

[0001] This invention relates to method of making footwear.

BACKGROUND

[0002] A variety of constructions for making footwear are used by the footwear industry. For the most part, each footwear construction has characteristics that make it particularly well-suited for efficient manufacturing and ease of production. Typically, in an effort to improve the comfort, durability, and the aesthetic appeal of the footwear, a number of different assembly methods can be used.

SUMMARY

[0003] In a general aspect of the invention, a method for making footwear includes providing a finished platform having a peripheral side region; providing an outsole unit; and providing an upper attached to the peripheral side region of the finished platform. The finished platform includes an insole; a sock lining unit having a peripheral portion for seaming and stitching, the sock lining unit attached to an upper surface of the insole; and a wrapper covering the peripheral side region of the finished platform, the wrapper seamed or stitched to the peripheral portion of the sock lining unit.

[0004] In embodiments of the invention, one or more of the following features may also be included. The insole of the finished platform includes a foam insole cover adhesively attached to the upper surface of the insole, a fiber tuck, and a steel shank. The finished platform is molded for heel height for a heel positioned in a heel portion of the underside region of the finished platform.

[0005] In certain embodiments, the wrapper forms a bottom cover having an outsole region marked for attachment of the outsole unit and a shank area for joining the bottom cover. The outsole region marked for attachment is positioned in the forepart of the bottom cover and the outsole unit is cemented and stitched to the outsole region marked for attachment. The bottom cover is seamed or stitched in the shank area of the bottom cover, and the bottom cover is further attached adhesively to the peripheral side region of the finished platform. The bottom cover is made of the same material as the upper.

[0006] As yet another feature, the upper is hand-sewn around the entire periphery of the finished platform with Opanka stitch series against the peripheral side region of the finished platform, thereby joining the upper to the finished platform.

[0007] Additionally, the sock lining unit comprises a sock forepart and a skeleton sock backpart, both adhesively attached to the foam insole cover. The sock lining unit further comprises a sock lining pad placed over a heel portion of the finished platform, covering the skeleton sock backpart.

[0008] According to another aspect of the invention, the insole is made of molded rubber material. The insole has an insole cavity in the upper surface for attaching the sock lining unit. And a foam insole cover is placed in the insole cavity and adhesively attached to the insole cavity.

[0009] In certain embodiments, the wrapper is a strip made from a same material as the upper, and the wrapper is attached to the sock lining unit by Opanka stitch series. The wrapper stitched to the sock lining forms an opening for the placement of the insole, and the wrapper is adhesively fixed to a side and a bottom periphery region of the insole.

[0010] As yet another feature, the upper is marked for hand-sewing with Opanka stitch series for placement of awl, and the upper is pre-punched with dots for hand-sewing. The upper is hand-sewed to the sock lining unit by Opanka stitch series simultaneously stitching the finished platform to the sock lining.

[0011] In certain embodiments, the finished platform has a plurality of cavities in the underside region for reducing the weight of the platform and giving it elasticity.

[0012] In embodiments of the invention, the outsole unit is made of molded rubber and has a cavity to accommodate the finished platform and a shank cavity to fix a steel shank cavity therein.

[0013] Additionally, a sole cement is applied to a bottom surface of the finished platform and an upper surface of the outsole unit for adhesively attaching the finished platform to the outsole unit.

[0014] According to yet another aspect of the invention, a method for making footwear includes attaching an insole to a sock lining unit having a peripheral portion for seaming and stitching; providing and securing a wrapper covering an underside region of the insole; attaching the finished platform to an outsole unit; and, securing an upper to the peripheral side region of the finished platform. Moreover, the wrapper is seamed to the peripheral portion of the sock lining unit. The wrapper attached to the insole forms a finished platform which has a peripheral side region.

[0015] Embodiments may have one or more of the following advantages.

[0016] A method for making footwear using the present invention provides the benefit of having a finished platform which can readily receive an upper. This permits simple and economical attachment of the upper to a finished platform.

[0017] In other words, in the process for completing the shoe, the advantage lies in providing a method of making footwear which reduces the need for complicated machinery or highly skilled workers. Given a finished platform to which an upper can be quickly attached to, the process efficiently streamlines production and manufacturing of shoes. This eliminates the need for working with various components which may delay production for the completed shoes. Thus, the method makes a simple and cost-favorable production possible.

[0018] Another advantage is that the process of sewing the upper to a finished platform gives added resilience and resistance to all the components of the shoe, protecting them from deterioration and leading to prolonged life of the shoe. With prolonged wearing, the finished platform is less prone to deformation due to its resilience and strength.

[0019] In addition, this method of making footwear inherently enhances the overall appearance of the footwear by permitting genuine hand-sewn seams, all around the periphery of the shoe. Another advantage of this shoe is enhanced comfort provided by the cushioned layers of the finished platform, significantly reducing foot and leg muscle fatigue, as well as the fashionable style resulting from these functional components.

[0020] Thus, the upper is enhanced by hand-sewn seams all around the periphery of the shoe, giving it a finished, aesthetically superior quality. The pre-engineered apertures used for creating the hand-sewn seams ensure accuracy of seaming and wrapping locations as required for improved fitting qualities.

[0021] The details of one or more embodiments of the invention are set forth in the accompanying drawings and the description below. Other features, objects, and advantages of the invention will be apparent from the description and drawings, and from the claims.

DESCRIPTION OF DRAWINGS

[0022] FIG. 1 is a schematic side view of a footwear.

[0023] FIG. 2 is a pictorial exploded view of the components of the footwear of FIG. 1.

[0024] FIG. 3 is a bottom view of the footwear of FIG. 1.

[0025] FIG. 4 is a perspective view of the footwear of FIG. 1.

[0026] FIG. 5 is a perspective view of another embodiment.

[0027] FIG. 6 is a pictorial exploded view of the components of the footwear of FIG. 5.

[0028] FIG. 7 is a bottom view of the footwear of FIG. 5.

DETAILED DESCRIPTION

[0029] Referring now to the figures in which identical elements are numbered identically throughout, a description of the embodiments of the present invention will now be provided.

[0030] Referring to FIG. 1, a sandal-type shoe 10 includes a shoe upper 12, an outsole unit 50, an insole 40, and a sock lining unit 30.

[0031] Shoe upper 12 has a vamp that can have various types of designs and constructions. The shoe upper 12 is shown stitched to a finished platform 20, forming the internal spacing where the wearer's foot is inserted (not shown). The upper 12 may include an opening for the toes. The shoe upper 12 is preferably made of leather and may also include an inner liner sewed to the inner surface of upper 12 which can be fabricated of materials (e.g., soft leather) selected to provide comfort to the wearer during walking. Prior to attachment to other components of the shoe 10, the shoe at this stage, includes a sewed upper with bottom portions of the upper 12 open for attachment with a finished platform 20.

[0032] Shoe upper 12 is similar to conventional sandal-type uppers with a side portion 13 of the upper 12 shaped to accommodate pre-punched holes around its periphery for hand-sewing. These pre-punched holes (not shown) are used, as will be described below, for attachment to a finished platform 20 in the construction of the completed shoe 10.

[0033] Shoe upper 12 is designed such that the lower perimeter of the upper 12 will fit within the contoured perimeter of the insole 40. The term ‘lower perimeter’ refers to the edge of the upper 12 that contacts the insole 40 in the finished platform 20.

[0034] Outsole unit 50 is formed of molded polyurethane. In other embodiments, the outsole unit can be produced of a plastic material, for example, from a vinyl polymer, polyolefin, polystyrene, or a rubber. The outsole unit 50 provides a flexible and durable structure which resists wear. Outsole unit 50 includes a bottom walking surface 52 and an opposed surface 54 opposite to the walking surface 52. In this embodiment, outsole unit 50 includes a separate heel portion 18. The outsole unit 50 is preferably designed to provide the silhouette and support for the shoe 10, which is aesthetically desirable and comfortable for the wearer.

[0035] In the present embodiment, the outsole unit 50 is secured to an outsole region 21 with heel 18 separately formed on the bottom walking surface 52. The outsole unit 50 of the present invention has a desired thickness across its length.

[0036] The heel 18, illustrated in FIGS. 1, 3, and 4 is attached to the insole 40. The heel 18 includes a support base 19 to provide additional heel support, lift, and non-skidability for the wearer. Notches 17 formed on the walking surface of the support base 19 assist by providing cavities to enhance the non-skid features of the heel 18.

[0037] Referring to FIG. 2, the insole 40 and sock lining unit 30 are described.

[0038] The insole 40 is a padded structure designed to provide cushioning and support to a wearer's foot. The insole 40 includes several layers: a molded insole 44, a steel shank 60, a fiber tuck 43, and a foam insole cover 42. Each of these layers may be used for alignment with the other layer components. The insole 40 also includes a peripheral insole region 47 and an underside region 49 for attachment to a wrapper 22, described further below.

[0039] The molded insole 44 is formed of a rigid fiber material and is covered by a metal reinforcement steel shank 60 which is embedded within the insole 40. The molded insole 40 extends generally from a heel portion 62 of the shoe 10 to the edge of the toe portion 61 of the shoe 10 and provides the structural rigidity to the heel portion 62 of the shoe where it is most needed. Moreover, the molded insole 44 supports the heel 18, which is attached to the outsole unit 50.

[0040] The insole 40 includes a foam insole cover 42 which is made of a foam cushion material with a covering of leather of suitable man-made material, in the form of a sock lining unit 30. The foam insole cover 42 is about 3 mm in thickness. The foam insole cover 42 is cushy and covers the molded insole 44 and the steel shank 60 and is bound tightly to the molded insole 44 by an adhesive glue. Preferably, the foam insole cover 42 is shaped in conformity with the molded insole 44, and is spaced from the stitches by about ½ inch about its periphery. When the various components of the shoe 10 are stitched together, the foam insole cover 42 is held securely at its edges by the gluing.

[0041] As constructed, the foam insole cover 42 provides enhanced wearing comfort of the shoe 10. At the same time, it is protected from wear and from being damaged while inserting or removing the foot. Depending upon the compressability of the foam, the shoe may provide different configuration and shapes, as a softer foam is used and pressed differently in different portions of the shoe 10.

[0042] In this embodiment, the sock lining unit 30 includes two components, a sock lining pad 32 and an inside layer made from a sock lining forepart 33 connected to a skeleton sock backpart 34. The sock lining forepart 33 and the skeleton sock backpart 34 is formed of a polyester material and covered by the sock lining pad 32 made, e.g., of pigskin leather. As the shoe 10 is assembled, the sock lining unit 30 has an opening 37 formed by the skeleton sock backpart 34. The opening 37 allows heel 18 to be securely attached to the insole 40 by either nails or other attachment means. In this embodiment, nails (not shown) are driven through an inner section 45 of the finished platform 20 and anchored into the fiber tuck 43. The opening 37 is then covered by the sock lining pad 32 so that the pad 32 is in direct contact with and covers the foam insole cover 42. Consequently, opening 37 allows more efficient cutting of the assembly materials such as those shown in FIG. 2 and the access to the inner section 45 of the finished platform 20 of the heel 18 is facilitated. The sock lining pad 32 is made of the same material as the upper 12 and wrapper 22, thus giving a uniform, aesthetically pleasing look to the finished platform 20. Although leather is the preferred material, different materials may be used. Additional padding layers may be added to the socklining unit 30, as necessary or as desired.

[0043] In some embodiments, the sock lining unit 30 may be decoratively quilted to provide an aesthetically pleasing look to the interior surface of the shoe 10. Moreover, the sock lining unit 30 includes a peripheral portion 35 for attaching to the upper 12 and the wrapper 22 described further below. This peripheral portion 35 becomes the peripheral side region 25 of the completed finished platform 20.

[0044] Referring to FIG. 3, the underside portion 54 of the assembled shoe 10 is illustrated. The walking surface 52 has the outsole unit 50 which includes a recessed channel 51 that the contact surface of the shoe 10. The recessed channel 51 forms a notch 41 on the outsole unit 50. Similarly, a recessed channel 53 on the heel 18 form a notch 17. In essence, the recessed channels 51 and 53 protect the outsole unit 50 and the heel 18, respectively, by ensuring that the contact between the ground and these components are minimized and the shoe can be worn for prolonged duration.

[0045] The walking surface 52 further includes a wrapper 22 preferably made of the same material as the upper 12. The qualities of the material, such as leather, should be tear resistant, or high quality stitched-in textile made of strong fiber material. The wrapper 22 includes a center seam 70 having stitches 72 on a first side 74 and a second side 76 of the center seam 70. As will be described in greater detail below, the wrapper 22 functions as a bottom cover 80 for the finished platform 20, which is secured to the underside region 49 of the insole 40. The bottom cover 80 covers the underside region 49 thereby forming the underside portion 54 of the shoe 10. Specifically, the center seam 70 serves to secure the wrapper 22 to the insole 40 of the shoe 10. FIG. 4 provides a perspective view better illustrating the stitches 72 on the first side 74 of the center seam 70 and the other components of the underside portion 54 of shoe 10. It can be seen that the bottom cover 80 has a shank area 23 for joining the bottom cover 23.

[0046] The construction method of this embodiment will now be described in conjunction with the figures.

[0047] In preparation for constructing shoe 10, the upper 12 is cut, stitched and finished. The various components of the insole 40 are adhesively secured together. Namely, the molded insole 44 is adhesively combined with the steel shank 60 and the fiber tuck 43 in a compact fashion, securely attaching all surfaces of the these components to form a tight, well-formed insole 40. The molded insole 40 can be molded to different shapes depending on a desired heel height.

[0048] The bottom cover 80 will be marked for outsole location, and thereafter folded at the center seam 70 to be seamed and stitched. The bottom cover 23 is seamed and stitched in the shank area 23 by stitches 72. The outsole unit 50 is then cemented and joined by stitches 59 securely attaching the outsole unit 50 to the leather bottom cover 80.

[0049] The bottom cover 80 is placed adhesively against the underside region 49 of the insole 40, ensuring proper alignment with the insole 40. Excess material from the bottom cover 80 is marked and trimmed so that the peripheral insole region 47 is covered adequately by the bottom cover 80. The bottom cover 80 also serves as a “wrapping strip” in a manner that permits the strip to be wrapped, or sidelasted, onto the insole 40. The fitting qualities are engineered into the attachment of the bottom cover 80 “wrapping strip” to the peripheral sides of the insole 40 and are dependent upon accurate stitching of this “wrapping strip” to the peripheral insole region 47 of the insole 40.

[0050] Finally, the finished platform 20 is constructed by attaching the sock forepart 33 and the skeleton sock backpart 34 of the sock lining unit 30 to the insole 40. The sock forepart 33 and the skeleton sock backpart 34 are adhesively placed onto the foam insole cover 42. The sock lining pad 32 may be adhesively placed over the opening 37 of the insole 40 either at this point of the construction process or after the finished platform has been secured to the outsole unit 50. Because shoe 10 can be made more comfortable by providing as many layers of cushion or foam inserts as desired, sock lining pad 32 is inserted into the finished platform 20 so as to be disposed between the finished platform and the foot of the wearer. So that the sock lining pad 32 does not dislodge, tear or bend when inserting or removing the foot from the shoe, adhesive gluing or other secure means for attachment must be accurately performed.

[0051] To form the shoe 10, the upper 12 is now hand-sewn using pre-punched holes in the upper 12 and the peripheral portion 35 of the sock lining unit 30 thereby attaching it to the finished platform 20. The stitching used is an Opanka stitch series. In certain embodiments, the stitching or seaming is done by passing a thread or other suitable means through pre-punched holes, forming a criss-cross stitch pattern. The stitching continues along the entire peripheral side region 25 of the finished platform, joining the upper 12 to the sock lining unit 30 and the wrapper 22. The joining of these components by stitching creates a one-piece “cavity”, the internal spacing of the shoe 10, which is comfortable on the foot.

[0052] The heel 18 is secured and nailed to the heel region 62 of the insole 40 covered with the bottom cover 80. Finally, the sock lining pad 32 can be inserted now or before forming the finished platform 20, over into internal spacing of the shoe 10 created by the upper 12 within which the wearer's foot is to be inserted. The completed shoe is shown in FIGS. 1 and 4.

[0053] In a further embodiment as shown in FIGS. 5-7, a finished platform 20 is provided which does not have a bottom cover 80. As illustrated in FIG. 5, the shoe 10 includes a shoe upper 12, an outsole unit 50, an insole 40, and a sock lining unit 30.

[0054] The shoe upper 12, preferably made from leather, may have a vamp of various types and styles such as closed toe or open toe designs. The shoe upper 12 is attached to the insole 40, forming what will be the internal spacing of the shoe. Shoe upper 12 may also include an inner liner sewed to the inner surface of upper 12 which can be fabricated of materials (e.g., soft leather) selected to provide comfort to the wearer during walking, in the same manner as described in connection with the previous embodiment.

[0055] Shoe upper 12 is similar to conventional sandal-type uppers with a side portion 13 of the upper shaped to accommodate pre-punched holes around its periphery for hand-sewing. These pre-punched holes (not shown) are used, as will be shown later, for attachment to a finished platform 20 in the construction of the shoe 10.

[0056] Outsole unit 50 is formed of molded polyurethane. Outsole unit 50 includes a bottom walking surface 52 and an opposed surface 54 opposite to the walking surface 52 which attaches to the insole 40. The outsole unit 50 provides a flexible and durable structure which resists wear.

[0057] In this embodiment, the outsole unit 50 may be formed by a one-piece molded outsole integrated with a heel 18, thereby simplifying the manufacturing process of the shoe. The outsole unit has a desired thickness across its length and includes an integrally molded, upstanding sidewall 57 extending around its periphery.

[0058] The opposed surface 54 of the outsole unit 50 is provided with an outsole cavity 55 and the open cells 56 for bonding with the underside region 49 of the insole 40, and an additional cavity 71 to accommodate the steel shank 60 (not shown). In general, this means that the outsole unit 50 in the form of the outsole cavity 55 and the open cells 56 provides sufficient structural integrity to support the wearer's weight without being crushed, while providing a reduced amount of material compared with a completely filled supporting outsole unit structure.

[0059] The outsole cavity 55 has a depth ranging from about 2 mm to about 4 mm. The outsole cavity 55 is slightly larger than the size of the insole 40 to provide a peripheral fit for adhesively securing and bonding the insole 40 to the opposed surface 54 of outsole cavity 55.

[0060] The heel 18 includes a support base 19 to provide additional heel support, lift, and non-skidability for the wearer, in the same manner as described in connection with the previous embodiment.

[0061] Referring to FIG. 6, the insole 40 and sock lining unit 30 are described.

[0062] The insole 40 for this embodiment has a simplified construction. It includes a molded insole 44 and a foam insole cover 42 of about 3 mm in thickness. Each of these layers may be used for alignment with the other layer. The insole 40 may also include a platform in lieu of the molded insole 44. The molded insole 44 is then covered with foam insole cover 42. The insole 40 also includes a peripheral insole region 47 and an underside region 49 for attachment to the outsole unit 50 and the wrapper 22.

[0063] The molded insole 44 is formed of a flexible rubber material, extending generally from the heel portion 62 of the shoe 10 to the edge of the toe portion 61 and the molded insole 44 provides a flexible structure for the shoe 10.

[0064] The insole 40 further includes a foam insole cover 42 made of a foam cushion material with a covering of leather of suitable man-made material, in the form of the sock lining unit 30. The molded insole 44 includes a cavity 63 to accommodate the foam insole cover 42. The foam insole cover 42 is cushy and covers the molded insole 44. Preferably, the foam insole cover 42 is approximately ⅜″ thick and is attached securely within the cavity 63 of the molded insole 44 by gluing. Depending upon the compressability of the foam insole cover 42, the shoe 10 may provide different configuration and shapes, as a softer foam is used and pressed differently in different portion of the shoe 10.

[0065] In this embodiment, the sock lining unit 30 includes only one component, a sock lining 32. The sock lining 32 may be made from one piece of any suitable material or it can be made from composite parts. The sock lining 32 may be decoratively quilted to provide an aesthetically pleasing look to the interior surface of the shoe. The sock lining 32, as well as the upper 12, may be provided with corresponding or matching surface ornamentation in order to impart to these components a coordinated appearance or stitching pattern.

[0066] Moreover, the sock lining unit 30 includes a peripheral portion 35 for attaching to the upper 12 and the wrapper 22, described further below. This peripheral portion 35 becomes the peripheral side region 25 of the completed finished platform 20.

[0067] Referring to FIG. 7, the underside portion 49 of the insole 40 is illustrated. The underside region 49 includes a strip of the wrapper 22 folded over the underside portion 49 and seamed or adhesively glued to the peripheral edge 47 of the underside portion 49. The strip of wrapper 22 is preferably made of the same material as the upper 12 such as leather, but any suitable material for the strip is appropriate. As desired, the wrapper 22 may be a connecting endless ring-like strip, especially in an embodiment such as that shown in FIGS. 5-7 rather than a strip of wrap with a finite length.

[0068] The underside region 49 of the insole 40 further includes cavities 48 having a honeycomb construction. These cavities reduce the weight and provide added elasticity to the finished platform 20.

[0069] A construction method for making this embodiment will now be described in conjunction with FIGS. 5-7.

[0070] In preparation for constructing shoe 10, the upper 12 is prepared as usual. The upper 12 may also include an opening for the toes as in the previous embodiment. The upper 12 is marked with pre-punched holes (not shown) for hand-sewing with Opanka stitch series of dots for placement of awl. The components of the insole 40 are adhesively secured together. Namely, the molded insole 44 is adhesively combined with the foam insole cover 42, securely attaching them to form a tight, well-formed insole 40. The molded insole 40 may also be formed to different shapes depending on the desired heel height. In this embodiment, the stitching is done by passing a thread through the pre-punched holes, forming a criss-cross stitch pattern.

[0071] The sock lining 32 of the sock lining unit 30 is thereafter cut in order to be placed above the foam insole cover 42. The peripheral portion 35 of the sockining unit 30 is marked with a series of dots for placement of awl or pre-punched holes may be formed for eventual hand-sewing in Opanka stitch series.

[0072] Foam insole cover 42 is attached adhesively onto the cavity 57 of the insole 40. Wrapper 22 is seamed with the peripheral portion 35 of the sock lining 32, along the entire periphery of the sock lining 32. In other words, the stitching continues along the entire peripheral side region 25 of the finished platform. This is achieved by forming a closing seam (not shown) joining the wrapper 22 to the sock lining unit 30 by placing the components to be seamed face to face and stitching close to the edge, which then results in a hidden seam. The closing seams can be performed by a sewing machine.

[0073] Consequently, a cavity is formed by joining the sock lining unit 30 and the wrap 22 for placement of the insole 40. The insole 40 is placed within the cavity, with the wrapper 22 adhesively fixed to the side 63 and peripheral edge 47 of the underside portion 49.

[0074] In other words, the wrapper 22 extends downwardly from the point of its attachment at the side of the insole 40 and is lasted into the underside region 49 of the insole 40. Thus, the peripheral edge 47 of the wrap 22 terminates at a point before covering the honeycomb cavity 48. In effect, this enables manufacture of the finished platform 20 with a minimum quantity of leather and thereby reduces the material cost of the shoe.

[0075] Moreover, the strip of wrap 22 becomes almost like an extension of the sock lining unit 30 in that it serves to anchor and hold the finished platform 20 together.

[0076] Once so bonded to the insole 40, the wrap 22 is sealed securely against the penetration of moisture and is guarded against scruffing and side blows imparted to the shoe 10.

[0077] Next, the peripheral edge 47 of the wrap 22 (FIG. 7) may be roughed in order to remove the leather finish of the wrapper 22 and to allow sole cement to penetrate the wrapper leather. The finished platform 20 is now completed for this embodiment.

[0078] The upper 12 is now attached to the finished platform 20, by hand-sewing the upper 12 using pre-punched holes, to the peripheral portion 35 of the sock lining unit 30 and attaching the upper 12 to the finished platform 20 with Opanka stitch series.

[0079] To complete the shoe 10, sole cement is applied to the honeycomb cavities 48 in the underside region 49 of the insole 40. For secure and tight bonding, sole cement is also applied in the outsole cavity 55, including the additional cavity 71 to accommodate the steel shank 60. This additional sole cement ensures adequate bonding of the insole 40 into the cavity 55 of the outsole unit 50. For this purpose, a last (not shown) is then inserted into the resulting one-piece finished platform 20 and the outsole unit 10 is pressed to form the secure bond. The lasting is accomplished by slipping a last into the internal spacing where the wearer's foot is inserted. The last is used as leverage so that the outsole unit 50 can be pressed to the finished platform 20 thus completing the construction of the shoe 10.

[0080] Although the invention, preferably relates to casual sandals, other fields of application are entirely within the scope of the invention, especially in the broad sector of footwear manufacturing. Thus, a number of embodiments of the invention have been described. Nevertheless, it will be understood that various modifications may be made without departing from the spirit and scope of the invention. Accordingly, other embodiments are within the scope of the following claims.