BALLET POINTE SHOE HAVING IMPROVED HEEL SEAM AND THROAT WITH CONCEALED PRE-STRESSED ELASTIC BAND

STATEMENT REGARDING FEDERALLY-SPONSORED RESEARCH OR DEVELOPMENT

Not applicable.

FIELD OF THE INVENTION

The invention relates to the field of pointe shoes for ballet dancing.

BACKGROUND OF THE INVENTION

The art of ballet dancing is a synthesis of grace, poise and fluidity of motion of the human form. Its mastery requires not only disciplined training but also considerable bodily strength, endurance and athleticism. Indeed, Albert Einstein once described dancers as “the athletes of God”. The physical demands ballet imposes on a dancer make it imperative that ballet pointe shoes, especially ballet pointe shoes, fit the dancer very well and provide appropriate support of the foot. Appropriate support is especially important in critical areas such as those supporting the toes, metatarsal region and arch. Good fit and appropriate support not only afford better comfort but also to reduce fatigue and the risk of injury or other maladies which may result from improper form, muscle fatigue, muscle strain, falling or other maladies which can be caused or exacerbated by ill-fitting or improperly supportive ballet pointe shoes. These may include pulled or torn muscles and ligaments, joint damage, sprains and conditions as tendonitis, posterior impingement, flexor hallucis longus tenosynovitis (a/k/a “trigger toe”), posterior compartment syndrome, achilles tendinopathy, plantar fasciitis and osteoarthritis. Such maladies can be painful and may require expensive medical treatment and/or temporary or permanent limitation or cessation of dancing or other physical activities. Some may even end the career of a dancer.

In a ballet pointe shoe, the forefoot support provided by the toe box of the shoe and appropriate support of the arch region are always important but especially so when a dancer enters and maintains certain positions or performs certain movements such as eleve' or releve' in which a dancer is supported on the toes with the heel of the foot elevated above the dance floor. The elevation of the heel is increased further when a dancer assumes a “demi-pointe” and further yet when fully “en pointe” where the dancer is supported on the very tips of the toes. In such movements, the toe box of the pointe shoe may bear substantially all of the weight the dancer and may additionally be subjected to impact forces or other dynamic forces.

The foot receiving opening, sometimes referred to in the art as the “throat” of a ballet pointe shoe, is typically surrounded by a sewn-on binding through which a drawstring is routed. The drawstring has free ends which project from an opening in the binding. The drawstring is typically routed through a passage which is conventionally formed by folding an elongated rectangular strip of binding material into a generally U-shaped cross section and sewing or otherwise securing the free edges of the folded strip of binding material around the throat of the shoe. The elongated channel formed inside the folded binding strip serves as the passage through which all but the free ends of the drawstring are routed. To help secure the shoe to the foot of a dancer, manually pulling the free ends of the drawstring to cinches the binding which surrounds the periphery of the throat of the ballet pointe shoe to foot of a ballet dancer. Once pulled taut, the free ends of the drawstring are then tied together to secure the shoe during use. Some consider the binding strip and the free projecting ends of the drawstrings to be unsightly. At the least they are conspicuous visual departures from the otherwise sleek exterior profile of the remainder of the shoe. The drawstring is also disadvantageous because of the tension required to keep it in place. By pulling the drawstring taut enough to stay on the foot, the dancer experiences discomfort and lingering pressure indentations from the drawstring. If the drawstring not pulled tight, the heel of the shoe will not stay on the foot and becomes a safety concern.

BRIEF SUMMARY OF CERTAIN EMBODIMENTS

Some embodiments of a ballet pointe shoe and/or a foot supporting structure for use in a ballet pointe shoe may include a monolithic toe box/shank body having a shank body which may underlie and support at least a portion of the sole of the foot of a dancer and a toe box. In some embodiments a shank insert may be removably and replaceably received in a receptacle present in the shank body.

In some embodiments, the shank insert can be removed and replaced without using tools at any time during the useful life of the pointe shoe. In some embodiments the shank insert may be selected from a set of shank inserts having different shapes and/or different flexural rigidity profiles.

Some embodiments of a ballet pointe shoe or a foot supporting structure for use in a ballet pointe shoe may have a monolithic toe box/shank body which may be formed of thermoplastic material.

In some embodiments however, a ballet pointe shoe may have a throat whose periphery is completely devoid of any binding strip or other externally visible binding. By avoiding the expense of providing a strip of binding material and the additional labor or other operational expense associated with attaching such a binding strip such embodiments provide a ballet pointe shoe which can be manufactured more quickly and economically but also one in which the exterior face of the outer fabric may extend completely to the upper edge of the throat thereby permitting a more uniform appearance having no visually conspicuous discontinuity at the upper edge of the throat as would otherwise be result if a binding strip were to be present there.

To aid in securing the foot of a wearer inside the foot compartment of ballet pointe shoe during use in a secure but aesthetically pleasing manner, some embodiments of a ballet pointe shoe may include a pre-stressed elastic band that may surround all or at least a major portion of the periphery a throat of the upper. The pre-stressed elastic band may be mounted in some embodiments interposed between outer fabric and the inner liner of the upper such that the entirety of the elastic band is completely concealed from external view. A ballet pointe shoe having a throat which is at least partially surrounded by such a concealed elastic band provides ballet dancers with significantly improved aesthetics as well as less risk of heel discomfort without sacrificing adequate securement of the throat region of the ballet pointe shoe to the foot of the ballet dancer during use. In some embodiments, pre-stressed elastic band may be a woven elastic band. Pre-stressed elastic band 8 may be sufficiently wide that the compressive force exerted on the foot of a wearer during use is distributed over a large enough area to avoid uncomfortably high pressure on portions of the foot compressed by force exerted by the pre-stressed elastic band.

In some embodiments the elastic band 8 may be comprised of two or more discrete elastic band segments at least one of which may not be continuous with, or secured directly to, one or more of the other elastic band segments.

Unlike a ballet pointe shoe of the type having a drawstring with externally projecting free ends which can be pulled and then tied together to cinch its foot receiving opening around the foot of a wearer, embodiments incorporating a pre-stressed elastic band interposed for concealment between the outer fabric and the inner liner of certain embodiments as described herein have several significant advantages. Surrounding all or at least a major portion of the foot receiving opening of the ballet pointe shoe with a pre-stressed elastic band eliminates the need to cinch and tie the ends of a drawstring and avoids the possibility of loosening or becoming untied during use. In embodiments in which a pre-stressed elastic band is mounted internally between the outer fabric and the inner liner, it can be mounted within the interior of the upper and thereby concealed completely from external view. This not only avoids the visible appearance of the drawstring but may reduce the risk of common injuries to the foot and ankle. Traditional drawstrings are believed to cause or contribute to causing bone spurs on the heel, tendonitis in the Achilles tendon and bursitis in the heel as pressure is applied to delicate structures of the ankle. With a concealed elastic surrounding the foot, the stress is removed from these structures allowing for foot protection and therefore reduce the chance of injury.

Unlike conventional ballet pointe shoes in which one or more layers of the shoe material are joined together at the rear of the heel portion of the upper by a seam which includes an exteriorly mounted strip of binding material which extends from a location at or beneath the base of the heel to a location at or near the throat of the shoe, some embodiments of a ballet pointe shoe may feature an improved heal seam structure which is devoid of an a exterior binder strip.

These and other embodiments of the invention are described in further detail below with reference to the drawings in which like reference numerals designate like items. In the detailed description, reference is made to the drawings briefly described below wherein like reference numerals designate like items and which show by way of non-limiting illustrations of some embodiments that may be practiced within the scope of the claims It is to be understood that other embodiments may be utilized and that various structural, methodological or of changes may be made without departing from the scope of the present disclosure or the claims and their legal equivalents.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of an embodiment of a ballet pointe shoe;

FIG. 2 is a top plan view of the embodiment of FIG. 1;

FIG. 3 is a bottom plan view of the embodiment of FIGS. 1 and 2;

FIG. 4A is a partial sectional view taken along section line S2 of FIG. 1;

FIG. 4B is a partial sectional view taken along section line S1 of FIG. 1;

FIG. 5A is a first part of a sectional view taken along line A-A of FIG. 2;

FIG. 5B is a second part of a sectional view taken along line A-A of FIG. 2

FIG. 6 is a second perspective view of the embodiment of FIGS. 1, 2 and 3;

FIG. 7 is a rear elevational view of the embodiment of FIGS. 1, 2 and 3;

FIG. 8 is a partial sectional view taken along section line S3 of FIG. 7;

FIG. 9 is a partial sectional view taken along section line S4 of FIG. 7;

FIG. 10 is a side elevational view of an embodiment of a foot supporting structure for use in a ballet shoe;

FIG. 11 is a upper side front perspective view of an embodiment of a foot supporting structure which shown with an elastic loop;

FIG. 12 is a underside perspective view of an embodiment of a foot supporting structure shown without an elastic loop;

FIG. 13 is a bottom plan view of an embodiment of a foot supporting structure shown with an elastic loop installed;

FIG. 14 is upper side rear perspective illustration of an example of a toe box and shank body formed as a monolithic structure;

FIG. 15 is a schematic illustration of an embodiment of a foot supporting structure having a monolithic toe box and shank body in the form of a monolithic structure and illustrating an example of a set of shank inserts and an example of a set of elastic loops which may be used therewith;

FIG. 16 is a side elevational view illustrating an embodiment of a foot supporting structure in a partially flexed condition;

FIG. 17 shows an example of a blank useful for forming a toe box reinforcing layer;

FIG. 18 is a top plan view of an embodiment of a ballet pointe shoe;

FIG. 19 is graph illustrating hypothetical examples of the flexural rigidity profiles of the shank inserts shown in FIG. 15;

FIG. 20 is a perspective view illustrating the insertion, removal, replacement or adjustment of a shank insert and an elastic loop of a foot supporting structure incorporated in a ballet pointe shoe and showing a shank insert partially inserted into or partially removed from the shank body thereof;

FIG. 21 is a sectional view taken generally along line A-A of FIG. 2 except illustrating the embodiment of FIGS. 1 and 2 in use in a first flexed condition;

FIG. 22 is a sectional view similar to that of FIG. 21 except illustrating the embodiment of FIGS. 1 and 2 in use in a second flexed condition corresponding to a demi-pointe position, and

FIG. 23 is a sectional view similar to that of FIG. 22 except illustrating the embodiment of FIGS. 1 and 2 in use in a third flexed condition corresponding to a an en-pointe position.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

FIGS. 1, 2, 3, 5A and 5B show an exemplary embodiment of a ballet pointe shoe 20. Ballet pointe shoe 20 may include an upper 22 having a vamp 24 adjacent its front end 25, a heel portion 26 adjacent its rear end 28, and side quarters 30a and 30b extending longitudinal direction 62 between the vamp 24 and the heel portion 26. The upper 22 of ballet pointe shoe 20 includes a platform 39 at its front end 25. Preferably, the platform 39 is at least substantially flat and may lie in a substantially vertical plane as can be seen for example in FIG. 5A. In some embodiments, the upper 22 may be covered by an outer fabric 6 whose exterior surface may make up all or at least a substantial portion of the exterior surface of the upper 22 and the foot compartment of the upper 22 may be lined with an inner liner 7. The outer fabric 6 and inner liner 7 may be made one or more other suitable natural and/or synthetic materials each having one or more layers. In some embodiments, the outer fabric 6 may be a fabric of silk satin and/or a synthetic satin or a fabric having an exterior face of a satin. In some embodiments, the outer fabric 6 may consist of, or may include, one or more layers of a fabric such as canvas or twill. The inner liner 7 in some embodiments may consist of, or may include, one or more layers of a woven or nonwoven fabric and/or a natural or synthetic leather or suede material.

Some embodiments of a ballet pointe shoe 20 may also include an insole 32 disposed within the upper 22 and an outsole 34 disposed beneath the upper 22 on the underside of the ballet pointe shoe 20. Insole 32 and outsole 34 may be formed of one of more layers of leather, suede, foam, fabric or any other one or more other suitable natural and/or synthetic material or combination of materials. The insole 32 may optionally be formed entirely of, or may include, one or more layers 10 of resilient foam and/or of one or more other cushioning materials to provide improved comfort and cushion the foot 41 of a wearer against impact forces. In some embodiments, insole 32 may include a top layer 11 of fabric or a natural or simulated leather or suede. The top layer 11 of some embodiments may be of a material of the same type as the inner liner 7 or of a material which substantially visually matches the color and/or surface finish of the inner liner 7.

The outsole 34 in some embodiments may be formed of one or more layers of a natural or synthetic leather or suede material and may be joined to the upper 22 by adhesive bonding, solvent bonding, thermal fusion bonding, ultrasonic welding, stitching or any other joining technique suitable for the materials used. Outsole may include a heel 38 which may be substantially co-planar with remainder of the outsole 34. Heel 38 need not be physically distinct remainder of the outsole 34 except for its location.

To aid in securing the foot 41 of a wearer inside the foot compartment of ballet pointe shoe 20 during use, some embodiments of a ballet pointe shoe 20 may include a pre-stressed elastic band that may surround all or at least a major portion of the periphery of the throat 42 of the upper 22. The pre-stressed elastic band 8 in some embodiments may be mounted in some embodiments interposed between outer fabric 6 inner liner 7, thereby being concealed from external view. In some embodiments, pre-stressed elastic band 8 may be a woven elastic band. Pre-stressed elastic band 8 is preferably sufficiently wide that the compressive force exerted on the foot of a wearer during use is distributed over a large enough area to avoid uncomfortably high pressure on portions of the foot 41 compressed by force exerted by the pre-stressed elastic band 8.

In some embodiments, the pre-stressed elastic band 8 may have a rectangular or substantially cross-sectional shape whose major dimension corresponds to the width of the pre-stressed elastic band 8 and whose minor dimension corresponds to the thickness of the pre-stressed elastic band 8. However, the cross-sectional shape of pre-stressed elastic band 8 need not be rectangular or substantially rectangular. An elastic band having any suitable cross-sectional shape will suffice. In some alternative embodiments pre-stressed elastic band 8 may be one having an oval or oblong cross-sectional shape.

To provide adequate securement to the throat region of a ballet pointe shoe 20 to the foot of a ballet dancer during use in a manner which provides most comfort to the ballet dancer, embodiments in which the elastic band 8 has a cross sectional shape whose major dimension is at least three times greater than its minor dimension are particularly preferred. In some embodiments the pre-stressed elastic band 8 may have a major dimension of about five to six millimeters (5 to 6 mm) and a minor dimension of about one half of one millimeter to one point three millimeters (0.5 to 1.3 mm) in a stretched condition as installed in ballet pointe shoe 20 that is not being worn. In some preferred embodiments, the pre-stressed elastic band 8 may have a cross-sectional aspect ratio which is greater than or equal to three to one (3:1) when in a condition as installed in ballet pointe shoe 20 that is not being worn. In some embodiments, the cross-sectional aspect ratio of the elastic band 8 may be within a range of three to one (3:1) to twelve to one (12:1) when in a condition as installed in ballet pointe shoe 20 that is not being worn. In some embodiments, the pre-stressed elastic band 8 may have a spring constant of about zero point one six Newtons per meter (0.16 N/m).

As installed in some embodiments of ballet pointe shoe 20, pre-stressed elastic band 8 may be pre-stressed during manufacture of the ballet pointe shoe 20 by being stretched under tensile force to a length which is substantially greater than its unstretched length. In some embodiments, the length of pre-stressed elastic band 8 as installed in a ballet pointe shoe 20 may exceed its unstretched length by fifteen to twenty percent (10% to 30%). In some embodiments, the length of pre-stressed elastic band 8 as installed in a ballet pointe shoe 20 may exceed its unstretched length by fifteen to twenty percent (15% to 20%). In some embodiments pre-stressed elastic band 8 may be formed entirely, or in part, of a natural or synthetic rubber. In some embodiments pre-stressed elastic band 8 may be formed entirely, or in part, of a woven material in which fibers of one or more natural or synthetic materials such as cotton, nylon and/or rayon may be interwoven with rubber strips. While in some embodiments pre-stressed elastic band 8 may permissibly be made of a material that comprises or consists of a natural and/or synthetic rubber material, or a material that includes natural and/or synthetic rubber, the term “elastic” is used herein in the sense of being elastically stretchable and is not to be construed as requiring or being limited to a natural or synthetic rubber material.

In some embodiments, pre-stressed elastic band 8 may be mounted internally between the outer fabric 6 and the inner liner 7. In some such embodiments pre-stressed elastic band 8 may be included in a manner as shown in the examples shown in FIGS. 4A and 4B. As illustrated therein, upper edge portions of the outer fabric 6 and inner liner 6 may be folded inward toward one another and joined together by a joint 13 which may be substantially concealed from external view. In some embodiments joint 13 may be a stitched joint but any type of joint 13 suitable for the materials of which outer fabric 6 and the inner liner 7 are made may be used. By way of some nonlimiting examples, joint 13 may be a joint formed by sewn stitches and/or by adhesive bonding, solvent bonding, thermal fusion bonding, ultrasonic welding, or any other joining technique suitable for the materials used. Once secured by joint 13 the pre-stressed elastic band 8 may in some embodiments be further secured by being adhered to the inside face of outer fabric 6 using a glue or other adhesive.

In some embodiments, the heel portion 26 of ballet pointe shoe 20 may include one or more one or more resilient convex support panels 14 interposed between outer fabric 6 inner liner 7. At least a portion of a resilient convex support panel 14 may be of a three-dimensional shape having a compound curvature which is such that at least a portion of the resilient convex support panel 14 bows convexly outward toward the outer fabric 7 in order to support the outer fabric 6 of the heel portion 26 of upper 22 in a desired three-dimensional contour. A resilient convex support panel 14 can be flexible to a relatively high degree but must be sufficiently resilient that when an overlying portion of upper 22 is deformed by application of an external force which disrupts its aforementioned compound curvature, the resilient convex support panel 14 spontaneously elastically reverts to the aforementioned compound curve and by so doing forcibly restores the overlying portion of the outer fabric 6 to its desired three-dimensional contour. In some embodiments, a portion 40 of at least one convex support panel 14 may extend beneath a portion of the heel 38 of the outsole 34 as can be seen by way of non-limiting example in FIGS. 3 and 5B.

In some embodiments a resilient convex support panel 14 may be formed by injection molding polypropylene, polyurethane or any other suitable thermoplastic material so that its three-dimensional shape having a compound curvature is formed during the injection molding process and is present even before the resilient convex support panel 14 is incorporated into the heel portion 26 of ballet pointe shoe 22. In some embodiments a resilient convex support panel 14 may be formed in-situ during the process of assembling a ballet pointe shoe 22. In some embodiments such can be achieved by depositing a molten or semi-molten material, such as a hot melt adhesive, directly or indirectly onto an interior surface of the outer fabric 6 in the heel region 26 at a time when the outer fabric 6 is supported on a shoe last or other form member having the three-dimensional surface contour corresponding to that desired for the part of the heel region 26 on which the material is deposited such that upon cooling the deposited material becomes a resilient convex support panel 14.

In some embodiments a resilient convex support panel 14 may be formed of a woven or non-woven sheet material which may be glued or otherwise adhered directly or indirectly onto an interior surface of the outer fabric 6 in the heel region 26 when the outer fabric 6 is supported on a shoe last or other form member having the three-dimensional surface contour corresponding to the contour desired for the part of the heel region 26. In some such embodiments, a resilient convex support panel 14 in such manner from a nonwoven thermoplastic sheet material such as the polyester/pvc thermoplastic material such as that which is available from Polimeros Y Derivados, S.A. De C.V. of Michoacan, Leon, Mexico under the designation “Polyflex M-60”. That material includes a layer of PVC (polyvinyl chloride) disposed on a layer of non-woven polyester. It has a nominal unit weight of five hundred forty (540) grams per square meter, a nominal thickness of six tenth of one millimeter one (0.6 mm) and a minimum adhesion of three pound-feet (3 lb. ft). After positioning a piece of such material directly or indirectly on an interior surface of the outer fabric 6 in the heel region 26 at a time when the outer fabric 6 is supported on a shoe last or other form member having the three-dimensional surface contour corresponding to the exterior contour desired for the part of the heel region 26 application of sufficient heat and pressure causes the piece of material to assume the appropriate compound curvature which persists in a resilient manner after the material cools. In embodiments in which resilient convex support panel 14 is made of Polyflex M-60 applying forty five pounds per square inch (45 psi) pressure for ten seconds (10 sec.) while the material is at temperature of one hundred thirty degrees Celsius (130° C.) is sufficient for this purpose.

Unlike conventional ballet pointe shoes in which one or more layers of shoe materials are joined together at the rear of the heel portion of the upper by a seam which includes an exteriorly mounted strip of binding material which runs vertical from the base of the heel to a location at or near the throat of the shoe, some embodiments of a ballet shoe 20 may feature an improved heal seam construction which is devoid of an external binder strip as will now be described with reference to FIG. 3 and additional reference to FIGS. 6, 7, 8 and 9.

In some embodiments, rearward edge portions of outer layer 6 may be joined at the heel portion 26 by way of a secure but visually inconspicuous seam 15 which may extend between a first location located beneath, at or near the rearward end of the outsole 34 to a second location located at or near the upper edge 9 of the throat 42 of the ballet pointe shoe 20. Seam 15 may include a first joint 16 by way of which inwardly turned edge portions 6a and 6b of outer fabric 6 may be secured to one another. In some embodiments joint 16 may extend substantially continuously along substantially the entire length of seam 15. In some other embodiments, joint 16 may extend along at least a major portion of the length of seam 15. In some embodiments joint 16 may be interrupted at one or more locations along the length of seam 15.

In some embodiments seam 15 may also include one or more other joints 17 each of which secures the inwardly turned edge portion 6a or 6b of outer fabric 6 to the portion of the outer fabric 6 which over overlies that same inwardly turned edge portions 6a or 6b. In certain preferred embodiments, any or all of joints 16 and 17 may be stitched joints formed by sewing the outer fabric material 6 with a suitable thread or other stitching material. In some embodiments any or all of joints 16 and 17 may be formed in any manner a suitable for the material(s) selected. By way of some nonlimiting examples, any of joints 16 and/or 17 may be an adhesive joint formed by adhesive bonding, a solvent boned joint formed by solvent bonding, a thermally fused joint formed by thermal bonding, a ultrasonically joint formed by ultrasonic welding, or any other type of joint formed using any joining technique suitable for the materials used. In embodiments in which a joint 17 is a stitched joint, stitch portions 17a may be exposed on the exterior of outer fabric 6 but by closely matching the color of the stitching material to the color of the exterior surface 12 of the outer fabric 6 and/or by judicious selection of the stitching pattern used, any exposed stitch portions 17a of a joint 17 can be one which is visually quite inconspicuous.

In some embodiments which include a pre-stressed elastic band 8 extending around at least a portion of the throat 42 of a ballet pointe shoe 20, one or more terminal ends 18 of a pre-stressed elastic band 8 may be secured to the outer fabric 6 by way of a joint 19 as illustrated in FIG. 8. In some such embodiments, one or more of joints 19 may be stitched joints formed by sewing the outer fabric material 6 with a suitable thread or other stitching material. In some embodiments one or more joints 19 may be an adhesive joint, a solvent bonded joint, a thermally fused joint formed by thermal bonding, an ultrasonically welded joint. In embodiments in which a joint 19 is a stitched joint, one or more portions 19a of those stitches may be exposed on the exterior of outer fabric 6 but by closely matching the color of the stitching material to the color of the exterior surface 12 of the outer fabric 6 and/or by judicious selection of the stitching pattern used, exposed stitch portions 19a of a joint 19 can be visually quite inconspicuous.

As indicated in FIGS. 8 and 9, some embodiments the heel portion 26 of a ballet pointe shoe 20 may include one or more joints 21 each of which may secure an outwardly turned edge portion 7a or 7b of inner liner 7 to the portion of the inner liner 7 which overlies that same respective outwardly turned edge portion 7a or 7b. In certain preferred embodiments, any or all of joints 16 and 17 may be stitched joints formed by sewing the inner liner material 6 with a suitable thread or other stitching material. In some embodiments any joint 21 may alternatively be an adhesive joint, a solvent bonded joint, a thermally fused joint formed by thermal bonding, an ultrasonically welded joint.

The upper 22 of a ballet pointe shoe 20 may include a foot supporting structure 50 which may be disposed entirely or at least partially inside the upper 22 during use. The foot supporting structure 50 may include a toe box 53 and a shank assembly 54. The toe box 53 may include a base 57. The shank assembly 54 may include a shank body 58 and a shank insert 60. In some embodiments a shank assembly 54 may optionally include one or more elastic bands 101 as described in further detail below. Some or all of the shank assembly 54 may extend in a rearward longitudinal direction 62b from the base 57 of the toe box 53. For convenience of reference only, some aspects of the foot supporting structure 50 and/or pointe shoe 20 incorporating same, may sometimes be described herein with reference to an imaginary longitudinal axis 49 which may extend in a longitudinal direction 62 and lie in an imaginary plane which at least approximately equally bisects the foot supporting structure 50 and/or pointe shoe 20. The imaginary longitudinal axis 49 may, but need not necessarily, represent an axis of symmetry of the foot supporting structure 50 and/or a ballet pointe shoe 20.

The toe box 53 may have a peripheral wall 56 which together with the base 57 defines an interior cavity 55 which receives at least a front portion of the foot 41 of a ballet dancer during use. The peripheral wall 56 of the toe box 53 may optionally be completely penetrated at one or more location(s) with a plurality of openings (not shown) to provide improved ventilation of body heat and moisture and more rapid evaporation of perspiration.

The peripheral wall 56 of toe box 53 may include a suitably structurally supportive front wall 51 having an outer surface 52. In some embodiments, the outer surface 52 may be substantially planar and wall 51 may provide mechanical support for the platform 39. Alternatively, in some embodiments the front wall 51 may itself form all or part of the platform 39.

Referring now to FIG. 5A, foot-supporting structure 50 in some embodiments may be provided with one or more interior and/or exterior cushioning layers 48 of foam, felt or other cushioning material. In some embodiments a cushioning layer 48 may be overlie all or at least substantial portion of the exterior surface 52 of front wall 51 of the toe box 53 at a location interposed longitudinally between the portion of the outer fabric which covers the platform 39. In addition to cushioning against impact forces during use of ballet pointe shoe 20, a cushioning layer 48 in the location just described also functions as sound-deadening which helps to soften the sound of the platform 39 impacting a dance floor. In lieu, or in addition to, the cushioning layer 48 just mentioned, some embodiments may include a second cushioning layer 48a at one or more locations between the interior of the toe box 53 and the toes and/or other portions of the foot 41 of a wearer for improved comfort and absorption of impact forces. In some embodiments such second cushioning layer 48a may overlie some or all of the base 57 of the toe box 53 and/or some or all of the interior side of the front wall 51 of the toe box 53 and/or the interior side of at least the forward portion of the peripheral wall 56 of the toe box 53 which overlies the front ends of the toes of a dancer during use.

In some embodiments the shank assembly 54 may include a shank body 58 and at least one shank insert 60 which may be mechanically coupled to the shank body 58 in a manually detachable and replaceable manner an example of which will be described in further detail below. In some embodiments, the shank body 58 may be mechanically coupled, directly or indirectly, to the base 57 of toe box 53. In some embodiments a forward portion 66 of the shank body 58 may optionally extend beneath and/or merge seamlessly into the base 57 of the toe box 53.

In some particularly preferred embodiments, the entire shank body 58 and the entire toe box 53 may be formed as a monolithic structure, that is, a structure which consists of single unit without connecting initially separate parts as contrasted with a structure comprised of two or more initially separate parts which are subsequently joined or fastened together. In some embodiments, such monolithic structure may be formed of a thermoplastic or a thermoplastic elastomer such as thermoplastic polyurethane (TPU) or a thermoplastic polyurethane (TPU) blend. Such a monolithic structure can be made for example by injection molding the toe box 53 and the shank body 58 of foot supporting structure 50 as a unitary member which may sometimes be referred to herein as a monolithic toe box/shank body 71. An example of one of many suitable thermoplastic materials from which a monolithic toe box/shank body 71 can be injection molded as a monolithic structure is a thermoplastic polyurethane which is commercially available under the product name Prismathane® HPU 780A from Prisma Montelur Compostos Termoplastos of Campo Bom, Brazil. In some less preferred embodiments, the peripheral wall 56 and/or base 57 of the toe box 53 and/or the shank body 58 may be made from one or more initially separate parts which may be joined together in any suitable manner.

In some especially preferred embodiments monolithic toe box/shank body 71 may have a peripheral wall 56 which forms an integral bracing cup 75. Bracing cup 75 may preferably be of sufficient strength and thickness to provide by itself the mechanical support of the forefoot necessary during use of ballet pointe shoe 20. The portion of the peripheral wall 56 which forms bracing cup 75 can be in some embodiments, but need not necessarily be of uniform cross sectional thickness in any plane perpendicular to longitudinal axis 49 and/or in any plane parallel to longitudinal axis 49. In some embodiments, bracing cup 75 may at least partially surround a portion of the toe box 53 which receives at least a major portion of some or all of the phalanges of one foot 41 a ballet dancer. In some embodiments a bracing cup 75 may be located to at least partially surround all, or at least a major portion, of the hallux (i.e. big toe) of a dancer. In some embodiments a bracing cup 75 may be located to at least partially surround at least a major portion of the hallux as well at least a major portion of the second toe. In some embodiments a bracing cup may be located to at least partially surround at least a major portion of the hallux as well at least a major portion of the second toe and at least a major portion of the third toe. In some embodiments a bracing cup 75 may be located to at least partially surround at least a major portion of the hallux as well at least a major portion of the second toe and at least a major portion of the third toe and at least a major portion of the fourth toe. Bracing cup 75 may in some embodiments comprise the entirety of the peripheral wall 56 and base 57 of the bracing cup 53. In some more preferable embodiments however the longitudinally rearward end 79 of the bracing cup 75 terminates at least about one quarter inch to one inch (¼ in. to 1 in.) or more short of the free outer edge 80 of the peripheral wall peripheral wall 56. In some embodiments, bracing cup 75 may not be completely continuous in its cross-section perpendicular to axis 49. In more preferred embodiments however, bracing cup 75 may be of a cross-section perpendicular to axis 49 which forms a continuous ring around the phalangeal region of the foot 41 a ballet dancer.

In some embodiments, at least the dorsal side of the longitudinally rearward end 79 of the bracing cup 75 may have a U-shaped profile as viewed from a top plan view perspective. An example of such a U-shaped profile is illustrated by that portion of the rearward end 79 of the bracing cup 75 shown in broken lines in the top plan view of FIG. 18. The U-shape profile may preferably have a curvature approximating the a curvature of the dorsal portion of the foot 41 on which force is exerted from the end 75 of the bracing cup 75 at some times during use. In some embodiments the curvature of the U-shaped profile is preferably such as to distribute that pressure over as much of the area of that dorsal portion of the foot as possible. The U-shaped profile of the longitudinally rearward end 79 of the bracing cup 75 provide a ballet dancer with improved comfort and stability.

In some embodiments a monolithic toe box/shank body 71 may include an integral wing 84 in each lateral side of the toe box 53. Each wing 84 in some embodiments may have a free lower edge 86 which may extend adjacent to a portion of the shank body 58 but be separated therefrom. In some embodiments each wing is preferable thinner in cross section and much more flexible than the bracing cup. In some embodiments each wing 84 may have a thickness which tapers such that the wing 84 becomes thinner with increasing distance in the rearward longitudinal direction 62b. Such taper can be a monotonic taper in some embodiments and can be but need not be a linear taper. In some embodiments a wing 84 may taper in a stepwise or discontinuous manner.

In certain preferred embodiments, the separation between the lower edge 86 of each wing may be bridged by a reinforcing sheet 82 which mechanically couples each wing 84 to shank body 58. In some embodiments, reinforcing sheet 82 may comprise a layer of sheet material at least a portion of which spans at least a portion of lower edge 86 to secure the wing 84 to the shank body 58 and may be attached to at least one wing 84 and shank body 58. In some embodiments a reinforcing sheet 82 may be made of a material such as that the cotton and polyester sheet material such as that which is available from Polimeros Y Derivados, S.A. De C.V. of Michoacan, Leon, Mexico under the designation “Oroz 00” which may be adhered to wing 84 with an adhesive or by solvent bonding using toluene or other suitable solvent.

In some embodiments reinforcing sheet 82 may also overlie and be attached to other portions of toe box 53 to serve as further mechanical reinforcement if needed or desired. In some such embodiments reinforcing sheet 82 may be formed from a blank 90 of sheet material shaped in a form similar to that illustrated by way of non-limiting example in FIG. 17. A reinforcing sheet 82 of the shape of blank 90 may have a front edge 95 which, when installed, may extend to or near the peripheral edge of the front surface 52 of the wall 51 of the toe box 53, a rear edge 96 which may extend to or near the outer edge 80 of the peripheral wall 56.

In some embodiments, the peripheral wall 56 of the toe box 53 of a monolithic toe box/shank body 71 may include at least one zone 97 is substantially softer and more compliant than the bracing cup 75. In some embodiment such a zone may comprise the portion of the toe box 53 which lies between the rearward edge 79 of the bracing cup 75 and the outer edge 80 of the peripheral wall 56 of the toe box 53. In some embodiments zone 97 may be formed as a portion of toe 56 which is substantially thinner in cross section than the cross-sectional thickness of the bracing cup 75. In some embodiments zone 97 may have a cross sectional thickness which tapers such that the zone 97 becomes thinner with increasing distance in the rearward longitudinal direction 62b. Such taper can be a monotonic taper in some embodiments and can be but need not be a linear taper. In some embodiments a zone may taper in thickness in a stepwise or discontinuous manner.

The shank body 58 of a monolithic toe box/shank body 71 in some embodiments may include a receptacle 61 by way of which a shank insert 60 can be mechanically coupled to the shank body 58 in a manually detachable and replaceable manner such that at any time during the useful life of ballet pointe shoe 20 a shank insert 60 to removed or removed and replaced with another shank insert 60. In some embodiments, the receptacle 61 may be either a slot or a pocket which penetrates the shank body 58 in the longitudinal direction 62. The receptacle 61 may include an opening 65 through which a shank insert 60 may be manually inserted into the shank body 58 and manually removed from the shank body 58 by a user or other person. In some embodiments, shank body 58 may optionally be penetrated by one or more openings (not shown) other than the opening 65 of receptacle 61 in order to facilitate manufacture of a monolithic toe box/shank assembly 71 by a process such as injection molding.

In some embodiments, a shank insert 60 may be a removable and replaceable shank insert 60 selected from a set 77 of shank inserts 60 in which one or more of the shank inserts 60 in the set 77 have different respective bending stiffness characteristics than others. From among the shank inserts 60 in the set 77 one, such as a distributor, seller or a user, may select a particular shank insert 60 whose bending stiffness characteristics may best suit the needs of a particular use and/or the preferences of a particular customer, purchaser or dancer. For example, one or more shank inserts 60 in a given set 77 may have a higher flexural rigidity than one or more other shank inserts 60 in the same set 77 and/or may have a lower flexural rigidity than others in the same set 77. As used herein, the term “flexural rigidity” refers to the resistance offered by a shank insert 60 as it undergoes bending in response to an external load applied in a direction substantially normal to an upper surface 59 of the shank insert 60.

In some embodiments one or more shank inserts 60 in a set 77 may have a flexural rigidity profile which differs from the flexural rigidity profile of one or more other shank inserts 60 in the same set 77. As used herein, the term “flexural rigidity profile” refers to flexural rigidity as a function of position along the length L of a shank insert 60 in the longitudinal direction 62.

In some embodiments a set 77 of shank inserts 60 may include two or more shank inserts 60 whose rigidity characteristics differ from one another. In some embodiments, a set 77 may include one or more of the shank inserts 60 having a flexural rigidity profile which is substantially flat, that is, one in which flexural rigidity is substantially constant over its longitudinal length, L. However, it is preferable but optional that such a set 77 include at least two or more shank inserts 60 whose respective flexural rigidities, though both constant, differ from one another in absolute value.

In some embodiments, a set 77 may include two or more shank inserts 60 whose respective flexural rigidity profiles have the same maximum absolute values of flexural rigidity. However, it is preferable for a set 77 to alternatively or additionally include at least two, and most preferably more than two, shank inserts 60 whose respective longitudinal flexural rigidities have respective maximum values differ from one another in absolute value. In certain embodiments, a set 77 may include two or more shank inserts 60 having respective flexural rigidity profiles in which the minimum absolute value of flexural rigidity for those shank inserts 60 is the same value but it is preferable for a set 77 to alternatively or additionally include at least two, and most preferably more than two, shank inserts 60 whose respective minimum flexural rigidities differ from one another in absolute value. Alternatively or additionally, a given one or more of the shank inserts 60 in a set 77 may have a flexural rigidity which varies as a function of longitudinal position. For example, the flexural rigidity of a given shank insert 60 at some points or regions along its length in the longitudinal direction 62 may be higher or lower than at other such points or regions.

By way of non-limiting hypothetical examples, FIG. 19 shows flexural rigidity profiles 81, 83 and 85 for each of the three shank inserts 60a, 60b and 60c illustrated in FIG. 15. Each of the shank inserts 60a, 60b and 60c has an overall length L in the longitudinal direction 62. In the drawings, positions in the longitudinal direction 62 are indicated for convenience of illustration in relative terms as spanning a range extending from zero percent (0%) to one hundred percent (100%) of overall length, L. Likewise, flexural rigidity is also indicated for convenience of illustration in FIG. 19 in relative terms as percentages spanning a range from zero percent (0%) to one hundred percent (100%) of the maximum absolute value present at any longitudinal position along the length L. Certain embodiments may include a set 77 of shank inserts which includes at least one, or preferably more than one, shank insert 66 whose maximum and minimum flexural rigidities both differ from the maximum and minimum flexural rigidities of one or more other shank inserts 60 in that same set 77.

In some embodiments, a shank insert 60a, 60b and 60c may include at least a first segment 88 and a second segment 91 which are disposed mechanically in series with one another in the longitudinal direction 62. Preferably, the flexural rigidity of the first segment 88 is significantly greater than the flexural rigidity of the second segment 91. In some embodiments the flexural rigidity of the first segment 88 may be at least five percent (5%) greater than, and most preferably at least twenty five percent (25%) greater than, the flexural rigidity of the second segment 91. In certain preferred embodiments, the flexural rigidity of the second segment 91 may be twenty five percent to eighty five percent (25% to 85%) less than the flexural rigidity of the first segment 88. In the examples illustrated in FIG. 15, the flexural rigidity of each second segment 91 is about eighty percent (80%) less than the flexural rigidity of the first segment 88. Thus, the first segment 88 of each shank insert 60a, 60b, 60c extends in longitudinal direction 62 over a first longitudinal region 89 which has a greater resistance to bending than a second longitudinal region 92 over which its second segment 91 extends.

In some embodiments, one or more shank inserts 60 present in a given set 77 may have a first segment 88 whose length and/or position in the longitudinal direction 62 is different from the longitudinal length and/or longitudinal position of the first segment 88 of one or more other shank inserts 60 in that set 77. For example, the shank insert 60b illustrated in FIG. 15 has a first segment 88 whose longitudinal length is greater than that of the first segment 88 of the shank insert 60a but is less than that of the first segment 88 of the shank insert 60c. While three shank inserts have been described as making up a set 77 only for the sake of illustration, it is to be understood that a set 77 of shank insert 60 may contain any arbitrary number of shank inserts 60 greater than or equal to two.

In some embodiments, one or more of the shank inserts 60 in a set 77 may have a second segment 91 whose length and/or position in the longitudinal direction 62 differs from longitudinal length and/or longitudinal position of the second segment 91 of one or more other shank inserts 60 in that set 77. For example, the shank insert 60b illustrated in FIG. 15 has a second segment 91 whose longitudinal length is less than that of the second segment 91 of the shank insert 60a but is greater than that of the second segment 88 of the shank insert 60c.

In some embodiments, one or more of the shank inserts 60a, 60b, 60c of set 77 may also include an intermediate segment 93 interposed longitudinally between a first segment 88 and a second segment 91 such that the intermediate segment 93 extends in longitudinal direction 62 over an intermediate region 94 which is located between the first region 89 and the second region 92 of its length. Preferably, the intermediate segment 93 has a flexural rigidity profile which varies with longitudinal position in a manner which effects a substantially smooth and continuous transition from the flexural rigidity profile of the first segment 88 to the flexural rigidity profile of the second segment 92. Preferably, but not necessarily, the transition is monotonic. In some embodiments the flexural rigidity profile the intermediate section 93 may be substantially linear. In some embodiments, the flexural rigidity profile of the intermediate section 93 of one or more of the shank inserts 60 in a set 77 may include a substantially inverse sigmoid shaped transition portion such as that which is included in the intermediate portion of each of the flexural rigidity profiles 81, 83 and 85 shown in FIG. 19.

In some embodiments, the first segment 88 of a shank inset 60 may be formed of a first material while a second segment 91 thereof may be formed of a second material of higher elastic modulus than the first material. For example, a shank insert 60 may be formed by an injection molding process in which a first segment 88 may be a thermoset material, such as a phenolic or a thermosetting resin, or a thermoplastic material such as polypropylene, polycarbonate, acrylonitrile butadiene styrene (ABS) or other material which may be co-injected or co-molded with a second material which has a lower flexural rigidity to form the second segment 90. In some embodiments, the second segment 90 may be formed of a second material such as thermoplastic polyurethane (TPU) or a thermoplastic polyurethane (TPU) blend. As an option the first segment 88 may be made of a composite material, such as a thermoset or thermoplastic material which is blended with one or more reinforcing materials such as fiberglass, Kevlar®, carbon fiber, plant fiber or other reinforcing filler in an amount sufficient to make the first segment 88 of a shank insert 60 a desired degree more rigid than its second segment 91.

While in some embodiments a shank insert 60 may be substantially uniform cross-sectional size and shape over its length, L, such need not be the case. It is to be understood that the flexural rigidity profile of a shank insert 60 is not determined solely by the material or materials of which it is made but is also dependent on shape and dimensional factors. Thus, a desired flexural rigidity profile may be achieved, at least in part, by varying the shape and/or dimensions of a shank insert 60 at various longitudinal positions or regions along its length L. It is not a requirement that one or more shank inserts 60 in a set 77 be made of more than one material.

In certain embodiments, the foot supporting characteristics of a ballet pointe shoe 20 or foot supporting structure 50 for use in a ballet pointe shoe 20 may be customized or adjusted. Some such embodiments may include a shank insert 60 which may be selectively heated and reshaped at any time after initial manufacture of the shank insert 60. In some embodiments, this may be achieved by carrying out a method which includes the steps of: (a) forming at least a portion of the shank insert of a thermoplastic material, (b) softening the shank insert by applying heat, (c) applying a first bending moment to the shank insert 60 to reshape the shank insert 60 into an altered shape which differs from its previous shape, the first bending moment being either a hogging bending moment or a sagging bending moment, and (d) lowering the temperature of all, or at least said portion, of the shank insert 60 to a temperature which is sufficiently below the softening temperature to permit the altered shape to be retained semi-permanently that is, retained even after the applied bending moment has been removed, unless and until the thermoplastic material is subsequently heated to, or above, a softening temperature and reshaped by application of a second bending moment into a subsequent altered shape. In some embodiments step (b) above may be carried out by heating all, or at least said portion, of the shank insert 60 to a softening temperature of the thermoplastic material, the softening temperature being a temperature, or a temperature range, which is below the melting temperature of the thermoplastic material. In some embodiments step (c) above may be carried out by applying the first bending moment manually. In some embodiments step (c) above may be carried out by applying the first bending moment by forcing the shank insert 60 into contact with the surface of a die, the die surface being of a shape which determines the altered shape of the shank insert 60. In some embodiments the altered shape of the shank insert 60 may be an arcuate shape. In some embodiments the altered shape of the shank insert 60 may be a curved shape. In some embodiments a subsequent altered shape of the shank insert 60 may be a second arcuate shape. In some embodiments a subsequent altered shape of the shank insert 60 may be a second curved shape.

Heat for softening a shank insert 60 may be generated or applied in any suitable manner such as, for example, by forced hot air heating using a hair dryer or heat gun, heating in an a conventional oven, convection oven, microwave heating, infrared heating or immersion in hot water or other hot liquid. A bending moment for re-shaping a shank insert 60 may be applied in any suitable manner, either by hand or otherwise. In some embodiments a bending moment may be applied to a shank insert 60 manually or with the aid of a machine.

In some embodiments, the methods just described may optionally comprise the step of re-shaping the shank insert 60 into a subsequent altered shape after the steps (a) through (d) just described have been carried out. Such optional step may, in some embodiments, comprise the substeps of: (i) heat-softening the shank insert 60 by reheating all, or at least said portion, of the shank insert 60 to a softening temperature of the thermoplastic material, (ii) applying a second bending moment to the shank insert 60 to reshape the shank insert 60 into a subsequent altered shape, the second bending moment being either a hogging bending moment or a sagging bending moment, and (iii) lowering the temperature of all, or at least said portion, of the shank insert 60 to a temperature which is sufficiently below the softening temperature to permit the shank insert to retain the subsequent altered shape semi-permanently. In some embodiments the optional step of re-shaping the shank insert 60 into a subsequent altered shape can be repeated on as many one or more arbitrary occasions as the needs or preferences of a dancer dictate by repeating the substeps (i) through (iii) just described in this paragraph. In some embodiments the optional step of re-shaping the shank insert 60 into a subsequent altered shape may be carried out by applying the second bending moment by forcing the shank insert 60 into contact with the surface of a second die, the second die surface being of a shape which determines the subsequent altered shape of the shank insert 60. Examples of suitable thermoplastic materials of which all or at least a portion of the shank insert 60 may be made in order to facilitate selective heating and reshaping of the shank insert 60 include but are not limited to polypropylene or a thermoplastic elastomer such as a thermoplastic polyurethane (TPU) or a thermoplastic polyurethane (TPU) blend.

In use, a shank insert 60 whose flexural rigidity profile may best suit the needs of a different application and/or the individual physical characteristics (e.g. third aspect, strength, etc.) of a particular ballet dancer and/or individual preferences of that ballet dancer is selected from a set 77 which may include at least two shank insets 60 whose respective flexural rigidity profiles differ from one another as to one or more parameters. Such parameters may include magnitude and/or in shape and/or longitudinal position at which magnitude changes and/or rate of change of magnitude. The shank insert 60 selected from a set 77 is then inserted into the receptacle 61 in the shank body 58. To replace one shank insert 60 with another from the set 77, a selected shank insert 60 is inserted into the receptacle 61 after any shank insert 60 previously present in the receptacle 61 has been removed the receptacle 61.

In one example of alternative mode of use a ballet pointe shoe 20 may be worn and used for ballet dancing or ballet dance training with either no shank insert 60 present at all or with an installed shank insert 60 which is highly flexible over its entire working length. In such alternative mode of use a ballet pointe shoe 20 can be used in lieu of what is commonly referred to in the art as a “demi-pointe shoe”. Thus, as used herein and in the claims the interchangeable terms “pointe shoe” and “ballet pointe shoe” are not to be construed to exclude demi-pointe shoes.

In some embodiments, insertion, removal and/or replacement of a shank insert 60 may be carried out in a particularly convenient manner by eversion of (that is, by turning inside-out) a rear portion of the upper 22 of the shoe 20 sufficiently to provide functional access to the receptacle 61. This option eliminates the necessity of providing any door, window, port or other opening in the upper 22 to provide for such access. A further advantage of this method is that is that once the upper 22 is restored to a non-everted state, such as that shown in FIGS. 1 through 4, the interior wall of the rear end 28 of the upper limits rearward longitudinal travel of the tab 69, if a tab 69 is present, and the shank insert 60 thus aiding retention of the shank insert 60 in the receptacle 61 while the ballet pointe shoe 20 is being worn.

In certain embodiments, the toe box 53 or at least a portion of the wall 56 of toe box 53 may be made of one or more thermoplastic materials of a type capable of being selectively heated and reshaped at any time after initial manufacture of the foot supporting structure 50 and/or the ballet pointe shoe 20 in which the foot supporting structure 50 is incorporated. This may be achieved by carrying out the steps of: (a) heating all, or at least said portion of, the wall 56 to a softening temperature of the thermoplastic material, the softening temperature being a temperature or temperature range which is below the melting temperature of the thermoplastic material, (b) applying external force to the softened material to reshape at least a portion of the interior cavity 55 of the toe box 53 into an altered shape which differs from its previous shape, and (c) lowering the temperature of the thermoplastic material to a temperature which is sufficiently below the softening temperature to permit the altered shape to be retained semi-permanently that is, retained unless and until the thermoplastic material is subsequently heated to, or above, its softening temperature and reshaped by application of force into some other altered shape, even after the applied re-shaping force has been removed. One example of a suitable thermoplastic material of which all or at least a portion of the wall 56 of toe box 53 may be made in order to facilitate selective heated and reshaping of the toe box 53 is a thermoplastic elastomer such as thermoplastic polyurethane (TPU).

In some embodiments, the method of re-shaping toe box 53 may optionally comprise step of re-shaping the toe box 53 into a subsequent altered shape after the steps (a) through (c) described in the paragraph immediately above have been carried out. Such optional step may, in some embodiments, comprise the substeps of: (i) re-heating all, or at least said portion of, the wall 56 to a softening temperature of the thermoplastic material, (ii) applying external force to the softened thermoplastic material to reshape at least a portion of the interior cavity 55 of the toe box 53 into a subsequent altered shape, and (iii) lowering the temperature of the thermoplastic material to a temperature which is sufficiently below the softening temperature to permit the subsequent altered shape to be retained semi-permanently. In some embodiments the optional step of re-shaping the toe box 53 into a subsequent altered shape can be repeated one or more times on any one or more arbitrary occasions as the needs or preferences of a dancer dictate by repeating the substeps (i) through (iii) just described.

It is to be understood that the entirety of the wall 56 of the toe box 53 can be formed entirely of thermoplastic material in some embodiments. In other embodiments, only one or more portions of wall 56 where reshaping of the toe box 53 may be formed of thermoplastic material. In some embodiments, one or more regions of wall 56 may be formed of a different respective thermoplastic material than other regions of wall 56. In some embodiments one or more regions of wall 56 where re-shaping may not be desired may be formed in whole or in part of material other than a thermoplastic material.

In some embodiments, an external force for carrying out re-shaping of the interior cavity 55 may be applied to the wall 56 of toe box 53 while it is in a heat-softened state at a time when the foot 41 of a particular user is present in foot supporting structure 50 and/or the ballet pointe shoe 20 in which the foot supporting structure 50 is incorporated so that the interior cavity 55 of the toe box 53 may be reformed into an altered shape which more closely conforms to the size and/or shape of the foot 41 of that particular user and/or better suits the preferences of that particular user. Reshaping force may be applied to the toe box 53 in any suitable manner, either by hand or otherwise. In some embodiments the external force may be applied by hand such as by pressing or squeezing at least a portion of the of the wall 56 of toe box 53. In some embodiments, an external force for carrying out re-shaping of interior cavity 55 may be applied to the wall 56 of toe box 53 while it is in a softened state at a time when a forming die of desired size and shape is present in supporting structure 50 and/or the ballet pointe shoe 20 in which the foot supporting structure 50 is incorporated so that the interior cavity 55 of the toe box may be reformed into an altered shape which more closely conforms to the size and/or shape of the forming die. In some embodiments a forming die may be inserted into the toe box manually and/or by a machine or with the aid of a machine. In some embodiments, a forming die may consist of a shoe last or a forward portion of a shoe last.

Heat for softening the thermoplastic material of the toe box 53 may be generated and applied in any suitable manner such as by forced hot air heating using a hair dryer or heat gun, heating in an a conventional oven, convection oven, microwave heating, infrared heating or immersion in hot water or other hot liquid.

Re-shaping of the interior cavity 55 of a toe box 53 herein can be carried out at any time or place after initial manufacture such as at a point of sale or even at a point of use of a foot supporting structure 50 and/or a ballet pointe shoe 20. Re-shaping of the interior cavity 55 of toe box 53 affords not only a better fitting and more comfortable ballet pointe shoe 20 but also makes it possible to provide proper fitting ballet pointe shoe 20 for different dancers without need to manufacture and inventory as many different sizes and/or shapes of ballet pointe shoe 20 as would otherwise be required. Also, the re-shaping of interior cavity 55 can be carried out at any time or place after initial manufacture such as at a point of sale or even at a point of use in order to adjust customize the ballet pointe shoe 20 to suit the needs or preferences of a particular dancer.

Moreover, re-shaping of the interior cavity 55 wall 56 of toe box 53 as described herein can be carried out repeatedly as many times as may be desired over the useful of the foot supporting structure 50 and/or a ballet pointe shoe 20 in order to suit the needs or preferences of a particular dancer at any given point in time. Such needs and preferences, can change from time to time for a variety of reasons. For example, a ballet pointe shoe 20 of a young dancer may be re-shaped one or more times to accommodate changes in the size and/or shape of the of foot due to growth of the dancer as the dancer grows. Re-shaping of the interior cavity 55 of toe box 53 may also be carried out to accommodate temporary or permanent changes in the size and/or shape of the of foot 41 a dancer due to swelling or injury. For instance, a dancer whose foot may swell or develop a blister or other tender area may desire to reshape the interior cavity 55 of toe box 53 to relieve pressure on the affected area. Conversely, a particular injury or condition of the foot 41 of a dancer may benefit by re-shaping of the interior cavity 55 of toe box 53 to provide increased pressure or support for the foot 41 at one or more areas within cavity 55. Once the foot injury or condition is resolved, the foot supporting structure 50 and/or the ballet pointe shoe 20 in which the foot supporting structure 50 is incorporated may optionally be re-shaped yet again to restore the interior cavity 55 of the toe box 53 to a prior shape or to re-shape it into a new subsequent altered shape which may differ from any prior shape.

Some embodiments of a foot supporting structure 50 and/or a ballet pointe shoe 20 may optionally include an elastic loop 101. In some embodiments, an elastic loop 101 be formed in part or entirely of an elastic band 99 and which may at least partially surround or overlap a portion of the foot 41 of a dancer during use. The loop 101 may be mechanically coupled to a midsole portion of the shoe 20 or foot supporting structure 50 in such a way that in use, the loop 101 may continuously exert an elastic force which urges the midsole, and an insole 32 if one is present, toward the sole of the foot 41 of the dancer. In some embodiments the midsole may comprise or include a shank body 58 and/or a shank insert 60. In some embodiments, the elastic loop 101 may be mounted such that during use, an upper portion 103 of the loop 101 may also overlap an instep portion of the foot 41 such that in use, the upper portion 103 of the loop 101 continuously applies elastic compressive force to the instep of the dancer. Mutually opposed lower portions 105a, 105b of the loop 101 may be located at a position in the longitudinal direction 62 which preferably lies within a range 107 of longitudinal positions extending along at least a portion of the longitudinal span of the arch of the foot 41 of the dancer. The loop 101 may include side portions 106 each of which may extend between upper portion 103 and a respective one of the lower portions 105a and 105b. In some embodiments, loop 101 may be formed of a single piece of material. In other embodiments loop 101 may be formed of two or more pieces of material which may be joined to one another to form all or part of loop 101.

In some embodiments an elastic loop 101 may be mounted in a longitudinally repositionable manner such that the longitudinal position of at least its lower portions 105a, 105b can be selected by a user and/or adjusted from time to time by a user from one longitudinal position to another within a range 107. In some embodiments, loop 101 may be mounted by capturing a portion of loop 101 between two structures lying beneath the insole 32. In some embodiments a portion of loop 101 may be routed beneath the shank body 58 and captured in a repositionable manner between the shank body 58 and the lower inside surface of the upper 22 so that in use, the weight exerted by a foot of dancer and the elastic force of the loop 101 hold the loop 101 in place without requiring the loop 101 to be glued, stapled or otherwise permanently fastened to the ballet pointe shoe 20 at a particular longitudinal position. In some embodiments, an optional elastic loop 101 may be secured by being captured between the shank body 58 a portion of a shank insert 60 which projects in the rearward direction 62b from the opening 65 of receptacle 61 when the shank insert 60 is fully inserted into the receptacle. In use of such embodiments the weight of the dancer forcibly clamps the elastic loop 101 in a desired position in longitudinal direction. In some embodiments an elastic loop 101 can at any time be easily repositioned longitudinally relative to shank body 58 by removing the shoe from the foot 41 and manually adjusting its longitudinal position relative to shank body 58.

In some embodiments an elastic loop 101 may be mounted manner such that loop 101 is not only longitudinally repositionable but is also removable and/or replaceable with another loop 101. As one example FIG. 20 shows an embodiment of a ballet pointe shoe 20 having an upper 22 and shank body 58 whose rearward portions are temporarily manually separable from one another to a degree adequate to form between them a temporary gap 109 of sufficient size to permit loop 101 to be longitudinally repositioned along shank body 58 and/or removed from the shoe 20 and/or replaced with another loop 101. If desired, a replacement elastic loop 101 may be one whose width and/or opening size and/or thickness may differ from the width and/or opening size and/or thickness of an elastic loop 101 which it replaces. Alternatively or in addition to any such dimensional differences, a replacement elastic loop 101 may optionally be one whose spring constant differs from that of an elastic loop 101 which it replaces.

Elastic loop 101 can be, but need not necessarily be, formed entirely of a material which is elastically stretchable, that is, a material elongates elastically when a tensile force is applied but returns to substantially its original length after the tensile force is removed. In some embodiments, elastic loop 101 may include one or more segments which are not of an elastically stretchable material provided loop 101 includes at least one segment which is elastically stretchable. In some embodiments loop 101 may be formed entirely, or in part, of a natural or synthetic rubber. In some embodiments elastic loop 101 may be formed entirely, or in part, of a woven material in which fibers of one or more natural or synthetic materials such as cotton, nylon and/or rayon may be interwoven with rubber strips. While in some embodiments an optional elastic loop 101 may permissibly be of a material that comprises or consists of a natural and/or synthetic rubber material, or a material that includes natural and/or synthetic rubber, the term “elastic” is used herein in the sense of being elastically stretchable and is not to be construed as requiring or being limited to a rubber material.

In some embodiments, an elastic loop 101 may be selected from a set 110 which may include two or more elastic loops 101a, 101b, 101c, 101n which may differ from one another in any one or more of the respects which will now be described. For example, one or more elastic loops 101 in a set 110 may differ from one or more other elastic loops 101 in the same set 110 with respect to their unstretched foot opening size. As can be seen in FIG. 15 for example elastic loop 101b may have a smaller unstretched inside diameter than elastic loops 101a and/or 101c while an elastic loop 101n may have an unstretched inside diameter greater than that of elastic loops 101a and/or 101c. In some embodiments, a set 110 may include at least one elastic loop 101 having a width, W1, which may be wider or narrower than the width, W2 of at least one other elastic loop 101c in the same set 110. A dancer may thus select whichever of the two or more elastic loops 101 in a set 110 the dancer may find to be most comfortable at a particular time or for a particular purpose. A set 110 may include at least one elastic loop 101 having a spring constant (k) which is greater than or less than the spring constant of at least one other elastic loop 101 in the same set 110. Spring constant refers to the unit change in elastic force per change in unit length of elastic loop 101 as it is stretched. Thus, for a given length by which an elastic loop 101 may stretch during use, one or more of the elastic loops 101 in a set 110 may exert a higher or lower elastic force on the foot of a dancer than one or more other elastic loops 101 in the same set 110 thereby permitting a dancer to select from the set 101 whichever elastic loop 101 therein may provide a desired amount of elastic force. A set 110 may include at least one elastic loop 101 having an unstretched length which may be greater than or less than the unstretched length of at least one other elastic loop 101 in the same set 110.

In some embodiments, the lower portions 105a, 105b and side portions 106a, 106b of an elastic loop 101 may be located within upper 22 just to the inside of the side quarters 30a and 30b in such a way that in use, the foot 41 of a dancer is subjected at all times to compressive elastic force, not only at the instep where such compressive force may be applied by the upper portion 103 of the loop 101, but also along both lateral sides of the foot 41 where such compressive force may be applied by the side portions 106a, 106b of the elastic loop 101. In certain embodiments an elastic loop 101 may be mounted such that at least a part of one or both of its lower portions 105a, 105b is positioned to underlie at least a portion of the arch of the foot 41 of a dancer. Elastic loop 101 may thus continuously exert a compressive force on at least that portion of the arch at all times during use, providing or increasing support at the arch and/or other portions of the sole of the dancer's foot 41 even at times when dancer may completely or partially airborne or otherwise disposed such that the force exerted on the insole 32, or the shank body 58 may lack a vector component directed normal to the insole 32 or the shank body 58 sufficient to provide a desired degree of support at the arch and/or other portions of the sole of the dancer's foot 41 due to the weight of the dancer alone.

In some embodiments, an elastic loop 101 may be a continuous loop such as in the case of the examples 101a, 101b, 101c 101n shown in FIG. 15. Alternatively, as illustrated in FIG. 2, an elastic loop 101 may be interrupted at one or more locations such as between a pair of ends 111a and 111b. Optionally, ends 111a and 111b of an elastic loop 101 may be mechanically coupled to one another, either directly, or indirectly by way of one or more structurally intermediate members 112 as represented schematically in FIG. 2. In some embodiments one or both ends 111a, 111b of an elastic loop 101 may be fastened to a shank body 58 which may thus serve as a structurally intermediate member 112 by way of which the ends 111a, 111b of an elastic loop 101 may be indirectly mechanically coupled to one another.

While embodiments of a ballet pointe shoe 20 which include an elastic loop 101 may be used during ballet performances and/or during ballet training with or without an elastic loop 101 installed, a ballet pointe shoe 20 having elastic loop 101 installed is particularly useful during ballet training as the pressure exerted by the elastic ring 101 on the foot of the dancer provides tactile feedback which can assist the dancer in sensing that their foot 41 is properly centered within the toe box 53.

In some embodiments, one or more shank inserts 60 and the receptacle 61 in which it may be received are configured such that the one or more shank inserts 60 underlie all or substantially all of the base 57 of the toe box 53 when shank insert 60 is installed fully in the receptacle 61. In some embodiments, the forward end 172 of one or more full installed shank inserts 60 may even extend sufficiently far in the longitudinal direction 62 to lie beneath at least a portion of the front wall 51 of the toe box 53.

However, there is significant advantage to alternative embodiments in which one or more shank inserts 60 and the receptacle 61 are configured such that the when the shank insert 60 is installed fully in the receptacle 61, the forward end 172 of the shank insert 60 lies at a position in longitudinal direction 62 which is sufficiently rearward of the longitudinal position at which the interior base of the front wall 51 meets the base 57 of the toe box 53 that in use under the weight or expected weight of the dancer, a ballet pointe shoe 20 in which the foot supporting structure 50 is incorporated can bend at an angle of least two degrees (2°) in the longitudinal region which lies forward of the extreme forward end of the shank insert 60 as the dancer transitions into a demi-pointe position or a full en pointe position. In some embodiments, the flexural properties of foot supporting structure 50 and the pointe shoe 20 may be selected such that the bending angle may be limited to a range of two degrees (2°) to not more two more than five degrees (5°) under the weight or expected weight of a dancer. One significant advantage afforded by the embodiments which have been described in this paragraph is that if testing, dancers have reported an unexpected ease in transitioning into a demi-pointe position or a full en pointe position. In such embodiments, the forward end of a fully installed shank insert 60 lies a distance 173 rearward of the longitudinal position at which the interior surface of the front wall 51 meets the base 57 of the toe box 53. In some such embodiments, distance 173 may be a distance of two millimeters (2 mm). In some such embodiments distance 173 may be a distance of two millimeters (2 mm) within a tolerance of about minus five percent (−5%) to about plus seventy five percent (+70%).

In some embodiments, a foot supporting structure 50 may have a monolithic toe box/shank body 71 in which the shank body 58 includes one or more zone of weakening 177 which provide increased flexibility over a path which extends in a direction transverse to the longitudinal direction 62. In some embodiments a zone of weakening 177 may extend along a path which extends in straight line. However, in some embodiments a zone of weakening 177 may follow a path which bows forwardly in longitudinal direction as shown by way of example in FIGS. 12 and 13.

In some embodiments, a foot supporting structure 50 may have a shank body 58 whose upper surface, including some or all of the base 57 of the toe box 53, may be curved, at least when the shank body 58 is in a condition in which no shank insert 60, which might otherwise alter the shape of that surface is installed in the shank body 58. For example, in some embodiments some or all of the upper surface of the shank body 58 may follow a curve 182 as shown in FIG. 10. In some embodiments curve 182 may have a radius in a range extending from about seven inches (7 in.) to about fourteen inches (14 in.). In some embodiments some or all the upper surface of the shank body 58 may include only a simple curve such as curve 182. In some other embodiments, some or all the upper surface of the shank body 58 may comprise a compound curved surface.

In some embodiments, a shank assembly 54 of a foot supporting structure 50 or ballet pointe shoe 20 incorporating same may include a shank insert 60g at least a longitudinal portion of which may be shaped as a convex curve 85 as schematically illustrated in FIG. 15.

In some embodiments, as illustrated in FIGS. 10 and 11 an optional elastic loop 101 may be secured to the shank body 58 by being captured between a shank insert 60. In use of such embodiments the weight of the dancer forcibly clamps the elastic loop 101 in a desired position in longitudinal direction.

In interpreting the present disclosure and the claims, references of the form “A and/or B” encompass any and every combination and subcombination of elements A and B, namely, (i) A but not B, (ii) B but not A, and (ii) both A and B. References of the form “A, B, and/or C” likewise encompass any and every combination and subcombination of elements A, B and C. Where the present disclosure or any of the claims may recite “a” or “a first” item or the equivalent thereof, such disclosure includes one or more such items and does not require or exclude two or more such items. Numerical or ordinal indicators such as first, second or third for items are used to distinguish between the items, and do not require or limit the number of such items elements and do not indicate, require or limit a particular position or order of such items unless expressly and clearly stated otherwise.

Descriptions made with reference to “some embodiments”, “an embodiment”, “embodiments”, “other embodiments” “alternative embodiments”, “other embodiments”, “various embodiments” or the like mean that the description is applicable to at least one embodiment of the invention and each such reference may refer to one or more of the same embodiments or to different embodiments. The terms “comprising,” “including,” “having,” and the like, as used with respect to one or more embodiments, are synonymous. In some cases features, items steps or other subject matter are described herein as being optional or using terms such as “optional” or “optionally”. However, lack use of such terms in connection with the description of any other features, items steps or other subject matter does not in any way mean or imply that such other features, items steps or other subject matter are required or are not optional.

As an aid to understanding, various actions, operations or steps may sometimes be presented herein or described herein in sequence. However, the order of description or written presentation herein is not to be construed to mean or imply that such must necessarily occur in a corresponding order or sequence unless otherwise expressly and clearly stated or logically essential. Some actions, operations or steps may permissibly be performed in an order or sequence other than the order of their description or written presentation herein unless otherwise expressly and clearly stated or logically essential. Unless otherwise expressly and clearly stated or logically essential, actions, operations or steps described herein may be combined or divided. Unless otherwise expressly and clearly stated or logically essential, any description herein of any one or more actions, operations or steps does not preclude any one or more other preceding, succeeding and/or intervening actions, operations or steps irrespective of whether or not such preceding, succeeding and/or intervening actions, operations or steps are described or disclosed herein.

Unless otherwise expressly and clearly stated or logically essential, any illustration or description herein of any one or more items, structures or elements being “connected to”, “coupled to”, “joined to” or “secured to” any one or more specified items, structures or elements shall not be construed to preclude such connection, coupling or securement being either made indirectly, by way of one or more other specified or unspecified items structures or elements, or being made directly.

While the invention has been described with reference to various preferred embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents substituted for elements thereof without departing from the scope of the invention and that modifications may be made to adapt to a particular situation or application of the invention without departing from the scope of the invention. The invention is not limited to the particular embodiments disclosed. Rather, the invention covers all embodiments which are within the scope of the claims, either literally or under the Doctrine of Equivalents.

	Number	Date	Country
	62925729	Oct 2019	US
	62794589	Jan 2019	US

	Number	Date	Country
Parent	16701652	Dec 2019	US
Child	16746263		US
Parent	PCT/US2019/058206	Oct 2019	US
Child	16701652		US

BALLET POINTE SHOE HAVING IMPROVED HEEL SEAM AND THROAT WITH CONCEALED PRE-STRESSED ELASTIC BAND

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Abstract

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CROSS-REFERENCE TO RELATED APPLICATIONS

Provisional Applications (2)

Continuation in Parts (2)