Composite sole

Abstract

The invention relates to a composite sole for a shoe, more particularly to an insert adhesively laminated to one or both of opposing upper and lower component to form the sole of an athletic shoe. The insert is adhesively incompatible with the upper and lower sole components and an adhesion promoter may be positioned between the insert and at least one of the upper and lower sole components to adhesively bond the insert to at least one or both of the upper and lower sole components.

1 . A composite sole, comprising an insert positioned between upper and lower materials, wherein the insert is adhesively incompatible with the upper and lower materials, wherein the upper and lower materials are adhesively bonded together, wherein an adhesion promoter is positioned between the insert and at least one of the upper and lower materials to adhesively bond the insert to at least one of the upper and lower materials. 
     
     
         2 . The composite sole of  claim 1 , wherein the upper and lower materials comprise a polymer material and wherein the insert comprises a metal or metal alloy. 
     
     
         3 . The composite sole of  claim 2 , wherein the insert comprises one of: titanium, a titanium alloy, magnesium, a magnesium alloy, aluminum, or aluminum alloys. 
     
     
         4 . The composite sole of  claim 2 , wherein the polymeric material comprises one of a thermosetting and/or thermoplastic resin. 
     
     
         5 . The composite sole of  claim 3 , wherein the thermosetting resin is substantially at least mostly, if not completely, a C-staged thermosetting resin. 
     
     
         6 . The composite sole of  claim 1 , wherein the upper and lower materials are carbon fiber laminates. 
     
     
         7 . The composite sole of  claim 1 , wherein the insert is chemically and/or mechanically adhesively bonded to one or both of upper and lower materials and wherein the upper material is chemically and/or mechanically adhesively bonded to the lower material. 
     
     
         8 . The composite sole of  claim 7 , wherein the adhesion promoter is chemically and/or adhesively bonded to the insert and at least one of the upper and lower materials. 
     
     
         9 . The composite sole of  claim 1 , wherein individually and separately the upper and lower materials comprise a homopolymer, copolymer and/or polymer alloy selected from the group of polymers consisting of polyolefins, polystyrenes, polyvinyls, polyacrylics, polyhalo-olefins, polydienes, polyoxides, polyesthers, polyacetals, polysulfides, polythioesters, polyamides, polythioamides, polyurethanes, polythiourethanes, polyureas, polythioureas, polyimides, polythioimides, polyanhydrides, polythianhydrides, polycarbonates, polythiocarbonates, polyimines, polysiloxanes, polysilanes, polyphosphazenes, polyketones, polythioketones, polysulfones, polysulfoxides, polysulfonates, polysulfoamides, polyphylenes, and combinations and/or mixtures thereof. 
     
     
         10 . The composite sole of  claim 1 , further comprising one or more of:
 a) one or more vent ports;   b) one or more cleat interconnecting elements; and   c) one or more studs.   
     
     
         11 . The composite sole of  claim 1 , wherein the insert further comprises one or more tabs extending radially from the insert. 
     
     
         12 . The composite sole of  claim 11 , wherein the composite sole further comprises opposing interior and exterior surfaces, wherein insert further comprises interior and exterior portions, wherein the interior portion of the insert comprises the one or more tabs positioned between the upper and lower materials and wherein the exterior portion of the insert comprises the portion of the insert forming at least a portion of the exterior surface of the composite sole. 
     
     
         14 . A shoe, comprising an upper interconnected to a composite sole comprising an insert positioned between upper and lower materials, wherein the insert is adhesively incompatible with the upper and lower materials, wherein the upper and lower materials are adhesively bonded together, wherein an adhesion promoter is positioned between insert and at least one of the upper and lower materials to adhesively bond the insert to at least one of the upper and lower materials. 
     
     
         13 . A method for making a composite sole, comprising:
 a) providing an insert and upper and lower sole materials, wherein the insert is adhesively incompatible with the upper and lower materials;   b) treating at least one of the insert, the upper material and lower material with an adhesion promoter;   c) positioning in registration, at least some of the insert between the upper and lower materials in a mold, wherein the insert positioned in registration with upper and lower materials forms a composite sole assembly;   d) applying at least one of heat and pressure to the composition sole assembly to adhesively bond the insert to at least one of the upper and lower materials to form a composite sole; and   e) removing the composite sole from the mold.   
     
     
         13 . The method of  claim 12 , wherein the insert comprises one of: titanium, a titanium alloy, magnesium, a magnesium alloy, aluminum, or aluminum alloys and wherein the polymeric material comprises one of a thermosetting and/or thermoplastic resin. 
     
     
         14 . The method of  claim 13 , wherein the applied heat and/or pressure are sufficiently affective to at least mostly, if not completely, C-stage the thermosetting resin. 
     
     
         15 . The method of  claim 12 , wherein the upper and lower materials are carbon fiber laminates. 
     
     
         16 . The method of  claim 12 , wherein the adhesion promoter is chemically and/or adhesively bonded to the insert and at least one of the upper and lower materials. 
     
     
         17 . The method of  claim 12 , wherein individually and separately the upper and lower materials comprise a homopolymer, copolymer and/or polymer alloy selected from the group of polymers consisting of polyolefins, polystyrenes, polyvinyls, polyacrylics, polyhalo-olefins, polydienes, polyoxides, polyesthers, polyacetals, polysulfides, polythioesters, polyamides, polythioamides, polyurethanes, polythiourethanes, polyureas, polythioureas, polyimides, polythioimides, polyanhydrides, polythianhydrides, polycarbonates, polythiocarbonates, polyimines, polysiloxanes, polysilanes, polyphosphazenes, polyketones, polythioketones, polysulfones, polysulfoxides, polysulfonates, polysulfo amides, polyphylenes, and combinations and/or mixtures thereof. 
     
     
         18 . The method of  claim 12 , wherein the insert has one or both of a) one or more vent ports and b) one or more cleat interconnecting elements; and wherein one or more studs are formed on the composite sole during the step d). 
     
     
         19 . The method of  claim 12 , wherein the insert further comprises one or more tabs extending radially from the insert. 
     
     
         20 . The method of  claim 19 , wherein the composite sole further comprises opposing interior and exterior surfaces, wherein insert further comprises interior and exterior portions, wherein the interior portion of the insert comprises the one or more tabs positioned between the upper and lower materials and wherein the exterior portion of the insert comprises the portion of the insert forming at least a portion of the exterior surface of the composite sole.