Novel Vamp, and Injection Moulding Process for Forming a Vamp

Abstract

A composite vamp includes a first, relatively softer layer shaped and dimensioned to define a periphery of the vamp and the profile of an upper surface of the vamp, and a second, relatively harder layer bonded to the first layer, which second layer is adapted to overlie the instep region of a foot and shaped to match the instep region of the foot.

1 .- 29 . (canceled)  
   
   
       30 . A composite vamp including: 
 a first, relatively softer layer shaped and dimensioned to define a periphery of the vamp and the profile of an upper surface of the vamp; and    a second, relatively harder layer bonded to the first layer, which second layer is adapted to overlie the instep region of a foot and shaped to match the instep region of the foot;    wherein the second, relatively harder layer is injection moulded about the first, relatively softer layer.    
   
   
       31 . A composite vamp according to  claim 30 , further including an intermediate reinforcement element disposed between said layers and of a rigidity to facilitate maintenance of said profile.  
   
   
       32 . A composite vamp according to  claim 31 , wherein said intermediate reinforcement element is a carbon composite element.  
   
   
       33 . A composite vamp according to  claim 31 , wherein said intermediate reinforcement element is a pre-shaped reinforced textile.  
   
   
       34 . A composite vamp according to  claim 31 , wherein said intermediate reinforcement element is a reinforced plastic.  
   
   
       35 . A composite vamp according to  claim 31 , wherein said intermediate reinforcement element is a steel insert.  
   
   
       36 . A composite vamp according to  claim 30 , comprising a one piece component to be incorporated into a shoe or boot.  
   
   
       37 . A composite vamp according to  claim 30 , wherein said first layer is a plastics material.  
   
   
       38 . A composite vamp according to  claim 30 , wherein said first layer is a leather or synthetic leather.  
   
   
       39 . A composite vamp according to  claim 30 , wherein said profile includes surface features selected from one or more of concavity, ridges and peaks.  
   
   
       40 . A composite vamp according to  claim 30 , wherein said second layer is chemically bonded or welded to the first layer.  
   
   
       41 . A composite vamp according to  claim 30 , including at least one front surface that is concave and has a radius of curvature substantially the same as or slightly greater than the radius of curvature of a selected ball.  
   
   
       42 . A composite vamp according to  claim 30 , formed integral with a shoe or boot.  
   
   
       43 . A composite vamp according to  claim 30 , approximately M-shaped in cross-section.  
   
   
       44 . A composite vamp according to  claim 30 , having one or more longitudinal ridges or ribs.  
   
   
       45 . A method of forming a composite vamp including: 
 shaping a piece of relatively soft material in a mould;    injecting a plastic into said mould or into a second mould on at least one side of the soft material;    bonding the injected material to the soft material; and    curing the injected plastic while shaping it by means of the mould to provide a bonded, relatively harder layer of material adjacent the soft material that is adapted to overlie the instep region of a foot and shaped to match the instep region of the foot, while the relatively softer material forms a layer that is shaped and dimensioned to define a periphery of the vamp and the profile of an upper surface of the vamp.    
   
   
       46 . A method according to  claim 45 , wherein said relatively softer material is a plastics material.  
   
   
       47 . A method according to  claim 45 , wherein said relatively softer material is a leather or synthetic leather.  
   
   
       48 . A method according to  claim 45 , further including forming said piece of relatively soft material so that said profile includes surface features selected from one or more of concavity, ridges and peaks.  
   
   
       49 . A method according to  claim 45 , wherein said bonding is by chemical bonding or welding.  
   
   
       50 . A method according to  claim 45 , further including providing an intermediate reinforcement element between said layers.  
   
   
       51 . A method according to  claim 50 , wherein said intermediate reinforcement element is a carbon composite element.  
   
   
       52 . A method according to  claim 50 , wherein said intermediate reinforcement element is a pre-shaped reinforced textile.  
   
   
       53 . A method according to  claim 50 , wherein said intermediate reinforcement element is a reinforced plastic.  
   
   
       54 . A method according to  claim 50 , wherein said intermediate reinforcement element is a steel insert.  
   
   
       55 . A method according to  claim 45 , wherein said vamp is formed integral with a shoe or boot.  
   
   
       56 . A method according to  claim 45 , including forming said vamp to be approximately M-shaped in cross-section.  
   
   
       57 . A method according to  claim 45 , including providing the vamp with one or more longitudinal ridges or ribs.