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Патент USA US2106845

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Feb. 1, 1938.
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2,106,845
MANUFACTURE OF SHOE BOTTOM UNITS
:
Filed May 1, 1936
2 Sheets-Sheet l
Feb. 1, 1938,
2,106,845
R. E. HOPKINS
MANUFACTURE OF SHOE BOTTOM UNITS
Filed May 1, 195a
2 Sheets__sheet 2
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68
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Patented Feb. I, 1938
’ 2,106,845
UNITED STATES
PATENT OFFICE
2,106,845
MANUFACTURE OF SHOE BOTTOM UNITS
Raymond E. Hopkins, Weymouth, Mass, assignor
to United Shoe Machinery Corporation, Pater
son, N. J., a corporation of New Jersey
Application May 1, 1936', Serial No. 77,373
12 Claims. (Cl. 12-146)
This invention relates to the manufacture of
insoles and outsoles having complementary fore
part portions.
In a copending application, Serial No. 26,217,
?led June 12, 1935, in the name of Albert Boot,
there is disclosed a method of making a so-called
“insole-outsole combination” consisting of an
outsole having a central forepart projection
and an insole having a correspondingly located
opening which is complemental to the outsole
projection. In the practice of the method re
ferred to the insole and the outsole are split from
a laminated blank comprising a layer of outsole
material and a layer of insole material, the layers
being secured together by means of cement, and
the splitting operation is performed by a matrix
roll type of splitting machine having matrix and
die rolls which ?ex and deform the forepart of
the blank so that the cut of a straight-edged
, splitting knife will form the opening in the insole
and the corresponding projection on the outsole.
It is desirable in some instances to have the in
soles formed wholly or partially of one of the
well-known fabricated or “manufactured” mate
rails which are of a character adapted to serve as
a substitute for leather. An example of such
material is a composition of wood pulp and latex
and such material is commonly supplied in sheets
of laminated formation. Considerable difficulty
is often experienced in performing splitting op
erations of the type referred to upon laminated
blanks, and particularly upon blanks having in
sole layers of fabricated material, because of the
fact that the splitting knife, in starting that por
tion of the out which is to form the insole open
ing, has a tendency to enter or follow along the
plane of adhesion between the insole and outsole
layers or to enter between the plies of the fabri
cated insole material and thus is liable to make
an undesirable ragged cut through the insole
material.
One object of the present invention is to over
come the above-mentioned difficulties in the
manufacture
combinations.
of
complemental
insole-outsole
.
To the accomplishment of this object, it is
proposed to prepare the blank for the splitting
operation by preliminarily cutting inwardly from
the upper surface of the layer of insole material
thereby initiating the division of the blank into
an insole having an opening therein and an
outsole having a projection complemental to the
insole opening, and thereafter completing the di
vision of the blank by means of a. splitting knife
, which in its operation passes idly through said
preliminary cut. This preliminary cut or incision
may be made in the insole layer either before or
after that layer has been secured to the outsole
layer and preferably the out should be shaped so
as to constitute part of the opening which is to
be formed in the insole by the splitting knife. By
properly locating such a preliminary cut in the
insole layer the knife of the spitting machine,
when it reaches the cut in the course of the split
ting operation, will pass readily through the 10
cut and the portion of the knife which is in line
with the cut will have no tendency to remain in,
or to enter and follow along, the plane of adhe
sion between the insole and outsole layers after
reaching the deformed portion of the blank. 15
Moreover, in cases where insole material of lami
nated formation is employed, the splitting knife
will have no tendency to enter between the sev
eral plies of the insole layer as it operates to cut
the insole opening and the outsole projection.
The presence of the preliminary cut in the insole
layer thus insures clean cutting and proper shap
ing of the forward end portion of the insole open
ing and the outsole projection where, in the ab
sence of such a cut, ragged cutting and mutila- 25
tion of the insole material is very liable to take
place where the splitting knife starts the cut de
?ning the insole opening.
Invention is also to be recognized as residing in
the step products hereinafter described and
claimed which result from the practice of my im
proved method of manufacturing soles.
The invention will now be explained with refer
ence to the accompanying drawings, in which
Fig. 1 is a perspective view of a laminated sole
blank of the type employed in the practice of
my improved method;
Fig. 2 is a fragmentary elevational view of a
portion of a sole rounding machine illustrating
the operation of the machine upon the sole blank
shown in Fig. 1';
-
Fig. 3 is a perspective view of the sole blank as
it 'appears after it has been rounded to impart
substantially a ?nal edge contour thereto and
after the preliminary incision has been made
through the insole layer to facilitate the per
formance of the splitting operation;
Fig. 4 is a longitudinal sectional view of the for
ward end portion of the blank illustrating the
operation of making the preliminary incision in 50
the insole layer;
Fig. 5 is a cross-sectional view of a portion of
a matrix roll type splitting machine showing a
sole blank about to be operated upon by the split
ting knife;
55
2,106,845
2
Fig. 6 is a fragmentary View in vertical section
of the matrix rolls of the splitting machine illus
trating the operation of the rolls upon the cen
tral forward portion of the sole blank;
Fig. 7 is a longitudinal sectional view on an en
larged scale of the forward portion of a laminated
sole blank the margin of which is being split in
the plane of adhesion between the insole and out
sole layers, the ?gure showing how the blank is
10 distorted by the action of the matrix rolls in the
Bertrand, in order to impart to the insole layer
a contour somewhat smaller than that to be im
parted to the outsole layer in order to provide
space for receiving the upper materials which are
to be lasted over the insole without causing these
materials to project over the edge of the outsole.
As indicated in Fig. 2, such a double knife
rounding machine comprises upper and lower
patterns 32 and 34 between which the laminated
sole blank is located, and upper and lower round 10
vicinity of the preliminary incision in the insole
ing knives 38 and 38 which are caused to travel
layer and showing the appearance of the blank
around the edges of the patterns 32 and 34, re
spectively. In the use of this machine the lower
after the splitting has proceeded to the point
where the knife is about to enter that incision;
Fig. 8 is a view similar to Fig. '7 but showing
rounding knife 38, following the contour of the
the appearance of a sole blank the margin of
layers of the sole blank, thus determining the
?nal outline of the outsole layer 22, while the
upper knife 35, following the contour of the pat
tern 32 which is smaller than the pattern 34, cuts
downwardly through the insole layer 24 along
which is being split in a plane extending through
the outsole layer near the plane of adhesion be
tween the insole and outsole layers;
Fig. 9 is a cross-sectional View of the forepart
of the insole produced when the margin of a sole
blank is split as indicated by Fig. 7;
Fig. 10 is a cross-sectional view of the forepart
of the outsole produced when the sole blank is
split as indicated by Fig. 7;
pattern 34, trims both the insole and outsole .
a path located within that of the lower knife 38,
thus cutting the insole layer somewhat smaller
than the outsole layer. At the completion of the
rounding operation, if the insole and outsole lay
ers were cemented together only in their central .
Fig. 11 is a cross-sectional view of the insole ' forward portions, the strip of waste material
produced when the sole blank is split as indicated
severed from the insole layer by the upper round
by Fig. 8;
ing knife 36, being unsecured to the outsole layer,
Fig. 12 is a cross-sectional view of the outsole
30 produced when the sole blank is split as indicated
by Fig. 8;
will fall clear of the sole blank, whereas in cases
where the insole and outsole layers are cemented 30
together throughout the areas of their contact
Figs. 13 and 14 are perspective views of the
insole and the outsole shown in Figs. 11 and 12,
ing surfaces the waste strip defined by the
rounding knife may be readily peeled off from
respectively;
the outsole layer and discarded. After the re
moval of the waste strip the rounded sole blank 35
will ‘then appear as indicated in Fig. 3. It will
be seen that the edge of the insole layer 24 is
Fig. 15 is a fragmentary perspective view of in
sole and outsole blanks which have been cut to
sole shape before being secured together; and
Fig. 16 is a fragmentary perspective View of
the sole blank showing a mark for gaging the lo
40 cation of the preliminary incision.‘
In the practice of my improved method of mak
ing soles, as herein illustrated, I provide a lam
inated sole blank 20 by securing together by
means of a suitable adhesive a layer 22 of out
45 sole material such as sole leather and a layer 24
of any suitable insole material. For convenience
these two layers will be referred to hereinafter
as the outsole layer 22 and the insole layer 24.
The insole layer 24 may advantageously consist of
50 fabricated or so-called manufactured material
such, for example, as a composition of wood pulp
and latex, and, as illustrated, the insole layer is
itself of laminated formation comprising, as best
shown in Figs. '7 and 8, a plurality of layers 26
55 which are adhesively secured together. In mak
ing up the sole blank 20, the outsole and insole
layers 22 and 24 may be secured together
throughout the entire areas of their contacting
faces or, if desired, the insole layer 24 may be
60 secured to the outsole layer only in the central
portion of its forepart, for example, in an area
such as that bounded by the dotted line 28 in
Fig. 1, such area corresponding in shape and lo
cation substantially to that of the projection
65 which is ultimately to be formed upon the out
spaced inwardly relatively to the edge of the out
sole layer 22.
In order to facilitate clean cutting during that
part of the splitting operation which is to form
the forward portions of the insole opening and
the outsole projection, the sole blank is next pre
pared, in accordance with my improved method,
by forming a preliminary incision 4t (Fig. 3) in 45
the insole layer 24, the incision 46 being located
where the forward end of the outsole projection
is to be formed. As shown, the incision 40 is so
shaped, and it is extended through the insole
layer at such an angle to the surface of the latter,
that when the incised portion of the sole blank
has been distorted by the matrix and die rolls
of the splitting machine the plane of the incision
will coincide substantially with the plane of the
splitting knife so that the knife will pass through
the incision without cutting the insole layer.
The angular relation of the incision {it to the sur
face of the insole layer is such as to correspond
to the angle of the bevel out which is to, de?ne
the insole opening and the outsole projection.
Conveniently, the incision 45-53 may be formed by
a hand tool, such as the chisel~like tool 42 shown
in Fig. 4, the cutting edge of which is preferably
curved transversely so that the cut formed there
by will be curved to correspond substantially to
formed by means of a so-called double knife
the lengthwise curvature of the beveled edge
which is to be formed at the front end of the
outsole projection. While the sole blank is dis
torted during the splitting operation in the man
ner which will be hereinafter described, the 70
curved incision 4!] will become straightened so
that it may be entered by the straight cutting
rounding machine, such for example as that dis
closed in the copending application Serial No.
75 734,650, ?led July 11, 1934, in the name of F. E.
the location of the incision in the sole blank may
be gaged by means of a mark or indentation 44 75
sole.
>
After the outsole and insole layers have been
secured together to form a laminated sole blank
he blank is out to sole shape by a rounding or
70 die-cutting operation. Preferably, although not
necessarily, this sole shaping operation is per
edge of the splitting knife. As herein illustrated,
2,106,845v
(Fig. 1) which may be made, for example, by
means of a properly located die 45 (Fig; 2) on the
pattern 32 of the rounding machine.
After the incision 40 has been cut in the insole
layer of the sole blank the sole blank is ready
for the splitting operation which may be advan
tageously performed by means of a machine of
the general type of that disclosed in a copending
application, Serial No. 759,846, ?led December 31,
10 1934, in the name of William D. Thomas. In the
use of this machine the forepart of the sole
blank is temporarily ?exed or deformed by de
pressing a portion thereof corresponding in shape
and location to that of the opening to be pro
15 duced in the insole so that the depressed portion
will avoid the knife of the splitting machine by
means of which the blank is divided.
As indicated in Fig. 5, the splitting machine
comprises a single straight-edged splitting knife
20 46, an adjustable upper matrix roll 48, and a lower
die roll 50 which is yieldingly mounted so as to
press the work toward the upper roll. The upper
roll 48 has formed therein a cavity or matrix 52
shaped to conform in outline to that of the open
25 ing to be formed in the forepart of the insole,
while the lower roll 55 has formed thereon a
projection or die 54 that is complemental to the
cavity 52 in the upper roll. The cavity 52 and
the projection 54 are so related to each other and
30 to the work, as indicated in Fig. 5, that they will
coact to deform the material of the sole blank
at a point- beginning at the incision 40, as indi
cated in Fig. 7, and continuing rearwardly to
where the rearward extremity of the outsole pro
35 jection is to be located. The upper roll may be
adjusted relatively to the knife 46 so that as the
3
enter the incision and will have no tendency to
tear or mutilate the material in that portion of
the blank which is being temporarily held in a
?exed and deformed condition by the cooperative
action of the die and matrix rolls. In cases
where the insole and outsole layers of a laminated
sole blank are to be separated by the passage of
the splitting knife along the plane of adhesion
between those layers the portion of the knife
which is to out around the temporarily deformed 10
central. forward portion of the insole layer will
have no tendency to remain between the insole
and outsole layers but will enter and readily pass
through the incision in the insole layer. In the
case of a sole blank the insole layer of which is 15
of laminated formation, there will be no tend
ency for the knife to enter between any of the
plies of the insole material. In any case the
presence of the incision 4B in the insole layer of
the sole blank will insure that the opening which 20
is to be formed in the insole and the correspond
ing projection which is to be formed on .the out
sole as a result of the splitting operation will
each ‘be de?ned by a clean cut in its forward por
tion instead of by a ragged out such as might be
produced if no preliminary incision were made in
the insole layer of the blank.v
After the deformed portion of the sole blank
has been advanced past the splitting knife and
after the material operated upon has had an 30
opportunity to react from the deforming pressure
of the matrix rolls, the resulting insole and out
sole will appear as shown in Figs. 9 and 10, re
spectively, or as shown in Figs. 11 and 12, respec
tively, depending upon whether the marginal 35
portion of the forepart of the blank is split in
the plane of adhesion between the insole and
sole blank is being fed past the knife the knife
will operate to split the marginal portion of the
forepart of the blank substantially in the plane
40 of adhesion between the insole and outsole lay
outsole layers (as in Figs. 9 and 10) or in a plane
intersecting the outsole layer (as in Figs. 11 and
ers, or so that the knife will pass idly between the
If the adjustment of the splitting machine '
12) .
is such that the cutting edge of the knife 46 '
uncemented marginal portion of those layers in
bears the relation to the sole blank indicated
Figs. 8, 11, 12, 13, and 14, the splitting operation,
conventionally by the dotted line 60 in Fig. 6,
the insole and outsole produced by the splitting
operation will appear as shown in Figs. 9 and 10,
respectively, the insole 62 being composed en
tirely ofvthe material of the original insole layer
and the outsole 64 being composed only of the
material of the original outsole layer, except in
the central portion of its forepart where the 50
projection 66 (which is complemental to the open
ing 68 in the insole) is composed entirely of insole
material.
If, however, the adjustment of the splitting
machine is such that the cutting edge of the 55
splitting knife bears the relation to the work in
dicated by the dotted line 10 in Fig. 6, then the
in addition to dividing the laminated sole blank
resulting insole and outsole will appear as shown
cases where they are cemented together only in
their central forward portions. Alternatively,
45 however, the machine may be adjusted so that
in splitting the marginal portion of the forepart
of a laminated sole blank the knife will ' cut
through the outsole layer close to the plane of
adhesion but at a slight distance therefrom. The
splitting
of the marginal portion of the forepart
50
of a sole blank in the plane of adhesion between
the insole and outsole layers is illustrated in
Fig. 7, whereas the splitting of that portion of a
blank through the outsole layer is illustrated in
55 Fig. 8. If the marginal portion of the blank is
split through the outsole layer, as illustrated in
into an insole and an outsole, will result also in
60 the removal from the margin of the outsole layer
of a thin waste strip or portion of scrap material
around the margin of the insole.
v
in Figs. 11 and 12, respectively, the insole I62
having a thin skiving 12 of outsole material se
60
cured to the original insole layer, while the edge
thickness of the outsole I64 is reduced an amount
When, in the course of the feeding of the sole
blank past the splitting knife, the incision 4B in
corresponding to the thickness of the skiving 12.
While, as herein described, the laminated sole
blank is rounded to ‘sole shape after its compo 65
nent layers have been secured together and the
preliminary incision 40 is made in the insole lay
er after that layer has been secured to the out
sole layer, it is practicable, and may in some
cases be desirable, as indicated in Fig. 15, to 70
round or die out the outsole and insole layers 22
and 24 to sole shape and to form a preliminary
incision I40 in the insole layer before securing
the latter to the outsole layer.
75 the sole blank reaches the knife, the knife ‘will
1 Having described my invention, what I claim 75
The manner in which the central forward por
tion of a sole blank is deformed by the action of
65 the die and matrix rolls is illustrated in Figs. 6,
7, and 8 and Figs. 7 and 8 also clearly disclose
the location of the preliminary incision 4t rela
tively to the distorted central portion of the sole
blank and show that the incision, after being
70 straightened out by the deformation‘ of the blank,
is located in position to be readily entered by the
knife.
.
4
2,106,845
as new and desire to secure by Letters Patent of
the United States is:
1. In shoemaking methods, that improvement
which consists in securing two layers of mate
rial together by means of adhesive to form a
laminated sole blank, making a preliminary cut
extending through one of said layers near the
toe end of the blank thereby initiating the di
vision of said blank by a rearwardly progressing
10 splitting operation into an insole having an open
ing in its forepart and an outsole havinga fore
part projection complemental to said opening, and
thereafter making a second cut complementing
said ?rst cut and completing said division of said
15 blank.
2. In shoemaking methods, that improvement
which consists in providing a laminated sole blank
comprising an outsole layer and an insole layer
having formed therein a preliminary incision
20' adapted to constitute the forward portion of a
‘central forepart opening subsequently to be
formed in said insole layer, entering a knife
within said preliminary incision, and relatively
moving the blank and the knife to cause the
25 knife to extend said incision around the central
forepart portion of the insole, thereby complet
ing the formation of a central opening in the
forepart of the insole and forming on the fore
part of the outsole a central projection which is
complementary to the opening in the insole.
3. In shoemaking methods, that improvement
which consists in forming in an insole blank a
preliminary incision shaped and arranged to con
stitute the forward portion of a central forepart
opening subsequently to be formed therein, secur
ing said insole blank and an outsole blank to
gether in face-to-face relation, thereby providing
a laminated blank, and dividing said laminated
blank into an insole having a central forepart
opening and an outsole having a central forepart
projection complemental to said opening by means
of a splitting knife which, in the course of its
operation upon the laminated blank, passes
through said preliminary incision.
4. In shoemaking methods, that improvement
which consists in‘sec'uring an insole blank and
an outsole blank together in face-to-face relation,
thereby providing a laminated blank, making a
skeleton insoles of laminated formation‘ which
consists in making in a laminated insole blank a
preliminary cut shaped and arranged to consti
tute part of a central opening to be formed in
said blank, and subsequently deforming the cen
tral forward portion of the blank and feeding
the blank thus deformed, past a straight-edged
splitting knife to cause said knife to pass through
said preliminary cut without entering between
the layers constituting said blank and. thereafter 10
to extend said preliminary cut around the de
pressed portion of the blank, thereby completing
the formation of said central opening in said
blank.
.
'7. In methods of making soles, that improve 15
ment which consists in securing together in face
to-face relation by means of adhesive a blank of
insole material and a blank of outsole leather,
thereby forming a unitary laminated sole blank,
making a preliminary incision in said blank of 20
insole material, passing said laminated sole blank
between a roller having a die shaped to flex the
central forward portion of said blank out of the
plane of the rest of the blank and a second roller
having a matrix adapted to receive said ?exed 25
sole blank portion, and while said blank is thus
?exed between said rollers, rotating said rollers
and advancing the blank edgewise past a straight
edged knife, thereby splitting the blank into an
insole comprising said insole material and having 30
an opening in its forepart, and an outsole having
a main portion comprising said outsole material
and having upon its forepart a projection corn
plemental to said insole opening and during said
splitting operation causing said knife to pass 35
through said preliminary incision in said insole
blank.
8. In methods of making soles, that improve
ment which consists in securing together in face
to-face relation by means of adhesive an insole
layer and an outsole layer, thereby providing a
single composite blank of laminated formation,
making a preliminary cut through said insole
layer in a position to coincide with the forward
extremity of an opening subsequently to be 45
formed in said layer, and dividing said composite
blank into an insole having a central forepart
opening and an outsole having a central forepart
preliminary cut extending through said insole projection complemental to said opening by
blank, temporarily deforming said laminated means of a splitting knife which in operating
blank by depressing its central forward portion upon the marginal portion of the forepart of said 50
and while the blank is thus deformed relatively blank splits the blank in a plane substantially
moving the blank and a straight-edged splitting parallel to the plane of adhesion between its
knife to cause the knife to divide the blank into layers and located within said layer of outsole
55 an insole and an outsole and in so doing to pass
through said preliminary cut and thereafter to
continue said out and thereby to form an open
ing in the insole blank and a projection on the
outsole blank complementary to said opening.
60" 5. In shoemaking methods, that improvement
which consists in securing together an insole blank
and an outsole blank in their central forward por~
tions on1y,'thereby providing‘a single laminated
sole blank, making a preliminary incision through
65 the insole blank at the forward end of that por
tion of said blank which is secured to the outsole
blank, thereby initiating the division of said lami
nated sole blank into an insole having a central
forepart opening and. an outsole having a cen
70 tral forepart projection complemental to said
opening, passing a splitting knife through said
incision in the insole blank, and thereafter op
erating said knife to complete the division of said
laminated blank into an insole and an outsole.
75
6. That improvement in methods of making
material and which in operating upon the central 55
forward portion of the blank passes first through
said preliminary incision without cutting said
insole layer and thereafter cuts through the cen
tral forward portion of said layer.
9. In the manufacture of soles, that step prod 60
uct which consists in a sole blank of a thickness
equal to the combined thickness of an insole and
an outsole into which said blank is to be divided
and having a preliminary cut extending obliquely
inward from one side of the toe portion of the
blank to a depth equal to the thickness of said
insole and in a position to be entered by a knife
in the act of dividing the blank into an insole
having a central forepart opening and an outsole
having a central forepart projection comple
mental to said opening.
65
10. In the manufacturelof soles, that step prod
uct which consists in a laminated sole blank com
prising an insole layer and an outsole layer se
cured together in face-to-face relation, said blank
755
5
2,106,845
having a preliminary cut extending through said
insole layer in position to be entered by a split
ting knife in the operation of dividing said blank
into an insole having an opening in its forepart
and an outsole having a forepart projection com
plemental to said insole opening, said out being
located where the forward end portion of said
insole opening is to be formed.
11. In the manufacture of soles, that step
10 product which consists in a laminated sole blank
comprising an insole layer and an outsole layer
secured together in face-to-face relation, said
blank having an incision in said insole layer
shaped to correspond to the shape of the forward
15 end portion of a central opening subsequently to
be formed in said layer in the process of dividing
said blank into an insole having an opening in
its forepart and an outsole having a forepart
projection complemental to said opening.
12. In the manufacture of soles, that step
product which consists in an insole blank pre
pared for the performance of a skeletonizing
operation thereon by having ‘formed therein a
preliminary cut for facilitating the entrance of a
skeletonizing knife into the material of the insole
blank, said out being shaped and arranged to
constitute the forward portion of the opening to
0
be formed in the blank.
RAYMOND E. HOPKINS.
1U
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