Field
This invention relates to articles of footwear, elements thereof, and related methods of manufacturing.
Description of the Related Art
In many types of footwear, the lower or underfoot portion of the footwear can include a midsole that is directly attached to an upper. The midsole can be designed primarily to provide stability for the foot and/or attenuate shock. An outsole can be attached to the midsole and is often designed to resist wear and provide traction.
When running and walking, generally a wearer's foot makes initial contact with the ground surface on the lateral portion of the heel area. At initial contact, runners typically strike the ground at a force of 2.5 times their body weight, which may be repeated at a rate of 180 times per minute (90 times per minute for each foot). Footwear is thus often designed such that its sole has a desired firmness and/or resiliency to provide for a desired impact cushioning.
Modern footwear is a combination of elements, which can cooperatively interact to reduce weight, while increasing comfort, cushioning, stability and durability. However, these goals are sometimes in conflict with each other, and as a result, in an effort to achieve one of these objectives, a deleterious effect on one or more other goals can occur.
The cushioning in most athletic shoes can be supplied through a foam midsole that may provide ample cushioning when new, but can have a tendency to lose some of its cushioning ability over time due to failure of the structured materials by the application of repeated shear and vertical forces. One trend in the footwear industry is towards thickening the midsoles of athletic shoes to enhance the cushioning effect of the sole. An added thickness of foam, however, can cause the sole to have an undesired stiffness in bending or other undesirable characteristics. The footwear described herein can provide a number of advantageous features that can be utilized alone or in combination. For example, by providing improved cushioning, stability, and/or elastic spring arrangements within the footwear, the footwear can be tailored to the forces to which that portion of the shoe is subjected while meeting the demands of shock absorption, comfort and stability.
In some embodiments, a shank for an article of footwear can include a substantially planar base portion extending within a first plane in the longitudinal and lateral directions, a substantially planar ramp portion designed to absorb footwear loads in a vertical direction, the ramp portion extending, in an uncompressed state, within a second plane that is oblique to the first plane. The base portion and the ramp portion can be arranged such that they do not overlap in the vertical direction. In some embodiments, footwear can include an upper designed to receive an upper portion of a user's foot, an outsole coupled to the upper and designed to engage with a ground surface, and a shank.
In some embodiments, a sole assembly for an article of footwear can include an outsole designed to engage with a ground surface and a midsole designed to receive a bottom portion of a wearer's foot. The outsole can be divided into a first portion located at a forefoot portion of the sole assembly and a second portion located at an arch portion of the sole assembly, the first portion being affixed to the midsole and the second portion being detached from the midsole. The second portion can be designed to contact the midsole in a compressed state due to an absorbed footwear load and is designed to form a gap between the second portion and the midsole when the absorbed footwear load is removed.
In some embodiments, a method of manufacturing an article of footwear can include positioning a shank designed to absorb footwear loads on top of an outsole designed to engage with a ground surface, positioning a midsole designed to receive a lower portion of a bottom portion of a user's foot on top of the shank and outsole, and securing the midsole to the outsole such that the shank is secured between the midsole and the outsole to form a sole assembly.
As should be apparent, the footwear described herein can provide a number of advantageous features and benefits. It is to be understood that in practicing the invention, an embodiment can be constructed to include one or more features or benefits of embodiments disclosed herein, but not others. Accordingly, it is to be understood that any illustrated embodiments are provided as examples and should not be construed as limiting, particularly since embodiments can be formed to practice the invention that do not include each of the features of the disclosed embodiments.
The invention will be better understood from reading the description which follows and from examining the accompanying figures. These are provided solely as non-limiting examples of the invention.
Reference will now be made in detail to the embodiments of the invention, examples of which are illustrated in the accompanying drawings.
Footwear 10 can extend in a longitudinal direction 12, lateral direction 14, and vertical direction 16, and can be divided into several portions, such as a heel portion 18, arch portion 20, forefoot portion 22, and toe portion 24, which corresponds to the portion of the wearer's foot within footwear 10. As described further herein, footwear 10 can be assembled from various pieces, such as an upper 26, and a sole assembly 28 that can include a midsole 30, an outsole 32, and a shank 34. The various parts of footwear 10 are described in further detail below.
Upper 26 can be designed to receive and secure an upper portion of a user's foot. Upper 26 can be attached directly or indirectly to one or more pieces of footwear 10, such as midsole 30 and/or outsole 32, and can be fabricated from various suitable materials, such as stitched fabric, leather, canvas, nylon, and/or other types of suitable natural or synthetic materials. Upper 26 can be made from a single material or a combination of materials. In some embodiments, upper 26 can include a lightweight and breathable engineered synthetic mesh. Upper 26 can additionally include a seam-free material that is welded to the breathable mesh to provide additional strength.
The particular activity for which the footwear is designed for can impact the material or materials used to construct upper 26. For example, a basketball shoe upper, a heavier material such as leather may be used, which in some cases can provide improved support to a wearer's foot and ankle than canvas or nylon. A running shoe upper, for example, might be formed of certain synthetic materials that are relatively lightweight, breathable, and/or easy to clean.
In some embodiments, upper 26 can further include one or more reflective patches or other reflective elements. In some embodiments, upper 26 can include one or more logos or other similar elements, which can for example be protected with a cover, such as a transparent or non-transparent thermoplastic polyurethane (TPU) cover.
Upper 26 can include laces to allow a wear to removably secure their foot within the footwear. In some embodiments, upper 26 can additionally or alternatively include latches, straps, or one or more other suitable fasteners.
Midsole 30 can be designed to cushion and/or receive a lower portion of a user's foot. In some embodiments, a foot receiving surface of midsole 30 can be substantially planar or can be contoured to the shape of a wearer's foot. Midsole 30 can, for example, be attached directly or indirectly to one or more pieces of footwear 10, such as upper 26, shank 34, and/or outsole 32, and can be made from a foam, such as ethylene vinyl acetate (EVA), polyester ethyl vinyl acetate (PEEVA), compression molded ethyl vinyl acetate (CMEVA), polyurethane, rubber, foamed rubber, or another suitable material or combination of materials. In some embodiments, footwear 10 can include a soft inner sole member, such as a sock liner, positioned between midsole 30 and the wearer's foot.
Outsole 32 can be designed to cushion a user's foot and/or engage with a ground surface 46. Outsole 32 can, for example, be directly or indirectly attached to one or more pieces of footwear 10, such as upper 26, shank 34, and/or midsole 30 and can be made from an abrasive-resistant material, such as a hard rubber. Outsole 32 can include a lateral outsole arm 38, a medial outsole arm 40 (shown, for example, in
As shown for example in
In such a balanced and uncompressed configuration, a gap 48 can be formed between heel portion 18 of outsole 32 and ground surface 46 to allow footwear 10 to rotate to or from heel portion 18 during a step. In some embodiments, gap 48 can be approximately 25 mm. Another gap 50 can be formed between a distal end of outsole arm 38 and ground surface 46 to allow outsole arm 38 to rotate along curved bottom surface 44 while keeping contact with ground surface 46 during a step. Another gap 52 can be formed between the distal end of outsole arm 38 and midsole 30 to allow outsole arm 38 to flex towards midsole 30 during a step. In some embodiments, gap 52 can be greater than 10 mm. In some embodiments, gap 52 is approximately 11 mm. Another gap 54 can be formed between the distal end of outsole arm 38 and outsole ramp portion 42 to allow outsole arm to flex towards outsole ramp portion 42 during a step. Another gap 56 can be formed between toe portion 24 and ground surface 46 to allow footwear 10 to rotate to or from toe portion 24 during a step.
In some embodiments, outsole 32 can be divided into a first portion located at forefoot portion 22 of sole assembly 28 and a second portion (which can, for example, correspond to lateral outsole arm 38 and medial outsole arm 40) located at arch portion 20 of sole assembly 28. As shown for example in
In some embodiments, shank 34 can be designed to elastically absorb footwear loads, provide a propulsive spring energy when compressed, and/or provide structural rigidity to footwear 10. Shank 34 can include a plurality of substantially planar portions, some or all of the portions having a uniform thickness. For example, in some embodiments, the thickness of one or more portions of shank 34 can be approximately 1.5 mm.
Shank 34 can be designed to elastically deform under absorbed footwear loads. For example, in some embodiments, such as the embodiment shown in
As shown for example in the embodiment of
Base portion 58 can be positioned within footwear 10 at a corresponding forefoot portion 22 such that ramp portion 60 is positioned at a corresponding arch portion 20 of footwear 10. Such a configuration can serve to encourage a mid-foot strike by the wearer and in some embodiments can allow footwear 10 to balance with heel portion 18 raised above ground surface 46, as shown for example in
In some embodiments, base portion 58 can include a first substantially planar shank arm 72 and a second substantially planar medial shank arm 74, which can respectively correspond to a lateral side and medial side of footwear 10. Both shank arms 72 and 74 can be laterally offset from ramp portion 60 and can extend within a plane formed by base portion 58 towards a longitudinal distal direction away from base portion 58. In some embodiments, first shank arm 72 can be located on an lateral side of ramp portion 60 opposite from second shank arm 74. Such a configuration can, for example, provide improved stability for shank 34 and footwear 10 and/or can reduce pronation of footwear 10 during use.
Base portion 58 and ramp portion 60 can be arranged such that they do not overlap in vertical direction 16. For example, as shown in the top view of shank 34 in
Shank 34 can include a neck portion 78 connecting ramp portion 60 to base portion 58. Neck portion 78 can, for example, be designed to flex to allow ramp portion 60 to deform from the uncompressed state to the compressed state. As such, neck portion 78 can serve as a flexure hinge for shank 34.
In some embodiments, shank 34 can include a flared landing portion 62 extending from a distal end of ramp portion 60. Landing portion 62 can include a lateral flap portion 64 extending from bend 66 and a medial flap portion 68 extending from bend 70. Lateral flap portion 64 and medial flap portion 68 can extend substantially in longitudinal and vertical directions (12, 16). Lateral flap portion 64 can be positioned to correspond to a lateral side of a user's foot, and medial flap portion 68 can be positioned to correspond to a medial side of the user's foot, one or both flap portions 64, and 68 can be designed to provide lateral support to footwear 10 or another function.
Shank 34 can be made of a suitable carbon fiber, metal, fiberglass, plastic, or another suitable material. In some embodiments, shank 34 is made of multiple different materials, such as, for example, a first material overlaying a second material, or a first portion of shank 34 being a first material and a second portion of shank 34 being a second material. One or more portions of shank 34 can be made of a single piece of material or multiple pieces of materials. For example, base portion 58, ramp portion 60, neck portion 78, lateral shank arm 72, and medial shank arm 74 can all be a single unitary piece of material.
To provide a desired traction for footwear 10, outsole 32 can include geometries of protrusions and/or recessions designed to increase friction between outsole 32 and ground surface 46. Such geometries can, for example, be chosen based on the particular activities that footwear 10 is designed or expected to be used for. For example, outsole 32 can include one or more treads 92 protruding therefrom. Treads 92 can for example be formed from die-cut blown rubber, carbon rubber, or other suitable materials. As shown in
Outsole 32 can further include one or more grooves for improved traction, ornamentation, weight reduction, ventilation, or other purposes. For example, outsole 32 can include groove 102 formed within outsole ramp portion 98. In some embodiments, groove 102 can be formed within outsole 32 such that groove 102 reveals a bottom surface of shank 34 (as shown for example in
As shown for example in
The choice of materials for the parts described herein can be informed by the requirements of cost, aesthetics, mechanical properties, temperature sensitivity, biocompatibility, moldability properties, or any other factor apparent to a person having ordinary skill in the art. For example, one or more parts of footwear 10 can be made of a polymer, gel structure, foam structure, and/or a stiffer support structure, such as carbon fiber that provides desired softness, flexibility and shock absorbing properties.
Further, it should be appreciated that the exemplary embodiments of the invention are not limited to the exemplary footwear shown and described herein. Although this invention has been described in conjunction with exemplary embodiments outlined herein, various alternatives, modifications, variations and/or improvements, whether known or that are, or may be, presently unforeseen, may become apparent. Accordingly, the exemplary embodiments of the footwear, described herein are intended to be illustrative, not limiting. The various changes may be made without departing from the spirit and scope of the invention.
The drawings and the foregoing description are not intended to represent the only form of the invention in regard to the details of its construction and manner of operation. In fact, it will be evident to one skilled in the art that modifications and variations may be made without departing from the spirit and scope of the invention. Changes in form and in the proportion of parts, as well as the substitution of equivalents, are contemplated as circumstances may suggest or render expedient; and although specific terms have been employed, they are intended in a generic and descriptive sense only and not for the purpose of limitation, the scope of the invention being delineated in the following claim set.
Further, the purpose of the foregoing Abstract is to enable the U.S. Patent and Trademark Office and the public generally, and especially the scientists, engineers and practitioners in the art who are not familiar with patent or legal terms or phraseology, to determine quickly from a cursory inspection the nature and essence of the technical disclosure of the application. The Abstract is not intended to be limiting as to the scope of the present invention in any way.
The present application claims priority to U.S. Provisional Application No. 61/833,808, filed Jun. 11, 2013, the entire contents of which is hereby incorporated by reference.
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