Bi-component/binder fiber insole

Abstract

A flexible shoe insole ( 8 ) is formed from essentially bi-component fiber ( 1 ) having a first low melting point for one component and a second higher melting point for a second component. The fiber is entangled ( 3 ) to form a fabric. The fabric thereafter is heated ( 4 ) to a temperature sufficient to melt the first component of the bi-component fiber ( 1 ) without causing permanent structural impairment of or to the second component, and the thickness of the fabric is reduced ( 5 ) to a pre-selected thickness.

1 . A flexible shoe insole consisting essentially of bi-component fiber having a first low melting point for one component and a second higher melting point for a second component, entangling the fibers to form a fabric, the fabric being heated to a temperature sufficient to melt the first component of the bi-component fiber without permanent structural impairment of the second component, and reducing the thickness of the fabric to a pre-selected thickness. 
     
     
         2 . The insole of  claim 1  or the first component is a hot melt material. 
     
     
         3 . The insole of  claim 2  wherein the second component is polyester fiber having a melting point of at least 400 degrees F. 
     
     
         4 . The insole of  claim 1  wherein the thickness is reduced by passing the fabric through at least one set of rollers. 
     
     
         5 . The insole of  claim 4  wherein one of the first and second components of the bi-component fiber has a color associated with it. 
     
     
         6 . The insole of  claim 5  wherein the weight of the insole is constant but the thickness of the insole is variable. 
     
     
         7 . The insole of  claim 6  wherein the thickness is controlled by the thickness of at least one of the first and second components of the bi-component fiber. 
     
     
         8 . The insole of  claim 1  wherein the fibers are entangled by needle punching. 
     
     
         9 . An insole for a shoe constructed by the steps of:
 providing a bi-component fiber having a first low melting point component and a second high melting point component;   forming the fiber into a fabric;   heating the fabric sufficiently to melt the first component so as to bond the second component of the fabric;   passing the fabric through at least one set of rollers to reduce the material of the thickness of the fabric;   cooling the fabric;   forming at least one insole from the fabric.   
     
     
         10 . The insole of  claim 8  wherein the fibers are entangled by needle punching. 
     
     
         11 . The insole of  claim 8  wherein at least one of the components of the bi-component fiber is polyester fiber having a melting point of at least 400 degrees F. 
     
     
         12 . The insole of  claim 8  wherein the thickness is reduced by passing the fabric through at least one set of rollers. 
     
     
         13 . The insole of  claim 8  wherein one of the first and second components of the bi-component fiber has a color associated with it. 
     
     
         14 . The insole of  claim 8  wherein the weight of the insole is constant but the thickness of the insole is variable. 
     
     
         15 . The insole of  claim 8  wherein the thickness is controlled by the thickness of at least one of the first and second components of the bi-component fiber. 
     
     
         16 . A method of forming an insole comprising the steps of;
 forming a fabric from essentially bi-component fiber, the fiber having a first low melting component and a second higher melting point component;   heating the fabric sufficiently to melt the first component so as to bond the second component of the fabric;   passing the material through at least one set of rollers to obtain a pre-determined thickness of the material.   
     
     
         17 . The method of  claim 15  wherein the fabric is constructed substantially of one hundred percent bi-component fibers 
     
     
         18 . The method of  claim 15  wherein at least one of the components of the bi-component fiber is polyester fiber having a melting point of at least 400 degrees F. 
     
     
         19 . The method of  claim 17  wherein the thickness of the material is controlled by the thickness of at least one of the first and second component of said bi-component fiber. 
     
     
         20 . The method of  claim 18  wherein the bi-component fiber comprises first and second separate fiber strands. 
     
     
         21 . The method of  claim 19  wherein the fibers are entangled by needle punching.