Field of the invention

The invention relates to a method of manufacturing a footwear.

Further, the invention relates to a footwear comprising at least one strap and at least one strap anchor.

Even further, the invention relates to a footwear manufactured by a method according to the invention.

Furthermore, the invention relates to a mold for applying a sole such as a midsole or an outer sole to a footwear upper by a direct injection process.

Background of the invention

It is well-known in the art of manufacturing footwear, that there is an increasing request and demand for high-quality footwear uppers. Especially footwear uppers designed for hiking and other outdoor activities are typically designed and manufactured in strong and wear-resistant materials leading to a higher cost for materials.

An example of a prior art footwear, e.g. a sandal comprises a sole and a footbed or an insole, wherein the sole is attached to the footbed, for example by cementing. The sandal may be suitable for outdoor activities and may have adjustable straps. Securing of the straps to the sole of the prior art footwear will typically be by an extension of the straps between the footbed or insole and the sole of the sandal. Thus, according to such a prior art sole construction, the straps may be secured to the sole construction by the strap extending continuously as one piece of material between the soles e.g. an outer sole and a footbed. The strap may be merged in the sole or footbed or the strap may solely be positioned between the layers and may be attached to the two layers e.g. with adhesives. A further example of an article of footwear having straps is disclosed by US 5,896,684 A. This document discloses a sandal having a sole that is molded onto a plurality of locating members such that these are open to the footbed of the sandal, but otherwise embedded in the molding material. The locating members are designed for receiving mounting strips, to which straps are connected. Thus, the mounting strips are each attached to a locating member from above and are releasably fixed by means of a tongue.

Further, an example of a prior art sandal is disclosed by US 6,349,486 Bl, which discloses a sandal having straps that can be changed by the user. The straps are attached to strap clips that each can be assembled with an assembly base, where a spring clip locks the strap clip in place. The assembly bases are embedded into the sole of the sandal such that only an outer edge is exposed.

Even further, US 2021/378351 Al discloses an open-toed footwear, e.g. a thong sandal, which is configured with an exchangeable strap. The sandal has a front housing well, into which a front insert attached to the strap can be inserted and two side housing wells, into which side inserts can be inserted.

In view of the prior art footwear it is realized that there is a need for a method that reduces material consumption and which provides for a cheaper and more flexible footwear manufacturing process.

Summary of the invention

The invention relates to a method for manufacturing a footwear, said footwear comprising an upper having at least one strap, said method comprising the steps of a) providing at least one strap, b) providing at least one strap anchor, c) attaching said at least one strap anchor to said at least one strap, d) providing a footbed or an insole having at least one strap anchor aperture, an upper side and a lower side, wherein said at least one strap anchor aperture extends from said upper side to the lower side of said footbed or insole, e) fixating said at least one strap to said footbed or insole by introducing said strap anchor in said strap anchor aperture from the upper side and f) applying a midsole and/or an outer sole to said lower side.

The inventive method for manufacturing a footwear has several advantages over prior art involving an efficient and flexible attachment of a footwear upper having at least one strap to a footbed or insole.

The present invention makes it possible to attach a footwear upper having at least one strap, e.g. a sandal having straps where the straps are fixed with a sole. Hereby, the straps are attached to the sole efficiently with an optimized handling process and further with a significant reduction of the use of materials, especially the material used for the straps, since the strap material need not pass from one side to the other under the e.g. footbed, making the manufacturing cost-efficient.

Furthermore, the need for locating members, assembly bases or the like that according to examples of prior art as mentioned above need to be molded into a sole part is avoided, since according to the invention a strap anchor that has been attached to a strap is simply e.g. inserted in and e.g. through an aperture of the footbed or insole wherein said at least one strap anchor aperture extends from the upper side to the lower side of the footbed or insole.

Even further, it is noted that according to the invention, a midsole and/or an outer sole is applied to the lower side of the footbed, whereby e.g. the aperture and the strap anchor introduced herein are closed off. Thereby, constructions having e.g. locating members, assembly bases, etc. embedded in a sole member as it is disclosed in prior art examples as mentioned above are avoided according to the invention and an e.g. relatively simple aperture can be used for fixating the strap anchor, since it is subsequently closed off and the strap anchor is prevented from moving e.g. downwards. Thus, a cost-efficient construction is provided by the invention, which furthermore provides an improved flexibility. According to an embodiment, step d) may comprise providing a footbed or insole having a number of strap anchor apertures corresponding to a number of strap anchors provided by a specific upper.

According to an embodiment, step a) may be performed subsequent to step b).

According to an embodiment, subsequent to step d) an intermediate layer may be provided.

According to an embodiment, the intermediate layer may be adhered to the lower side of the footbed or insole.

According to an embodiment, step e) may comprise snapping said strap anchor through said strap anchor aperture.

It will be understood that this may be performed in a multitude of manners but wherein essentially the strap anchor may be introduced into and passes through the aperture with at least a part subsequently being on the lower side of the strap anchor aperture with a certain flexible or spring-effected action that ensures a secure fixation.

According to an embodiment, the strap and strap anchor may be provided in an advance step.

Hereby, the attachment of the straps to the anchor straps may not be made in the same manufacturing step as fixing the strap to a footbed e.g. the manufacturing of the straps and and/or the strap anchor may made be at one manufacturing unit and fixing the strap with the anchor strap may be made at a different manufacturing unit. The manufacturing steps may of course also be made at the same manufacturing unit.

According to an embodiment, the strap anchor may be provided as a part sectioned from a profile bar. Hereby, manufacturing costs may be optimized as the material for the strap anchors may be provided with the desired flexible characteristics in a cost-efficient way.

According to an embodiment, the footwear may be a sandal.

According to embodiments of the invention, a sandal may be understood as any type of sandal, however, and highly advantageously a sandal according to embodiments of the invention may be an outdoor sandal or a sport sandal or other types of sandals where an efficient and durable fixing of the straps to a sole is needed.

According to an embodiment, the footwear may be a shoe.

According to an embodiment, at least two sole layers of the footwear may comprise a footbed, an intermediate layer and an outer sole.

According to an embodiment, the strap anchor may comprise at least two ribs.

According to an embodiment, the at least two ribs may comprise an outward rib and an inward rib.

According to an embodiment, the at least two ribs may comprise an outward rib and an inward rib and wherein the width of the inward rib is wider than the outward rib.

Hereby, it may be achieved that sufficient anchoring effect can be achieved, e.g. by the combined width of the outward rib and the inward rib, while simultaneously ensuring that the strap can be placed relatively close to the edge of the sandal due to the outward rib being shorter.

According to an embodiment, the intermediate layer may comprise textile.

According to an embodiment, the intermediate layer may comprise leather. According to an embodiment, the midsole and/or the outer sole may be manufactured by direct injection process and wherein the sole is adhered to the lower layer of the footbed or insole or the intermediate layer.

According to an embodiment, the midsole and/or the outer sole may be adhered to the lower layer of the footbed or insole or the intermediate layer by a cementing process.

Examples of manufacturing the sole layers may be that the midsole is adhered to an intermediate layer and an outer sole is injected onto the intermediate layer. Another example hereof may be that the outer sole is adhered to the intermediate layer e.g. by a cementing process.

According to an embodiment, the method may comprise applying a sole, e.g. a midsole and/or an outer sole, to the upper by direct injection process.

According to an embodiment, the direct injection process may comprise direct injection process material.

According to an embodiment, the direct injection process material may be TPR, PVC, EVA, TPU and/or PU.

According to an embodiment, the sole e.g. the outer sole and/or the midsole, may comprise natural materials and/or synthetic materials, said natural materials and/or synthetic materials comprising leather, TPR, PVC, EVA, TPU, TPE, PEBA and/or PU.

According to an embodiment, the intermediate layer may be configured with at least part of its perimeter exceeding the perimeter of the footbed or insole and wherein the exceeding parts, e.g. trim parts, at a subsequent step are trimmed of. According to an embodiment, the trim parts of the intermediate layer may during manufacture serve to close a mold cavity, when manufacturing a sole layer, e.g. an outer sole or a midsole, to be adhered to the footwear.

Hereby, it may be achieved that injected material, e.g. when injected in the mold cavity and/or when expanding, may be prevented from seeping or escaping out between the edges of the footbed or insole and the sides of the mold.

According to an embodiment, a formed, e.g. milled or cut, part of an insole or midsole may during manufacture serve to close a mold cavity, when manufacturing a sole layer, e.g. an outer sole or a midsole, to be adhered to the footwear.

Hereby, the injected material, e.g. when injected in the mold cavity and/or when expanding, may in an alternative embodiment be prevented from seeping or escaping out between the edges of the footbed or insole and the sides of the mold.

According to an embodiment, the method may comprise at least one punching process in at least one layer.

Hereby, one or more apertures may be manufactured in a relatively simple and efficient manner, e.g. a punching of apertures in the footbed or insole, in an intermediate layer, etc., whereby throughgoing holes, which will be referred to as apertures, can be made in the footbed or insole and/or in one or more intermediate layers.

According to an embodiment, the method may comprise positioning, via the at least one strap anchor at least one tube channel across and beneath the footbed or insole for accommodating at least one strap.

Hereby, the strap may be allowed to move underneath the e.g. footbed and be adjusted by e.g. the user.

According to an embodiment, the footbed may comprise at least one aperture. According to an embodiment, the length L of the footbed aperture may be at least 0.2 cm, such as at least 0.5 cm, such as between 0.2 cm to 10 cm, such as between 0.5 cm to 8 cm, such as between 1 cm to 6 cm, such as between 2 cm to 4 cm.

According to an embodiment, the width W2 of the footbed aperture may be the same or less than the width of the upper substance.

Here, the upper substance should be understood as any material or combinations of material making up the upper, e.g. straps, upper parts, etc. The width of the upper may vary according to the material of the upper and thus, the width W2 may vary accordingly.

According to an embodiment, the intermediate layer may comprise at least one aperture.

According to an embodiment, the length L of the intermediate layer aperture may be at least 2 mm, such as at least 5 mm, such as between 2 mm to 100 mm, such as between 5 mm to 80 mm, such as between 10 mm to 60 mm, such as between 20 mm to 40 mm.

According to an embodiment, the width W1 of the intermediate layer aperture may be at least 5 mm, such as at least 10 mm, such as at least 20 mm, such as between 5 mm to 20 mm, such as between 8 mm to 15 mm.

According to an embodiment, the distance D2 from the edge E of the footbed to the footbed aperture may be at least 3 mm, such as at least 5 mm, such as at least 7 mm, such as between 2 mm to 20 mm, such as between 5 mm to 10 mm.

According to an embodiment, the distance DI from the edge E of the intermediate layer to the intermediate layer aperture may be at least 2 mm, such as at least 5 mm, such as at least 7 mm, such as between 2 mm to 20 mm, such as between 5 mm to 10 mm. According to an embodiment, the footwear strap may comprise leather.

According to an embodiment, the footwear strap may comprise textile.

According to an embodiment, the strap anchor may be adherable with PU (Polyurethane).

Hereby, the further advantage may be achieved that the strap anchor can be readily fixed to the construction by the sole material, in case the sole material is an injected PU material.

According to an embodiment, the strap anchor material may be TPU.

According to an embodiment, the strap anchor material may be TPU and the sole material may comprise leather, TPR, PVC, EVA, TPU, TPE, PEBA and/or PU.

Hereby, the strap anchor is compatible and binds to the sole material of e.g. PU.

According to an embodiment, the strap anchor may comprise at least one perforation.

Hereby, a mechanical and tighter binding of the sole material to the strap anchor is provided. The at least one perforation may mediate an effective and strong binding of e.g. sole material to the strap anchor, e.g. by mechanical bonding of the materials when the strap anchor has one or more perforations in e.g. the lower parts, e.g. the ribs. Similar effects may be achieved when applying cementing. Further, it is noted that instead of perforations or in addition to perforations grooves or the like may be made in the strap anchor to enhance the bonding.

According to embodiments of the invention, the strap anchor outward rib and the strap anchor inward rib may have any suitable length.

According to an embodiment, the length of the outward rib may be between 2 mm to 30 mm, such as between 7 mm to 20 mm, such as between 10 mm to 15 mm. According to an embodiment, the length of the inward rib may be between 3 mm to 30 mm, such as between 7 mm to 20 mm, such as between 10 mm to 15 mm.

According to an embodiment, the method may comprise applying a sole such as a midsole or an outer sole to the upper by a direct injection process by means of a mold comprising a first side mold, a second side mold and a bottom mold, wherein the first side mold comprises a first side mold upper and the second side mold comprises a second side mold upper, wherein the first side mold upper and the second side mold upper are releasably fixed to the first side mold and the second side mold, respectively.

Hereby, the flexibility of the mold construction may be enhanced, e.g. since it may be achieved that the mold may be used in connection with various footwear configurations, shapes, forms, etc. since the first side mold upper and the second side mold may easily be changed, e.g. with a set having another height or thickness.

According to an embodiment, the first side mold upper and the second side mold upper may be provided in sets with at least two different thicknesses. Hereby, the mold may quickly be modified to handle different thicknesses of e.g. midsole constructions.

According to a second aspect, the invention relates to a footwear comprising

- at least one strap,

- at least one strap anchor, wherein said at least one strap and at least one strap anchor are assembled,

- a footbed or an insole having at least one strap anchor aperture, an upper side and a lower side, wherein said at least one strap and said at least one strap anchor are attached to the footbed or insole, and

- a midsole and/or an outer sole attached to said lower side.

The footwear may be configured according to the above-mentioned embodiments, e.g. the embodiments as provided by the method according to any of claims 1- 45. According to an embodiment, the footwear may be a sandal.

According to a third aspect, the invention relates to a footwear manufactured according to any of claims 1- 45.

According to an embodiment, the footwear may be a sandal.

The footwear according to the present invention provides advantages such as improved cost-efficiency, e.g. since it is made possible to attach a footwear upper having at least one strap, e.g. a sandal having straps and where the strap(s) is/are fixed with a sole. The straps of the footwear may be attached to the sole efficiently with an optimized handling process and further with a significant reduction of the use of materials, especially the material used for the straps, since the strap material need not pass from one side to the other under the e.g. footbed, thereby making the manufacturing cost- efficient.

Furthermore, the need for locating members, assembly bases or the like that according to examples of prior art as mentioned above need to be molded into a sole part is avoided, since according to the invention a strap anchor that has been attached to a strap is simply e.g. inserted in and e.g. through an aperture of the footbed or insole wherein said at least one strap anchor aperture extends from the upper side to the lower side of the footbed or insole. Thus, a multitude of design variations and configurations are made possible according to the invention.

Even further, it is noted that the footwear according to the invention comprises a midsole and/or an outer sole that is/are applied to the lower side of the footbed, whereby e.g. the aperture and the strap anchor introduced herein are closed off. Thereby, constructions having e.g. locating members, assembly bases, etc. embedded in a sole member as it is disclosed in prior art examples as mentioned above are avoided according to the invention and an e.g. relatively simple aperture can be used for fixating the strap anchor, since it is subsequently closed off and the strap anchor is prevented from moving e.g. downwards. Thus, a robust and yet relatively uncomplicated construction of the footwear is provided by the invention, which furthermore provides an improved flexibility.

According to a further aspect, the invention relates to mold for applying a sole such as a midsole or an outer sole to a footwear upper by a direct injection process, said mold comprising a first side mold, a second side mold and a bottom mold, wherein the first side mold comprises a first side mold upper and the second side mold comprises a second side mold upper, wherein the first side mold upper and the second side mold upper are releasably fixed to the first side mold and the second side mold, respectively.

Hereby, it may be achieved that the flexibility of the mold construction may be enhanced, e.g. since the mold may be used in connection with various footwear configurations, shapes, forms, etc. since the first side mold upper and the second side mold may easily be changed, e.g. with a set having another height or thickness.

According to an embodiment, the first side mold upper and the second side mold upper may be provided in sets with at least two different thicknesses. Hereby, the mold may quickly be modified to handle different thicknesses of e.g. midsole or outer sole constructions.

According to an embodiment, said mold may be configured for manufacturing a footwear, using a method according to any one of claims 1-45.

The footwear according to embodiments of the invention may be any type of footwear such as e.g. a sneaker, sport’s shoe, formal shoe, boot, lace up shoe, slip ons, loafers, sandals or any other type of footwear.

Sandals should be understood as an open type of footwear, consisting of a sole held to the wearers foot by a strap or straps going over the instep and sometimes around the ankle. Sandals may also have a heel. Sandals vary in how much of the foot that is exposed, however, the common understanding is that a sandal leaves all or most of the foot exposed.

The sandals according to embodiments of the invention may be any type of sandals such as flip flops, sports sandals, everyday flats, dressy flats, slides, wedge sandals, gladiator sandals, thong sandals, off-road sandals or any other type of sandal.

The footwear upper according to embodiments of the invention, e.g. footwear upper comprising parts such as one or more straps and/or other parts of the upper, may be of any material such as e.g. leather, natural leather, textile, knitted material, reinforcing fabric, reconstructed fibers, woven or non-woven material based on natural or synthetic fibers or any other type of material.

According to embodiments, the footwear upper and footwear upper straps may be of the same material or may be e.g. two different materials e.g. a footwear upper in leather and straps in e.g. textile.

Leather may be any type of leather such as e.g. full grain or top leather, corrected or embossed grain, split suede, nubuck sueded grain, reconstructed, reconstituted, bonded or fiber leather or any other type of leather. In principle, the leather can derive from any source, including bovine hide, horse hide, goat skin, sheep skin, camel skin, kangaroo hide or the like.

“Bovine” as used herein means, with referral to the traditional taxonomic grouping, a group of animals including e.g. cattle, ox, yak etc.

The term “reconstructed” fiber refers to staple fibers produced on the basis of a number of mechanically sub-divided protein fibrils. The reconstructed fiber may be formed from a protein suspension directed through a nozzle onto a surface for drying. The suspension is dried to remove water and solvent from the suspension and thereby the reconstrued fiber is formed e.g. on a belt or a cylinder surface. Such a manufacturing method of reconstructing fibers on the basis of protein fibrils is e.g. illustrated in WO 2018/149950 or WO 2018/149949 for the use in relation to collagen.

The term “staple fiber” refers to fibers of discrete length and may be of any composition. Staple fiber may e.g. be provided by division of a keratin-based filament into discrete staple fibers of a certain length. The length may vary dependent on the application.

“Nonwoven” as used herein and as defined generally by European Disposables and Nonwovens Association (EDANA) is an engineered fibrous assembly, primarily planar, which has been given a designed level of structural integrity by physical and/or chemical means, excluding weaving, knitting or paper making. Nonwovens can be manufactured in two main ways; felted or bonded. The fabrics use fibers rather than yarns; these are laid randomly or in a uniform way to make web-like layers. They are held together by either the felting or bonding process.

“Woven” as used herein is generally a woven fabric made by an interlacing of two or more threads.

“Reinforcing” as used herein should be understood as a reinforcing fabric comprising high strength fiber that can be woven or nonwoven. To benefit from the strength properties of the fibers, typically at least one layer will contain the high strength fibers in an oriented fashion, such as woven (including uniweave), monodirectional or multidirectional fabrics.

Direct injection process should be understood as the process of introducing a molten and/or liquid material into a cavity of a mold to achieve a desired shape. The process can be used for the production of outsole or decorative details. During the process, a molten material, normally a polymer, e.g. including such materials as PU, rubber, latex, etc., is forced into the cavity of a mold. The process may be known as DIP or direct injection process and they may be used interchangeably.

Furthermore, it is noted that the manufacturing and possibly attachment of a sole part, e.g. an outer sole, may involve a casting process, e.g. where molten material is poured or otherwise introduced into a mold having at least partly the shape of the sole part, e.g. the outer sole.

The sole can be manufactured from any materiel such as e.g. thermoplastic Rubber, Thermoplastic elastomer (TPE), Injection Molding Resin (TPR), Polyvinyl chloride (PVC), polyurethane (PU), Thermoplastic Polyurethane (TPU), Ethylene Vinyl Acetate (EVA), PEBA (Polyether block amide) and/or the like suitable for a direct injection process. Furthermore, the sole material can be manufactured using other materials, such as e.g. leather, for example a leather outsole, a leather footbed, etc., which for example may be bonded into the footwear by the DIP technology. The sole can also comprise several parts possibly manufactured from different materials. Such parts may be molded into the sole or may be attached to the sole by e.g. an adhesive or the like.

Unless otherwise noted in the present application, the meaning of DIP is to be understood as the process of integrating a sole, e.g. a midsole and/or an outer sole, with an upper or at least a part of an upper by and during a DIP process.

Thus, single elements, e.g. pressure absorbers or sole parts may be DIP’ed in separate processes (without being attached to the sole) and then subsequently be inserted into the mold by means of which the sole or a part of the sole is to be molded and integrated with the upper or at least a part of the upper.

Cemented process should be understood as process where the sole is manufactured separately and attached to e.g. an upper or intermediate layer with adhesive. The manufacturing process according to embodiments of the invention may be a manual process or may be an at least partly automatic process.

Various exemplary embodiments and details are described hereinafter with reference to the figures when relevant. It should be noted that the figures may or may not be drawn to scale and the figures are only intended to facilitate the description of the embodiments.

The figures

The invention will be explained in further detail below with reference to the figures of which

Fig. la and fig. lb illustrate a footwear according to the prior art,

Fig. 2 illustrates a cross-section of a footwear sole construction according to the prior art,

Fig. 3a-3b illustrate a footwear and a footbed or insole according to embodiments of the invention,

Fig. 4a-4f illustrate examples of components for the manufacturing of the footwear according to embodiments of the invention,

Fig. 5a-5d illustrate in a schematic manner sequences of a method of applying a strap anchoring in a footbed according to an embodiment of the invention, seem in a transverse sectional view of the footbed and the strap anchoring,

Figs. 5e-h illustrate in a schematic manner corresponding to Figs. 5a-5d various embodiments of the strap anchoring in a footbed and various constructional details,

Fig. 6a illustrate a footwear according to an embodiment of the invention comprising a plurality of intermediate sublayers,

Fig. 6b-f illustrate a footwear according to an embodiment of the invention comprising various strap and/or upper constructions as well as various sole part combinations, Fig. 7 illustrate a footbed or insole according to an embodiment of the invention together with an intermediate layer, for example for a footwear as shown in Fig. 6b,

Figs. 8a-8f illustrate an example of a mold for a direct injection process according to embodiments of the invention together with various embodiments of a footwear and sole embodiments according to the invention,

Figs. 9a-9b illustrate in a schematic manner a transverse sectional view of various footwear configurations according to embodiments of the invention,

Fig. 10 shows, seen from above, an embodiment of a mold for direct injection of footwear according to an embodiment of the invention, wherein mold upper parts are exchangeable, and

Fig. 11 shows a sideview of the second side mold of the mold shown in Fig. 10 in an enlarged view.

Detailed description

With reference to Fig. la and lb a prior art footwear will be elucidated. The footwear is a sandal that comprises a sole 4 and a footbed 30 or an insole, wherein the sole 4 is attached to the footbed 30, for example by cementing as is normally the case according to the prior art. The sole 4 may also be known as an outsole (or outer sole, as it may also be referred to in the present application) and may have various patterns suitable for the application for which the sandal is designed. It may be a sandal suitable for outdoor activities with adjustable straps as e.g. a cross strap 12 across the base of the toes connected to the heel straps 14 with a lateral strap 16 positioned along the outside of the foot connecting the toe strap 12 and heel strap 14 systems. The strap system may also be known as a tether strap system and may be connected in various combinations according to the application of the sandal.

Fig. lb is a variant of Fig. la illustrating the prior art sandal as described above on a human foot in phantom showing how a wearer secures the sandal to the foot. Securing of the straps to the sole of the prior art footwear 2 will typically be by an extension of the straps between a footbed or insole and the sole of the sandal and will be further elucidated in Fig. 2.

With reference to Fig. 2, a prior art sole construction is shown as an example of the securing the straps 10 to the sole construction 6 by the strap 10 extending continuously as one piece of material between the soles e.g. an outer sole 4 and a footbed 30. The strap may be merged in the sole or footbed or the strap may solely be positioned between the layers and may be attached to the two layers e.g. with adhesives.

With reference to Fig. 3a, a footwear 2 according to embodiments of the invention is elucidated. The footwear 2 is a sandal that comprises an outer sole 4 and a footbed 30 or an insole and between these two layers, an intermediate layer 40 is positioned according to an embodiment of the invention. The intermediate layer 40 will further be explained below. The intermediate layer 40 may e.g. be a textile layer and may have various thicknesses according to the application and designs of the intermediate layer. The thickness may correspond to the thickness of the outward and inward rib of a strap anchor 20 (cf. e.g. Fig. 5d), as will also be explained in more details below, and thus, the intermediate layer may provide an even surface which is an advantage before applying an outer sole.

It is noted, though, that depending on the materials used for the outer sole 4 and the footbed 30 and the particular method of applying the outer sole 4, an intermediate layer 40 may not be needed. This will be explained in detail further below.

The intermediate layer 40 may be a Strobel or gasket material which typically may have a thickness of 0.5 to 2.0 mm. In the context of the present invention, the thickness of the intermediate layer may e.g. be at least 0.5 mm, such as at least 0.7 mm, such as at least 0.9 mm, such as at least 1 mm, such as at least 2 mm, such as at least 5 mm, such as at least 7 mm, such as between 0.5 mm to 5 mm, such as between 1 mm to 7 mm, such as between 3 mm to 15 mm, such as between 6 mm to 12 mm. A footbed in the present context, unless otherwise noted, may thus e.g. include both insole (if present), different sole members and/or layers. In particular embodiments of the invention further layers or members may be attached to the footbed or the layers may be included within the footbed. Hereby, several variations of the order of the material of the footbed are possible either as a single material or as sandwich constructions of materials.

With reference to Fig. 3b, a schematic example of a footbed or insole 30 is illustrated and shows the location of the footbed or insole upper side 34 and should be understood as the side of the footbed or insole that would become in closest contact with the foot. The figure further illustrates the location of the footbed or insole lower side 36 and should be understood as the side of the footbed or insole that would become in proximity to the ground, e.g. facing downward when worn by a user during normal use.

With reference to Fig. 4a, a schematic example of an intermediate layer 40 and a footbed 30 is illustrated.

From the figure the intermediate layer 40 and footbed 30 are illustrated separately, however, it should be understood that during the manufacturing of the footwear, the footbed 30 may be adhered to the intermediate layer 40 in the order so the footbed 30 is in contact with the wearers foot and the intermediate layer 40 is to be adhered to an outer sole 4, possibly via a midsole. Thus, it will be understood that during manufacture, an adhesive may be applied to at least one of the intermediate layer 40 and the footbed 30 shown in Fig. 4a and the two parts may be assembled by e.g. flipping one over and positioning it on top of the other.

The intermediate layer 40 and footbed or insole 30 further comprise apertures 32, 42, that should be understood as perforations in relevant sizes in the material of the intermediate layer and the footbed or insole. The apertures 32, 42 may correspond to strap anchors 20 as it will be further explained below. The width W2 of the footbed aperture 32 in the transverse direction may be smaller than the width W1 of the intermediate layer aperture 42. The width W2 of the footbed aperture 32, in the transverse direction, may essentially correspond to the (combined) width of the strap and the strap anchor. The width W1 of the intermediate layer aperture 42 may essentially correspond to the width of the strap anchor, e.g. the width of the strap anchor at its lower part. This will be explained in further details below.

With reference to Fig. 4b, a schematic example of a strap anchor 20 is illustrated. A part of a strap 10 for a piece of footwear is shown, which strap 10 has been attached to a strap anchor 20 as it will be explained in further detail further below. However, as shown the strap anchor 20 comprises a vertical rib 22, to which the strap may be attached, e.g. by stitching, e.g. as indicated in Fig. 4b by a stitching 27, by attachment by an adhesive or in any other suitable manner. The strap anchor 20, which generally may be a profile in the shape of an inverted T-figure, has an outward rib 24 and an inward rib 26. As shown, the outward rib 24 is shorter than the inward rib 26 and the total width of the outward rib and the inward rib may have the same width as the width W1 of the aperture 42 in the intermediate layer. It is noted that the inward rib 26 may be shorter than the outward rib 24, depending on the specific embodiments and particular configurations and that the inward rib 26 and the outward rib 24 may be essentially of equal width as well.

Further, when the strap anchor 20 is positioned in an aperture 42 in the intermediate layer 40, the intermediate layer and strap anchor positioned in an aperture provides a smooth and straight level when applying a sole.

With reference to Fig. 4c, a further embodiment of the strap anchor 20 is shown, wherein the strap anchor comprises one or more grooves 21 and/or one or more perforation 23. Such groove and/or perforation may be manufactured in various sizes and mediates an effective and strong binding of e.g. sole material to the strap anchor by mediating a mechanical bonding of the materials.

In Fig. 4d a further embodiment of the strap anchor 20 attached to a strap 10 is shown, wherein the strap 10 is attached to the other side of the vertical rib 22 (compared to Fig. 4b), e.g. the side facing the inner of the sandal. The actual method of attaching is not indicated here, but as mentioned above it may be by a stitching, by attachment by an adhesive or in any other suitable manner.

In Fig. 4e a further embodiment of the strap anchor 20 attached to a strap 10 is shown, wherein the strap 10 comprises two layers 10a and 10b. These two layers may for example be two layers of e.g. leather, textiles etc. and it will be apparent that they may differ from each other. One may for example be an outer leather layer and the other may be a material functioning as a lining. A multitude of examples may be mentioned, and it will be further apparent that more than two layers 10a, 10b may be used for the strap 10. As shown in Fig. 4e, the layers 10a, 10b of the strap 10 may be moved slightly away from each other at the end, possibly by a splitting operation, and the strap 10 is subsequently combined with the vertical rib 22 of the strap anchor 20 by e.g. pulling the strap onto the vertical rib 22, i.e. with one layer on each side of the vertical rib 22. Subsequent to this, the strap 10 may be attached to the vertical rib 22, e.g. by stitching 27 as indicated in Fig. 4e. It is noted that the strap 10 may be broader than the vertical rib 22 and that the sides of the strap 10, e.g. the two layers 10a and 10b, thus may remain attached to each other at the sides, e.g. forming a pocket or the like, when being e.g. pulled onto the vertical rib 22, e.g. as indicated in Fig. 4e. As illustrated, the strap 10 and the attachment to the vertical rib 22 may hereby be configured in a more symmetric fashion.

Fig. 4f illustrates a possible cost-efficient way of providing a plurality of strap anchors 20 that may be provided with suitable lengths to fulfill the specific needs, e.g. depending on the actual footwear. A profile bar 28 is shown in a perspective view, e.g. a profile bar provided by extruding a suitable synthetic material, and as illustrated, the strap anchors 20 are provided by performing transverse separations 29, for example by sectioning, cutting or the like.

Fig. 5a is a schematic view of a transverse section of part of a footbed 30, to the underside of which an intermediate layer 40 is attached as it will be further explained below. Furthermore, part of a strap 10 for a piece of footwear is shown, which strap 10 has been attached to a strap anchor 20 as it has been explained above and as it will be explained in further detail further below. As shown the strap anchor 20 comprises a vertical rib 22, to which the strap may be attached, e.g. by stitching or in any other suitable manner. The strap anchor 20, which generally may be a profile in the shape of an inverted T-figure, has an outward rib 24 and an inward rib 26. As shown, the outward rib 24 is shorter than the inward rib 26, but the opposite may also be possible as well. Also, it is noted that the outward rib 24 and the inward rib 26 may be of equal width.

As further shown in Fig. 5a, the footbed 30 comprises an aperture 32, which may have been punched or made in any other suitable manner. The aperture 32 may have a width in the transverse direction which essentially corresponds to the combined width of the strap 10 and the vertical rib 22. Further, the aperture 32 may have a length in the longitudinal direction of the footbed 30, which essentially corresponds to the length of the strap anchor 20.

Even further, the intermediate layer 40, which may be e.g. a textile layer, that is adhered to the underside of the footbed 30, also comprises an aperture 42, which essentially has a width in the transverse direction that essentially corresponds to the combined width of the outward rib 24 and the inward rib 26. Furthermore, the aperture 42 may have a length in the longitudinal direction of the intermediate layer 40, which essentially corresponds to the length of the strap anchor 20, e.g. the length of the outward rib 24 and the inward rib 26.

When applying a strap anchoring in a footbed according to the illustrated example, the strap anchor 20 with the strap 10 attached may first be tilted and then pushed into the aperture 32 and the aperture 42 with the inward rib 26 first as shown in Fig. 5b and indicated with the arrow, until the vertical rib 22 meets the edge of the footbed 30. Hereafter, the strap anchor 20 is tilted in the reverse direction again as indicated with the curved arrow in Fig. 5c, while simultaneously force is applied downward, whereby the material of the footbed 30 and the strap anchor 20, e.g. the outward rib 24, will flex and reversibly deform. Thus, the outward rib 24 will snap through the aperture 32 in the footbed and click into place as shown in Fig. 5d. Variations and modifications of this method of applying a strap anchor are possible. Thus, the strap 10 will be secured from moving upwards due to the inward rib 26 and the outward rib 24 being locked in place by the underside of the footbed 30. Further, the strap 10 and the strap anchor 20 will be secured from moving laterally due to the edges of the aperture 42 in the intermediate layer 40 and the aperture 32 in the footbed 30. Even further, the strap anchor 20 will furthermore be secured, e.g. from moving downwards, by a midsole or outsole that may be applied subsequently by cementing e.g. a rubber or latex sole onto the intermediate layer 40 or by a midsole or outsole that may be formed subsequently by e.g. casting or by e.g. direct injection molding of e.g. polyurethane (PU). It is noted that such a PU molding will attach to the intermediate layer 40 as well as the strap anchor 20, e.g. the lower part of the strap anchor 20, and thereby further increase the securing of the strap anchor 20 and the strap 10.

The midsole may be able to have different thickness depending on e.g. various designs of the footwear, softness of the sole layers, etc. as it will be exemplified in the following.

According to an embodiment, the sole layer may comprise more than one intermediate layer 40.

According to a possible further embodiment, the intermediate layer may not be necessary, for example in case the outsole material may bond directly to the anchor straps as well as the footbed or insole material.

Fig. 5e illustrate in a schematic manner corresponding to Figs. 5a-5d an embodiment of the strap anchoring in a footbed 30 and the intermediate layer 40, where, after the strap anchor 20 with the attached strap 10 has been pushed, snapped, “clicked” or the like into place, the material of the footbed 30 is seen returning partly to its original shape, e.g. at the upper part, whereby the material of the footbed 30 is closing more or less tightly around the strap 10. Thus, a pleasing appearance may be achieved as well as the advantage that moisture, dirt particles etc. may not enter into the sole construction. It is noted that it is a requirement to achieve this that the footbed material has a certain degree of flexibility and that the apertures 32 in the footbed 30 are made such that they correspond to the shape of the strap 10 combined with the vertical rib 22 of the strap anchor 20 and such that the apertures 32 has at least slightly smaller dimensions than the strap 10 combined with the vertical rib 22, at least in the transverse direction.

Fig. 5f illustrate in a schematic manner corresponding to Fig. 5e an embodiment of the strap anchoring in a footbed 30 and the intermediate layer 40, where the attachment of the strap 10 to the strap anchor 20 is of a type as illustrated in Fig. 4e. As illustrated in Fig. 5f, the material of the footbed 30 may return to its original shape, e.g. at the upper part, in a manner giving a better fit around the strap 10.

Furthermore, Fig. 5g shows in a schematic manner an embodiment of the strap anchoring in a footbed 30 and the intermediate layer 40 as shown in Fig. 5f, but where it furthermore is illustrated that the intermediate layer 40 may extend a distance outside the perimeter of the footbed or insole 30, which distance may form a trim part 44 of the intermediate layer 40. This trim part 44 may subsequent to the manufacturing of the footwear, e.g. the sandal, be trimmed off, but during the manufacture, e.g. in connection with DIP manufacturing of a midsole or an outer-sole, this trim part 44 may advantageously be utilized for closing the mold, e.g. for fixing the footbed with the footwear upper in relation to the mold as it will be further elucidated further below. The trim part 44 may for example have a size of around 7 mm, e.g. be at least 3 mm, or at least 5 mm, and may be in an interval from 5 mm to 10 mm, e.g. in an interval from 3 to 12 mm or even more.

Even further, Fig. 5h shows in a schematic manner an embodiment of the strap anchoring in a footbed 30 and the intermediate layer 40, wherein it furthermore is illustrated that a tube channel 46 may be positioned and/or fixed via a strap anchor 20, whereby the tube channel 46 may be positioned between the footbed or insole 30 and e.g. a midsole, e.g. a midsole that is applied by DIP injection or in another manner. Thus, as illustrated by the double-arrow, the strap 10 may be moved underneath the footbed/insole 30, e.g. in order to adjust the strap. With reference to Fig. 6a, a footwear 2 according to embodiments of the invention is elucidated. The footwear 2 is a sandal that comprises a cross strap 12, a heel strap 14, a lateral strap 16, an outer sole 4 and a footbed 30 or an insole and between these two layers, at least one intermediate layer 40, 40a, 40b are positioned according to an embodiment of the invention. The intermediate layers 40, 40a, 40b may be in any suitable material, e.g. a textile layer, and may have various thicknesses according to the application and designs of the intermediate layer. The cross strap 12 may consist of two pieces of material that are adhered e.g. by Velcro or buckles. The cross strap may also only be one piece of material as illustrated in Fig. 6b and the size of the cross strap 12 may vary. The cross strap 12 may have the form as a thin strap or may be broader as shown in Fig. 6b or may even have the size and the form as a footwear upper.

A cross strap 12 may only have one strap anchor 20 or may have several strap anchors 20 as illustrated in Fig. 6b. In particular in case the cross strap is broad, a plurality of strap anchors 20 may be used and even more so in case a large part of the upper is fixated to the sole construction by strap anchors 20. In case the upper part forms a curvature, e.g. for example in relation to a nose part, the strap anchors 20 may have a relatively small length in order to be arranged in a curve.

As exemplified in Fig. 6c, the footwear 2 may not have a heel strap 14 or as exemplified in Fig. 6d, the footwear may have a heel cap that are fastened by at least two or a plurality of strap anchors, e.g. corresponding to the fastening of the broad cross strap 12 as illustrated in Fig. 6d.

As further illustrated in Fig. 6e, which essentially corresponds to the embodiment shown in Fig. 6a, it is exemplified that the footbed or insole 30 may have two or more layers, e.g. footbed or insole sublayers 30a and 30b as shown. Thus it should be noted that different thicknesses of the footbed or insole 30 may be allowed. It is noted that the footbed or insole 30 may comprise more than two sublayers, e.g. depending on the actual configuration of the footwear. As illustrated in Fig. 6f, which essentially corresponds to the embodiment shown in Fig. 6e, it is furthermore exemplified a midsole 37 may be comprised in the sole configuration, e.g. placed between the intermediate layer 40a and the outsole 4, and that such midsoles 37 may have different thicknesses and/or may comprise two or more layers.

With reference to Fig. 7, a further embodiment of the invention is shown where the apertures of the intermediate layer 40 and footbed 30 may be more than one as was illustrated in Fig. 4a but may be several apertures 42 and 32 and may even constitute the total circumference of the aperture 40 or footbed 30. As mentioned above, when the upper part to be fastened to the sole constructions forms a curvature, e.g. for example in relation to a nose part, the apertures 42 and 32 may have a relatively small length L in order to be arranged in a curve as compared to the length L, when it is e.g. the heel strap that is being fastened with a single strap anchor at each end of the strap.

Even further, in Fig. 7, it is shown that the aperture or apertures 42 in the intermediate layer 40 may be arranged with a distance DI to the edge E of the intermediate layer 40 and that the aperture or apertures 32 in the intermediate layer 30 may be arranged with a distance D2 to the corresponding edge of the intermediate layer 30.

Fig. 8a illustrates a mold 50 for a direct injection process according to embodiments of the invention. Thus, this figure shows schematically a mould 50, seen in a cross- sectional view, which mould 50 may be utilized for direct injection moulding of e.g. a midsole and/or an outer sole onto an e.g. sandal or another piece of footwear.

The mold may have been manufactured out of metal, for example aluminum by e.g. CNC machinery and may as shown in fig. 8a comprise a first side mold 52, a second side mold 54 and a bottom mold 56, which are arranged in such a manner that the mold may be opened and closed e.g. by the first side mold 52 and the second side mold 54 being able to be moved in horizontal directions as indicated with the arrows A, B and by the bottom mold 56 being arranged to be moved in the vertical direction as indicated with the arrow C.

The first side mold 52 and the second side mold 54 may be provided with a first side surface 53 and a second side surface 55, respectively, that have been made during e.g. CNC milling, and which generally define a desired form of a side part of a shoe sole to be molded. Further the bottom mold 56 may correspondingly be provided with a bottom inner surface 57, which have been made during the e.g. CNC milling and which generally has a form corresponding to a desired form of the underside of the shoe sole to be molded.

As shown in Fig. 8a, the mold 50 may be utilized for manufacturing an e.g. sandal, based on a footbed 30, an intermediate layer 40 and an upper comprising a cross strap 12 and possibly other straps or upper parts that are anchored to the footbed 30 and the intermediate layer 40 by means of strap anchors 20, e.g. corresponding to the construction shown in Fig. 5g. The upper of the sandal may by means of e.g. a last 70 (as indicated in a cross sectional view in Fig. 8a) be lowered down onto the mold 50 as indicated by the arrow D, until it is located on top of the mold 50, e.g. the top of the first side mold 52 and the second side mold 54 as shown in Fig. 8b, where the trim parts 44 of the intermediate layer 40 are shown closing the mold 50 such that a closed mold cavity 60 has been formed.

Possibly, the trim parts 44 may here be releasably fixed or held to the first side mold 52 and the second side mold 54 by a holding member, by vacuum or in any other suitable manner in order to provide a satisfactory closing of the mold.

As further shown in Fig. 8c, the bottom mold 56 may be moved upwards to define the thickness of the outsole that is to be molded in the mold cavity 60 and subsequently injected material 80 may be introduced, e.g. injected into the mold cavity 60. The injected material 80 will expand to fill the mold cavity 60 and will thus before curing adhere to the underside of the intermediate layer 40 and the bottom of the strap anchors 20. When the injected material has cured, the mold 50 may be opened and the trim parts 44 may be trimmed away, possibly together with any trimming of the edge of the molded outsole.

Fig. 8d illustrates an alternative embodiment, wherein a pre-made outsole 90 has been introduced into the mold cavity 60 prior to the mold being closed. Subsequent to this, the bottom mold 56 may be moved upwards to define the thickness of the combination of the outsole and a midsole that is to be molded in the mold cavity 60. Thereafter, injected material 80 may be introduced, e.g. injected into the mold cavity 60 on top of the outsole 90. The injected material 80 will expand to fill the mold cavity 60 and will thus before curing adhere to the underside of the intermediate layer 40 and the bottom of the strap anchors 20 and furthermore to the outsole 90. When the injected material has cured, the mold 50 may be opened and the trim parts 44 may be trimmed away, possibly together with any trimming of the edge of the molded midsole.

Fig. 8e illustrates a further embodiment, wherein the footbed or insole 30 of the footwear that as explained above may comprise two or more layers, may have one of these layers being formed, e.g. for example by milling or cutting, to be able to close the mold. Thus, instead of closing the mold by trim parts of the intermediate layer 40, the mold may be closed by the milled or cut insole 31.

This may for example be the case, when the footbed or insole comprises a leather component that may be suitably cut or milled.

Fig. 8f illustrates a further embodiment, wherein the midsole 37 of the footwear may be formed, e.g. for example by milling or cutting, to be able to close the mold. Thus, instead of closing the mold by trim parts of the intermediate layer 40, the mold may be closed by the milled or cut midsole 37.

This may for example be the case, when the midsole comprises a leather component that may be suitably cut or milled. Further, Figs. 9a and 9b show in a schematic manner a transverse sectional view of various footwear configurations according to embodiments of the invention.

In Fig. 9a, a footbed 30 is illustrated with strap anchors 20 and wherein the footbed 30 may comprise a leather part and possibly an intermediate layer, wherein the leather part may be milled to provide a closing part 3 la at the lower part of the footbed, which closing part 31a extends circumferentially and which may serve to close the mold as it has been elucidated above. Further, Fig. 9a shows that the footwear configuration comprises an injected outer sole or midsole 82.

Fig. 9b illustrates in a similar manner that a tube channel 46 as it has been explained above may be comprised in the footbed 30 and that an intermediate layer is comprised in the construction, which intermediate layer has trim parts 44 extending circumferentially around the sole for to closing of the mold. Also, Fig. 9b shows that the footwear configuration comprises an injected outer sole or midsole 82.

Fig. 10 shows, seen from above, an embodiment of a mold 50 for direct injection of footwear according to an embodiment of the invention, wherein upper parts of the mold are exchangeable. As it has been explained above, the mold comprises a first side mold 52 and a second side mold 54 that may be moved away and towards each other as illustrated with the double-arrows A and B to form a mold cavity 60 together with e.g. a footwear upper and a bottom mold (not shown in Fig. 10).

In order to enhance the flexibility of the mold construction and in order to be able to use the mold in connection with various footwear configurations, a first side mold upper 102 may be combined with the first side mold 52 and a second side mold upper 104 may be combined with the second side mold 54. As shown, the first side mold upper 102 and the second side mold upper 104 may together form a rim around the mold and may each correspond to the form of the respective side molds. Each side mold upper may be fixed to the respective side mold by means of a first side mold clamp 106 and a second side mold clamp 108, respectively, which each may be fastened by fixation means 110 such as screws. As it will be elucidated in the following, the first side mold upper 102 and the second side mold upper 104 may together with the respective side mold clamps be exchangeable and may be provided with a plurality of e.g. height dimensions to match various footwear constructions, various midsole thicknesses, etc.

Fig. 11 shows a sideview of the second side mold 54 of the mold 50 shown in Fig. 10 in an enlarged view, where furthermore, the mold cavity 60 and an example of an injection channel 112 is shown. Here, it is further shown that the second side mold upper 104 may be formed to follow the form of the rim 114 of the second side mold 54 and that the second side mold clamp 108 at its lower part has a corresponding form, while it at its upper part may be essentially flat to provide e.g. a suitable fastening form for the fixation means 110, e.g. bolts, screws or the like. Also, as shown the second side mold upper 104 may provide a height extension as indicated by the double-arrows 118. Furthermore, an example of an indication of the side of a midsole 116 is shown in Fig. 11 and as it will be understood, the first and the second side mold uppers and possibly also the corresponding clamps may be changed to correspond to the actual size of e.g. the midsole of a footwear configuration. Thus, the first and the second side mold uppers and possibly also the corresponding clamps may be at hand in a suitable numbers and sizes, whereby the first and the second side mold may be utilized for a multitude of footwear forms, shapes, midsole thicknesses, etc. and that only the first and the second side mold uppers need to be changed to match the actual e.g. midsole thickness.

In the above description, various embodiments of the invention have been described with reference to the drawings, but it is apparent for a person skilled within the art that the invention can be carried out in an infinite number of ways, using e.g. the examples disclosed in the description in various combinations, and within a wide range of variations within the scope of the appended claims. List

2 Footwear

4 Outer sole

6 Sole construction

10 Strap

10a, 10b Strap layer

12 Cross strap

14 Heel strap

16 Lateral strap

18 Human foot

19 Lower part of upper

20 Strap anchor

21 Groove

22 Vertical rib

23 Perforation

24 Outward rib

26 Inward rib

27 Stitching

28 Profile bar

29 Separation

30 Footbed or insole

30a, 30b Footbed or insole sublayers

31 Milled or cut insole

31a Closing part

32 Aperture in footbed

34 Footbed upper side

36 Footbed lower side

37 Midsole

38 Heel cap

40 Intermediate layer

40a, 40b Intermediate sublayers

42 Aperture in intermediate layer 44 Trim part of intermediate layer

46 Tube channel

50 Mold for direct injection

52 First side mold

53 First side surface

54 Second side mold

55 Second side surface

56 Bottom mold

57 Bottom inner surface

60 Mold cavity

70 Last

80 Injected material

82 Injected outer sole or midsole

90 Pre-made outsole

102 First side mold upper

104 Second side mold upper

106 First side mold clamp

108 Second side mold clamp

110 Fixation means

112 Injection channel

114 Rim of second side mold

116 Indication of side of midsole

118 Height extension