MILLING HEAD AND METHOD OF USING SAME

Abstract

Disclosed is a milling head for shaping a shoe support for an article of foot wear. The disclosed milling head includes abrasive surfaces that are configured to allow for the shaping of an unfinished block of support material on all of the top, side and medial arch area of the perimeter surfaces without removing the block of support material from a support such as a vacuum vise, and without the need to interchange milling heads. The disclosed milling head has a semi-spherical milling surface for milling a top surface of the shoe support and two conical milling surfaces for milling a perimeter surface and a medial arch area of the perimeter surface of the shoe support, respectively. The disclosed milling head saves costs of labor and time when shaping the block of support material.

Claims

1. A milling head having a plurality of milling surfaces for forming a shoe support from an unfinished block of support material, the milling head comprising: at least a first angled undercutting surface; and a curved surface, wherein each surface is provided with a cutting surface, wherein the at least first angled undercutting surface is configured to perform milling a milling operation on a perimeter surface of the unfinished block of support material, and wherein the curved surface is configured to perform milling on a top surface of the unfinished block of support material.

2. The milling head according to claim 1, further comprising: at least a second undercutting surface provided with a cutting surface, wherein the second angled undercutting surface is configured to perform a milling operation on the medial arch area of the perimeter surface of the unfinished block of support material.

3. The milling head according to claim 1, further comprising: an attachment means configured for insertion into a chuck of a drill.

4. The milling head according to claim 2, further comprising: an attachment means configured for insertion into a chuck of a drill.

5. The milling head according to claim 3, wherein the curved surface is disposed distal the attachment means and the at least first angled undercutting surface is disposed between the attachment means and the curved surface.

6. The milling head according to claim 4, wherein the curved surface is disposed distal the attachment means and the at least first angled undercutting surface and the at least second undercutting surfaces are disposed between the attachment means and the curved surface.

7. The milling head according to claim 1, wherein the at least first angled undercutting surface and the curved surface are integrally formed into a unitary structure.

8. The milling head according to claim 2, wherein the at least first angled undercutting surface, the at least second angled undercutting surface and the curved surface are integrally formed into a unitary structure.

9. The milling head according to claim 3, wherein the at least first angled undercutting surface, the at least second angled undercutting surface, the curved surface and the attachment means are integrally formed into a unitary structure.

10. The milling head according to claim 4, wherein the at least first angled undercutting surface, the at least second angled undercutting surface, the curved surface and the attachment means are integrally formed into a unitary structure.

11. The milling head according to claim 3, wherein the at least first angled undercutting surface, the curved surface and the attachment means are connected to one another by threading, spring clips, set screws, spring loaded locking pins and any combinations of the foregoing.

12. The milling head according to claim 4, wherein the at least first angled undercutting surface, the at least second angled undercutting surface, the curved surface and the attachment means are connected to one another by threading, spring clips, set screws, spring loaded locking pins and any combinations of the foregoing.

13. The milling head according to claim 1, wherein the milling head is configured to perform the milling operation of the perimeter surface and the top surface by high speed rotation, oscillation, vibration and any combinations of the foregoing.

14. The milling head according to claim 2, wherein the milling head is configured to perform the milling operation of the perimeter surface, the medial arch area of the perimeter surface and the top surface by high speed rotation, oscillation, vibration and any combinations of the foregoing.

15. The milling head according to claim 1, wherein the at least first angled undercutting surface comprises a conical surface, and wherein the curved surface comprises a semi-spherical surface.

16. The milling head according to claim 2, wherein each of the at least first angled undercutting surface and the second angled undercutting surface comprise a conical surface, and wherein the curved surface comprises a semi-spherical surface.

17. The milling head according to claim 1, wherein each cutting surface comprises an abrasive, a knife-like cutting surface, saw teeth, or any combinations of the foregoing.

18. The milling head according to claim 2, wherein each cutting surface comprises an abrasive, a knife-like cutting surface, saw teeth, or any combinations of the foregoing.

19. A milling head having a plurality of milling surfaces for forming a shoe support from an unfinished block of support material, the milling head comprising: an attachment end; a semi-spherical milling surface for shaping a top surface of the unfinished block of shoe support material; at least a first conical milling surface for shaping a perimeter surface of the unfinished block of shoe support material; and at least a second conical milling surface for shaping a medial arch area of the perimeter surface of the unfinished block of shoe support material, wherein the semi-spherical milling surface is disposed distal to the attachment end, wherein the at least first and at least second conical milling surfaces are disposed between the attachment end and the semi-spherical milling surface, and wherein each of the semi-spherical milling surface, the at least first conical milling surface and at least second conical milling surface is coated with an abrasive.

20. The milling head according to claim 19, wherein the at least first conical milling surface is disposed adjacent the semi-spherical milling surface and the at least second conical milling surface is disposed adjacent the attachment end.

21. The milling head according to claim 19, wherein the attachment end, the semi-spherical milling surface, the at least first conical milling surface and the at least second conical milling surface are of a unitary structure.

22. A method of forming a shoe support from an unfinished block of support material comprising: providing a milling head comprising: at least a first angled undercutting surface; at least a second angled undercutting surface; and a curved surface, wherein each surface has a cutting surface, placing an unfinished block of shoe support material in a position on a support, wherein the support firmly holds the unfinished block of shoe support material in place and provides for exposing the perimeter and medial arch surfaces to the action of the milling head, wherein the unfinished block of shoe support material has a top surface, a perimeter surface and a medial arch area of the perimeter surface; shaping the top surface with the curved surface; undercutting the perimeter surface with the at least first angled undercutting surface, and undercutting the medial arch area of the perimeter surface with the at east second angled undercutting surface, wherein the shaping of the top surface, the undercutting of the perimeter surface and the undercutting of the medial arch area of the perimeter surface is performed by moving the milling head in any combination of an X direction, a Y direction and a Z direction, and wherein the undercutting of the perimeter surface and the undercutting of the medial arch area of the perimeter surface are performed without removing the shoe support material from position on the support.

23. The method according to claim 22, wherein the milling head further comprises: a chuck shaft configured for insertion into a chuck of a drill.

24. The method according to claim 23, wherein the curved surface is disposed distal the chuck shaft and the at least first and at least second angled undercutting surfaces are disposed between the chuck shaft and the curved surface.

25. The method according to claim 22, wherein the at least first angled undercutting surface, the at least second angled undercutting surface and the curved surface are integrally formed into a unitary structure.

26. The method according to claim 23, wherein the at least first angled undercutting surface, the at least second angled undercutting surface, the curved surface and the chuck shaft are integrally formed into a unitary structure.

27. The method according to claim 22, wherein the at least first angled undercutting surface, the at least second angled undercutting surface and the curved surface are connected to one another by threading, spring clips, set screws, spring loaded locking pins and any combinations of the foregoing.

28. The method according to claim 23, wherein the at least first angled undercutting surface, the at least second angled undercutting surface, the curved surface and the chuck shaft are connected to one another by threading, spring clips, set screws, spring loaded locking pins and any combinations of the foregoing.

29. The method according to claim 22, wherein the milling head is configured to perform the milling operation of the perimeter surface, the medial arch area of the perimeter surface and the top surface by high speed rotation, oscillation, vibration and any combinations of the foregoing.

30. The method according to claim 22, wherein the at least first angled undercutting surface and the at least second angled undercutting surface each comprises a conical surface, and wherein the curved surface comprises a semi-spherical surface.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0028] The device and method according to the present disclosure will be more fully understood by reference to the following Figures in which like elements are referred to by like numerals throughout.

[0029] FIG. 1 is a side perspective view of a milling head according to a preferred embodiment of the present disclosure.

[0030] FIG. 2 is an overhead perspective view of the milling head of FIG. 1 according to a preferred embodiment of the present disclosure in a drill chuck disposed above a vacuum vise work bed.

[0031] FIG. 3 is an overhead perspective view of what is shown in FIG. 2, but including an unfinished block of shoe support material supported in place on the vacuum vise work bed.

[0032] FIG. 4 is a rear perspective view of the milling head of FIG. 1 in the process of contouring a top surface of the unfinished block of shoe support material as shown in FIG. 3.

[0033] FIG. 5 is a front perspective view of the milling head of FIG. 1 in the process of contouring a top surface of the unfinished block of shoe support material as shown in FIG. 4.

[0034] FIG. 6 is a rear perspective view of the milling head of FIG. 1 in the process of contouring a perimeter surface of the unfinished block of shoe support material as shown in FIG. 3.

[0035] FIG. 7 rear perspective view of the milling head of FIG. 1 contouring a medial arch area of the perimeter surface of the unfinished block of shoe support material as shown in FIG. 3.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

[0036] FIG. 1 shows a preferred milling head 100 according to the present disclosure. Milling head 100 has a chuck shaft end 102 and, disposed distally from chuck shaft end 102, a semi-spherical milling surface 104. Disposed between chuck shaft end 102 and semi-spherical milling surface 104 are two conical milling surfaces, a first conical milling surface 106 disposed proximal to chuck shaft end 102 and a second conical milling surface 108 disposed proximal to and integral with semi-spherical milling surface 104. In the embodiment shown in FIG. 1, first conical milling surface 106 has a more pronounced angled conical surface than second conical milling surface 108. As will be described in more detail in relation to other FIGS., in the embodiment shown in FIG. 1 first conical milling surface 106 is configured to undercut a medial arch area of the perimeter surface of an unfinished block of support material. Similarly, in the embodiment shown in FIG. 1, second conical milling surface 108 is configured to undercut a perimeter surface of an unfinished block of support material. Of course, the positions of first conical milling surface 106 and second conical milling surface 108 could be interchanged. Each of semi-spherical milling surface 104, first conical surface 106 and second conical surface 108 has an abrasive surface coating 110. In the embodiment shown in FIG. 1, the abrasive is arc-welded carbide that has been applied to a magnetized mandrill. The process of arc-welding provides the abrasive to each of the surfaces that is oriented substantially perpendicularly to each surface. Although not completely capable of being described as a true grit size, the coarseness of the resulting surface can be roughly compared to that of 60 grit sand/carbide-coated paper.

[0037] FIG. 2 shows milling head 100 according to FIG. 1 in place in a drill chuck 200 disposed above work surface 202. Associated with work surface 202 is a plurality of vacuum vise heads 204 and 206. In the embodiment shown in FIG. 2, there are two vacuum vise heads 206 for securing a rear (or heel) portion of an unfinished block of shoe support material thereto and a single vacuum vise head 204 for securing a front (or toe) portion of an unfinished block of shoe support material thereto. As is known to those of skill in the art, movements of drill chuck 200 and therefore of milling head 100 are controlled and guided by computer-implemented software. As such, fabricating a shoe support from an unfinished block of shoe support material can be substantially fully automated when the milling head of the present disclosure is used. This will be more clearly seen and understood with reference to the FIGS. that follow

[0038] FIG. 3 shows the milling head 100 according to FIG. 1 secured in drill chuck 200 above work surface 202 as shown in FIG. 2. In FIG. 3, an unfinished block of shoe support material 300 is secured to vacuum vise heads 204 and 206. Unfinished block of shoe support material 300 has a top surface 302, a perimeter surface 304 and a medial arch area 306 of the perimeter surface 304. As mentioned previously, drill chuck 200 is computer-controlled so as to be capable of moving in a plurality of directions, including those shown by axes 308. Axes 308 include an axis 310 in the X (lateral) direction, an axis 312 in the Y (longitudinal) direction and an axis 314 in the Z (vertical) direction relative to unfinished block of shoe support material. During operation, drill chuck 200 is directed by a computer implemented design program (not shown or described herein) to move milling head 100 in each of axis directions 310, 312 and 314 to contour the top surface 302, perimeter surface 304 and medial arch area 306 of perimeter surface 304 of unfinished block of shoe support material as required by the specifications of the particular shoe support being made.

[0039] FIG. 4 shows milling head 100 in position for milling top surface 302 of unfinished block of shoe support material 300. As can be seen in FIG. 4, semi-spherical milling surface 104 is in the process of contouring a three-dimensional profile to top surface 302 of unfinished block of shoe support material 300. As can also be seen, the heel portion 402 of unfinished block of shoe support material 300 is thicker than the toe portion 404 of the unfinished block of shoe support material 300. Contouring a three-dimensional profile to top surface 302 is accomplished, as mentioned with respect to FIG. 3, by the computer implemented design program moving milling head 100 in each of the directions of axis 310 in the X direction, axis 312 in the Y direction and axis 314 in the Z direction.

[0040] FIG. 5 is similar to FIG. 4 except that the view of the orientation of milling head 100 with respect to unfinished block of shoe support material 300 is shown differently. As is more clearly seen in FIG. 5, heel portion 402 has a greater thickness 502 than the thickness 504 of toe portion 404. The contouring of top surface 302 of unfinished block of shoe support material 300 by the computer implemented design program moving milling head 100 in each of the directions of axis 310 in the X direction, axis 312 in the Y direction and axis 314 in the Z direction can be more clearly appreciated with respect to FIG. 5.

[0041] FIG. 6 shows milling head 100 in position for milling perimeter surface 304 of unfinished block of shoe support material 300. As can be seen in FIG. 6, second conical milling surface 108 is as an angle that is configured to impart a slight undercut to perimeter surface 304. That is to say that the width A-A across top surface 302 of unfinished shoe support material 300 is greater than the width B-B across the perimeter surface 306 of unfinished shoe support material 300 at the same longitudinal point C-C along the length of unfinished block of shoe support material 300. The undercut provided to perimeter surface 304 allows for ease of insertion and withdrawal of the finished shoe support into and out of a shoe.

[0042] FIG. 7 shows milling head 100 in position for milling medial arch area 306 of unfinished block of shoe support material 300. As can be seen in FIG. 7, first conical milling surface 106 is at an angle that is configured to impart a more substantial undercut to perimeter surface 304 than second conical milling surface 108 imparts to perimeter surface 304. That is to say that the width B-B across medial arch area 306 of the perimeter surface 304 of unfinished shoe support material 300 is less than the width B-B provided after second conical milling surface 108 performs the undercut at the same longitudinal point C-C along the length of unfinished block of shoe support material 300. In operation, milling head 100 performs the undercut to unfinished block of shoe support material 300 by localized movement in X direction 310 toward the middle or inside area of unfinished block of shoe support material 300. The undercut provided to perimeter surface 304 by first conical milling head 106 allows for correct medial arch support to the unfinished block of shoe support material for the particular wearer.

[0043] As used herein, the terms first, second, top and medial are used merely for descriptive purposes and to provide for an understanding of the relative configuration of the embodiments of the present disclosure. The use of such terms is neither intended to nor necessary for the practice of the embodiments set forth in the present disclosure.

[0044] Although the present disclosure describes in detail certain embodiments, it is understood that variations and modifications exist known to those skilled in the art that are within the disclosure. Accordingly, the present disclosure is intended to encompass all such alternatives, modifications and variations that are within the scope of the disclosure as set forth in the disclosure.