Shoe sole and method

Abstract

A shoe outsole and method of manufacture wherein the outsole is formed using recycled rubber granules generated during the shoe manufacturing process, the recycled rubber granules being used as a filler material and being mixed with various thermoplastic materials or vulcanized rubber to form the shoe outsole. The recycled rubber granules are mixed with the thermoplastic material or vulcanized rubber to form a filled elastomer which includes at least 50% by weight of a virgin thermoplastic material and no more than about 30% by weight of the recycled rubber granules.

1 . A method of making a shoe outsole comprising the steps of:
 providing recycled rubber granules;   mixing the recycled rubber granules with a thermoplastic elastomer to form a filled elastomer; and   forming the filled elastomer into an outsole.   
     
     
         2 . The method of  claim 1  wherein the thermoplastic elastomer is a virgin thermoplastic material, and wherein the filled elastomer includes at least 50% by weight of the virgin thermoplastic material. 
     
     
         3 . The method of  claim 1  wherein the filled elastomer includes no more than about 30% by weight of the recycled rubber granules. 
     
     
         4 . The method of  claim 1  wherein the thermoplastic elastomer includes virgin thermoplastic rubber, and wherein the filled elastomer includes at least 50% by weight of the virgin thermoplastic rubber. 
     
     
         5 . The method of  claim 1  wherein the thermoplastic elastomer includes a thermoplastic material and a reground thermoplastic material, and wherein said filled elastomer includes at least 50% by weight of the virgin thermoplastic material. 
     
     
         6 . The method of  claim 5  wherein said filled elastomer includes about 30% by weight of said recycled rubber granules, about 50% by weight of said virgin thermoplastic material, and about 20% by weight of said reground thermoplastic material. 
     
     
         7 . The method of  claim 6  wherein said reground thermoplastic material includes reground thermoplastic rubber. 
     
     
         8 . The method of  claim 6  wherein said virgin thermoplastic material includes virgin thermoplastic rubber. 
     
     
         9 . A method of making a shoe outsole comprising the steps of:
 providing recycled rubber granules;   mixing said recycled rubber granules with vulcanized rubber in predetermined quantities to form a filled elastomer; and   forming the filled elastomer into an outsole.   
     
     
         10 . The method of  claim 9  wherein said filled elastomer includes at least 50% by weight of said vulcanized rubber. 
     
     
         11 . The method of  claim 9  wherein said filled elastomer includes no more than 30% by weight of said recycled rubber granules. 
     
     
         12 . A method of making a shoe outsole comprising the steps of:
 providing recycled rubber granules;   mixing said recycled rubber granules with virgin thermoplastic rubber and reground thermoplastic rubber in predetermined quantities to form a filled elastomer comprising at least 50% by weight of said virgin thermoplastic rubber; and   forming the filled elastomer into an outsole.   
     
     
         13 . The method of  claim 12  wherein said filled elastomer includes no more than 30% by weight of said recycled rubber granules. 
     
     
         14 . A molded shoe outsole comprising:
 a thermoplastic elastomer; and   recycled rubber granules mixed with said thermoplastic elastomer to form a filled elastomer, said filled elastomer including no more than about 30% by weight of said recycled rubber granules.   
     
     
         15 . The molded shoe outsole of  claim 14  wherein said thermoplastic elastomer includes a virgin thermoplastic material, said filled elastomer including at least 50% by weight of said virgin thermoplastic material. 
     
     
         16 . The molded shoe outsole of  claim 15  wherein said virgin thermoplastic material includes a virgin thermoplastic rubber. 
     
     
         17 . The molded shoe outsole of  claim 16  wherein the remaining portion of said filled elastomer includes reground thermoplastic rubber. 
     
     
         18 . The molded shoe outsole of  claim 17  wherein said filled elastomer includes about 30% by weight of said recycled rubber granules, about 50% by weight of said virgin thermoplastic rubber, and about 20% by weight of said reground thermoplastic rubber. 
     
     
         19 . A molded shoe outsole comprising:
 vulcanized rubber; and   recycled rubber granules mixed with said vulcanized rubber in predetermined quantities to form a filled elastomer, said filled elastomer including at least 50% by weight of said vulcanized rubber and no more than about 30% by weight of said recycled rubber granules.