Method for making foamed sole pads

Abstract

A method for making foamed sole pads includes the steps of: a) providing a profiled foam blank including at least one blank unit that has a substantially sole shape outline, and that has front and heel portions, a top profiled surface, and a bottom profiled surface symmetrical to the top profiled surface; b) dividing the foam blank along a cutting plane between the top and bottom profiled surfaces to provide at least two foam blank slices; c) bonding a fabric layer to a surface of each of the foam blank slices; d) heating each of the foam blank slices; e) compression molding each of the foam blank slices to form the sole pads; and f) trimming the sole pads.

1 . A method for making foamed sole pads, comprising the steps of:
 a) providing a profiled foam blank including at least one blank unit that has a substantially sole shape outline, and that has front and heel portions, a top profiled surface, and a bottom profiled surface symmetrical to the top profiled surface;   b) dividing the foam blank along a cutting plane between the top and bottom profiled surfaces to provide at least two foam blank slices;   c) bonding a fabric layer to a surface of each of the foam blank slices;   d) heating each of the foam blank slices;   e) compression molding each of the foam blank slices to form the sole pads; and   f) trimming the sole pads.   
   
   
       2 . The method as claimed in  claim 1 , further comprising a step of roughening the surface of each of the foam blank slices prior to step c). 
   
   
       3 . The method as claimed in  claim 2 , wherein the roughening step is conducted via ultraviolet irradiation. 
   
   
       4 . The method as claimed in  claim 1 , wherein a reinforcing plate is embedded in the profiled foam blank in step a). 
   
   
       5 . The method as claimed in  claim 4 , wherein the reinforcing plate is embedded in at least one of the front and heel portions of the profiled foam blank. 
   
   
       6 . The method as claimed in  claim 1 , wherein a mold having a plurality of positioning pins is used to position each of the foam blank slices in step e). 
   
   
       7 . The method as claimed in  claim 1 , wherein the front and heel portions have different hardnesses. 
   
   
       8 . The method as claimed in  claim 1 , wherein the foam blank slices are substantially the same in shape and size.