(19) United States
`(12) Patent Application Publication (10) Pub. No.: US 2004/0261297 A1
`(43) Pub. Date:
`Dec. 30, 2004
`Park
`
`US 2004O261297A1
`
`(54) ETHYLENE VINYLACETATE BASED FILM
`FOR CROSSLINKED BLOWN EVA FOAM,
`SHOE COMPONENTS USING THE SAME,
`AND METHOD FOR MANUFACTURING
`THEREOF
`(76) Inventor: Hyung Jun Park, Haeundae (KR)
`Correspondence Address:
`SUGHRUE MION, PLLC
`2100 PENNSYLVANIAAVENUE, N.W.
`SUTE 800
`WASHINGTON, DC 20037 (US)
`(21) Appl. No.:
`10/602,893
`(22) Filed:
`Jun. 25, 2003
`Publication Classification
`
`(51) Int. Cl. .............................. A43B 13/38; CO8J 9/26;
`
`(52) U.S. Cl. ............. 36/87; 521/92; 264/46.4; 264/321;
`264/324; 36/43
`
`(57)
`
`ABSTRACT
`
`A method for manufacturing Shoe components using EVA
`copolymer of film Shape having a thickness of 0.01 to 2 mm,
`preferably 0.1 to 1.0 mm and a Surface roughness variations
`which cannot be easily discriminated through touch or Sight,
`and a shoe component manufactured by the method are
`provided. The method overcomes the drawbacks caused
`during the process of manufacturing a shoe component with
`different mechanical physical properties or colors. The
`method allows for ease of manufacture of a shoe component
`with two or more types of colors or physical properties,
`through a single foam molding process using a film with less
`variation and ease of processing, to thereby Simplify manu
`facturing procedures and reduce manufacturing costs. In
`addition, a high quality shoe component with no additional
`Seam-line is obtained.
`
`MacNeil Exhibit 2156
`Yita v. MacNeil IP, IPR2020-01139, Page 1
`
`

`

`Patent Application Publication Dec. 30, 2004 Sheet 1 of 24
`FIG.1
`
`US 2004/0261297 A1
`
`Compression Molding Process
`
`injection Molding Process
`
`SA1
`
`sheet/pellet type material
`Select-measure
`
`palet type materia
`
`SB12
`
`into mold
`mold cooling/releasing
`at low temperature
`
`mold shut
`
`
`
`
`
`
`
`SB1
`
`SC
`
`SD1
`
`SE1
`
`SA2
`
`SB2
`
`SC2
`
`SD2
`
`SE2
`
`shoe component
`
`shoe component
`
`Heat/Cold Mold Compression
`Re-molding Preocess
`
`Cold mold Compression
`Re-molding Process
`
`SF1
`
`insert intermediate form
`into mold
`
`insert intermediate form
`into mold after external
`heating
`
`SF2
`
`SG1
`
`mold shut-
`compressing/heating
`
`mold shut-
`compression/heating
`
`SG2
`
`SH1
`
`SH2
`
`final form
`shoe component
`
`final form
`ahoe copoment
`
`MacNeil Exhibit 2156
`Yita v. MacNeil IP, IPR2020-01139, Page 2
`
`

`

`Patent Application Publication Dec. 30, 2004 Sheet 2 of 24
`FIG.2
`
`US 2004/0261297 A1
`
`S1A
`
`S2A
`
`S3A
`
`S4A
`
`S3AB
`
`compression/
`foam moding
`
`compression/
`foam moding
`N asSembing 1.
`Compression
`compression
`
`S5A
`
`patial form of
`
`Compression
`
`S4AB
`patia form of
`
`in on
`
`S1B
`
`S2B
`
`S3B
`
`S4B
`
`S5B
`
`MacNeil Exhibit 2156
`Yita v. MacNeil IP, IPR2020-01139, Page 3
`
`

`

`Patent Application Publication Dec. 30, 2004 Sheet 3 of 24
`FIG3
`
`US 2004/0261297 A1
`
`
`
`
`
`Sall
`
`Sb.1
`
`SC1
`
`SC1
`
`Se1
`
`
`
`
`
`
`
`
`
`
`
`
`
`Compression
`re-molding
`
`
`
`FIG.4
`
`film/sheet/pellet type material A
`With being vacuum/copression
`molding
`
`Sa2
`
`
`
`preform A + film type material B
`stacking/combining
`
`Sb2
`
`
`
`
`
`
`
`eating/compressing
`
`
`
`foafin ?nolding
`
`Corn pression
`re-molding
`
`
`
`final form
`
`SC2
`
`SC2
`
`Se2
`
`MacNeil Exhibit 2156
`Yita v. MacNeil IP, IPR2020-01139, Page 4
`
`

`

`Patent Application Publication Dec. 30, 2004 Sheet 4 of 24
`
`US 2004/0261297 A1
`
`FIG.5
`
`FIG.6b
`
`
`
`MacNeil Exhibit 2156
`Yita v. MacNeil IP, IPR2020-01139, Page 5
`
`

`

`Patent Application Publication Dec. 30, 2004 Sheet 5 of 24
`
`US 2004/0261297 A1
`
`FIG.6C
`
`colored material
`
`mold
`
`Soft Cutting
`member
`
`\
`colored part of concave/
`convex in mold
`
`e OWe
`
`Sr.
`
`MacNeil Exhibit 2156
`Yita v. MacNeil IP, IPR2020-01139, Page 6
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`

`

`Patent Application Publication Dec. 30, 2004 Sheet 6 of 24
`
`US 2004/0261297 A1
`
`F.G. 6d
`
`Colored material
`
`
`
`soft Cutting
`
`colore-ground
`material
`
`FIG.6e
`
`part the colored
`
`inserting ground
`material
`
`heating/foaming
`
`MacNeil Exhibit 2156
`Yita v. MacNeil IP, IPR2020-01139, Page 7
`
`

`

`Patent Application Publication Dec. 30, 2004 Sheet 7 of 24
`
`US 2004/0261297 A1
`
`FIG.7
`
`W3
`
`R1
`
`B2
`
`R1
`
`
`
`R2
`
`SS
`
`anaeataea.
`
`
`
`W4
`
`W2
`
`
`
`
`
`
`
`MacNeil Exhibit 2156
`Yita v. MacNeil IP, IPR2020-01139, Page 8
`
`

`

`tion lica
`Pa
`t A
`pp
`ten
`
`
`
`icatio
`blic
`ion
`Pl
`
`04
`De
`C. 30, 20
`
`She
`8 0
`4 f 2
`et
`
`
`
`20 US
`
`1. A 7 29
`04/
`61
`
`02
`
`FIG.9
`
`G.10a
`F
`
`
`
`
`
`
`
`
`
`
`
`r RS s 88 s s 88. s O
`SRS s 88 88 C R s $ s $ 8. 8. s 8
`388 s s 3. s 68 88 8.
`C 8. $ 3.
`383 8.
`88 8. 8 8.
`
`
`
`MacNeil Exhibit 2156
`Yita v. MacNeil IP, IPR2020-01139, Page 9
`
`

`

`Patent Application Publication Dec. 30, 2004 Sheet 9 of 24
`
`US 2004/0261297 A1
`
`FIG.1Ob
`
`
`
`FIG 1 OC
`
`MOON-SUN
`
`MacNeil Exhibit 2156
`Yita v. MacNeil IP, IPR2020-01139, Page 10
`
`

`

`Patent Application Publication Dec. 30, 2004 Sheet 10 of 24
`FIG 11 a
`
`US 2004/0261297 A1
`
`film type material Cut
`acoording tp Color
`
`4.
`
`FIG 11 b
`
`film type material Cut
`according to color/shape
`
`
`
`MacNeil Exhibit 2156
`Yita v. MacNeil IP, IPR2020-01139, Page 11
`
`

`

`Patent Application Publication Dec. 30, 2004 Sheet 11 of 24
`
`US 2004/0261297 A1
`
`FIG.12
`
`
`
`insert film type material
`Combined COOrant into mold
`
`FIG.13a
`
`p
`
`insert Structure
`
`MacNeil Exhibit 2156
`Yita v. MacNeil IP, IPR2020-01139, Page 12
`
`

`

`Patent Application Publication Dec. 30, 2004 Sheet 12 of 24
`
`US 2004/0261297 A1
`
`FIG.13b
`
`insert film material Combined Structure
`
`N N
`
`F.G. 13C
`
`ca,
`
`S.
`
`remove Streucture after foaming
`
`MacNeil Exhibit 2156
`Yita v. MacNeil IP, IPR2020-01139, Page 13
`
`

`

`Patent Application Publication Dec. 30, 2004 Sheet 13 of 24
`
`US 2004/0261297 A1
`
`FIG.13C
`
`
`
`
`
`FG, 14a
`
`MacNeil Exhibit 2156
`Yita v. MacNeil IP, IPR2020-01139, Page 14
`
`

`

`Patent Application Publication Dec. 30, 2004 Sheet 14 of 24
`
`US 2004/0261297 A1
`
`F.G. 14b
`
`film type material Cut
`according to physical property Or Shape
`
`2
`s
`
`FIG.14C
`
`
`
`Combined Stacked material
`
`MacNeil Exhibit 2156
`Yita v. MacNeil IP, IPR2020-01139, Page 15
`
`

`

`Patent Application Publication Dec. 30, 2004 Sheet 15 of 24
`
`US 2004/0261297 A1
`
`FG. 15a
`
`AP
`
`RP
`
`FIG. 15b.
`
`film type material according to
`physical property Or shape
`
`ga
`
`MacNeil Exhibit 2156
`Yita v. MacNeil IP, IPR2020-01139, Page 16
`
`

`

`Patent Application Publication Dec. 30, 2004 Sheet 16 of 24
`FIG.15C
`
`US 2004/0261297 A1
`
`Combined Stacked material
`
`FG 16a
`
`
`
`MacNeil Exhibit 2156
`Yita v. MacNeil IP, IPR2020-01139, Page 17
`
`

`

`Patent Application Publication Dec. 30, 2004 Sheet 17 of 24
`
`US 2004/0261297 A1
`
`FG. 16b
`
`film type material Cut acCOrding to
`physical property Or Shape
`
`23
`
`FG.16C
`
`Combined stacked material
`
`MacNeil Exhibit 2156
`Yita v. MacNeil IP, IPR2020-01139, Page 18
`
`

`

`Patent Application Publication Dec. 30, 2004 Sheet 18 of 24
`
`US 2004/0261297 A1
`
`FIG 17a
`
`AP
`
`RP
`
`HAP
`
`FIG 17b
`
`2.
`
`HAP
`
`MacNeil Exhibit 2156
`Yita v. MacNeil IP, IPR2020-01139, Page 19
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`

`

`Patent Application Publication Dec. 30, 2004 Sheet 19 of 24
`
`US 2004/0261297 A1
`
`FIG. 18 a
`
`
`
`EVA material perforated
`With a desired patten
`
`s
`Colored EVA film
`patten after molding for forming patten
`
`MacNeil Exhibit 2156
`Yita v. MacNeil IP, IPR2020-01139, Page 20
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`

`

`Patent Application Publication Dec. 30, 2004 Sheet 20 of 24
`
`US 2004/0261297 A1
`
`FG 18b
`
`roll milling
`
`
`
`Shaping by Vacuum Suction
`or up-down press molding
`
`insert mold after
`perforate patten
`
`MacNeil Exhibit 2156
`Yita v. MacNeil IP, IPR2020-01139, Page 21
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`

`

`Patent Application Publication Dec. 30, 2004 Sheet 21 of 24
`
`US 2004/0261297 A1
`
`Cushion with thickness 1.0mm cylinder Shape
`
`
`
`0.7mm of foaming shape
`
`it is
`
`thickness 0.7mm of foaming mold Shape
`
`MacNeil Exhibit 2156
`Yita v. MacNeil IP, IPR2020-01139, Page 22
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`

`

`Patent Application Publication Dec. 30, 2004 Sheet 22 of 24
`
`US 2004/0261297 A1
`
`F.G. 19b
`
`perforated film type material
`With Cushion Site
`
`insert Combined Stacked materal
`into mold
`
`t
`
`heating
`
`s S s s
`
`
`
`stacking
`Cylinder Shape
`
`
`
`
`
`final molding
`
`0.4mm or 0.7mm
`
`MacNeil Exhibit 2156
`Yita v. MacNeil IP, IPR2020-01139, Page 23
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`

`

`Patent Application Publication Dec. 30, 2004 Sheet 23 of 24
`
`US 2004/0261297 A1
`
`FIG. 19C
`
`
`
`
`
`perforated
`part
`
`perforated part
`
`MacNeil Exhibit 2156
`Yita v. MacNeil IP, IPR2020-01139, Page 24
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`

`

`Patent Application Publication Dec. 30, 2004 Sheet 24 of 24
`
`US 2004/0261297 A1
`
`FIG.19d
`
`3.5mm part
`
`7.0mm part
`
`
`
`2.0mm part
`
`0.5mm part
`
`MacNeil Exhibit 2156
`Yita v. MacNeil IP, IPR2020-01139, Page 25
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`

`

`US 2004/0261297 A1
`
`Dec. 30, 2004
`
`ETHYLENE WINYLACETATE BASED FILM FOR
`CROSSLINKED BLOWN EVA FOAM, SHOE
`COMPONENTS USING THE SAME, AND METHOD
`FOR MANUFACTURING THEREOF
`
`BACKGROUND OF THE INVENTION
`0001) 1. Field of the Invention
`0002 The present invention relates to an ethylene vinyl
`acetate (EVA) based compound film having a thickness of
`0.01 to 2 mm, preferably, 0.1 to 1.0 mm, rather than a
`conventional form in Sheet shape having a thickness of 2.5
`to 3.0 mm or a palletized shape having a thickness of 3.0 to
`4.0 mm and a height of 4 to 5.0 mm. The present invention
`also relates to shoe components including an insole, mid
`Sole, unitsole of midsole and outsole, an upper, and upper
`components. Shoe components produced through the manu
`facturing method using the film of the present invention
`have a wide variety of colors and outer appearances. In
`addition, it is possible to design and produce shoe compo
`nents with their own colors and mechanical properties
`including density, hardness, abrasion, resiliency, compres
`sion set and stiffness/flexibility in consideration of function
`of each shoe component.
`0003 2. Description of the Related Art
`0004.
`In a conventional method, shoe components
`including an upper component, midsole, outsole, insole and
`a unitsole of midsole and outsole are produced by using a
`foamed article or articles obtained from the processes per
`formed after completion of the foaming process, wherein the
`article is made of an EVA copolymer having a shape of a
`hard plate sheet, pellet or a chip having a thickness of 2.5
`mm or higher, and a Surface non-uniformity which can be
`easily discriminated by touch or Sight. Shoe components are
`produced by a compression molding or injection molding
`process (primary process) and a compression re-molding
`process (Secondary process). The above-described conven
`tional method will be explained in detail with reference to
`FIG. 1, as follows. In FIG. 1, S stands for step.
`0005 Primary Process: Foam Molding Process
`0006 (1) Compression Molding Process
`0007 A1) A material is selected, measured and weighed
`in consideration of the relations of the Volume, physical
`property and expansion ratio or the mold cavity related to
`them. The pieces of the material obtained by cutting a sheet
`Stock or weighing palletized EVA copolymer compound.
`(step SA1).
`0008 B1) The material is put into the cavity of an
`open/shut type compression molding mold which is propor
`tionally miniatured shape of the Shoe component by certain
`percentages in consideration of the relations between the
`volume of the crosslinked blown EVA form and expansion
`ratio of the compound. (step SB1).
`0009. The molding mold is pressed and heated for a
`predetermined time period (step SC1).
`0010 The molding die is released and rapidly open (step
`SD1), when it is possible to form a cell structure from the
`gas including N, CO, CO, NH generated during the
`process of decomposition of the foaming agent during the
`
`Step SC1, and the material in the molding die has a low
`Viscosity permitting a foaming process.
`0011. The volume of the crosslinked blown EVA form
`may differ in accordance with the expansion ratio and the
`shape of the internal part of the molding mold, that is,
`volume of the cavity, design of mix proportion of EVA
`compound and purposes of the blown EVA form. The
`volume of the form is 120 to 140% of the final shoe
`component when the form is used in a Secondary compres
`Sion molding process. The Volume of the form is determined
`by the shape of the cavity of the molding mold which is
`miniatured in consideration of the volume of the form
`according to the formability required for the Secondary
`compression re-molding process and changes of physical
`properties occurring before and after the Secondary com
`pression re-molding process, and the expansion ratio of the
`material.
`0012. In cases where the primary compression molded
`body is shaped into an EVA Sponge plate, cut and Surface/
`shape grinded, bonded to the other material and used as a
`final shoe component, or in cases where the primary com
`pression molded body is used as a final shoe component
`without performing a Secondary compression re-molding
`process, the form has a Size and physical properties which
`are not stable.
`0013 E1) Therefore, the form is cooled for a predeter
`mined time period in the space with no pressure (step SE1).
`This step is for stabilization of the structure and shape of the
`individual cell in the form, and Volume and physical prop
`erties of the form in consideration of the design reference
`Size of the component or product.
`0014. The form obtained through the step SE1 is used as
`a shoe component after performing the processes including
`a trimming, cutting and bonding, or used as an intermediate
`form for a compression re-molding process, a Secondary
`process. The intermediate form has a density 60 to 70% or
`a volume 120 to 140% of the final form, in consideration of
`the compression re-molding process.
`0015. In steps SC1 and SD1, a compression molding
`machine has a molding part which is Selectively maintained
`at a vacuum State So as to achieve improved flowability and
`formability of the material. This is to overcome drawbacks
`of the conventional compression molding method, including
`a non-uniformity of flow and low formability of the material.
`0016 (2) Injection Molding Process
`0017. An injection molding process mainly uses a pellet
`type EVA copolymer, as described with reference to FIG. 1.
`0018 A2) Apellet type material is measured and weighed
`in consideration of the volume of the mold cavity and
`expansion ratio of the palletized compound. (Step SA2).
`0019 B2) The material is molten in an injecting machine
`and injected into the cavity of the injection molding mold
`along the channel of the molding mold (step SB2).
`0020. The Subsequent processes include steps SC2 and
`SE3, explained below. However, in some cases, the material
`is molten in the injecting machine, injected into the cavity of
`the warm injection mold that being heated at a very lower
`temperature, cooled So as to avoid premature reaction of the
`blowing agent dispersed in the injected compound. and
`
`MacNeil Exhibit 2156
`Yita v. MacNeil IP, IPR2020-01139, Page 26
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`US 2004/0261297 A1
`
`Dec. 30, 2004
`
`released (step SB12). Subsequently, steps SB1 to SE1 of the
`compression molding process can be performed for the
`resultant material.
`0021 C2) The molding mold is pressed and heated for a
`predetermined time period (step SC2).
`0022 D2) The molding mold is released and rapidly open
`(step SD2).
`0023 E2) The form is cooled for a predetermined time
`period in the Space with no pressure (step SE2).
`0024 Detailed descriptions on steps SD2 and SE2 are
`identical with the description on steps SD1 and SE1 of the
`compression molding process.
`0025 (1) Heat/Cold Mold Compression Re-Molding Pro
`
`CCSS
`0026. This process is for producing a final form from the
`intermediate form obtained from the compression or injec
`tion molding process described above.
`0027 F1) The intermediate form which has volume 120
`to 140% of the final form is compulsorily put into the cavity
`of the compression molding mold (step SF1).
`0028. The cavity of the molding mold is designed to
`correspond to the Size and shape of the final form, and the
`molding mold is generally made of an aluminum material
`having a high thermal conductivity.
`0029 G1) The molding mold is shut and applied with a
`predetermined temperature and pressure (step SG1).
`0030 H1) The molding mold is cooled and released (step
`SH1), thereby obtaining a final form.
`0031. The heat/cold mold compression re-molding pro
`cess including steps SF1 to SH1 is for a component with a
`large thickness, like a midsole, outsole, unitsole and an
`insole. The heat/cold mold compression re-molding proceSS
`is widely known as a representative technique of the Sec
`ondary re-molding proceSS performed in association with the
`compression molding process and the injection molding
`proceSS.
`0.032 The upper component or insole which can be
`formed of a form having a Small thickneSS and low accuracy
`of molding, is produced through a cold mold compression
`re-molding process.
`0033) (2) Cold Mold Compression Re-Molding Process
`0034) F2) The intermediate form is heated by an external
`heating Source, and loaded into the cavity of an open type
`cold molding die (step SF2).
`0035 G2) The material is cold shaped by applying a
`predetermined pressure through the core of the upper part of
`the molding mold. (step SG2)
`0036 H2) The pressure is released and the cold molded
`form is released from the molding mold So as to be used as
`a final form (step SH2).
`0037. The EVA crosslinked blown EVA form produced
`through the first and Second processes, by using a hard sheet
`or pellet, has drawbacks as follows.
`0.038
`First, it is conventional knowledge obtained
`through bio-mechanical Studies and experiments, that shoe
`
`Sole components for each part of the wearer's foot need
`differentiated functions. For example, it is desirable to form
`the lateral side of the rear foot of the wearer from the
`material having a low hardneSS or hard material for Sup
`porting an arch part, and the fore foot part from the material
`having a cushioning capability.
`0039. In a conventional method, each part of EVA forms
`compose a Sole unit of Shoe having different physical
`properties is independently formed and bonded with each
`other after formation so as to satisfy the above-described
`need for differentiated functions.
`0040. As shown in FIG. 2, forms A and B are produced
`through steps S1A to S5A and S1B to S5B, and assembled
`and bonded in a step S6AB. Alternatively, foam molded
`forms obtained from the compression or foam molding Steps
`S3A and S3B are assembled with each other in a step S3AB,
`and compression re-molded in a Step S4AB to as to thereby
`obtain a final form. However, the above-described conven
`tional method has drawbacks with respect to complex manu
`facturing procedures, high manufacturing costs, and degra
`dation of outer appearance and function including defects in
`adhesion.
`0041) Second, in a conventional method, each shoe part
`is manufactured independently, assembled and bonded with
`each other, and painted or printed independently So as to
`obtain a variety of colors and designs. This causes restric
`tions in design and deterioration of durability and produc
`tivity, while increasing costs.
`0042. Third, each shoe part has different physical prop
`erties and is manufactured through independent forming and
`bonding procedures So as to achieve improved abrasion
`resistance, cushioning, Stability and wearing comfort.
`0043. Fourth, The shapes of the material used in a con
`ventional method do not allow for a wide range of Selection,
`making it impossible to accomplish a wide variety of
`functions from each portion of a Sole component foamed by
`crosslinked blown EVA form. That is, it is hard to obtain a
`final form with light weight, high abrasion resistance and
`regional multi density design within a single form through
`the primary foam molding proceSS or the Secondary com
`pression re-molding process.
`0044 Fifth, use of a conventional sheet or pellet type
`EVA compound causes increases in manufacturing proce
`dures and costs, preventing diversification of physical prop
`erties and design of each part of the form.
`0045 Sixth, use of a conventional sheet type EVA com
`pound causes non-uniformity of Surface and high variation
`in thickness, for example 2.5 to 3.0 mm. Therefore, when the
`Sole component is obtained through the primary foam mold
`ing process or Secondary compression re-molding process, it
`is hard to obtain quality reproducibility for a mass produc
`tion. The Shape of the sheet type material has to be con
`trolled in X, Y and Z axes, and it is extremely difficult to
`accurately control the shape in every axes or boundaries of
`each EVA forms used in different color or physical property
`within a single form of the component during the foam by
`either compression or injection molding includes compres
`Sion re-molding process, to fit the Standard of design.
`0046) Seventh, a conventional method where the primary
`compression molded body is shaped into an EVA Sponge
`
`MacNeil Exhibit 2156
`Yita v. MacNeil IP, IPR2020-01139, Page 27
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`US 2004/0261297 A1
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`Dec. 30, 2004
`
`plate, cut and Surface/shape grinded, bonded to the other
`material and used as a final Shoe component, produces
`Significant amount of wastes during cutting and grinding
`proceSSeS.
`
`SUMMARY OF THE INVENTION
`0047 Therefore, it is an object of the present invention to
`provide an EVA based film for crosslinked foam, having a
`thickness of 0.01 to 2.0, preferably 0.1 to 1.0 mm, and a
`Simplified proceSS for obtaining a single form with one or
`more physical properties or colors, in consideration of
`changes of material in each process, So as to manufacture
`shoe components for a mass production.
`0.048 Second, it is an object of the present invention to
`provide a shoe component manufacturing method allowing
`for differential design/manufacture for each Shoe component
`and improved durability and stability through the diversified
`physical properties.
`0049. Third, it is an object of the present invention to
`permit, in an effective manner, each shoe component to have
`different colors and designs, while simplifying decorative
`processes and improving function of each component, to
`thereby achieve increased value and quality of the Shoe as a
`final product.
`0050 Fourth, it is an object of the present invention to
`provide a shoe component manufacturing method allowing
`for improved abrasion resistance, cushioning, deformation
`resistance, wearing comfort and Supporting force.
`0051
`Fifth, it is an object of the present invention to
`provide a manufacturing method allowing for a wide variety
`of colors and designs through a simplified foam molding
`proceSS for obtaining a form having a unitsole of midsole
`and outsole. The manufacturing method permits each shoe
`component to have different physical properties.
`0.052
`Sixth, it is an object of the present invention to
`provide a manufacturing method for Simplifying shoe com
`ponent manufacturing procedures and reducing costs by
`reducing the number of molding molds.
`0.053 Seventh, it is an object of the present invention to
`provide a manufacturing method allowing for reduced
`defective ratio through the Simplified and reliable processes
`for forming components and ease of design and application
`of properties for a high functional shoe, while achieving
`components with consistent quality of the Shoe component.
`0.054
`Eighth, it is an object of the present invention to
`provide a manufacturing method allowing for ease of control
`of components and processes at a lower cost compare to
`conventional methods.
`0.055
`Ninth, it is an object of the present invention to
`provide a manufacturing method allowing for ease of manu
`facture of component having a large thickness, for example,
`midsole, component having a Small thickness, for example,
`insole, upper or upper component, and component with large
`and Small thicknesses.
`0056 Tenth, it is an object of the present invention to
`provide a manufacturing method allowing for use of not
`only other foam material or compound, for instance, EVA
`and other foaming process related ingredient dispersed
`blown rubber compound or thermoplastic resin but also
`
`various kind of conventional materials. Such as woven and
`non-woven textile, Synthetic leather, natural leather which
`can be integrated shape with the film type EVA compound
`through either chemically or physically bond each other
`during or after calendaring process of the form EVA film
`material.
`0057 Eleventh, it is an object of the present invention to
`provide a manufacturing method allowing for reduction of
`industrial wastes.
`0058 To accomplish the above objects of the present
`invention, there is provided an EVA based film for
`crosslinked form in an EVA based composition, wherein the
`film has a thickness of 0.01 to 2.0 mm, and the EVA based
`composition consists of EVA based resin, dicumyl peroxide
`(DCP) as a crosslinking agent, and an inorganic matter as a
`foaming agent, Selected from a group consisting of JTR-M,
`stearic acid, MgCO3, TiO2, CaCO3 and ZnO.
`0059. The composition is obtained by a bi-component
`calender molding proceSS performed before or after a cal
`ender molding process, together with a Staple fiber, textile
`fabric, non-fabric, artificial leather, foam rubber compound
`and/or thermoplastic resin composition.
`0060. The film has a thickness of 0.1 to 11.0 mm.
`0061 The calender molding process is performed at a
`low temperature ranging from 30 to 80 degree C.
`0062) There is provided a method for manufacturing shoe
`components using EVA based composition, the method
`including a first Step of cutting an EVA copolymer film
`having a thickness of 0.01 to 2 mm; a Second Step of Stacking
`and/or combining the cut films to a cavity of a molding die;
`a third Step of covering the molding die and applying heat
`and pressure to the molding die; and a fourth Step of
`releasing preSSure from the molding die, removing the cover,
`and producing foam.
`0063. There is provided a method for manufacturing shoe
`components using EVA based composition, the EVA film
`having a thickness of 0.1 to 1.0 mm.
`0064. There is provided a method for manufacturing shoe
`components using EVA based composition, the film being
`provided with enhanced physical properties by mixing a
`Staple fiber or textile fabric, non-fabric, artificial leather,
`foam rubber compound and/or thermoplastic resin compo
`Sition to the EVA copolymer during manufacturing pro
`CCSSCS.
`0065. In the second step, textile fabric and/or non-fabric,
`natural/artificial leather and rubber are used together with
`the film.
`0066 Futher, there is provided a method for manufactur
`ing shoe components which the film is provided with
`enhanced physical properties or appearance by bi-compo
`nent calender molding the film type EVA copolymer with
`woven fabric or the film having watersoluble polymer;
`processing the molded material into the tape or wire type
`material; weaving or knitting the material; and Solving the
`waterSoluble polymer.
`0067. There is provided a method for manufacturing shoe
`components using EVA based composition, the film includ
`ing two or more types which have different physical prop
`erties and colors.
`
`MacNeil Exhibit 2156
`Yita v. MacNeil IP, IPR2020-01139, Page 28
`
`

`

`US 2004/0261297 A1
`
`Dec. 30, 2004
`
`0068 There is provided a method for manufacturing shoe
`components using EVA based composition, the film includ
`ing two or more types having one or more regular or random
`pattern and/or characters printed thereon.
`0069. There is provided a method for manufacturing shoe
`components using EVA based composition, the film having
`a plurality of holes perforated therethrough in a wide variety
`of shapes or is cut into one or more films.
`0070 There is provided a method for manufacturing shoe
`components using EVA based composition, the films bring
`Stacked and/or combined in the Second Step, in Such a
`manner that the lateral side of heel or rear foot or arch of mid
`foot is further hardened as compared other parts So as to
`achieve increased Supporting force, and the medial Side of
`heel or rear foot or center of fore foot has a cushioning
`capability, elasticity and restoring force relatively higher
`than those of the lateral side of heel or rear foot or arch of
`mid foot.
`0071. There is provided a method for manufacturing shoe
`components using EVA based composition, the films being
`Stacked and/or combined in the Second Step, in Such a
`manner that the part of Shoe contacting toes of the wearer
`has a low hardneSS and high cushioning capability, and the
`arch has a Supporting force, thus permitting each part of a
`Single form to have different physical properties.
`0.072 There is provided a method for manufacturing shoe
`components using EVA based composition, the film being
`Stacked and/or combined in the Second Step, using a sheet
`and/or pellet type material or EVA copolymer material
`which is cooling molded into the State before foam produc
`tion.
`0073. There is provided a method for manufacturing shoe
`components using EVA based composition, one or more
`films used in the Second step being Stacked and/or combined
`by using an EVA copolymer preform.
`0.074 There is provided a method for manufacturing shoe
`components using EVA based composition, the EVA copoly
`mer preform having a Stereographic shape.
`0075. In film stacking process of the present invention, a
`film mixed with a pigment or additives for exhibiting colors
`or visual effects different from the color of the stacked films,
`is disposed at the top, rear or side Surface of the layer of the
`Stacked films.
`0.076 The method further includes a step of accommo
`dating a structure into the Stacked films and removing the
`Structure after a foam molding proceSS So as to form a Space
`in the layer of the stacked films.
`0077. The method further includes a step of injecting a
`film or form passed through the foaming process into a
`molding die and compression remolding the film or form.
`0078. The method further includes a step of mixing a
`foam thermoplastic resin and/or rubber material with a
`predetermined portion and/or layer in the Second Step. and
`Stacking and/or combining the mixture, and a step of bond
`ing shoe components formed of different materials and
`passed through the compression re-molding process.
`0079 The material mixed with the predetermined portion
`and/or layer in the Second Step is disposed at the lowest layer
`in the cavity of the molding die.
`
`0080. The shoe component manufactured by the method
`of the present invention has an EVA copolymer preform
`formed integrally with the Shoe component.
`0081. The preform has a stereographic shape.
`0082 The shoe component manufactured by the method
`of the present invention has a Sole with an outermost layer
`and a Subsequent layer. The outermost layer includes a top
`Surface, Side Surface and a bottom Surface of the Sole. The
`outermost layer has perforations or is cut. The Subsequent
`layer is provided with a predetermined color, pattern and/or
`characters formed integrally therewith. The layer with per
`forations or which is cut has a rear Surface exposed outward.
`0083. There is provided a shoe component manufactured
`by the manufacturing method of the present invention.
`
`DESCRIPTION OF THE DRAWINGS
`0084 FIG. 1 illustrates primary and secondary molding
`processes showing a conventional method of manufacturing
`shoe components using a sheet or pellet type EVA copoly
`mer,
`0085 FIG. 2 illustrates a conventional method of manu
`facturing a shoe component using a sheet or pellet type EVA
`copolymer, wherein the shoe component is constituted by
`two parts with different physical properties and colors,
`0.086
`FIG. 3 illustrates a method of manufacturing a
`shoe component using a film type EVA copolymer according
`to the present invention;
`0087 FIG. 4 illustrates a method of manufacturing a
`shoe component using a film type EVA copolymer and
`material obtained through a preforming process according to
`the present invention;
`0088 FIG. 5 is a cross section view illustrating a shoe
`component manufactured by using a film type EVA copoly
`mer according to the 1st embodiment of the present inven
`tion;
`0089 FIGS. 6a to 6e are cross section views illustrating
`shoe components manufactured by using a film type EVA
`copolymer and which have different colors and physical
`properties according to the 2nd embodiment of the present
`invention;
`0090 FIG. 7 is a cross section view illustrating shoe
`insoles manufactured by using a film type EVA copolymer
`and which have different colors and physical properties
`according to the 3rd embodiment of the present