DESCRIPTION

The invention which is the subject-matter of the present patent application relates to an assembly insole, particularly but not exclusively for safety footwear.

As known, the assembly or construction insole is one of the fundamental components in the production of a shoe and at the same time it constitutes the base for supporting the foot. Therefore, the way in which an assembly insole is created constitutes the performance of the shoe itself in terms of comfort for the user and also in terms of safety and quality of the shoe itself.

In particular, in the field of the production of safety footwear, the manufacturing process of an anti perforation assembly insole meets the need of the market and of the end consumer to have safety shoes which, in addition to meeting the maximum safety requirements, allow to have/obtain maximum comfort during the intensive use to which the shoe is subject, in the dynamic as well as static phase.

As known, safety shoes are an individual protection device suitable for protecting the foot against external harmful factors and they consist of

- an upper, made of different materials, able to wrap the foot at the upper and lateral part which usually also has a transpiration function;

- a cap made of steel or composite material for protection;

- a rigid stiffener;

- the sole or tread, made of various materials to obtain specific resistances.

Given the specific use for which safety shoes are intended, they must also meet the safety requirements according to current regulations, which guarantee their use in all risky conditions to which the worker is subject.

It is known that safety shoes use an assembly insole made of anti-perforation fabric with one or more layers or an assembly insole with integrated stainless steel plate.

The assembly insole made of anti-perforation fabric with one or more layers or the assembly insole with integrated stainless steel plate must pass the perforation resistance tests required by the mandatory regulations to guarantee the protection of the entire sole of the foot against external elements and sharp objects, such as nails and/or similar objects.

The safety shoes as manufactured and described involve poor comfort for the user due to the structure of the shoe itself which is rigid to ensure maximum protection of the foot and does not allow optimal comfort during use. State of the art

In the state of the art, solutions are known related to the production of anti-perforation devices, applied to shoes, some of which are the subject-matter of patent application.

For example, patent application US6151803 relates to an improvement in walking through the application of "V" cuts while a portion is turned downwards and curved towards the shoe; the main disadvantage of the solution described by the patent US6151803 is that it does not guarantee comfort throughout the sole of the foot as the structure of the patent is mainly aimed at the front part/toe of the foot.

Application US2002043005 identifies the solution for covering the steel/kevlar plate with a soft material which can be EVA or a similar material which will then be covered with a membrane which will be glued or edged to the steel or Kevlar base; the main disadvantage of what is described in the application US2002043005 is that the layer of soft material is not integrated into the anti perforation assembly insole and it rests externally as a body unconnected with the structure. This causes the internal volumes of the shoe to decrease and therefore less comfort.

The solution described in patent application number US5996255A relates to the production of several layers of metal or anti-perforation fabric, said padding being subsequently sewn between the upper and the sole; the main disadvantage of the described solution is that it is not a real padding with ergonomic material but a simple superimposition of layers of anti-perforation fabric. In the patent IT102016000003160, owned by the writer, according to the manufacturing process described and claimed the assembly insole is pressed in order to create, for the entire length, a recess of about 4 mm, obtaining a pressing shape into which a thermoplastic elastomeric material is inserted having elastic properties and shape memory. In particular, according to what is described and claimed in the document IT10201600003160, the thermoplastic elastic material is beehiveshaped, contained by a perforated weave fabric.

According to what is described in patent IT102016000003160, the insole is substantially flat and once the thermoplastic material is inserted, a sufficient cushioning effect is not achieved, in particular in the rear area of the heel, during walking.

A further disadvantage of the solution described and claimed in patent IT102016000003160 is that it is not possible, if necessary, to replace the alveolar thermoplastic material as it is contained by the perforated weave fabric.

A further disadvantage of the solution described and claimed in patent IT102016000003160 is that the pressing shape is obtained for the entire length, that is from the rear end corresponding to the positioning of the heel, along the central part corresponding to the positioning of the metatarsus up to the front end corresponding to the positioning of the fingers.

According to the invention which is the subject-matter of patent IT102016000003160, the cushioning material inserted into the pressing shape is also present in correspondence with the forefoot, making the shoe thus made not perfectly compatible with the provisions of the law as regards the assessment of the mechanical risk in safety shoes relative to the part of the steel and/or composite material cap.

Aim of the invention which is the subject-matter of this patent application is to provide an assembly insole, preferably but not exclusively in anti-perforation fabric, suitably structured to ensure maximum comfort in safety footwear and which does not have the disadvantages of the state of the art described.

A further aim of the invention which is the subject-matter of this patent application is therefore to obtain a safety shoe which is comfortable for the user without precluding safety during use.

This and further aims are achieved by the invention which is the subject-matter of the present patent application, in particular by means of a method of pressing a first element and obtaining a pressing shape into which a filling material is inserted, said pressing shape having a length shorter than the length of the first element itself and extending from the rear end towards the front end up to the position of the metatarsus.

In a preferential but not exclusive embodiment, by pressing the first element, a suitably sized shape is obtained so as to have a greater depth at the rear with respect to the depth of the shape in the forefoot area.

The shape thus obtained is then filled with a thermoplastic elastomeric material having elastic properties and shape memory, said material having then a greater thickness in the rear end and smaller thickness in the front end so as to obtain, once inserted into the shape, a coplanarity of the system.

In a preferential but not exclusive embodiment, the assembly insole made according to what is described above can be previously associated with a plate, preferably but not exclusively in stainless steel, previously shaped in the same way as the shape of the assembly insole made according to what is described hereinafter.

The invention which is the subject-matter of the present patent application is shown in Table 1 in which Fig 1, Fig 2 Graphic exemplification of a part of the assembly insole (10) which is the subject-matter of the present patent application;

Fig 3: Graphic exemplification of a second part of the assembly insole (10) which is the subject- matter of the present patent application;

Fig 4: Graphic exemplification of the assembly insole (10) which is the subject-matter of the present patent application;

Fig 5: Graphic exemplification of a second preferential embodiment of the assembly insole (10) which is the subject-matter of the present patent application.

According to the invention which is the subject-matter of the present patent application, the assembly insole (10) which is the subject-matter of the present patent application consists of a first element (1) which extends from a front toe (1.11) to a rear end (1.12) and which includes an internal shape (2, Fig 1) which extends from the front area (2.1 Fig 1), corresponding to the forefoot, up to the rear area (2.2 Fig 1), corresponding to the position of the heel. According to the invention which is the subject-matter of the present patent application, the length L2 (Fig 2) of the internal shape (2. Fig 1) is shorter than the length LI (Fig 2) of the first element (1, Fig 1.2).

According to the invention which is the subject-matter of the present patent application, the depth of the shape (2 Fig 1) in correspondence with the front area (2.1 Fig 1) is smaller than the depth of the shape (2 Fig 1) in correspondence with the rear area (2.2 Fig 1).

In a preferential but not exclusive embodiment, the depth of the rear area (2.2) is between 20mm and 10mm; in a preferential but not exclusive embodiment, the depth of the front area (2.1) is between 7mm and 5mm.

In a preferential but not exclusive embodiment, the shape (2, Fig 1,2) made according to what has been described above, is obtained by pressing the material in which the first element (1) is made.

In a preferential but not exclusive embodiment the pressing of the first element (1, Fig 1) is carried out with special moulds, in particular to allow the material of which it is made not to lose its peculiar technical characteristics, especially in case it is made of anti-perforation fabric.

With reference to Fig 1, in order to improve the flexibility of the first element (1), in the front part (1.1, Fig 1) of the shape (2, Fig 1) a series of further horizontal pressings (9 _n -i - 9 _n , Fig 1) is made, suitably spaced from each other.

A filling element (3, Fig 3) having a length L3 (Fig 3) equal to or at the least shorter than the length L2 (Fig 2) of the shape (2, Fig 1) is inserted into the shape (2, Fig 1,2) made according to what has been previously described; in the rear area (3.2, Fig 3) the filling element (3) has a height equal to or at the most greater than the depth of the rear area (2.2, Fig 1) of the shape (2).

In the front area (3.1, Fig 3) the filling element (3, Fig 3) has a height equal to or at the most greater than the depth of the front area (2.1. Fig 1) of the shape (2); according to what has been previously described, in the rear area (3.2, Fig 3) the height of the filling element (3, Fig 3) is greater than its height in the front area (3.1, Fig 3).

In a preferential but not exclusive embodiment, the filling element (3, Fig 3) consists of a thermoplastic and shape memory elastomer.

By inserting the filling material (3) into the shape (2) of the first element (1) the assembly insole (10, Fig 4) is obtained which is the subject-matter of the present patent application.

In a preferential but not exclusive embodiment, the height of the filling element (3) may be a few millimetres greater than the overall depth of the shape (2) so as to be easily removable and replaceable.

The shape memory material (3) is about 3 mm higher than the space obtained by pressing (1 Fig. 2), such that it protrudes from the assembly insole. This is to allow the insert to be replaced, which is thus interchangeable.

DESCRIPTION OF A FIRST PREFERENTIAL EMBODIMENT

With reference to Fig 1,2, 3, 4, in a first preferential embodiment, the assembly insole (10) which is the subject-matter of the present patent application consists of a first element (1) made of antiperforation fabric which extends from a front toe (1.11) up to a rear end (1.12) and which includes an internal shape (2, Fig 1) which extends from the front area (2.1 Fig 1), corresponding to the forefoot, up to the rear area (2.2 Fig 1), corresponding to the position of the heel. According to the invention which is the subject-matter of the present patent application, the length L2 (Fig 2) of the internal shape (2. Fig 1) is shorter than the length LI (Fig 2) of the first element (1, Fig 1,2). According to the invention which is the subject-matter of the present patent application, the depth of the shape (2 Fig 1) in correspondence with the front area (2.1 Fig 1) is smaller than the depth of the shape (2 Fig 1) in correspondence with the rear area (2.2 Fig 1).

In a preferential but not exclusive embodiment, the depth of the rear area (2.2) is between 20mm and 10mm; in a preferential but not exclusive embodiment, the depth of the front area (2.1) is between 7mm and 5mm. In a preferential but not exclusive embodiment, the shape (2, Fig 1,2) made according to what has been previously described, is obtained by pressing the anti-perforation fabric of which the first element (1) is made.

In a preferential but not exclusive embodiment, the pressing of the first element (1, Fig 1) is carried out with special moulds, in particular to allow the material of which it is made not to lose its peculiar technical characteristics, especially in case it is made of anti-perforation fabric.

With reference to Fig 1, in order to improve the flexibility of the first element (1), in the front part (1.1, Fig 1) of the shape (2, Fig 1) a series of further horizontal pressings (9 _n -i - , Fig 1) is made, suitably spaced from each other.

A filling element (3, Fig 3) having a length L3 (Fig 3) equal to or at the least shorter than the length L2 (Fig 2) of the shape (2, Fig 1) is inserted into the shape (2, Fig 1,2), made according to what has been previously described; in the rear area (3.2, Fig 3) the filling element (3) has a height equal to or at the most greater than the depth of the rear area (2.2, Fig 1) of the shape (2).

In the front area (3.1, Fig 3) the filling element (3, Fig 3) has a height equal to or at the most greater than the depth of the front area (2.1. Fig 1) of the shape (2); according to what has been previously described, in the rear area (3.2, Fig 3) the height of the filling element (3, Fig 3) is greater than its height in the front area (3.1, Fig 3).

In a preferential but not exclusive embodiment, the filling element (3, Fig 3) consists of a thermoplastic and shape memory elastomer.

By inserting the filling material (3) into the shape (2) of the first element (1) the assembly insole (10, Fig 4) is obtained which is the subject-matter of the present patent application.

DESCRIPTION OF A SECOND EMBODIMENT

With reference to Fig 1,2,3, 4 and 5, in a second preferential embodiment, the assembly insole (10) which is the subject-matter of the present patent application consists of a first element (1) made of fabric which extends from a front toe (1.11) to a rear end (1.12) and which includes an internal shape (2, Fig 1) which extends from the front area (2.1 Fig 1), corresponding to the forefoot, up to the rear area (2.2 Fig 1), corresponding to the position of the heel. According to the invention which is the subject-matter of the present patent application, the length L2 (Fig 2) of the internal shape (2. Fig 1) is shorter than the length LI (Fig 2) of the first element (1, Fig 1,2).

According to the invention which is the subject-matter of the present patent application, the depth of the shape (2 Fig 1) in correspondence with the front area (2.1 Fig 1) is smaller than the depth of the shape (2 Fig 1) in correspondence with the rear area (2.2 Fig 1). In a preferential but not exclusive embodiment, the depth of the rear area (2.2) is between 20mm and 10mm; in a preferential but not exclusive embodiment, the depth of the front area (2.1) is between 7mm and 5mm.

In a preferential but not exclusive embodiment, the shape (2, Fig 1,2) made according to what has been previously described, is obtained by pressing the fabric of which the first element (1) is made. In a preferential but not exclusive embodiment, the pressing of the first element (1, Fig 1) is carried out with special moulds, in particular to allow the material of which it is made not to lose its peculiar technical characteristics.

With reference to Fig 1, in order to improve the flexibility of the first element (1), in the front part (1.1, Fig 1) of the shape (2, Fig 1) a series of further horizontal pressings (9 _n -i - 9 _n , Fig 1) is made, suitably spaced from each other.

A filling element (3, Fig 3) having a length L3 (Fig 3) equal to or at the least shorter than the length L2 (Fig 2) of the shape (2, Fig 1) is inserted into the shape (2, Fig 1,2), made according to what has been previously described; in the rear area (3.2, Fig 3) the filling element (3) has a height equal to or at the most greater than the depth of the rear area (2.2, Fig 1) of the shape (2).

In the front area (3.1, Fig 3) the filling element (3, Fig 3) has a height equal to or at the most greater than the depth of the front area (2.1. Fig 1) of the shape (2); according to what has been previously described, in the rear area (3.2, Fig 3) the height of the filling element (3, Fig 3) is greater than its height in the front area (3.1, Fig 3).

In a preferential but not exclusive embodiment, the filling element (3, Fig 3) consists of a thermoplastic and shape memory elastomer.

By inserting the filling material (3) into the shape (2) of the first element (1) the assembly insole (10, Fig 4) is obtained which is the subject-matter of the present patent application.

According to the second preferential embodiment, the insole (10) is then associated with a plate (5, Fig 5), preferably but not exclusively made of stainless steel, said plate (5) being provided with a pointed front end (5.11 Fig 5) and a rear end (5.12).

The plate (5, Fig 5) has an internal shape (4, Fig 5) which extends from a front area (4.1, Fig 5), corresponding to the forefoot, up to the rear area (4.2 Fig 5), corresponding to the position of the heel. According to the invention which is the subject-matter of the present patent application, the length L4 (Fig 5) of the internal shape (4 Fig 5) is shorter than the length L5 (Fig 5) of the plate (5, Fig 1,2). Furthermore, according to the preferential embodiment, the length L4 (Fig 5) of the internal shape (4, Fig 5) of the plate (5, Fig 5) is equal to or at the least shorter than the length L2 (Fig 2) of the shape (2, Fig 1) of the assembly insole (10).

According to the invention which is the subject-matter of the present patent application, the depth of the shape (4 Fig 5) in correspondence with the front area (4.1 Fig 5) is smaller than the depth of the shape (4 Fig 5) in correspondence with the rear area (4.2 Fig 5).

According to the preferential embodiment described, the depth of the shape (4 Fig 5) in correspondence with the front area (4.1 Fig 5) is equal to or at the most greater than the depth of the shape (2 Fig 1) in correspondence with the front area (2.1 Fig 1) of the assembly insole (10) and the depth of the shape (4, Fig 5) in correspondence with the rear area (4.2 Fig 5) is equal to or at the most greater than the depth of the shape (2, Fig 1) in correspondence with the rear area (2.2) of the assembly insole (10).

In order to improve the flexibility of the assembly insole (10)/plate (5) system, in the front part (4.1 Fig 5) of the shape (4 Fig 5) a series of further horizontal pressings (7 _{n i} - 7 _n Fig 2) is made suitably spaced from each other.

Regardless of the construction methods described above, according to the invention which is the subject-matter of the present patent application at the front (3.1, Fig 3) the filling element has a height equal to or at the most greater than the depth of the front area (2.1, Fig 1) of the shape (2) and at the rear (3.2, Fig 3) the filling element (3) has a height equal to or at the most greater than the depth of the rear area (2.2, Fig 1) of the shape (2); according to what has been previously described, at the rear (3.2, Fig 3) the height of the filling element (3) is greater than its height in the front area (3.1).

In a preferential but not exclusive embodiment, the filling element (3, Fig 3) consists of a thermoplastic and shape memory elastomer. In a preferential but not exclusive embodiment, the height of the filling element may be a few millimetres greater than the overall depth of the shape (2) so as to be easily removable and replaceable.

The shape memory material (3) is about 3 mm higher than the space obtained by pressing (2 Fig. 2), such that it protrudes from the assembly insole.

This is to allow the insert to be replaced, which is thus interchangeable.