Method for fabricating a footwear sole

Abstract

A method for forming a footwear sole is disclosed. Specifically, there is provided a sole mould for fabricating high-quality shoe soles with great efficiency and a method of using such a mould, wherein the soles feature good air permeability and perfect match with the feet by automatically adapting themselves to the shape of the feet. The sole mould includes a first mould for injection-moulding the underside of a leather layer, and a second mould for injection-moulding the upper surface of the leather layer to form the sole. Further, the first mould is configured in the same shape as the fore sole of the foot and the second mould is configured in the shape of a complete sole.

1 . A method for forming a footwear sole comprising a fore sole and a rear sole, the method comprising:
 providing a midsole layer having one or more midsole injection holes and one or more midsole bores distributed thereon, the midsole injection holes and the midsole bores extending between an underside of the midsole layer and an upper surface of the midsole layer;   providing a first female mould comprising one or more first downward concave cavities and first raised areas;   placing said midsole layer onto said first female mould, and aligning said midsole injection holes and said midsole bores with said first downward concave cavities provided in said first female mould;   providing a first male mould comprising a first injection area comprising one or more of first bores and one or more first injection holes;   assembling and fixing said first male mould and said first female mould so that each of said midsole bores and said midsole injection holes are respectively aligned with each of said first bores and each of said first injection holes; and   a step A3 comprising infusing a first formula plastic into said first male mould by way of said first injection holes and said midsole injection holes into said first downward concave cavities, wherein said first formula plastic is channeled through each of said first injection holes and each of said midsole injection holes into each of said downward concave cavities and shaped up resulting in raised soles lines on said fore sole, and further wherein said first formula plastic inside each of said first downward concaves passes through each of said midsole bores and into each of said first bores to form one or more protuberances which are embedded with said midsole layer; and   splitting said first male mould and said first female mould to remove said midsole layer comprising said raised sole lines and said protuberances; and   a step B comprising taking said midsole layer out of said first male mould and said first female mould and placing said midsole layer into a shoe sole-shaped second mould for injection moulding with a second formula plastic to form one or more second raised sole lines on the upper surface of the midsole layer, the second raised sole lines being embedded with the protuberances to thereby anchor the first raised sole lines with the second raised sole lines.   
     
     
         2 . The method of  claim 1 , wherein said step B comprises:
 a step B1 comprising providing a second female mould and placing said midsole onto said second female mould so that said first raised lines match with said one more second downward concaves of said second female mould;   a step B2 comprising providing a second male mould comprising a second injection area comprising one or more second upward concave cavities and one or more second injection holes and assembling and fixing said second male mould and said second female mould, such that each of said one or more protuberances protrudes inside each of said one or more second upward concave cavities; and   a step B3 comprising infusing said second formula plastic into each of said one or more second upward concave cavities through said one or more second injection holes such that said second formula plastic is moulded with said midsole layer and with each of said one or more protuberances to form said one or more second raised sole lines on the upper surface of the midsole layer.   
     
     
         3 . The method of  claim 2 , wherein said step B1 further comprises:
 positioning a middle plate on top of the said second female mould;   placing said midsole layer on said middle plate;   matching said first raised injection area on said underside with said one or more second downward concave cavities of said second female mould; and   infusing said second formula plastic into an upwardly-concaved third injection area for forming said rear sole.   
     
     
         4 . The method according to  claim 1 , wherein said first formula plastic is softer than said second formula plastic. 
     
     
         5 . The method according to  claim 1 , wherein said bores and said injection holes have a diameter of 2 mm to 10 mm. 
     
     
         6 . The method according to  claims 1 , wherein said midsole layer comprises leather. 
     
     
         7 . A footwear sole fabricated according to the method of  claim 1 .