WO2001003535A1 - Shoe insole, shoe insole material and method of making the same - Google Patents

Shoe insole, shoe insole material and method of making the same Download PDF

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Publication number
WO2001003535A1
WO2001003535A1 PCT/GB2000/002462 GB0002462W WO0103535A1 WO 2001003535 A1 WO2001003535 A1 WO 2001003535A1 GB 0002462 W GB0002462 W GB 0002462W WO 0103535 A1 WO0103535 A1 WO 0103535A1
Authority
WO
WIPO (PCT)
Prior art keywords
polypropylene
fibres
bonding agent
woven
web
Prior art date
Application number
PCT/GB2000/002462
Other languages
French (fr)
Other versions
WO2001003535B1 (en
Inventor
Susan Gwynneth Johnson
Original Assignee
Texon Uk Limited
Texon Materiales, S.L.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Texon Uk Limited, Texon Materiales, S.L. filed Critical Texon Uk Limited
Priority to AU55539/00A priority Critical patent/AU5553900A/en
Publication of WO2001003535A1 publication Critical patent/WO2001003535A1/en
Publication of WO2001003535B1 publication Critical patent/WO2001003535B1/en

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Classifications

    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/44—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling
    • D04H1/46—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres
    • D04H1/498—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres entanglement of layered webs
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/54—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving
    • D04H1/541—Composite fibres, e.g. sheath-core, sea-island or side-by-side; Mixed fibres
    • D04H1/5412—Composite fibres, e.g. sheath-core, sea-island or side-by-side; Mixed fibres sheath-core
    • A—HUMAN NECESSITIES
    • A43—FOOTWEAR
    • A43B—CHARACTERISTIC FEATURES OF FOOTWEAR; PARTS OF FOOTWEAR
    • A43B13/00—Soles; Sole-and-heel integral units
    • A43B13/02—Soles; Sole-and-heel integral units characterised by the material
    • A43B13/04—Plastics, rubber or vulcanised fibre
    • A—HUMAN NECESSITIES
    • A43—FOOTWEAR
    • A43B—CHARACTERISTIC FEATURES OF FOOTWEAR; PARTS OF FOOTWEAR
    • A43B13/00—Soles; Sole-and-heel integral units
    • A43B13/38—Built-in insoles joined to uppers during the manufacturing process, e.g. structural insoles; Insoles glued to shoes during the manufacturing process
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/44—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling
    • D04H1/46—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres
    • D04H1/48—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres in combination with at least one other method of consolidation
    • D04H1/485—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres in combination with at least one other method of consolidation in combination with weld-bonding
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/54—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving
    • D04H1/541—Composite fibres, e.g. sheath-core, sea-island or side-by-side; Mixed fibres
    • D04H1/5418—Mixed fibres, e.g. at least two chemically different fibres or fibre blends
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H13/00—Other non-woven fabrics

Definitions

  • This invention relates to a shoe insole, a shoe insole material and a method of making the same.
  • shoe where used herein is to be understood as denoting outer footwear generally whether ready for wear or in the course of manufacture.
  • One method of manufacturing shoes which is used extensively includes the shaping of the shoe upper by bag-lasting in the "Strobel" method.
  • Strobel method a shoe insole is attached to a marginal portion of a shoe upper by sewing, to form a bag.
  • a foot-shaped last is introduced into the thus-formed bag to impart a desired three-dimensional shape to the shoe upper.
  • a sole is then provided for the shoe either by attaching a pre-formed sole unit to the shoe upper and the shoe insole by use of a suitable adhesive, or the sole is applied by injection moulding directly onto the upper/ insole.
  • One of the various objects of the present invention is to provide an effective shoe insole.
  • Another of the various objects of the present invention is to provide an improved shoe insole material in which cutting scrap can be recycled.
  • Another of the various objects of the present invention is to provide an improved method of making a shoe insole material in which cutting scrap can be recycled.
  • the invention may be considered to provide a shoe insole comprising a non-woven bonded fibre fabric in which at least 60% by weight of the insole is polypropylene (melting point about 160°C) and the remainder is a polyolefin bonding agent of lower melting point than the polypropylene.
  • the polyolefin bonding agent is a polyethylene bonding agent (melting point about 120°C); however provided that the melting point of the bonding agent is sufficiently lower than the melting point of the polypropylene but above temperatures encountered in normal wear of the shoe and other shoe making procedures, other bonding agents may be used, for example co-polymers of olefms with other monomers, provided that the bonding agent is compatible with the polypropylene to the extent that a melt of the polypropylene and bonding agent can be extruded to form fibres in a recycling process.
  • a polyethylene bonding agent melting point about 120°C
  • other bonding agents may be used, for example co-polymers of olefms with other monomers, provided that the bonding agent is compatible with the polypropylene to the extent that a melt of the polypropylene and bonding agent can be extruded to form fibres in a recycling process.
  • the invention may be considered to provide a method of making a shoe insole according to claim 1 comprising procuring a non-woven fibre web in which at least 5 % by weight of the web is provided by bonding fibres which comprise a bonding agent of lower melting point than polypropylene and the remainder of the fibres comprise polypropylene and subjecting the web to heat whereby to melt the bonding agent thus to bond adjacent polypropylene fibres to one other and thereby form said non- woven bonded fibre fabric.
  • the bonding fibres which comprise a bonding agent may be bi-component fibres consisting of polypropylene and polyolefin bonding agent.
  • these fibres are of the core/sheath type with a core comprising polyolefin and a sheath of polyolefin bonding agent.
  • the bonding agent is polyethylene homopolymer.
  • the bonding fibres comprise between 100% and 30% by weight of the total fibres in the web, the balance being polypropylene fibres.
  • the bonding fibres may be bi- component fibres of a core/sheath, or other type or they may be fibres obtained by recycling scrap material in accordance with the invention, the scrap material having been re-melted and extruded to form fibres comprising a blend of polyolefin and bonding agent.
  • the non- woven fibre web is attached to a woven polypropylene fabric, conveniently a woven polypropylene tape scrim, by needle punching at a relatively high penetration, for example greater than 10mm penetration, before subjecting this assembly to heat.
  • the heat treatment can be achieved by through-air heat bonding, by calendering, by embossing, by a combination of these or by other means.
  • the web is treated by exposing it to hot air at a temperature greater than the softening point of the bonding agent and less than that of the polypropylene and then passing the material through the nip between calender rolls, the calender rolls being heated to a temperature greater than the softening point of the bonding agent and less than the softening point of the polypropylene.
  • the temperature to which the material is exposed should not be sufficiently high to cause excessive shrinkage of the polypropylene fibres and scrim (where present) which have a tendency to shrink when exposed to heat at a temperature below their normal melting point).
  • the non- woven fibre web is suitably made by one of the techniques well known to those skilled in the art; a preferred technique comprises forming a blend of polypropylene fibres and bonding fibres comprising polypropylene and bonding agent and forming a carded web.
  • the carded web is then, conveniently, consolidated by light needle-punching before attaching the web to a woven polypropylene tape scrim by needle punching at high penetration as discussed above.
  • non-woven fibre web comprismg polypropylene fibre and a bonding agent is made by blending polypropylene fibres and bonding fibres to form the non- woven web
  • additional bonding agent may be supplied by other means, for example impregnating a binder web with a latex comprising the binding agent (preferably polyethylene) or by dispersmg a bonding agent in powder form at a substantially uniform distribution throughout the fibre web.
  • the preferred bonding fibres are bi-component fibres, some or all of the bonding fibres may be fibres solely of bonding agent.
  • the invention may be considered to provide a material suitable for use in the manufacture of shoe insoles comprising a non-woven bonded fibre fabric in which at least 90% by weight is polypropylene, comprising a needled non- woven fibre web and a polyolefin bonding agent of lower melting point than the polypropylene.
  • the polyolefin is polyethylene.
  • a material in accordance with the invention comprises a polypropylene woven fabric to which the non-woven fibre web has been attached by needling.
  • a material in accordance with the invention is made by a method in accordance with the invention.
  • a material suitable for use in the manufacture of shoe insoles and its method of manufacture in accordance with the invention. It will be realised that this material, insoles cut therefrom and the method have been selected for description to illustrate the invention by way of example.
  • a blend consisting of 70% by weight polypropylene fibres and 30% by weight bonding fibres is carded to produce a web which is consolidated by light needle punching (or tacking) using 40 gauge needles with a needle punch density of 45 per cm 2 and 12 mm penetration.
  • the tacked web is then attached by needle punching to a woven polypropylene tape scrim at a higher needle penetration; in carrying out the illustrative method the needle punch density is a 150 per square centimetre and the penetration is 13 mm, using 40 gauge needles.
  • the polypropylene tape scrim is available from Don and Low with the reference PP1590MSN and has a weight of about 93 grams per square metre.
  • the polypropylene fibres were 6.7 decitex fibres of 60 mm average length supplied by J & J Haigh under the trade name LEOLENE.
  • the bonding fibres were core/sheath bi-component fibres, believed to consist of 50% by weight polypropylene core and 50% by weight polyethylene homopolymer bonding agent sheath supplied by FIBERVERSIONS under the name ES-C PHIL.
  • the intermediate material produced by needling the web onto the polypropylene tape scrim had a weight of 386 grams per square metre and a gauge of 2.5 mm.
  • the thus formed intermediate material was then passed through a heated oven having an air temperature of 140°C and passed through the nip between a pair of calender rolls the rolls also being heated to a temperature of 140°C.
  • the nip gap was set at 1.5 mm and the speed of travel of the material through the oven and the calender rolls was 0.62 m/minute.
  • the material was cooled sufficiently and wound up into a roll.
  • the shoe insole material thus produced had a weight of about 396g per square metre and a gauge of about 1.71 mm.
  • the material had a stitch tear strength measured by the SATRA physical test method PC.33/STD.176M entitled "Strength at Right Angles to Stitch Perforations in Upper Materials” modified to use 4 needles over a one cm length (the end needles being 1 cm apart) instead of the 17 needles per inch of that test (Gabor Needle Pull Out test) of about 12 Kg/cm in the axial direction and about 13.3 in the transverse direction.
  • the tensile strength (kg/2.54 cm) is about 42 in the lengthwise direction and 72 in the transverse direction.
  • Load at 5 mm extension (kg) is about 35 (lengthwise) and about 62 (transverse) and at 10 mm extension about 16.5 (lengthwise) and 27 (transverse).
  • Shoe insoles embodying the invention were cut from the illustrative material in a known manner using a cutting press and found to be suitable for use in making shoes by the Strobel process.
  • the cutting scrap formed when the insoles are cut from the illustrative shoe material is melted and re-extruded to form fibres comprising mainly polypropylene but also a percentage of bonding agent.
  • These recycled fibres are used, in carrying out a method in accordance with the invention generally similar to the illustrative method, to replace some of the fibres in the non- woven fibre web. Conveniently, they may replace a proportion of the polypropylene fibres and a suitable proportion of the bonding fibres.
  • the fibres may comprise 100% bonding fibres (that is fibres comprising both polypropylene and polyethylene).

Abstract

A shoe insole suitable for use in making shoes by the Strobel method comprises a non-woven bonded fibre fabric in which at least 60 % by weight of the insole is polypropylene and the remainder is a polyolefin bonding agent of lower melting point than the polypropylene. A method of making this insole comprises procuring a non-woven fibre web in which at least 5 % by weight of the web is provided by fibres which comprise a bonding agent of lower melting point than polypropylene and the remainder of the fibres comprise polypropylene attaching the web to a polypropylene scrim by needling and subjecting the web the heat whereby to melt the bonding agent thus to bond adjacent polypropylene fibres to one other and thereby form said non-woven bonded fibre fabric.

Description

SHOE INSOLE, SHOE INSOLE MATERIAL AND METHOD OF MAKING THE SAME
This invention relates to a shoe insole, a shoe insole material and a method of making the same.
The term "shoe" where used herein is to be understood as denoting outer footwear generally whether ready for wear or in the course of manufacture.
It is well known to make shoe insoles comprising non-woven needled fibre fabric; for example, such materials are supplied by the applicant company under their registered trademark "Texon" .
One method of manufacturing shoes which is used extensively includes the shaping of the shoe upper by bag-lasting in the "Strobel" method. In the Strobel method a shoe insole is attached to a marginal portion of a shoe upper by sewing, to form a bag. A foot-shaped last is introduced into the thus-formed bag to impart a desired three-dimensional shape to the shoe upper. A sole is then provided for the shoe either by attaching a pre-formed sole unit to the shoe upper and the shoe insole by use of a suitable adhesive, or the sole is applied by injection moulding directly onto the upper/ insole. In the lasting process, as the last is forced into the bag, the shoe upper and the insole, and also the stitches securing them together are subjected to considerable force and it is important to ensure that the shoe insole has sufficient tensile strength and stitch-holding capability. In modern society it is also desirable to make use of any scrap material. Previously proposed Strobel insole products have used consumer waste - for example insole materials manufactured by the applicant company have contained polyester fibre produced from recycled plastics bottles. Insole materials produced from non- woven fibres are typically manufactured by forming a sheet of the material by standard non-woven manufacturing techniques and cutting the insoles from the sheet using suitable cutting knives in a well known fashion. However, such a technique leaves a proportion of scrap which in the past has not been able to be re-used.
One of the various objects of the present invention is to provide an effective shoe insole.
Another of the various objects of the present invention is to provide an improved shoe insole material in which cutting scrap can be recycled.
Another of the various objects of the present invention is to provide an improved method of making a shoe insole material in which cutting scrap can be recycled.
In one aspect the invention may be considered to provide a shoe insole comprising a non-woven bonded fibre fabric in which at least 60% by weight of the insole is polypropylene (melting point about 160°C) and the remainder is a polyolefin bonding agent of lower melting point than the polypropylene. Preferably the polyolefin bonding agent is a polyethylene bonding agent (melting point about 120°C); however provided that the melting point of the bonding agent is sufficiently lower than the melting point of the polypropylene but above temperatures encountered in normal wear of the shoe and other shoe making procedures, other bonding agents may be used, for example co-polymers of olefms with other monomers, provided that the bonding agent is compatible with the polypropylene to the extent that a melt of the polypropylene and bonding agent can be extruded to form fibres in a recycling process.
In another aspect the invention may be considered to provide a method of making a shoe insole according to claim 1 comprising procuring a non-woven fibre web in which at least 5 % by weight of the web is provided by bonding fibres which comprise a bonding agent of lower melting point than polypropylene and the remainder of the fibres comprise polypropylene and subjecting the web to heat whereby to melt the bonding agent thus to bond adjacent polypropylene fibres to one other and thereby form said non- woven bonded fibre fabric.
In carrying out a method in accordance with the invention the bonding fibres which comprise a bonding agent may be bi-component fibres consisting of polypropylene and polyolefin bonding agent. Suitably, these fibres are of the core/sheath type with a core comprising polyolefin and a sheath of polyolefin bonding agent. Suitably, the bonding agent is polyethylene homopolymer.
In a preferred method in accordance with the invention the bonding fibres comprise between 100% and 30% by weight of the total fibres in the web, the balance being polypropylene fibres. In carrying out a method in accordance with the invention the bonding fibres may be bi- component fibres of a core/sheath, or other type or they may be fibres obtained by recycling scrap material in accordance with the invention, the scrap material having been re-melted and extruded to form fibres comprising a blend of polyolefin and bonding agent.
In a preferred method in accordance with the invention the non- woven fibre web is attached to a woven polypropylene fabric, conveniently a woven polypropylene tape scrim, by needle punching at a relatively high penetration, for example greater than 10mm penetration, before subjecting this assembly to heat.
In carrying out a method in accordance with the invention the heat treatment can be achieved by through-air heat bonding, by calendering, by embossing, by a combination of these or by other means. In a preferred method the web is treated by exposing it to hot air at a temperature greater than the softening point of the bonding agent and less than that of the polypropylene and then passing the material through the nip between calender rolls, the calender rolls being heated to a temperature greater than the softening point of the bonding agent and less than the softening point of the polypropylene. The temperature to which the material is exposed should not be sufficiently high to cause excessive shrinkage of the polypropylene fibres and scrim (where present) which have a tendency to shrink when exposed to heat at a temperature below their normal melting point).
In carrying out a method in accordance with the invention the non- woven fibre web is suitably made by one of the techniques well known to those skilled in the art; a preferred technique comprises forming a blend of polypropylene fibres and bonding fibres comprising polypropylene and bonding agent and forming a carded web. The carded web is then, conveniently, consolidated by light needle-punching before attaching the web to a woven polypropylene tape scrim by needle punching at high penetration as discussed above.
Whereas, in carrying out preferred methods in accordance with the invention the non-woven fibre web comprismg polypropylene fibre and a bonding agent is made by blending polypropylene fibres and bonding fibres to form the non- woven web, additional bonding agent may be supplied by other means, for example impregnating a binder web with a latex comprising the binding agent (preferably polyethylene) or by dispersmg a bonding agent in powder form at a substantially uniform distribution throughout the fibre web. Although the preferred bonding fibres are bi-component fibres, some or all of the bonding fibres may be fibres solely of bonding agent.
In another aspect the invention may be considered to provide a material suitable for use in the manufacture of shoe insoles comprising a non-woven bonded fibre fabric in which at least 90% by weight is polypropylene, comprising a needled non- woven fibre web and a polyolefin bonding agent of lower melting point than the polypropylene. Preferably in a material in accordance with the invention the polyolefin is polyethylene.
Preferably a material in accordance with the invention comprises a polypropylene woven fabric to which the non-woven fibre web has been attached by needling.
Suitably, a material in accordance with the invention is made by a method in accordance with the invention. There now follows a detailed description of one material suitable for use in the manufacture of shoe insoles, and its method of manufacture in accordance with the invention. It will be realised that this material, insoles cut therefrom and the method have been selected for description to illustrate the invention by way of example.
In carrying out the illustrative method, a blend consisting of 70% by weight polypropylene fibres and 30% by weight bonding fibres is carded to produce a web which is consolidated by light needle punching (or tacking) using 40 gauge needles with a needle punch density of 45 per cm2 and 12 mm penetration. The tacked web is then attached by needle punching to a woven polypropylene tape scrim at a higher needle penetration; in carrying out the illustrative method the needle punch density is a 150 per square centimetre and the penetration is 13 mm, using 40 gauge needles. The polypropylene tape scrim is available from Don and Low with the reference PP1590MSN and has a weight of about 93 grams per square metre.
The polypropylene fibres were 6.7 decitex fibres of 60 mm average length supplied by J & J Haigh under the trade name LEOLENE. The bonding fibres were core/sheath bi-component fibres, believed to consist of 50% by weight polypropylene core and 50% by weight polyethylene homopolymer bonding agent sheath supplied by FIBERVERSIONS under the name ES-C PHIL.
The intermediate material produced by needling the web onto the polypropylene tape scrim had a weight of 386 grams per square metre and a gauge of 2.5 mm. The thus formed intermediate material was then passed through a heated oven having an air temperature of 140°C and passed through the nip between a pair of calender rolls the rolls also being heated to a temperature of 140°C. The nip gap was set at 1.5 mm and the speed of travel of the material through the oven and the calender rolls was 0.62 m/minute. The material was cooled sufficiently and wound up into a roll. The shoe insole material thus produced had a weight of about 396g per square metre and a gauge of about 1.71 mm. The material had a stitch tear strength measured by the SATRA physical test method PC.33/STD.176M entitled "Strength at Right Angles to Stitch Perforations in Upper Materials" modified to use 4 needles over a one cm length (the end needles being 1 cm apart) instead of the 17 needles per inch of that test (Gabor Needle Pull Out test) of about 12 Kg/cm in the axial direction and about 13.3 in the transverse direction. The tensile strength (kg/2.54 cm) is about 42 in the lengthwise direction and 72 in the transverse direction. Load at 5 mm extension (kg) is about 35 (lengthwise) and about 62 (transverse) and at 10 mm extension about 16.5 (lengthwise) and 27 (transverse). Strain (%) at maximum load is about 8.5 (lengthwise and 7.9 (transverse). Tear strength (kg) is about 22.3 (lengthwise) and about 22 (transverse). These properties are comparable with those of materials currently used in the manufacture of Strobel insoles and sufficient for the illustrative material to be suitable for use in the manufacture of Strobel insoles.
Shoe insoles embodying the invention were cut from the illustrative material in a known manner using a cutting press and found to be suitable for use in making shoes by the Strobel process.
The cutting scrap formed when the insoles are cut from the illustrative shoe material is melted and re-extruded to form fibres comprising mainly polypropylene but also a percentage of bonding agent. These recycled fibres are used, in carrying out a method in accordance with the invention generally similar to the illustrative method, to replace some of the fibres in the non- woven fibre web. Conveniently, they may replace a proportion of the polypropylene fibres and a suitable proportion of the bonding fibres. As noted above, the fibres may comprise 100% bonding fibres (that is fibres comprising both polypropylene and polyethylene).

Claims

1. A shoe insole comprising a non-woven bonded fibre fabric in which at least 60% by weight of the insole is polypropylene and the remainder is a bonding agent of lower melting point than the polypropylene.
2. An insole according to claim 1 wherein the bonding agent is a polyolefin.
3. An insole according to claim 2 wherein the bonding agent is polyethylene.
4. A method of making a shoe insole according to any of claims 1 to 3 comprising procuring a non-woven fibre web in which at least 5 % by weight of the web is provided by bonding fibres which comprise a bonding agent of lower melting point than polypropylene and the remainder of the fibres comprise polypropylene, attaching the web to a woven fabric comprising polypropylene by needle punching, and subjecting the web attached to the fabric to heat whereby to melt the bonding agent thus to bond adjacent polypropylene fibres to one other and thereby form said non- woven bonded fibre fabric.
5. A method according to claim 4 wherein the fibres which comprise a bonding agent are bi-component fibres consisting of polypropylene and polyolefin bonding agent.
6. A method according to claim 5 wherein the fibres are of the core/sheath type with a core comprising polypropylene and a sheath of polyolefin bonding agent.
7. A method according to any one of claims 4 to 6 wherein the bonding fibres comprise between 100% and 30% by weight of the total fibres in the web, the balance being polypropylene fibres.
8. A method according to any one of claims 4 to 7 wherein the bonding agent is polyethylene.
9. A method accordmg to any one of claims 4 to 8 in which the woven polypropylene fabric is a woven polypropylene tape scrim.
10. A method according to any one of claims 4 to 9 wherein the web is heated by exposing it to hot air at a temperature greater than the softening point of the bonding agent and less than that of the polypropylene.
11. A method according to any one of claims 4 to 10 wherein the material is passed through the nip between calender rolls, the rolls being heated to a temperature greater than the softening point of the bonding agent and less than the softening point of the polypropylene.
12. A method according to any one of claims 4 to 11 wherein some, at least, of the bonding fibres are formed from re-cycled scrap material according to any one of claims 14 to 18.
13. A method of making a shoe insole substantially as hereinbefore described.
14. A material suitable for use in the manufacture of shoe insoles comprising a non- woven bonded fibre fabric in which at least 60% by weight of the material is polypropylene comprising a non-woven fibre web attached to a woven polypropylene fabric by needle punching and a bonding agent of lower melting point than the polypropylene.
15. A material according to claim 14 wherein the bonding agent is a polyolefin.
16. A material according to claim 15 wherein the polyolefin is polyethylene.
17. A material according to any one of claims 14 and 16 wherein the woven polypropylene fabric is a woven polypropylene tape scrim.
18. A material according to any one of claims 14 to 17 made by a method according to any one of claims 4 to 18.
PCT/GB2000/002462 1999-07-08 2000-06-27 Shoe insole, shoe insole material and method of making the same WO2001003535A1 (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
AU55539/00A AU5553900A (en) 1999-07-08 2000-06-27 Shoe insole, shoe insole material and method of making the same

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
GB9915879.2 1999-07-08
GBGB9915879.2A GB9915879D0 (en) 1999-07-08 1999-07-08 Shoe insole shoe insole material and method of making the same

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WO2001003535A1 true WO2001003535A1 (en) 2001-01-18
WO2001003535B1 WO2001003535B1 (en) 2001-03-15

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AU (1) AU5553900A (en)
GB (1) GB9915879D0 (en)
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Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB1600745A (en) * 1978-05-15 1981-10-21 British United Shoe Machinery Sheet material
US4594283A (en) * 1984-04-05 1986-06-10 Kuraray Co., Ltd. Shoemaking material and production thereof
US4603075A (en) * 1984-04-10 1986-07-29 Texon, Inc. Insole composites and processes for manufacturing insole composites and footwear materials
US5607798A (en) * 1994-08-25 1997-03-04 Kimberly-Clark Corporation Soft and strong thermoplastic polymer and nonwoven fabric laminates
US5824613A (en) * 1994-08-09 1998-10-20 Hercules Incorporated Laminates comprising textile structures comprising linear low density polyethylene fibers

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB1600745A (en) * 1978-05-15 1981-10-21 British United Shoe Machinery Sheet material
US4594283A (en) * 1984-04-05 1986-06-10 Kuraray Co., Ltd. Shoemaking material and production thereof
US4603075A (en) * 1984-04-10 1986-07-29 Texon, Inc. Insole composites and processes for manufacturing insole composites and footwear materials
US5824613A (en) * 1994-08-09 1998-10-20 Hercules Incorporated Laminates comprising textile structures comprising linear low density polyethylene fibers
US5607798A (en) * 1994-08-25 1997-03-04 Kimberly-Clark Corporation Soft and strong thermoplastic polymer and nonwoven fabric laminates

Also Published As

Publication number Publication date
AU5553900A (en) 2001-01-30
WO2001003535B1 (en) 2001-03-15
TW438577B (en) 2001-06-07
GB9915879D0 (en) 1999-09-08

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